Abstract: The aim of this paper is to confirm the effect of key
design parameters, the punch radius and punch angle, on rupture of the
expansion tube using a finite element analysis with a ductile damage
model. The results of the finite element analysis indicated that the
expansion ratio of the tube was mainly affected by the radius of the
punch. However, the rupture was more affected by the punch angle
than the radius of the punch. The existence of a specific punch angle,
at which rupture did not occur, even if the radius of the punch was
increased, was found.