Effect of flower pattern on the curvature of high-strength steel pipe in roll forming

Subject Areas : Analytical and Numerical Methods in Mechanical Design

M. Karimi Firouzjaei ¹ , H. Moslemi Naeini ² , B. Abbaszadeh ³ , M.M. Kasaei ⁴

1 - Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
2 - Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
3 - Faculty of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
4 - Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), University of Porto, Porto, Portugal |Department of Mechanical Engineering, Qazvin Branch, Islamic Azad University, Qazvin, Iran

Received: 2022-09-21 Accepted : 2022-09-21 Published : 2022-06-01

Keywords: Finite Element Modeling, Cold roll forming process, Flower pattern design, Pipe curvature distribution, High strength steel,

Abstract :

The geometrical characteristic of products is one of the crucial quality indicators in the cold roll forming process. In this process, an appropriate flower pattern for rolls is vital to achieve the desired geometry and quality for high-strength steel pipes. In this paper, four different flower patterns, including circular, edge bending, double radius, and reverse bending are designed for the roll forming process of the high-strength steel pipe. Then, the effect of the flower pattern on the curvature distribution of the deformed strip is investigated using finite element analysis. The accuracy of the finite element model is evaluated by performing experimental tests. The results show that forming the strip with the reverse bending flower pattern leads to a more uniform curvature distribution in its cross-section, especially in the edge portion. Thus, this flower pattern design method is recommended for the roll forming process of the high-strength steel pipes.

References:

1. Toyooka, E. Yokoyama, A. Ejima, Deformation behaviour and fin-pass forming condition in the 26-inch cage forming ERW pipe mill, Kawasaki Steel Corporation, Japan, pp. 353-364, 1982.


2. Kiuchi, T. Koudabashi, T. Sato, Automated Design System of Optimal Roll Profiles for Roll-Forming of Welded Pipe and Tube, Proceedings of The Third International Conference on Steel Rolling, Tokyo, Japan, September 2-6, 1985.


3. Kiuchi, Optimum design of fin-rolls and fin-pass-schedule of roll forming of pips, Proceedings of The International Conference on Tomorrows Tube, Tokyo, Japan, July 15-18, 1986.


4. S. Trishevskiy, M. E. Doktorov, Geometrical Parameters of Continuos Smooth Transition Section in Shaping of Curved Profiles and Tubes(From Strip), Russian Metallurgy, No. 1, pp. 50-58, 1974.. H. Ona, T. Jimma, H. Kozono, T. Nakako, Development in CAD for Cold Roll Forming, Proceeding of the Twenty-Sixth MTDR Conference, Manchester: Springer, pp. 49-54, 1986.


5. MoslemiNaeini, M. SalmaniTehrani, S. Mazdak, V. Panahizadeh, Experimental investigation and simulation of the cold roll forming process of the pipe using the finite element analysis method, Solid Mechanics Engineering, pp. 35-48, 2012.(In persian)


6. Zeng, S. Li, Z. Yu, X. Lai, Optimization design of roll profiles for cold roll forming based on response surface method, Materials and Design, Vol. 30, No. 6, pp. 1930-1938, 2009.


7. Brunet, S. Mguil, P. Pol, Modelling of a roll-forming process with a combined 2D and 3D FEM code, Journal of Materials Processing Technology, Vol. 80, pp. 213-219, 1998.


8. Abeyrathna, B. Rolfe, P. Hodgson, M. Weiss, An extension of flower pattern diagram for roll forming, Advanced Manufacturing Technology, Vol. 83, No. 12, pp. 1683-1695, 2016.


9. R. Walker, R. J. Pick, Approximation of the axial strains developed during the roll forming of ERW pipe, Materials Processing Technology, Vol. 22, No. 1, pp. 29-44, 1990.


10. KarimiFirouzjaei, H. MoslemiNaeini, H. Farahmand, B. Abbaszadeh, M.M. Kasaei, Numerical and experimental investigation on flower pattern design methods in cold roll forming process of a high strength steel pipe. Modares Mechanical Engineering, Vol. 17, No. 10 , pp. 259-270, 2018.


11. Bhattacharyya, P. Smith, The development of longitudinal strain in cold roll forming and its influence on product straightness, Advanced Technology of Plasticity, Vol. 1, pp. 422-427, 1984.


12. Lindgren, Cold roll forming of a U-channel made of high strength steel, Journal of Materials Processing Technology, Vol. 186, No. 1, pp. 77-81, 2007.


13. SalmaniTehrani, M. Bahrami, Analytical and numerical study of deformation length in round pipe roll forming, Majlesi Mechanical engineering, pp. 25-35, 2010.


14. Mizutani, K. Nakajima, Development of a new forming process with vertical rolls for electric-resistance-welded pipes, Nippon Steel Corporation, Japan, pp. 895-910, 1981.


15. M. Kasaei, H. MoslemiNaeini, M. SalmaniTehrani, R. AziziTafti, Numerical and experimental investigation of strip deformation in cage roll forming process for pipes with low ratio of thickness/diameter. In AIP Conference Proceedings (Vol. 1315, No. 1, pp. 593-598). American Institute of Physics, 2011.


16. M. Kasaei, H. MoslemiNaeini, R. AziziTafti, M. SalmaniTehrani, Prediction of maximum initial strip width in the cage roll forming process of ERW pipes using edge buckling criterion. Journal of materials processing technology, Vol. 214, No. 2, pp.190-199, 2014.