Numerical and Experimental Analysis of Forming Rectangular Copper Pipes by Successive Rolling of Round Pipe Filled With Bismuth

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

علی  بصیرت نیا ¹ (دانشجوی کارشناسی ارشد، دانشکده مکانیک، دانشگاه آزاد اسلامی واحد خمینی شهر)
محسن  لوح موسوی ² (استادیار، دانشکده مکانیک، دانشگاه آزاد اسلامی واحد خمینی شهر)

Received: 2015-11-04 Accepted : 2015-11-04 Published : 2014-12-22

Keywords: Finite elements method, Cold Rolling, Rolling forming, Rectangular pipes, Re-forming pipes,

Abstract :

Because of their wide application in industries requiring high pressure and temperature, manufacturing square and rectangular pipes have attracted more attention than ever before.There are various methods such as extrusion, tensile and stress for manufacturing square pipes. Another method on which studies have focused in recent years is the re-forming of round pipes in order to turn them into square or rectangular ones. The methods suggested in these researches are all applicable for the manufacture of square pipes without the possibility of manufacturing rectangular pipes. The method introduced in this paper consists of filling the pipe with bismuth and rolling it in three successive stages. In this research, first, the intended process is simulated in Abaqus software, and then a real sample is manufactured by an experimental test. The manufactured sample is checked with regard to its dimensions and is compared with the results obtained from the simulation. The results of the study show that the method of filling the pipe with bismuth and moving it through three rollers is an appropriate method for the manufacture of thin-walled pipes with rectangular cross-section.

References:

[1] Kiuchi M, Shintani K, Tozawa M., Investigation into forming process of square pipe experimental study on roll forming process of noncircular pipe II, Journal of the Japan Society for Technology of Plasticity, 21/228, 1980, pp.73–80 [in Japanese].

[2] Kiuchi M., Overall study on roll forming process of square and rectangular pipes, In: Proceedings of the second international conference on rotary metalworking process, Straford Upon_Avon, 1982, pp. 213–26.

[3] Wen B., Using advanced tooling designs to reshape round tube into square and rectangular tubes, OH, USA: Roll-Kraft, Inc.

[4] Onoda Y., Nagamachi T., Kimura S., Effects of forming conditions on cross-sectional shapes of corner zones of square and rectangular steel pipes formed by extroll-forming process, Journal of the Japan Society for Technology of Plasticity, 3 ,1992, pp.573–578. (in Japanese).

[5] Onoda Y, Nagamachi T, Kimura S, Kitawaki T., Pushing load acting on ram and forming load acting on the idle rolls in extroll-forming mill for reshaping round welded steel pipes into square and rectangular shapes, Journal of the Japan Society for Technology of Plasticity,42, No.476, 1993, pp.478.

[6] Bayoumi, Laila S., Cold drawing of regular polygonal tubular sections from round tubes, International Journal of Mechanical Sciences, 43, 2001, pp. 2541–2553.

[7] Moslemi Naeni H., Kiuchi M., Kitawaki T., Kuromatsu R., Design method of rolls for reshaping processes of pipes with pentagonal cross-sections, Journal of Materials Processing Technology, 169, 2005, pp. 5–8.

[8] Leu D.K., Wu J.Y., Finite element simulation of the squaring of circular tube, International Journal of Advanced Manufacturing Technology, Vol. 25, 2005, pp. 691–699.

[9] Leu D.K., Finite-element simulation of the lateral compression of aluminum tube between rigid plates, International Journal of Mechanical Sciences, Vol. 41, 1999, pp. 621-638.

[10] Leu D.K., The shaping of a circular tube into a symmetric square-tube by finite-element modeling, Journal of Materials Processing Technology, Vol. 178, 2006, pp.287–296.

[11] Hwang Y.M., Elasto-plastic finite element analysis of squaring circular tube, Journal of Transactions of Nonferrous Metals Society of China, Vol. 18, 2008, pp.665-673.

[12] Bayoumi L., Attia A.S., Determination of the forming tool load in plastic shaping of a round tube into a square tubular section, Journal of Materials Processing Technology, Vol. 209, 2009, pp. 1835-1842.

[13] Abrinia K., Farahmand H.R., An upper bound analysis for the reshaping of thick tubes with experimental verification, International Journal of Mechanical Sciences, 2007, pp. 342-358.

[14] ابری‌نیا ک. ، تاجیار ع. ، تاثیر پارامترهای مختلف بر روی نیروی جداشونده در شکل دهی مجدد لوله گرد، دهمین کنفرانس مهندسی ساخت و تولید ایران، ICME 2010، دانشگاه صنعتی نوشیروانی بابل.