Continuous roll forming including in-line welding and post-cut within an ALE formalism

Crutzen, Yannick; Boman, Romain; Papeleux, Luc; Ponthot, Jean‐Philippe

doi:10.1016/j.finel.2018.01.005

Cited by 12 publications

(18 citation statements)

References 23 publications

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“…Furthermore, Kim et al [ 15 ] used the FEM to minimize the deformation of the band edge during roll forming. Many scientific publications have proven that the geometry of the open seam tube can be predicted correctly by means of FEM [ 16 , 17 , 18 , 19 ]. This also holds for residual stresses, which arise in the tube during roll forming, as shown by Bauer et al [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding

et al. 2022

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This paper presents a fully coupled three-dimensional finite element model for the simulation of a tube manufacturing process consisting of roll forming and high-frequency induction welding. The multiphysics model is based on the dual mesh method. Thus, the electromagnetic field, the temperature field, the elasto-plastic deformation of the weld bead, and the phase transformations within the material can be simulated for a moving tube without remeshing. A comparison with measurements shows that the geometry of the welded tube and the weld bead, the force on the squeeze rolls, the temperature along the band edges, and the hardness distribution within the heat-affected zone can be simulated realistically.

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Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding

et al. 2022

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“…The opening gap at twelve o'clock position of the O-shaped plate was affected by the radius of the lower part of U-mould, and the springback trend is different for different deformation areas. For the numerical simulation of the continuous roll forming process, some modeling techniques were proposed, and the roll forming of a closed unsymmetrical tubular rocker panel and a closed circular tube with welding and post-cut were simulated to verify the feasibility [3]. Cheng et al [4] revealed the mechanics law between strip and rolls in the roll forming of electrical resistance welding pipes by the numerical simulations, the results showed that the contact normal force plays a major role in the forming of the edge arc segment, and the straight segment restricts the deformation of strip.…”

Section: Introductionmentioning

confidence: 99%

The evolution of cross-sectional dimension for double wall brazed tube in the multi-pass roll forming

Liu

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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The manufacturing process of double wall brazed tube (DWBT) consists of the multi-pass roll forming from the flat strip to double wall structure and brazing process. And the poor roundness of cross section for DWBT in the multi-pass roll forming not only affects the forming accuracy and quality, but also restricts the subsequent brazing process of DWBT. Thus, the parameters of Hill’48 yield criterion for the steel strip were firstly determined in this paper, and the reliable 3D finite element model of the multi-pass roll forming of DWBT was established based on ABAQUS/Explicit platform. Then the cross-sectional dimension of DWBT after each roll forming was analyzed. The results show that the multi-pass roll forming of DWBT requires the cooperation of the forming roller, horizontal roller and vertical roller, and the radius of the horizontal roller profile becomes larger with the increasing roll pass. The evolution of cross section is accompanied by the accumulation of equivalent strain, following the forming sequence of two arms on both sides, inner wall, outer wall and sizing process. An expression representing roundness is proposed, and it is concluded that the roundness of the outer tube is better than that of inner tube. Moreover, the cross-sectional distribution of the outer tube is more uniform along the circumferential direction.

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“…ALE formulations were used for the numerical simulation of a complex continuous-type roll-forming process using the in-house finite element code METAFOR and results were in good agreement with the classical Lagrange method [38]. Recently, the manufacturing chain, including the continuous roll-forming operation, the in-line welding process for closed sections, and the post-cut functions, was numerically simulated with the ALE method by Crutzen et al [39]. However, validation of the proposed modelling technique was needed as there was no available experimental data in the literature.…”

Section: Introductionmentioning

confidence: 99%

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

Topa

Cerik

Kim

2020

JMSE

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The development of numerical simulations is potentially useful in predicting the most suitable manufacturing processes and ultimately improving product quality. Seamless pipes are manufactured by a rotary piercing process in which round billets (workpiece) are fed between two rolls and pierced by a stationary plug. During this process, the material undergoes severe deformation which renders it impractical to be modelled and analysed with conventional finite element methods. In this paper, three-dimensional numerical simulations of the piercing process are performed with an arbitrary Lagrangian–Eulerian (ALE) formulation in LS-DYNA software. Details about the material model as well as the elements’ formulations are elaborated here, and mesh sensitivity analysis was performed. The results of the numerical simulations are in good agreement with experimental data found in the literature and the validity of the analysis method is confirmed. The effects of varying workpiece velocity, process temperature, and wall thickness on the maximum stress levels of the product material/pipes are investigated by performing simulations of sixty scenarios. Three-dimensional surface plots are generated which can be utilized to predict the maximum stress value at any given combination of the three parameters.

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Continuous roll forming including in-line welding and post-cut within an ALE formalism

Cited by 12 publications

References 23 publications

Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding

Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding

The evolution of cross-sectional dimension for double wall brazed tube in the multi-pass roll forming

A Useful Manufacturing Guide for Rotary Piercing Seamless Pipe by ALE Method

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