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Swage autofrettage process is used for internal forming and sizing of thick-walled tubes designed to withstand high internal pressures. In this process, a mandrel with a diameter slightly larger than that of the tube is pressed inside the tube and in so doing, creates the internal profile. This paper presents an experimental and numerical study of this process. Two dimensional axi-symmetric and three dimensional finite element analyses are used to investigate the effects of workpiece and mandrel geometry on the forming load and part quality. Experiments are carried out to validate the numerical results. © 2005 Elsevier Ltd. All rights reserved  

An analytical method for reconstructing residual stresses within axisymmetric cylinders is presented. The method uses the stress equilibrium and boundary conditions together with an Airy stress function that satisfies these conditions. The method allows the reconstruction of residual stresses from limited measurements. The analysis is also coupled to a least squares approximation and a regularization analysis to provide stability of the inverse problem. The application of the method is demonstrated for four cases; two correspond to analytical solutions for residual stresses created during autofrettage and two sets of experimental results for through wall measurements of residual stresses. In... 

In this paper a general variable material property (VMP) formulation for the solution of thick-walled tubes with constant axial strains was developed and compared with the alternative VMP method that is called the Hencky program The VMP method was initially developed for the analysis of plane stress and plane strain states. However, the actual autofrettage process is under constant axial strain, i.e., open-end and closed-end conditions. Results indicate very good agreement with the Hencky program. Our method is simple, accurate, and very efficient, so that the number of iterations for convergence reduces approximately to one-tenth of Hencky program iterations. The solution algorithm for... 

In this paper the effect of the re-autofrettage process on the residual stress distribution at the wall of a thick-walled tube is considered. For accurate material behavior modeling, it is assumed that the yield surface is a function of all the stress invariants. Also for estimating the behavior of the material under loading-unloading process, a modified Chaboche's hardening model is applied. For evaluation of this unloading behavior model a series of loading-unloading tests are conducted on specimens that are made of the high strength steel, DIN1.6959. In addition the finite element simulations are implemented to simulate the re-autofrettage process and to estimate the residual stresses.... 

Autofrettage is a technique for introducing beneficial residual stresses into cylinders. Both analytical and numerical methods are used for the analysis of the autofrettage process. Analytical methods have been presented only for special cases of autofrettage. In this work, an analytical framework for the solution of autofrettaged tubes with constant axial strain conditions is developed. Material behavior is assumed to be incompressible, and two different quadratic polynomials are used for strain hardening in loading and unloading. Clearly, elastic perfectly plastic and linear hardening materials are the special cases of this general model. This quadratic material model is convenient for the...