Abstract
The straightedge lineal roll forming technology is one of the flexible roll forming processes. It has been widely used in high frequency welding pipe production. This paper aimed to research the straightedge lineal roll forming mechanism and explore the steel strip deformation rules. Taken the HFW355 pipe production mill as object, the forming process and stands function were researched. The integrated forming process of Φ273 × 10 mm pipe was simulated by dynamic explicit elastic-plastic finite element method. The straightedge lineal roll forming process is consisted of pre-forming section, straightedge lineal forming section and fin-pass forming section. The equivalent plastic strain variation of strip in each forming section and rolling force distribution of each forming stand were obtained. The simulation result shown that the bigger plastic deformation occurs in the center and on the edge of the strip. The SLF section acted as a link between pre-forming section and fin-pass forming section to make the steel strip transition smoothly. The rolling force of edge bending stand is the biggest in pre-forming section. The plastic deformation of strip is the biggest in fin-pass forming stands. The research results provide a theoretical basis for roll pattern design. The maximum equivalent plastic strain value of the strip is from 0.064 in pre-forming section to 0.091 in SLF forming section until 0.130 and maximum equivalent plastic strain increases is about 42% in straightedge lineal roll forming process.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
Data availability
The data used to support the findings of this study are included within the article.
References
Ilani, M.A., Khoshnevisan, M.: Powder mixed-electrical discharge machining (EDM) with the electrode is made by fused deposition modeling (FDM) at Ti-6Al-4V machining procedure. Multiscale and Multidisciplinary Modeling, Experiments and Design. 3, 173–186 (2020)
Sun, B.F.: Study on Forming Mechanism and Manufacturability of ERW High Frequency Longitudinal Welded Pipe [D]. Qingdao: China University of Petroleum (EastChina) (2010). https://doi.org/10.7666/d.y1839818
Phan, N.H., Pi, V.N., Tuan, N.Q., Shirguppikar, S., Patil, M.S., et al.: Tool wear rate analysis of uncoated and AlCrNi coated aluminum electrode in EDM for Ti-6Al-4 V titanium alloy. In: Advances in Engineering Research and Application: Proceedings of the International Conference on Engineering Research and Applications, ICERA 2020, pp. 832–838. Springer International Publishing, Berlin (2021)
Phan, N.H., Pi, V.N., Shirguppikar, S., Patil, M.S., Ilani, M.A., Hung, L.X., …, Hung, T.Q.: Material removal rate in electric discharge machining with aluminum tool electrode for Ti-6Al-4V titanium alloy. In Advances in Engineering Research and Application: Proceedings of the International Conference on Engineering Research and Applications, ICERA 2020 (pp. 527–533). Springer International Publishing. (2021)
Hu, S.L.: Technical progress and development of product functionization of welded pipe. Steel Pipe 50(4), 1–5 (2021). https://doi.org/10.19938/j.steelpipe.1001-2311.2021.4.01.05
Han, F., Li, M.: Deformation mechanism of sheet based on contact normal pressure in roll forming. J. Huazhong Univ. Sci. Technol. (Natural Sci. Edition). 46(10), 69–73 (2018). https://doi.org/10.13245/j.hust.181012
Ji, X.P., Zhang, H., Ma, H.W.: Discussion on the development and research of the technology of large diameter hi-quality HFW pipe in abroad and domestic. Welded Pipe Tube 32(8), 10–15 (2009). https://doi.org/10.19291/j.cnki.1001-3938.2009.08.002
Hu, R.R., Wang, J.F. & Li, D.J. et al. Roll Pass Design of Flexible Forming HFW Pipe Mill [J], https://doi.org/10.19291/j.cnki.1001-3938.2017.04.007 (2017).
Han, F., Li, C.: Analysis of the action mechanism of influencing factors of roll forming force. China Mech. Eng., 1–9 (2022). http://kns.cnki.net/kcms/detail/42.1294.th.20220518.1028.008.html
Wang, S.J., Wu, Y.Q. & Lu, X. et al. Rolling Force Test of HFW Longitudinal Welded Pipe Cage Forming [J], https://doi.org/10.19291/j.cnki.1001-3938.2012.08.010 (2012).
Liu, G.S. & Guo, Z.J. Edge forming control of pipe billet of butt-welded pipe, https://doi.org/10.13228/j.boyuan.issn1003-9996.2002.06.019 (2002).
Li, D.J.: The review of HFW660&355 project engineering design of TTPCO. Rolling Equip. 3, 12–19 (2012)
Li, D.J., Hu, R.R., Zhang, C.L., et al.: Trial production and influencing factors analysis on properties of high frequency welding tubing. J. Iron Steel Res. 28(10), 75–78 (2016). https://doi.org/10.13228/j.boyuan.issn1001-0963.20160103
Wang, J.F., Li, D.J. & Han, B.Y. et al. Application Progress of Numerical Simulation in the Research of Welded Pipe Forming Process [J], https://doi.org/10.19291/j.cnki.1001-3938.2008.03.013 (2008).
Ilani, M.A., Khoshnevisan, M.: Mathematical and physical modeling of FE-SEM surface quality surrounded by the plasma channel within Al powder-mixed electrical discharge machining of Ti-6Al-4V. Int. J. Adv. Manuf. Technol. 112, 3263–3277 (2021)
Mahdavinejad, R.A., Ilani, M.A.: Superior advance research in the electro-discharge machining of Ti alloys. Int. J. Sci. Res. Mech. Mater. Eng. 3, 19–38 (2019)
Taherkhani, A., Ilani, M.A., Ebrahimi, F., Huu, P.N., Long, B.T., Van Dong, P., …, Van Duc, N.: Investigation of surface quality in cost of Goods Manufactured (COGM) method of µ-Al2O3 powder-Mixed-EDM process on machining of Ti-6Al-4V. Int. J. Adv. Manuf. Technol. 116(5–6), 1783–1799 (2021)
Ilani, M.A., Khoshnevisan, M.: Study of surfactant effects on intermolecular forces (IMF) in powder-mixed electrical discharge machining (EDM) of Ti-6Al-4V. Int. J. Adv. Manuf. Technol. 116(5–6), 1763–1782 (2021)
Ilani, M.A., Khoshnevisan, M.: An evaluation of the surface integrity and corrosion behavior of Ti-6Al-4 V processed thermodynamically by PM-EDM criteria. Int. J. Adv. Manuf. Technol. 120(7–8), 5117–5129 (2022)
Acknowledgements
This work was supported in part by Tianjin Science and Technology Program (Grant No. 18YFCZZC00120).
Author information
Authors and Affiliations
Contributions
All authors contributed to the study conception and design. Prof. Dian-jie Li and Mr. Long-qing Xu designed the study, complied the FE models, conducted the analysis, interpreted the results and wrote the manuscript. Ms. Ling-jun Li and Dr. Chong-feng Yue contributed FE simulating and data processing. Mr. Wen-jun Zhou and Mr. Chun-lin Zhang contributed to the discussion and background of the study. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.
Corresponding author
Ethics declarations
Competing interests
The authors have no competing interests to declare that are relevant to the content of this article.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Electronic supplementary material
Below is the link to the electronic supplementary material.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Li, Dj., Xu, Lq., Li, Lj. et al. Finite element simulation for straightedge lineal roll forming process of high frequency welding pipe. Int J Interact Des Manuf (2023). https://doi.org/10.1007/s12008-023-01298-5
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12008-023-01298-5