Title: Simulation of cage roll forming process of ERW pipes

Authors: Yinghong Peng, Jinmao Jiang, Dayong Li, Jianzeng Han, Jianxin Li

Addresses: Institute of Knowledge-Based Engineering, School of Mechanical Engineering, Shanghai Jiaotong University, 800 Dongchuan Road, Shanghai 200240, PR China. ' Institute of Knowledge-Based Engineering, School of Mechanical Engineering, Shanghai Jiaotong University, 800 Dongchuan Road, Shanghai 200240, PR China. ' Institute of Knowledge-Based Engineering, School of Mechanical Engineering, Shanghai Jiaotong University, 800 Dongchuan Road, Shanghai 200240, PR China. ' Baoshan Iron & Steel Co. Ltd., Shanghai 201900, PR China. ' Baoshan Iron & Steel Co. Ltd., Shanghai 201900, PR China

Abstract: Cage roll forming is an advanced and highly productive forming method of Electric Resistance Welded (ERW) pipes, and has been widely applied in the manufacturing of pipes. Due to the complexity of the cage roll forming process, few studies on the analysis of cage roll forming has been found and corresponding industrial practice depends greatly on experience rather than science-based design. In this paper, the whole cage roll forming process has been simulated with the explicit elasto-plastic finite element code LS-DYNA and the results of cage roll forming simulation are introduced. The Effective Plastic Strain (EPS) and deformed geometries are predicted during steel strip passing through different forming stages. The key characteristics of deformation configurations, such as the opening distances of trip edges and circumferential length are calculated and compared with practical measurement and good agreement is shown.

Keywords: cage roll forming; ERW pipes; opening value; work hardening; electric resistance welding; finite element method; FEM; simulation; effective plastic strain; EPS; deformation; steel strip.

DOI: 10.1504/IJMPT.2008.022142

International Journal of Materials and Product Technology, 2008 Vol.32 No.4, pp.388 - 405

Published online: 19 Dec 2008 *

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