FEM Simulation and Experimental Investigation of Reshaping of Thick Tubes in Different Passes

Tajyar, Ali; Abrinia, Karen

doi:10.1115/msec2009-84196

Cited by 5 publications

(5 citation statements)

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“…The C3D8R allows a fast calculation while assuring precise results, as shown in the previous work of Zou et al [12] for the roll forming process, Tajyar et al [13] for the non-circular tube forming process, Cai et al [14] for the roll forming process, Yang et al [15] and Guo et al [16] for the ring rolling process.…”

Section: Numerical Model Implementationmentioning

confidence: 87%

Wear-caused deflection evolution of a slide rail, considering linear and non-linear wear models

Kim

Quagliato

Park

et al. 2017

J. Phys.: Conf. Ser.

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Quantitative correlation between slip patterning and microstructure during tensile elongation in 6xxx series aluminum alloy S Ghodrat, H Pirgazi and LAI Kestens -Experimental-numerical evaluation of a new butterfly specimen for fracture characterisation of AHSS in a wide range of stress states I Peshekhodov, S Jiang, M Vucetic et al. Abstract. The research presented in this paper details an experimental-numerical approach for the quantitative correlation between wear and end-point deflection in a slide rail. Focusing the attention on slide rail utilized in white-goods applications, the aim is to evaluate the number of cycles the slide rail can operate, under different load conditions, before it should be replaced due to unacceptable end-point deflection. In this paper, two formulations are utilized to describe the wear: Archard model for the linear wear and Lemaitre damage model for the nonlinear wear. The linear wear gradually reduces the surface of the slide rail whereas the nonlinear one accounts for the surface element deletion (i.e. due to pitting). To determine the constants to use in the wear models, simple tension test and sliding wear test, by utilizing a designed and developed experiment machine, have been carried out. A full slide rail model simulation has been implemented in ABAQUS including both linear and non-linear wear models and the results have been compared with those of the real rails under different load condition, provided by the rail manufacturer. The comparison between numerically estimated and real rail results proved the reliability of the developed numerical model, limiting the error in a ±10% range. The proposed approach allows predicting the displacement vs cycle curves, parametrized for different loads and, based on a chosen failure criterion, to predict the lifetime of the rail.

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Section: Numerical Model Implementationmentioning

confidence: 87%

Wear-caused deflection evolution of a slide rail, considering linear and non-linear wear models

Kim

Quagliato

Park

et al. 2017

J. Phys.: Conf. Ser.

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“…Both fine and coarse zones are meshed utilizing the C3D8R hexahedron elements, which allows calculating precise results while reducing the overall computational time, as demonstrated by Zou et al 18 for the roll forming process, Tajyar and Abrinia 19 for the non-circular tube forming process, Cai et al 20 for the roll forming process, and Yang et al 21 and Guo and Yang 22 for the ring rolling process. The C3D8R is a general-purpose linear brick element, with reduced integration, in which the integration point is located at the center of the element volume.…”

Section: Erw Fe Process Chain Analysismentioning

confidence: 99%

Numerical investigation on the influence of the electro-resistance welding pipe manufacturing process on the local variation of the yield strength of the pipe material

Quagliato

Kim

Park

et al. 2020

Advances in Mechanical Engineering

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In the present research work, a finite element model of the electro-resistance welding pipe forming process chain is developed using the ABAQUS/Explicit software. The forming process, which is composed of 22 tandem roll stations, has been fully modeled in the developed finite element simulation. In order to account for the Bauschinger effect on the pipe material properties as a consequence of the loading and the unloading during the process, a non-linear kinematic hardening model has been utilized in all the proposed finite element simulation models. The constants for the non-linear kinematic hardening model were estimated by means of cyclic experiments on the K55 steel pipe material. In order to properly simulate the electric arc welding (electro-resistance welding) operation, the ABAQUS welding interface has been utilized to account for the joining between the two edges of the formed pipe as well as to assess the influence of the welding-induced temperature field on the residual stresses on the pipe material. The sizing operation, which is the final station of the electro-resistance welding process, has been also accounted in the developed finite element method model and is composed of six tandem rolls. To export and import the results between two different modules, a mapping strategy has been utilized and allowed exporting the element results, in terms of stress, strain, and temperature, and importing them into the following simulation module. Finally, in order to estimate the influence of each process station on the yield strength of the material, a finite element simple tension test simulation has been implemented in ABAQUS/Static, mapping the results of each station on the tensile specimen. This mapping operation allowed to estimate the yield stress of the material after each of the three process stations, a consequence of the residual stresses present in the material, and has been carried out on eight circumferential locations around the pipe, evenly spaced with a 22.5° angle. The model has been validated by comparing the geometrical results, in terms of average pipe diameter and thickness, obtained from the finite element model with those of the relevant industrial production, showing deviations equal to 1.25% and 1.35% (forming) and 1.29% and 1.43% (sizing), respectively, proving the reliability of the proposed process chain analysis simulation. The results will show how the process-induced residual stresses arising on the pipe material make the material yield strength to vary from station to station as well as having different values along the circumferential direction of the pipe.

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“…The technological process takes place thanks to the push of a reel, disposed upstream of the process, that forces the tube to pass in the four stands of rolls. Previously, several authors [12][13][14][15][16][17][18] analyzed how to simulate, using nonlinear FEM code, a metal strip behavior in the CRF process. The developed models take into account all of the non-linearities present in the rolling problem: material, geometric, boundary, and heat transfer.…”

Section: Fig 1: a Typical Crf Processmentioning

confidence: 99%

Validation of a FEM Model for the Simulation of the Cold Roll Forming Process

Formisano

Minutolo

Caraviello

et al. 2015

KEM

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Cold roll forming is a process for plastic deformation, which allows realizing profiles, with a defined section and established length, from the plastic deformation of a metal sheet. The sheet is induced to cross several stands of rolls, arranged along the same axis of advancing. The rolls induce plastic deformation in the sheet and then lead it to the desired geometric configuration. In order to control the geometric parameters of the plate during the profiling, it was created a FEM model to simulate the final stage of the technological process, developed by an industrial production line of a company located in Naples (Italy), that sells tubes with several cross sections. In this phase, the semi-finished product, having a circular cross section, is forced to cross through four stands of rolls. In this way, it changes the geometric condition of the cross section from circular to square. The model was carried out using a non-linear calculation code, which allows analyzing the parameters of interest in the different process steps. The results, obtained numerically, were compared with the experimental ones through the measurement of five specimens, obtained directly from technological process. The values of percentage deviation, regarding the external dimension and the thickness, for each step of advancement, do not exceed the 3% of error. Then, the analysis results denote the capability to simulate the cold roll forming process using finite element method.

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FEM Simulation and Experimental Investigation of Reshaping of Thick Tubes in Different Passes

Cited by 5 publications

References 0 publications

Wear-caused deflection evolution of a slide rail, considering linear and non-linear wear models

Wear-caused deflection evolution of a slide rail, considering linear and non-linear wear models

Numerical investigation on the influence of the electro-resistance welding pipe manufacturing process on the local variation of the yield strength of the pipe material

Validation of a FEM Model for the Simulation of the Cold Roll Forming Process

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