Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming
Abstract The increasing application of TA2 titanium profiles in marine and petrochemical industries has spurred in a growing demand for diverse forms, including U‐shaped, rectangular, and tubular thin‐walled profiles. Traditional methods like mechanical subtractive processing and extrusion, despite...
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| Format: | Article |
| Language: | English |
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Wiley
2024-11-01
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| Series: | Engineering Reports |
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| Online Access: | https://doi.org/10.1002/eng2.12913 |
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| author | Mingze Yue Jing Zhang Bing Xiao Gang Chen Qiang Fang Xinxin Tang Biyou Peng |
| author_facet | Mingze Yue Jing Zhang Bing Xiao Gang Chen Qiang Fang Xinxin Tang Biyou Peng |
| author_sort | Mingze Yue |
| collection | DOAJ |
| description | Abstract The increasing application of TA2 titanium profiles in marine and petrochemical industries has spurred in a growing demand for diverse forms, including U‐shaped, rectangular, and tubular thin‐walled profiles. Traditional methods like mechanical subtractive processing and extrusion, despite their prevalence, suffer from high production costs and low efficiency. As a metal sheet forming technology, roll forming stands out for its efficiency, accuracy, and capability of producing complex shapes continuously. Nevertheless, the application of cold rolling to TA2 profiles is challenging primarily due to its low elastic modulus and high yield strength. In view of this, this study employed finite element simulation to analyze the stress and strain distribution during the TA2 roll forming process, aiming to have a better understanding of edge wave defect formation mechanism. Orthogonal experiments were performed to assess the influence of frame spacing, forming speed, roll gap, and downhill amount, on edge wave defects. The findings revealed a predominant influence of the downhill amount. Maintaining the downhill volume at 0.6 times the tube diameter kept the longitudinal strain below 0.9%, effectively mitigating edge wave defects. Implementation of these optimized parameters in an actual TA2 roll forming process confirmed the reliability of the simulations. This study establishes a solid foundation for advancing the TA2 tube cold roll forming process, enhancing the production efficiency of titanium profiles, and shedding some light on current energy conservation and emission reduction. |
| format | Article |
| id | doaj-art-eb9c236173b2421ea6e655bcb31a4f18 |
| institution | OA Journals |
| issn | 2577-8196 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Wiley |
| record_format | Article |
| series | Engineering Reports |
| spelling | doaj-art-eb9c236173b2421ea6e655bcb31a4f182025-08-20T02:18:35ZengWileyEngineering Reports2577-81962024-11-01611n/an/a10.1002/eng2.12913Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll formingMingze Yue0Jing Zhang1Bing Xiao2Gang Chen3Qiang Fang4Xinxin Tang5Biyou Peng6School of Materials Science and Engineering Xihua University Chengdu ChinaSchool of Materials Science and Engineering Xihua University Chengdu ChinaSchool of Materials Science and Engineering Xihua University Chengdu ChinaSchool of Materials Science and Engineering Xihua University Chengdu ChinaState Key Laboratory of Polymer Materials Engineering Sichuan University Chengdu ChinaPanzhihua Iron and Steel Research Institute Panzhihua ChinaSchool of Materials Science and Engineering Xihua University Chengdu ChinaAbstract The increasing application of TA2 titanium profiles in marine and petrochemical industries has spurred in a growing demand for diverse forms, including U‐shaped, rectangular, and tubular thin‐walled profiles. Traditional methods like mechanical subtractive processing and extrusion, despite their prevalence, suffer from high production costs and low efficiency. As a metal sheet forming technology, roll forming stands out for its efficiency, accuracy, and capability of producing complex shapes continuously. Nevertheless, the application of cold rolling to TA2 profiles is challenging primarily due to its low elastic modulus and high yield strength. In view of this, this study employed finite element simulation to analyze the stress and strain distribution during the TA2 roll forming process, aiming to have a better understanding of edge wave defect formation mechanism. Orthogonal experiments were performed to assess the influence of frame spacing, forming speed, roll gap, and downhill amount, on edge wave defects. The findings revealed a predominant influence of the downhill amount. Maintaining the downhill volume at 0.6 times the tube diameter kept the longitudinal strain below 0.9%, effectively mitigating edge wave defects. Implementation of these optimized parameters in an actual TA2 roll forming process confirmed the reliability of the simulations. This study establishes a solid foundation for advancing the TA2 tube cold roll forming process, enhancing the production efficiency of titanium profiles, and shedding some light on current energy conservation and emission reduction.https://doi.org/10.1002/eng2.12913cold roll formingedge wavefinite element simulationTA2 sheet |
| spellingShingle | Mingze Yue Jing Zhang Bing Xiao Gang Chen Qiang Fang Xinxin Tang Biyou Peng Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming Engineering Reports cold roll forming edge wave finite element simulation TA2 sheet |
| title | Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming |
| title_full | Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming |
| title_fullStr | Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming |
| title_full_unstemmed | Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming |
| title_short | Numerical and experimental analysis of edge wave defect control during TA2 circular tube cold roll forming |
| title_sort | numerical and experimental analysis of edge wave defect control during ta2 circular tube cold roll forming |
| topic | cold roll forming edge wave finite element simulation TA2 sheet |
| url | https://doi.org/10.1002/eng2.12913 |
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