National University of Science and Technology “MISiS” (Moscow, Russia):

A. P. Kolikov, Dr. Eng., Prof., Chair of Metal Forming, e-mail: apkolikov@mail.ru

All-Russian Scientific and Research Institute of Tube Industry — RosNITI (Chelyabinsk, Russia):
D. Yu. Zvonarev, Cand. Eng., Head of Helical Rolling Laboratory

Staryi Oskol Technological Institute named after A. A. Ugarov — affiliate of National University of Science and Technology “MISiS” (Staryi Oskol, Russia):
I. M. Taupek, Cand. Eng., Associate Prof.

The developed methods are aimed on implementation in the form of algorithms and mathematical models; they allow to determine the deformation zone boundaries, the width and radius of the sheet side edge at every operation of the next billet forming in a step forming press by calculation in the magnitude of the depth of punch lowering and inclination relative to the longitudinal axis and longitudinal bending of the supports. This made it possible to calculate the depth of the punch lowering without the straight section formation and to obtain the defect-free profile of a tube billet in terms of geometry. Using the DEFORM-3D software package, a mathematical simulation of the plastic forming processes of the tube billet metal in the step forming press is conducted. According to the simulation results, it was concluded that distribution of residual (tensile) stresses is uneven in all control points in different sections of the J-shaped profile, which is formed in the step forming press. According to the results of simulation of the final forming process, a pattern of the residual stresses distribution in the initial, intermediate and final periods of the assembling the tube billet into the O-shaped profile and welding was obtained. It is shown that when expanding the pipe, the non-uniformity of the stress-strain state and residual stresses are reduced, resulting in the decrease in the out-ofroundness and equalization of the diameter along the tube length to the values meeting the customer requirements. The results of mathematical simulation implemented in the form of mathematical models with use of the computer calculation program enable to calculate the geometric dimensions of the tube billet plastic forming throughout the technological “sheet-to-pipe” process and, thus, determine the compliance of the geometric dimensions of 1.420 mm diameter tubes with current regulatory requirements documents.

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