Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding.

Christian Egger,Michael Schreiner,Wolfgang Tillmann,Marco Lüchinger

doi:10.3390/ma15031270

Christian Egger, Michael Schreiner + Show 2 more

Open Access

https://doi.org/10.3390/ma15031270

Copy DOI

Abstract

This paper presents a fully coupled three-dimensional finite element model for the simulation of a tube manufacturing process consisting of roll forming and high-frequency induction welding. The multiphysics model is based on the dual mesh method. Thus, the electromagnetic field, the temperature field, the elasto-plastic deformation of the weld bead, and the phase transformations within the material can be simulated for a moving tube without remeshing. A comparison with measurements shows that the geometry of the welded tube and the weld bead, the force on the squeeze rolls, the temperature along the band edges, and the hardness distribution within the heat-affected zone can be simulated realistically.

Highlights

The demand for tubes with high strength and ductility has grown in recent years, especially in the automotive industry
One mesh was generated for calculating the thermal, structural, and phase transformation pass within the tube, while a second mesh was generated for calculating the electromagnetic pass within the coil, the ferrite core, and the surrounding air
The geometry of the tube, the force on the squeeze rolls, the temperature distribution along the band edges, the phase types after welding, and the hardness distribution within the heat-affected zone obtained by means of finite element method (FEM) are presented and compared to measurements

Summary

Introduction

The demand for tubes with high strength and ductility has grown in recent years, especially in the automotive industry. In order to reduce the weight of cars, tubes are often used to replace parts which formerly were made of solid material [1,2]. Around 70% of steel tubes with a diameter of less than 300 mm are fabricated as longitudinal welded tubes [3]. In the tube manufacturing process, a steel band is formed into an open seam tube by roll forming. The remaining slit is closed by welding. The most common welding technique is high-frequency induction (HFI) welding

Methods

Results

Conclusion