Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe
In order to reduce the edge waves and defects of the strip in the forming process and obtain better properties of the strip, it is urgent to establish a better flexible cold forming process. In this paper, a finite element model of the production line was established to simulate the forming process,...
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MDPI AG
2025-04-01
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| author | Shengde Hu Junhao Zhao Yu Liu |
| author_facet | Shengde Hu Junhao Zhao Yu Liu |
| author_sort | Shengde Hu |
| collection | DOAJ |
| description | In order to reduce the edge waves and defects of the strip in the forming process and obtain better properties of the strip, it is urgent to establish a better flexible cold forming process. In this paper, a finite element model of the production line was established to simulate the forming process, and the effective stress distribution at the corner of the strip was simulated. The effect of cold working hardening was basically consistent with that calculated by the analytical method and tensile test results. A mathematical model of the maximum normal strain along the tangent direction of the strip’s outer edge of each pass was established. With the constraint conditions that the maximum value of the normal strain value of each pass is less than the critical value and the upper and lower limit of the horizontal value of each test factor, and the maximum value of the normal strain of each pass as the goal, the number of cold forming passes, the bending angle of each pass and the working roll diameter of the roll have been determined. The optimized process parameters were used in the simulations. No edge wave at the strip edge and no “Bauschinger effect” in forming before high-frequency induction welding was found. The method proposed in this paper can optimize the key process parameters before the production line is put into operation, minimize the possible buckling of the strip edge during the forming process, and reduce the possible loss caused by design defects. |
| format | Article |
| id | doaj-art-546ce9b8fb8a401a85fc9f17fe11a08b |
| institution | DOAJ |
| issn | 2075-4701 |
| language | English |
| publishDate | 2025-04-01 |
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| series | Metals |
| spelling | doaj-art-546ce9b8fb8a401a85fc9f17fe11a08b2025-08-20T03:13:52ZengMDPI AGMetals2075-47012025-04-0115445510.3390/met15040455Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded PipeShengde Hu0Junhao Zhao1Yu Liu2Faculty of Materials, Wuhan University of Science and Technology, Wuhan 430081, ChinaFaculty of Materials, Wuhan University of Science and Technology, Wuhan 430081, ChinaFaculty of Materials, Wuhan University of Science and Technology, Wuhan 430081, ChinaIn order to reduce the edge waves and defects of the strip in the forming process and obtain better properties of the strip, it is urgent to establish a better flexible cold forming process. In this paper, a finite element model of the production line was established to simulate the forming process, and the effective stress distribution at the corner of the strip was simulated. The effect of cold working hardening was basically consistent with that calculated by the analytical method and tensile test results. A mathematical model of the maximum normal strain along the tangent direction of the strip’s outer edge of each pass was established. With the constraint conditions that the maximum value of the normal strain value of each pass is less than the critical value and the upper and lower limit of the horizontal value of each test factor, and the maximum value of the normal strain of each pass as the goal, the number of cold forming passes, the bending angle of each pass and the working roll diameter of the roll have been determined. The optimized process parameters were used in the simulations. No edge wave at the strip edge and no “Bauschinger effect” in forming before high-frequency induction welding was found. The method proposed in this paper can optimize the key process parameters before the production line is put into operation, minimize the possible buckling of the strip edge during the forming process, and reduce the possible loss caused by design defects.https://www.mdpi.com/2075-4701/15/4/455flexible cold roll formingthick-wall square and rectangular steel tubeedge buckingmathematical modeloptimization |
| spellingShingle | Shengde Hu Junhao Zhao Yu Liu Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe Metals flexible cold roll forming thick-wall square and rectangular steel tube edge bucking mathematical model optimization |
| title | Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe |
| title_full | Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe |
| title_fullStr | Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe |
| title_full_unstemmed | Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe |
| title_short | Prediction and Prevention of Edge Waves in Continuous Cold Forming of Thick-Wall High-Strength Welded Pipe |
| title_sort | prediction and prevention of edge waves in continuous cold forming of thick wall high strength welded pipe |
| topic | flexible cold roll forming thick-wall square and rectangular steel tube edge bucking mathematical model optimization |
| url | https://www.mdpi.com/2075-4701/15/4/455 |
| work_keys_str_mv | AT shengdehu predictionandpreventionofedgewavesincontinuouscoldformingofthickwallhighstrengthweldedpipe AT junhaozhao predictionandpreventionofedgewavesincontinuouscoldformingofthickwallhighstrengthweldedpipe AT yuliu predictionandpreventionofedgewavesincontinuouscoldformingofthickwallhighstrengthweldedpipe |