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.
Highlights
Smart Manufacturing Technology R&D Group, Korea Institute of Industrial Technology, Division of Coast Guard Studies, College of Maritime Sciences, National Korea Maritime and Ocean University, Busan 49112, Korea
In the cold pilger rolling process, the load distributions and Q factor were found to vary according to the die groove shape
We developed a die groove shape design method and rolling force prediction model according to the die groove shape in the cold pilger rolling process to produce seamless pipes
Summary
The cold pilger rolling process is an incremental method for manufacturing metal tubes with uniform cross-sections using initial tubes, such as semi-seamless and seamless pipes. This pilger rolling process is called roto-rolling and in which a pipe is passed between the rocking set of the outer die and the hardened mandrel on the inside of the pipe. Compared to manufacturing the same hollow-type product by a cold drawing process, the cold pilger rolling process can achieve a cross-sectional reduction of approximately 90% in a single working cycle. The advantages of this process include a short working time, increased material utilization efficiency by reduced material use, and the rationalized spatial layout of the equipment [1,2]
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