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<p>This study introduces a novel solid granules bulging process for aluminum alloy four-way tubes, aiming to enhance forming precision and minimize defects in internal high-pressure forming. A three-dimensional finite element method–discrete element method coupling model (FEM-DEM coupling model), based on the uniform load distribution method, is developed to analyze the bulging process under three forming modes—free bulging, axial compression bulging, and composite bulging—to determine the optimal scheme. The model captures the influence of the solid granules medium (SGM) on material behavior at both mesoscopic and macroscopic scales. Three-dimensional contact distribution and normal contact force histograms illustrate force transmission changes within granules during bulging. Experimental validation shows a maximum deviation of 12.7% between simulated and measured wall thickness, confirming the accuracy of the model and consistency with deformation patterns.</p>

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Multiscale analysis of solid granules bulging of aluminum alloy four-way tube process via coupling FEM-DEM simulation

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • Haiwei Shi,
  • Changcai Zhao,
  • Bing Du,
  • Qingxing Zhu

摘要

This study introduces a novel solid granules bulging process for aluminum alloy four-way tubes, aiming to enhance forming precision and minimize defects in internal high-pressure forming. A three-dimensional finite element method–discrete element method coupling model (FEM-DEM coupling model), based on the uniform load distribution method, is developed to analyze the bulging process under three forming modes—free bulging, axial compression bulging, and composite bulging—to determine the optimal scheme. The model captures the influence of the solid granules medium (SGM) on material behavior at both mesoscopic and macroscopic scales. Three-dimensional contact distribution and normal contact force histograms illustrate force transmission changes within granules during bulging. Experimental validation shows a maximum deviation of 12.7% between simulated and measured wall thickness, confirming the accuracy of the model and consistency with deformation patterns.