Effects of Tool-Workpiece Friction Condition on Energy Consumption during Piercing Phase of Seamless Tube Production

Abstract

During the hot piercing phase of seamless tube production, friction and contact conditions between tools and workpiece significantly influence final product quality and energy consumption. The friction effects on the production of high alloyed steels like Super Cr13 steel are critical. This study analyses the effect of different friction conditions at the workpiece-tool interface in the piercing of Super Cr13 steel bars to minimize total energy consumption in such a manufacturing process. For this purpose, a three-dimensional finite element method (FEM) is employed to simulate and analyze the piercing process. The variety of tools (plunge, rollers, and Diescher disks) and contact conditions lead to differences in the applied stress at different workpiece areas. Consequently, various friction models and friction coefficients were selected for different interfaces. The relation between strain rate, temperature, and geometry of pierced tube are discussed, and the selected friction relation with total power and energy consumption is presented. Experimental tests have been used for FEM validation and result analysis, and finally, the most effective conditions with lower total energy consumption are presented.