Tube drawing analysis using upper bound and energy methods and validation by Cockcroft-Latham failure criteria

Cold tube drawing reduces the tube dimensions with closed tolerances and improves its mechanical properties. In this paper, there was an investigation into the cold drawing process with a floating plug using an upper bound analysis and energy method. The ring compression test was performed to determine the friction coefficient. Grooved pipe testing was done to determine the critical damage value. Simulation results confirmed the values of 0.05 for friction coefficient and 0.862 for critical damage value. Using the design of experiments with Taguchi method, the upper bound analysis was done and the correct design parameters were selected. For the selected parameters, the stress value of 289 MPa was obtained from the upper bound analysis. The design process was simulated using ABAQUS software and the results of the stress analysis at the die output showed the consistency of the upper bound analysis and simulation results.