Abstract
Flexible forming excellent (FFX) forming of electric resistance welding (ERW) pipe is an advanced roll forming method. In order to understand FFX forming mechanism and set reasonable roll parameters, five-point bending process and springback process for preforming section of ERW pipe FFX forming are analyzed. Under various assumptions, the bending process of sheet metal is divided into full elastic bending stage and elastic-plastic bending stage by analyzing the forming law and simplifying the contact state model of roll bending process. Based on the theory of plane bending theory, the five-point bending springback model is established. Mathematical expressions of bending curvature and rotation angle of arbitrary particle on plate under arbitrary state are derived. The curvature calculation formulas of each particle on plate after springback are obtained, and then the calculation formulas of bending angle and rebound angle after springback are obtained. The theoretical analysis results are verified by the wide plate five-point bending experiment. The theoretical value of springback angle agrees well with the experimental results. The maximum deviation of springback angle is 0.42 degrees. The results show that the five-point bending model is reasonable. It provides theoretical support for the preforming model of flexible roll forming.
Highlights
In recent years, electric resistance welding (ERW) pipe products have caused extensive concern [1, 2]
High-grade ERW pipes are mainly used for oil wells, submarine pipelines, oil and gas pipelines, some special purpose professional pipes, etc
The forming process for producing high-grade ERW pipes is mainly divided into two types: the first one is pressure forming, such as JCO forming and UOE forming
Summary
ERW pipe products have caused extensive concern [1, 2]. High-grade ERW pipes are mainly used for oil wells, submarine pipelines, oil and gas pipelines, some special purpose professional pipes, etc. Zhao et al [17] established the complex equation of planar bending elastic and successfully applied it to the expanding and setting round process On this basis, Zhao et al carried out some research on the prediction and control of the springback in setting round process for pipe-end of large pipe and the springback analysis of profile plane stretch–bending in the loading method of pretension and moment [18, 19]. Based on the classical elastic-plastic bending theory and the analytical theory of three-point bending and fourpoint bending of JCO welded pipe forming [21, 22], the in-depth study of the bending and springback process of the preforming process is carried out, and the mechanical model of the five-point bending springback of the plate is established It lays a theoretical foundation for realizing the prediction model of roll position parameters of the preformed section in FFX intelligent control system of ERW pipe
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