The flower pattern and rolls design for ERW pipes with the different specification in the flexible roll forming process

Cheng, Jiaojiao; Cao, Jian; Zhao, Jianwei; Liu, Jiang; Zhao, Rongguo; Liu, Shiquan

doi:10.1016/j.tws.2020.106809

Cited by 19 publications

(6 citation statements)

References 18 publications

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“…The UDF exible roll forming(USTB-Durable F) proposed by the domestic Cao research group [19], has established a exible and modular design and manufacturing realization path for multi-speci cation and multi-variety cold roll forming rolls, which reduced the time and cost of roll changing, improved the production e ciency, and realized the exible production of 7 kinds of circular tubes. With the market's higher and higher requirements for circular tubes, it is more and more important to vigorously research and develop exible roll forming technology for circular tubes.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Cao

Wang

Ruan

et al. 2023

Int J Adv Manuf Technol

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In view of the problems of poor exibility of conventional roll forming of circular tubes, the UDF (USTB-Durable F) exible roll forming method was used to model and simulate ve kinds of thin-walled circular tubes with different thicknesses and the same outer diameter, so as to verify the applicability of UDF exible roll forming method. In order to realize the commonality of UDF rolls, according to the roll positions of seven kinds of thin-walled circular tubes with different outer diameters and thicknesses within the speci cation range, mathematical models between tube speci cations and corresponding roll position parameters were established. Combined with the actual parameters of the thin-walled circular tube roll forming unit, the UDF forming process suitable for the exible forming of thin-walled circular tubes was obtained and compared with the conventional process by nite element simulation. Results show that the edge molding quality of the UDF process is better than that of the conventional process, and the amount of springback is less and the accuracy of the outer diameter of the section is high. The establishment of the roll position mathematical model and the special process parameters of the UDF exible roll forming method provides a reference for the development of exible production of roll forming of circular tubes.

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Section: Introductionmentioning

confidence: 99%

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Cao

Wang

Ruan

et al. 2023

Int J Adv Manuf Technol

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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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“…Their results indicated that tests with web side plates on both sides had near 10% shear strength more than tests with one web side plate. Cheng et al 14 did numerical tests using roll forming software COPRA as well as experimental tests to investigate the flexible roll forming of ERW pipes. The results showed that the distribution of transverse strain was optimized with the flexible design of the flower pattern.…”

Section: Introductionmentioning

confidence: 99%

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

Bidabadi

Naeini

Safdarian

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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In spite of product quality increase in the cold roll forming process by previous practical researches for defects prevention, there are some ill-considered defects such as over-bending, which diminished the product quality in the open section products of this process. This defect which happens by superfluous bending of sheet in the forming stand not only lead to defective products, but also trigger other defects such as edge wrinkling. Since in an elaborate process such as cold roll forming, forming parameters play an active role in defect prevention, the effect of some important parameters is investigated on the over-bending defect and product bending angle by doing 68 experimental tests and numerical simulations in the present study. The list of parameters which are investigated includes bend angle increment, flange width, strip thickness, radius of bend, strength of the materials, and inter-distance between successive stands. In addition, the reason behind the effect of each parameter on the accuracy of the bending angle is laid out. Results show that over-bending defect can be compensated or even eliminated by decreasing the bending angle in each stand, a technique called bending angle increment. Increasing the number of forming stands from two to five causes the over-bending to decrease from 6° to 0°. With bending angle increment being the most impactful factor, bending radius, flange width, and strip thickness have a decreasing impact on over-bending. This study also brings forward a reverse relationship between the strength of the material and the intensity of over-bending. The inter-distance between successive stands was found to have the least effect on over-bending. Results highlight the importance of pre-form rolls at the beginning of the roll forming line. Without the usage of pre-form rolls, the folding of strips on a 60° angle, cannot be done in one stand.

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The flower pattern and rolls design for ERW pipes with the different specification in the flexible roll forming process

Cited by 19 publications

References 18 publications

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes

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

Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods

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