Feasibility of synchronous compound hole expansion verified with numerical simulation based on the finite element analysis

Abstract The optimization of the technology used for compound hole expansion or the proposition of a novel hole expansion method with higher efficiency remains an issue. This article provides a new strategy of synchronous compound processing, relying on the integrated mandrel to complete the smooth hole expansion and the bushing expansion in a single drawing process. The finite element analysis was used to verify the feasibility and the surface wear effects of synchronous compound hole expansion. The synchronous strategy not only had a similar processing effect to the conventional asynchronous method but also performed the compound processing under conditions of low interference of the smooth hole expansion. Synchronous compound hole expansion is expected to play a practical role in the industrial field of high-strength hole expansion.