Abstract
In this study, a three-dimensional finite element (FE) modeling of multistage incremental tube burring was carried out to confirm a significantly crucial process path for the bar-tool-assisted incremental tube burring process proposed in our former study. The tube burring model of an aluminum alloy tube, A5083-O, of 400 mm diameter and 6.0 mm thickness using a bar tool of 65 mm diameter was used in the simulation and analyzed using an explicit dynamic FE code. A ductile fracture damage analysis of the process is also performed in the simulation. The distributions of thickness reduction ratio, forming force at each stage and final burring height are compared with the experimental results. The simulation results are in good agreement with the experimental results, and the validity of this analysis model is confirmed.
