Numerical simulation and experimental study on the multi-step upsetting of a thick and wide flange on the end of a pipe

Thick and wide flanges are necessary on pipes for connecting them to adjacent pipe lengths, but it is difficult to produce thick and wide flanges on the ends of pipes with a thickness of over 1.5 times the pipe wall thickness. In order to obtain such type of flange, the method of multi-step upsetting is developed in this paper, and the process is simulated using the FEM code DEFORM. The simulation results are analyzed and the method of determining the step-length is also discussed.