A new development of measurement technique for residual stresses generated by the cold tube drawing process with a fixed mandrel

The residual stresses during the cold tube drawing process affect the quality of the final tube products significantly. In this study, a new development of measurement technique that is built on the removing layer method (RLM) is developed to measure the axial and the hoop residual stresses (ARS, HRS) inside the tube wall for AISI 1010 steel. The tube is produced by the cold tube drawing process with a fixed straight mandrel (fixed plug). The RLM by milling process is performed on the inner and the outer surfaces of the tubes while the tee rosette strain gages (TRSGs) are fixed at the inner and the outer tube surfaces respectively for strain measurements. An axisymmetric finite element model (AFEM) based on explicit dynamic analysis is also performed to predict the ARS and the HRS within tube thickness. The experimental and finite element results are compared with variable X-ray diffraction (XRD) results. It is found that the results are in good agreement and the RLM is proved to be one of the appropriate methods to measure residual stresses inside the tube wall. The results showed that residual stresses present inside the tube wall are completely different by different reduction of areas of R = 16 and 23%.