Stress Concentration Factor of Expanded Aluminum Tubes Using Finite Element Modeling

This paper discusses the development of semi-empirical relations for the maximum stress concentration factor (SCF) around circular holes embedded in aluminum tubes under various expansion ratios and mandrel angles. Finite element models were developed to study the expansion of a typical aluminum tube with embedded holes of various sizes. An elastic perfectly-plastic material behaviour was used to describe the structural response of the tubes under expansion. Various hole-diameter-to-tubewall- thickness ratios, tube expansion ratios, and mandrel angles were considered to determine the stress state around the hole at zero and 90 degree locations from which the maximum SCF was determined. Semi-empirical relations for the maximum SCF using the Lagrange interpolation formulation were developed. The developed relations were found to predict the SCFs accurately.