Optimization of the Processes of Forming and Welding of Large-Diameter Pipes with the Help of Mathematic Simulation

Kolikov, A. P.; Zvonarev, D. Yu.; Ti, Sashkina; Sidorova, T. Yu.

doi:10.1007/s11015-020-00981-2

Cited by 4 publications

(1 citation statement)

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“…Straight weld large diameter tubes (LDT) are manufactured by different techniques: press forming or forming using bending machine [1][2][3][4][5]. Modern manufacturing lines (of Haeusler AG) include roller forming mill, roller device for bending of edges, welding-assembling mill for preparing of strip for welding, welding section, expander for making the final profile of the tube.…”

Section: Introductionmentioning

confidence: 99%

Modelling of the sheet forming while 3-roller bending process

Zhigulev¹,

Skripalenko²,

Fadeev³

et al. 2022

cisisr

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3-roller bending process was investigated using physical modelling and computer simulation. Main technological parameters influence on the formation of tube billet diameter are present; these main technological parameters are upper roller displacement and distance between axes of bearing rollers. Complete factorial experiment was conducted using bending machine, radius of the produced tube billet was set as response function. Conditions for conducting the complete factorial experiment using bending machine and techniques of tube billet radius estimation by graphical-analytical method are presented. At that least square method and SolidWorks software were applied. Regression equations for calculating tube billet diameter conditionally upper roller displacement and distance between axes of bearing rollers were obtained. Influence of these two factors on tube billet radius formation was demonstrated. Finite element method (FEM) computer simulation of the forming process was done with respect to parameters corresponding to parameters of physical modelling experiment using bending machine. FEM computer simulation was done using QForm software. QForm simulation was realized for elastic-plastic bending in terms of two-dimensional deformation. Point tracking was applied to calculate coordinates of the points of the formed sheet and bending parameters. It allowed estimation of the neutral line location in the formed sheet when bending stage was finished. Presented results of computer simulation are figures with trajectories of the tracked points; figures illustrating changing of distance between tracked points; graph of accumulated strain changing through sheet's thickness. New criterion for neutral line (neutral surface) was proposed for sheet bending process. Results of the research can be effective when exploring Heausler AG bending equipment.

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Section: Introductionmentioning

confidence: 99%

Modelling of the sheet forming while 3-roller bending process

Zhigulev¹,

Skripalenko²,

Fadeev³

et al. 2022

cisisr

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Deformation at continuous forming of longitudinal welded pipes

Samusev¹,

Kondrushin²,

Fadeev³

2021

Izv. vysš. učebn. zaved., Čern. metall.

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One of the effective methods for studying any process is its physical modeling, during which it is possible to verify the concepts and hypothesis obtained previously by theoretical modeling. In the laboratory of metal forming of NUST “MISIS” there is ERW mill 30 – 50 for the production and simulation of processes for the continuous forming of longitudinal welded pipes of small and medium diameter, their welding and calibration. This article discusses the deformation zone of a pipe billet, using the first two stands of a molding mill as an example with a calibration of a roll tool for a pipe diam. 50×1.5 mm. Based on the analysis of methods for calculating the parameters of real roll calibers, a model of contact interaction of the pipe billet with the first and second roll open stands was developed and areas of the deformation zone were determined including their sizes: non-intensive and intense impact; input and output contact zones; springing up. Analyzing the conditions of contact interaction of the pipe billet with roll calibers, parameters of the pipe billet in contact with the first-caliber rolls were determined in seven sections, taking into account the features of continuous forming. An analysis of the results has shown that the maximum longitudinal deformation occurred at the edge of the billet in section B – B and was equal to 1.04 %, and for the pipe billet bottom it was 0.92 %. For the experiment, a grid was applied to the pipe billet using a laser engraver. During forming, the trajectory deviation of the pipe billet bottom from horizontal axis was recorded, and sizes of the forming sections were determined. Comparison of theoretical and experimental values has shown that the discrepancy between them does not exceed 7 %.

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