Numerical simulation of axisymmetric tube bulging using a urethane rod

Many industrial components, such as axle casings, metal bellows, stepped hollow shafts, etc., are manufactured by axisymmetrically bulging metal tubes. Experimental studies have revealed a limited understanding of the process especially in terms of the stress and strain distribution in the formed product. The LS-DYNA finite element analysis code has been used to provide a simulation of axisymmetric bulging of copper tubes using a urethane rod as a bulging medium. Good correlation was achieved between the predicted and experimentally measured data for bulge height and thickness distribution in the formed component.