Comparative Study of Forward and Backward Flow Forming Process using Finite Element Analysis

Flow forming is a well known technique to produce cartridge case, rocket nose cones, rocket launcher casing etc. for defense industry. As the flow forming is the non linear plastic deformation process, it is required to understand the forces encountered and the strain distributions during the process for the efficient and successful product manufacturing. As it is a non linear plastic deformation process, still the force and strain distribution prediction is quite difficult. So that an attempt is made to predict the forces, stress, strain distributions in the present work, analysis has been carried out using ABAQUS/Explicit for forward and backward strategies. The work material has been taken as AA6063 due to its lighter weight, higher formability, ease of availability and versatile applications in aerospace and defense industry. The forces (axial, radial and circumferential) acting during the process have been obtained and reported along with the strain distribution in the length and thickness. It has been found that the axial and radial forces are higher in forward flow forming. The circumferential force is found higher in backward flow forming. Moreover plastic strain distribution along the thickness is found higher in forward flow forming and along length it is found higher in backward flow forming. The study will help to identify suitable strategy before actual production for different material and process conditions.