Computationally efficient finite element model for simulating a chipless flow-forming process

This paper describes a new approximate finite element analysis model for simulating a chipless flow-forming process. The analysis model relies on two fixed artificial planes of symmetry to define the analysis domain and reduce the computational time; these planes constrain the material. Roller tools rotate around the central axis of the process to make the analysis model statically identical to the actual process. Predictions based on models with domains that were 1/24th and 1/8th the size of the full domain were compared to check the sensitivity and validity of this technique. These predictions were also compared with experimental results from an actual automobile flow-forming process in terms of deformed shape. The predicted geometries on the artificial planes of symmetry were quite different from the experimental geometries, but those in the mid-plane were close. The 1/24th-domain model provided more-reliable predictions because of the finer mesh system used.