Profile Design of the Grooved Die and Rolling Force Prediction in the Cold Pilger Rolling Process

Abstract

The objective of this study was to design the die groove profile and predict the rolling force produced when employing the variable curvature rolls and mandrel for manufacturing seamless pipes using the cold pilger rolling process. The parameters of the key process design were the diameter of the initial tube and final product, as well as the feed amount, reduction area, principal deformation zone, and roller radius. The rolling forces during the pilger rolling process were theoretically calculated to enable their prediction, and the characteristics of the cold pilger rolling process were identified. The calculated values were in close agreement with the experimental data. The die groove design is important in the prediction process because the dimensional accuracy of the tubes and the life of the dies are highly dependent on this design. The presented design method can be successfully applied to fulfill this objective. The tube shape and adequate tolerance can be attained by using the proposed design method. The mechanical properties of the pipe are evaluated by calculating the Q factor.