Seversky Pipe Plant, Polevskoy, Russia
O. A. Panasenko, Head of the Tube Rolling Laboratory, Research Center, e-mail: PanasenkoOA@stw.ru

Ural Federal University named after the first President of Russia B. N. Yeltsin, Yekaterinburg, Russia
A. O. Khalezov, Postgraduate Student, Dept. of Metal Forming, e-mail: alekssanja633@mail.ru
D. Sh. Nukhov, Cand. Eng., Associate Prof., Dept. of Metal Forming, e-mail: d.s.nukhov@urfu.ru
E. A. Grigoriev, Bachelor’s Student, Dept. of Metal Forming, e-mail: egorik.grigirik@mail.ru

The study of metal forming in the processes of screw rolling and piercing of continuously cast workpieces is a non-trivial task. The theoretical description of these processes by classical analytical methods involves the adoption of various kinds of assumptions and simplifications. Currently, numerical methods of finite element modeling are widely used for the analysis of metal forming processes as an alternative to simplified analytical solutions. Due to the rejection of assumptions caused by mathematical difficulties, numerical methods have an advantage over analytical methods, although there are difficulties in determining the boundary conditions, the nature of the dependence of metal deformation resistance on the thermomechanical parameters of the plastic deformation process, etc. The paper considers the application of a method for evaluating the shape of a billet during screw piercing, taking into account the complex nature of the metal flow. The authors propose to take into account the influence of the “overflow” of metal at the entrance and exit from the local deformation area, and based on this, adjust the calculation of the width of the contact surface using finite element modeling of the screw piercing process. It was found that the analytical formulas greatly decrease the result of determining the width of the contact surface of the metal with the roll. The deviation of the results of the analytical calculation of the width of the contact surface from the results obtained during the industrial experiment was more than 40 %. The results of calculating the length of the contact surface, obtained using the proposed methodology using the QFORM program, differ from the result of physical modeling by 1.0 and 1.4 %, and the width of the contact surface is less than 10 %. Comparison of the calculated and experimental values of the contact surface area of the metal with the roll showed an decrease of the calculation by 5.5 %, obtained using the proposed methodology using the QFORM program.
The research was carried out with the financial support of the Ministry of Science and Higher Education of the Russian Federation (theme № FEUZ-2023-0015).

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