JSTP International session. Finite element analysis of a Mannesmann roll piercing process

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1 JSTP International session Finite element analysis of a Mannesmann roll piercing process AFDEX S. H. Sim1, J. M. Cho1, M. C. Lee2, M. S. Joun3 (speaker) S.H Sim J.M. Cho, M.C. Lee, M.S. Joun, Gyeongsang National Univ., Korea

2 Contents Introduction Literature survey Research aim Research objects Finite element analysis Process conditions Predictions Conclusions

3 Research objective Welded pipes and seamless pipes Different manufacturing processes -Welded pipes: Bending, welding -Seamless pipes: Roll piercing, extrusion Characteristics -Welded pipes: Cheap, low reliability -Seamless pipes: Expensive, high reliability, oil or plant industries Rigid-thermoviscoplastic FEM based on tetrahedral finite elements Intelligent remeshing Verification of the approach

4 Literature survey 1) Kazutake Komori, Kouta Mizuno, Study on plastic deformation in cone-type rotary piercing process using model piercing mill for modeling clay, Journal of Materials Processing Technology, , ) Ken-ichiro Mori, Hidenori Yoshimura, Kozo Osakada, Kazutake Komoria, Kouta Mizunob, Simplified three-dimensional simulation of rotary piercing of seamless pip by rigid- plastic finite-element method, Journal of Materials Processing Technology 80-81, , ) Kazutake Komori, Simulation of Mannesmann piercing process by the three-dimensional rigid-plastic finite-element method, International Journal of Mechanical Sciences 47, , ) B. Li, S.H. Zhang, G.L. Zhang, H.Q. Zhang, Prediction of 3-D temperature field of TP2 copper tubes in three-roll planetary rolling process, journal of materials processing technology ( ) ) Z. Pater, J. Kazanecki, J. Bartnicki, Three dimensional thermo-mechanical simulation of the tube forming process in Diescher s mill, Journal of Materials Processing Technology, Vol. 177, pp , ) W. A. Khudheyer, D. C. Barton, T. Z. Blazynski, A comparison between macroshear redundancy and loading effects in 2- and 3-roll rotary tube cone piercers, Journal of Materials Processing Technology, Vol. 65, pp , ) Kazutake Komor, Minoru Suzuki, Simulation of deformation and temperature in press roll piercing, Journal of Materials Processing Technology, Vol. 169, pp , ) Sudhir Chiluveru, Computational Modeling of Crack Initiation in Crossroll Piercing 9) Dr.-Ing. Karl-Heinz Brensing, Düsseldorf Dipl.-Ing. Baldur Sommer, Salzgitter Großrohre GmbH, Steel Tube and Pipe Manufacturing Processes

5 Pipe manufacturing processes Open die Forging Radial Forging Round billet ( <Φ450 ) Square billet (<Φ450) Preforming Press Tube Radial Forging (Mandrel) Hollow Ingot ( <Φ450 ) Mannesmann Process Cutting Heating Piercing Elongating Cooling Sizing Straightening

6 Concept of roll piercing process Conceptual diagram of Mannesmann roll piercing Roll piercing equpiment

7 Diescher s roll piercing process Research objects

8 Process design Work roll Pusher Mandrel Disk

9 Process and material conditions Rolls and tools Item velocity Law of friction Friction factor Initial temp. Work roll Disk Mandrel Pusher 60 rpm Sticking rpm Constant shear friction m/s Material conditions Initial temp. Ambient temp. Heat transfer coef. with dies W/m K Heat transfer coef. with environments W/m K Thermal conductivity 2 W/m K

10 Flow stress of material True stress(mpa) : SUJ(100Cr6) C n Strain rate(/s) True stress-strain rate curves

11 Predictions After 1.0 second 200 mm

12 Predictions After 2.0 seconds 210 mm

13 Predictions After 3.0 seconds 228 mm

14 Predictions After 4.0 seconds 262 mm

15 Comparison with Pater et al

16 Comparison with Pater et al Ellipticity Ellipticity Difference(%)

17 Comparison of temperature

18 Volume vs. Stroke Change of volume during simulation Volume Change (%) Stroke(s)

19 Predictions animation

20 Conclusions Mannesmann roll piercing with Diescher s type guiding disk was simulated by AFDEX 3D -Rigid-Thermoviscoplastic FEM -Intelligent remeshing with tetrahedral elements Comparison with Pater et al. -Good agreement in term of deformed shape -Much more reliable predictions

Available online at ScienceDirect. Procedia Engineering 81 (2014 )

Available online at ScienceDirect. Procedia Engineering 81 (2014 ) Available online at www.sciencedirect.com ScienceDirect Procedia Engineering 81 (2014 ) 197 202 11th International Conference on Technology of Plasticity, ICTP 2014, 19-24 October 2014, Nagoya Congress