Determination of the forming tool load in plastic shaping of a round tube into a square tubular section

The forming tool load in plastic shaping of a round tube into a square tubular section has been determined analytically and also numerically by applying finite element simulation. The theoretical results were compared to experimental measurements obtained in testing tube specimens using a specially designed test-rig simulating actual production conditions. The comparison has shown that the results obtained analytically were in fair agreement with those obtained experimentally, while the finite element simulation results were in agreement only at small deformation. The shaping load–displacement relationship obtained analytically was applied to predict the roll load and drawing force in drawing a round tube into a square tubular section through a head comprising four idle flat rolls. The results obtained from this application proved to be in fair agreement with those obtained from a previous more elaborate solution, which recommends the use of the analytical relationship, obtained to direct industrial application.