Finite Element Simulation of Double-Nosing Process for Manufacturing of the Special Engine Shell

The aim of this research is to study the double-nosing process in a tube. First, the single-nosing process was simulated and then experimentally tested. After validation of the simulation results, the double-nosing process was simulated. The main purpose of simulation is to shape the integrated production of the shell of a special engine through a double-nosing process. The process was simulated in cold conditions. The effects of friction coefficient, creating an obstacle at the end of the lower die, and creating a profile at the end of the tube on the final formed product and the die stresses were investigated. The results show that there is good agreement between experimental and simulation results. Reducing the friction coefficient reduces the middle buckling, and increasing the length of the profile from 50 to 100 mm increases the middle buckling and, as a result, reduces the length of the workpiece. Meanwhile, the effect of thermal profiles on the process has also been studied. A desirable product will be obtained after the noshing process by applying thermal profiles and mechanical properties at different temperatures. It takes about 110 tons of power to create this product. The maximum amount of plastic strain occurs at the top edge of the workpiece that undergoes the most deformation. The stresses created in the upper and lower dies are negligible, and the dies never enter the plastic phase.