Development of Roll-Less Forming Process for Ultra-Thin Wall Welded Pipe Production

The unique combination of high strength and low temperature toughness on heavy wall thickness coils allows higher operating pressures in large diameter spiral welded pipes and could represent a 10% reduction in life cycle cost on long distance gas pipe lines. One of the current processing routes for these high thickness grades is the thermo-mechanical controlled processing (TMCP) route, which critically depends on the austenite conditioning during hot forming at specific temperature in relation to the aimed metallurgical mechanisms (recrystallization, strain accumulation, phase transformation). Detailed mechanical and microstructural characterization on selected coils and pipes corresponding to the X80M grade in 24 mm thickness reveals that effective grain size and distribution together with the through thickness gradient are key parameters to control in order to ensure the adequate toughness of the material. Studies on the softening behavior revealed that the grain coarsening in the mid-thickness is related to a decrease of strain accumulation during hot rolling. It was also observed a toughness detrimental effect with the increment of the volume fraction of M/A (martensite/retained austenite) in the middle thickness of the coils, related to the cooling practice. Finally, submerged arc weldability for spiral welded pipe manufacturing was evaluated on coil skelp in 24 mm thickness. The investigations revealed the suitability of the material for spiral welded pipe production, preserving the tensile properties and maintaining acceptable toughness values in the heat-affected zone. The present study revealed that the adequate chemical alloying selection and processing control provide enhanced low temperature toughness on pipes with excellent weldability formed from hot rolled coils X80 grade in 24 mm thickness produced at ArcelorMittal Bremen.

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Finite Element Simulation and Experimental Study on Blow Forming of Plastic Cups

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.148-149.1319 ◽

2011 ◽

Vol 148-149 ◽

pp. 1319-1322

Author(s):

Xiao Hu ◽

Yi Sheng Zhang ◽

Hong Qing Li ◽

De Qun Li

Keyword(s):

Finite Element ◽

Thickness Distribution ◽

Viscoelastic Model ◽

Engineering Practice ◽

Fe Model ◽

Thin Wall ◽

Forming Process ◽

Element Simulation ◽

Physically Based ◽

Set Up

Blow forming process of plastic sheets is simple and easy to realize, thus, it is widely used for plastic thin-wall parts. In the practical production, an effective method is needed for the preliminary set-up of process parameters in order to achieve accurate control of thickness distribution. Thus, a finite element method (FEM) code is used to simulate blow forming process. For better description of complex material theological characteristics, a physically based viscoelastic model (VUMAT forms Buckley model) to model the complex constitutive behavior is used. Nonlinear FE analyses using ABAQUS were carried out to simulate the blow forming process of plastic cups. The actual values at different locations show a satisfactory agreement with the simulation results: as a matter of fact the error along the cell mid-section did not exceed 0.02 mm on average, corresponding to 5% of the initial thickness, thus the FE model this paper can meet the requirements of the engineering practice.

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Numerical Simulation and Process Analysis for Injection Forming about the Thin-Wall Conical Centrifugal Disc

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.941-944.2298 ◽

2014 ◽

Vol 941-944 ◽

pp. 2298-2304

Author(s):

Jian Hua Zhou ◽

Li Guo Liu ◽

Xue Ming He

Keyword(s):

Numerical Simulation ◽

Mathematical Model ◽

Glass Fiber ◽

Fiber Orientation ◽

Process Analysis ◽

Centrifugal Separation ◽

Thin Wall ◽

Forming Process ◽

Thin Wall Part

A numerical simulation mathematical model and sloved method about injection forming for thin-wall part was established. Based on it, Simulation of the injection forming process of centrifugal separation disc. Through the simulation of forming process for PA66 and PA66+30%GF two kinds of materials, realized the injection forming for centrifugal separation disc using PA66+30%GF. Through the anisotropy of glass fiber orientation, improve the stiffness and toughness for centrifugal disc.

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Investigation into Influence of Pre-Forming Depth on Multi-Stage Hydrodynamic Deep Drawing of Thin-Wall Cups with Stepped Geometries

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.457-458.1219 ◽

2012 ◽

Vol 457-458 ◽

pp. 1219-1222 ◽

Cited By ~ 3

Author(s):

Yu Zhu ◽

Min Wan ◽

Ying Ke Zhou ◽

Qing Hai Liu ◽

Nan Song Zheng ◽

...

Keyword(s):

Deep Drawing ◽

Failure Modes ◽

Thickness Distribution ◽

Steel Part ◽

Drawing Ratio ◽

Thin Wall ◽

Forming Process ◽

Hydrodynamic Deep Drawing ◽

Multi Stage ◽

Thin Walled

Hydrodynamic deep drawing (HDD) is an effective method for manufacturing complicated and thin-walled parts. Aiming at the forming process of the stainless steel part with 0.4 mm thick and complex stepped geometries, the technology scheme of multi-stage HDD assisted by conventional deep drawing (CDD) is proposed in consideration of wrinkling and destabilization in the unsupported region of the conical wall, and finite element models are built. As a key process parameter, pre-forming depth on the quality of the parts is explored with assistance of numerical simulations and verification experiments. Furthermore, the failure modes, including wrinkling and fracture during forming process are discussed; meanwhile, the optimum pre-forming depth is realized. The results indicate that the technological method is proven to be feasible for integral forming of thin-walled parts with a large drawing ratio and stepped geometries; moreover, the parts with uniform thickness distribution and high quality are successfully formed by adopting optimum pre-forming depth.

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Deformation Property and Suppression of Ultra-Thin-Walled Rectangular Tube in Rotary Draw Bending

Metals ◽

10.3390/met10081074 ◽

2020 ◽

Vol 10 (8) ◽

pp. 1074

Author(s):

Kunito Nakajima ◽

Noah Utsumi ◽

Yoshihisa Saito ◽

Masashi Yoshida

Keyword(s):

Wall Thickness ◽

Weight Reduction ◽

Electromagnetic Waves ◽

Thin Wall ◽

Rotary Draw Bending ◽

Forming Process ◽

Deformation Properties ◽

Rectangular Tube ◽

Lateral Constraint ◽

Draw Bending

Recently, miniaturization and weight reduction have become important issues in various industries such as automobile and aerospace. To achieve weight reduction, it is effective to reduce the material thickness. Generally, a secondary forming process such as bending is performed on the tube, and it is applied as a structural member for various products and a member for transmitting electromagnetic waves and fluids. If the wall thickness of this tube can be thinned and the bending technology can be established, it will contribute to further weight reduction. Therefore, in this study, we fabricated an aluminum alloy rectangular tube with a height H0 = 20 mm, width W0 = 10 mm, wall thickness t0 = 0.5 mm (H0/t0 = 40) and investigated the deformation properties in the rotary draw bending. As a result, the deformation in the height direction of the tube was suppressed applying the laminated mandrel. In contrast, it was found that the pear-shaped deformation peculiar to the ultra-thin wall tube occurs. In addition, axial tension and lateral constraint were applied. Furthermore, the widthwise clearance of the mandrel was adjusted to be bumpy. As a result, the pear-shaped deformation was suppressed, and a more accurate cross-section was obtained.

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Finite Element Analysis of Cold Expanding of Hollow Thin-Wall Tube

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.460-461.44 ◽

2011 ◽

Vol 460-461 ◽

pp. 44-47

Author(s):

Wei Hua Kuang

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Stress Distribution ◽

Equivalent Stress ◽

Element Model ◽

Thin Wall ◽

Forming Process ◽

Element Analysis ◽

Simulation Step ◽

The Finite Element Analysis

The cold expanding diameter process was simulated by the software of DEFORM. The finite element model of tube and dies were built. The object position definition, the inter object setting, movement definition and simulation step were correctly set. The deformation, total velocity distribution and equivalent stress distribution were predicted. The numerical simulation results showed that the finite element analysis could exactly describe the plastic deformation and stress distribution during the forming process.

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Application of Viscous Pressure Forming in Aeronautics and Astronautics

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.989-994.3306 ◽

2014 ◽

Vol 989-994 ◽

pp. 3306-3309

Author(s):

Ji Guang Li ◽

Jie Gang Zhang ◽

Jing Ping Liu ◽

Rui Feng Zhao ◽

Yang Li ◽

...

Keyword(s):

Basic Principle ◽

High Strength ◽

Thin Wall ◽

Forming Process ◽

Variable Diameter ◽

Thin Walled ◽

Viscous Pressure ◽

Viscous Pressure Forming ◽

Thin Wall Part ◽

Super Alloy

Viscous pressure forming (VPF) is a new developed sheet soft-punch forming process in 1900s. The basic principle and characteristics of VPF are described. The applications of VPF technologies of nickel-based super-alloy corrugated thin-walled part, asymmetrical thin-wall part with variable diameter, super-alloy thin-walled part with variable diameters, corrugated thin-walled part with larger diameter and small section are presented. The results show that VPF is suitable for the forming of parts with high strength, low plasticity, super thin-wall and complex shaped.

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Reducing Metal Consumption During Pipe Production on Electric-Welded Pipe Mills

Metallurgist ◽

10.1007/s11015-014-9963-6 ◽

2014 ◽

Vol 58 (7-8) ◽

pp. 600-602

Author(s):

I. T. Totskii ◽

A. S. Anan’ev ◽

O. L. Markin ◽

A. N. Shchennikov ◽

T. V. Tolmacheva

Keyword(s):

Pipe Production ◽

Metal Consumption ◽

Welded Pipe

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The Analysis to the Forming Process of Welded Pipe by Non-Linear Finite Element Method

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.291-294.585 ◽

2011 ◽

Vol 291-294 ◽

pp. 585-589

Author(s):

Jin Duo Ye ◽

Zhe Li ◽

Yu Ting Xi

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Numerical Modeling ◽

Roll Forming ◽

Parameter Study ◽

Forming Process ◽

Whole Process ◽

Non Linear ◽

Welded Pipe ◽

Element Method

Understanding the mechanism of the forming of the welded pipe may help the engineer to design the shape of forming rollers and forming technology. It is hard to study the forming process of the welded pipe by both the method of experiment and numerical modeling because of too much nonlinear factors included in the forming process such as elastic-plastic large deformation and non linear contact. Although many research works have been conducted in this field by the method of experiment or numerical modeling, but few of the works deal with the whole forming process of the welded pipe. The main difficulties in the numerical modeling are of huge computational labor time, witch has been over the ability of the hardware and software of the computer. The whole process of roll forming of welded pipe has been simulated by nonlinear finite element method with ANSYS and LS-DYNA solver, the distribution of both stresses and strains have been got successfully. Mapping meshes and the rigid models for rollers have been used in the analysis in order to decrease the number of the elements. Numerical results and parameter study have shown that the forming rollers of both the level and vertical are the key factors to the forming process. It is believe that the method used in the paper can also be used to study the forming process of both cage roll forming and flexible forming.

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