Finite element modeling of the forming operations of the plate-pipe conversion, taking into account the deformation of the rolling tool and welding deformations

The work is devoted to the study of forming operations used in the production of large diameter pipes (LDPE) using a three-roll bending machine (rollers). The Marc.Mentat software package has developed finite element models of the processes of roller forming, edge bending, assembly, welding and pipe expansion. The object of the study is a pipe with a diameter of 1420 mm with a wall thickness of 21.6 mm and a length of 12 m made of steel of strength group X70. Thin-walled (Shell) elements were used in the pipe model, which made it possible to carry out the modeling process relatively quickly without significant loss of calculation accuracy. A comprehensive finite element modeling of the forming operations of the sheet-pipe conversion has been carried out, taking into account the deformation of the upper roll of the bending machine and welding deformations. It is established that at each technological operation, an inhomogeneous stress-strain state (VAT) occurs in the pipe, which affects the final geometry of the pipes. It is shown that the greatest heterogeneity of VAT in the pipe is introduced by roll forming and edge bending. The developed complex finite element model can be used by researchers and technologists to calculate the settings of technological equipment and energy-strength parameters of forming operations.