Skip to main content
SpringerLink
Log in

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

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In view of the problems of poor flexibility of conventional roll forming of circular tubes, the UDF (USTB-Durable F) flexible roll forming method was used to model and simulate five kinds of thin-walled circular tubes with different thicknesses and the same outer diameter, so as to verify the applicability of UDF flexible 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 specification range, mathematical models between tube specifications 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 flexible forming of thin-walled circular tubes was obtained and compared with the conventional process by finite 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 flexible roll forming method provides a reference for the development of flexible production of roll forming of circular tubes.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18

Similar content being viewed by others

Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

References

  1. Han F, Liu JY, Ai ZQ, Hu M (2010) State of the art of research on roll forming process. J Plast Eng 17:53–60. https://doi.org/10.3969/j.issn.1007-2012.2010.05.012

    Article  Google Scholar 

  2. Brunet M, Sabourin F (1995) A simplified triangular shell element with a necking criterion for 3-d sheet-forming analysis. J Mater Process Technol 50:238–251. https://doi.org/10.1016/0924-0136(94)01384-D

    Article  Google Scholar 

  3. Tsang KS, Ion W, Blackwell P, English M (2017) Validation of a finite element model of the cold roll forming process on the basis of 3d geometric accuracy. Procedia Eng 207:1278–1283. https://doi.org/10.1016/j.proeng.2017.10.883

    Article  Google Scholar 

  4. Zheng JX, Zhang SH (2018) Influence on selection of material constitutive relation model for steel plate cold bending forming simulation. Foundry Tech 39:1298–1300. https://doi.org/10.16410/j.issn1000-8365.2018.06.040

    Article  Google Scholar 

  5. Cao JG, Wang L, Liu J, Liu XL, Zhao RG, He ZL (2017) Finite element simulation of roll forming process based on over-bend defect control of shaped tube. J Cent South Univ 48:2345–2351. https://doi.org/10.11817/j.issn.1672-7207.2017.09.013

    Article  Google Scholar 

  6. Liu XL, Cao JG, Chai XT, Liu J, Cheng JJ, Zhao RG (2018) Springback prediction of DP980 steel considering nonlinear elastic modulus in cold roll forming. J Harbin Inst Tech 50:137–143. https://doi.org/10.11918/j.issn.0367-6234.201707163

    Article  Google Scholar 

  7. Wang YS, Xu XD, Liu HJ, Liu J, Zhao RG (2022) Optimization of the forming method on torsion defect in cold-roll forming of Z section steel. ACS Omega 7:4804–4811. https://doi.org/10.1021/ACSOMEGA.1C04969

    Article  Google Scholar 

  8. Lindgren M (2007) An improved model for the longitudinal peak strain in the flange of a roll formed U-channel developed by FE-Analyses. Steel Res Int 78:82–87. https://doi.org/10.1002/srin.200705863

    Article  Google Scholar 

  9. Najafabadi HM, Naeini HM, Safdarian R, Safdarian R, Kasaei MM, Akbari D, Abbaszadeh B (2019) Effect of forming parameters on edge wrinkling in cold roll forming of wide profiles. Int J Adv Manuf Tech 101:181–194. https://doi.org/10.1007/s00170-018-2885-x

    Article  Google Scholar 

  10. Abeyrathna B, Rolfe B, Weiss M (2017) The effect of process and geometric parameters on longitudinal edge strain and product defects in cold roll forming. Int J Adv Manuf Tech 92:743–754. https://doi.org/10.1007/s00170-017-0164-x

    Article  Google Scholar 

  11. Gao Q, Liu WJ, Li D, Wang YL, Gao HQ, Xue T (2019) Research and implementation of the roll position automatic adjustment system based on roller parameters prediction. J Adv Manuf Syst 18:273–292. https://doi.org/10.1142/S0219686719500148

    Article  Google Scholar 

  12. Bidabadi BS, Naeini HM, Tehrani MS, Barghikar H (2022) Investigation of over-bending defect in the cold roll forming of U-channel section using experimental and numerical methods. P I Mech Eng B-J Eng 236:1380–1392. https://doi.org/10.1177/09544054221076628

    Article  Google Scholar 

  13. Feng SG (1994) Cage roll forming process. Welded Pipe and Tube 17:55–57. https://doi.org/10.19291/j.cnki.1001-3938.1994.06.014

    Article  Google Scholar 

  14. Han ZW, Liu C, Lu WP, Ren LQ, Tong J (2004) Experimental investigation and theoretical analysis of roll forming of electrical resistance welded pipes. J Mater Process Technol 145(3):311–316. https://doi.org/10.1016/j.jmatprotec.2003.07.010

    Article  Google Scholar 

  15. Liu ZY (2011) Advantages of FFX forming equipment and several views construction large-scale HFW unit in China. Welded Pipe and Tube 34:43–47. https://doi.org/10.19291/j.cnki.1001-3938.2011.01.010

    Article  Google Scholar 

  16. Zhou SJ, Luo CJ, Wu XY, Qi GZ (2010) Analysis of advantages of FFX forming technology. Steel Pipe 39:53–55. https://doi.org/10.3969/j.issn.1001-2311.2010.01.010

    Article  Google Scholar 

  17. Allwood JM, Utsunomiya H (2006) A survey of flexible forming processes in Japan. Int J Mach Tool Manu 46:1939–1960. https://doi.org/10.1016/j.ijmachtools.2006.01.034

    Article  Google Scholar 

  18. Ma LD, Chen S, Sun YW (2018) Simulation and experiment on pre-forming section of welded pipe FFX forming with explicit dynamic algorithm. J Plast Eng 25:207–210. https://doi.org/10.3969/j.issn.1007-2012.2018.02.030

    Article  Google Scholar 

  19. Cheng JJ, Cao JG, Zhao JW, Liu J, Zhao RG, Liu SQ (2020) The flower pattern and rolls design for ERW pipes with the different specification in the flexible roll forming process. Thin Wall Struct 154:1–18. https://doi.org/10.1016/j.tws.2020.106809

  20. Muller M, Barrans SM, Blunt L (2011) Predicting plastic deformation and work hardening during V-band formation. J Mater Process Technol 211:627–636. https://doi.org/10.1016/j.jmatprotec.2010.11.020

    Article  Google Scholar 

Download references

Funding

This work was supported by the Scientific and Technological Innovation Foundation of Foshan (BK22BE019), the University Teachers Characteristic Innovation Research Project of Foshan (2021DZXX20), the National Major Science and Technology Project of China (2019ZX06002001-004), and the Innovation Method Fund of China (2016IM010300).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology, Beijing, Beijing, 100083, China

    Jianguo Cao, Xuesong Wang, Kang Ruan, Jiaojiao Cheng & Zhidong Wei

  2. National Engineering Research Center of Flat Rolling Equipment, University of Science and Technology, Beijing, Beijing, 100083, China

    Jianguo Cao, Xuesong Wang, Kang Ruan, Jiaojiao Cheng & Zhidong Wei

  3. Institute of Artificial Intelligence, University of Science and Technology, Beijing, Beijing, 100083, China

    Jianguo Cao, Xuesong Wang, Kang Ruan, Jiaojiao Cheng & Zhidong Wei

  4. Shunde Innovation College, University of Science and Technology Beijing, Foshan, 528300, China

    Jianguo Cao & Kang Ruan

  5. Jiangsu Durable Machinery Corporation Limited, Yangzhou, 225100, Jiangsu, China

    Rongguo Zhao

Authors
  1. Jianguo Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xuesong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Kang Ruan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jiaojiao Cheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhidong Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Rongguo Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jianguo Cao: Conceptualization, supervision, project administration.

Xuesong Wang: Methodology, formal analysis, data curation, writing—original draft.

Kang Ruan: Investigation, data curation, validation.

Jiaojiao Cheng: Writing, review and editing; visualization.

Zhidong Wei: Writing, review and editing; visualization.

Rongguo Zhao: Software, resources, validation.

Corresponding author

Correspondence to Jianguo Cao.

Ethics declarations

Ethics approval

The authors claim that they are non-life science journals and there are no ethical issues.

Consent to participate

The authors claim that they agree to participate.

Consent for publication

The authors claim that they agree to publish.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

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.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Cao, J., Wang, X., Ruan, K. et al. Numerical simulation research on UDF flexible roll forming of multi-specification thin-walled circular tubes. Int J Adv Manuf Technol 127, 4503–4517 (2023). https://doi.org/10.1007/s00170-023-11824-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11824-0

Keywords

Search

Navigation