Numerical simulation of rotational symmetric tube bulging with inside pressure and axial compression

The process of rotational symmetric tube bulging with inside pressure and axial compression enables the standard tubes to be formed into different rotational symmetric hollow parts in such a way that their central part is expanded into a desired shape while the ends remain unchanged. The superposition of axial compression contributes to a more favorable forming stress state, which is reflected in larger forming limits and smaller wall thinning in the widened area. The problems characterizing the process are a limited range of compression stability and difficulties met when establishing and optimizing the technological parameters of the process whose course cannot be defined in an analytical way. Based on a physical model of the forming process a numerical model was built. Using ABAQUS code the model was simulated over the entire stress/forming region. The comparison of the computer simulated forming process with the experimentally obtained results showed that the model was highly accurate. Finally, the paper studies the influences of particular parameters on the stability of the process, showing on a practical example how it is possible to achieve tube bulging without wall thinning.