DEVELOPMENT OF DETERMINING METHODS FOR THE PARAMETERS OF BILLETS AT EDGE BENDING ON THE TESA 1420 LINE

The results analysis of numerical and experimental studies on edge bending at the 1420 line was performed. It determined the influence of about-edge zone of the billet on the quality of finished welded pipe. It was found that the geometry of the billet's edges effects further on the billet's parameters on preform zone of molding presses, assembly and welding mill and mechanical expander. The contact and non-contact areas of about-edge zone of the billet and the tool of edge bending press were determined. It was revealed that the deviation in the edge geometry effects further also on the quality of weld joint geometry and about-edge zone after welding and assemblage. These deviations later lead to such defects in the about-edge zone like longitudinal edges of mixing and deviation from the theoretical circle. A number of mathematical and experimental studies was performed on the geometric parameters of billets at edge-bending and it was stated that the about-edge zone of pipe billet under loading has form of the deforming tool, as pipe billet at loading covers it. Deforming tool of the edge-bending press has involute profile, i.e., bent part of the edge in the contact area should have involute profile during loading. To identify the nature of the distribution of pipe billet curvature the authors have investigated the pipe billets deformation using modem computer systems at the area of edge-bending. The results of the studies have shown: the contact area of the deforming tool and pipe billet, coordinates of the loop across the pipe billet width. Contact area the billet and deforming tool is about-edge zone of pipe billet which is in contacts with the lower deforming tool - the die and the upper deforming tool - the punch. According to the research it was found that the about-edge zone of the pipe billet does not completely cover the upper deforming tool and has both contact and non-contact portions, therefore, the curvature distribution pattern of the billet edge and the punch profile differ, and blown calculation methods need to be improved. The main parameters of billets at edge-bending were determined. A comparative analysis of the measurements results of edge geometry was made using experimental and computational methods.

1. Samusev S.V., Bol'dt V.V. Computation of corrugation mechanism of tube stock at production of longitudinal welded tubes. lzvestiya lUZov. Chernaya metallurgiya = lzvestiya. Ferrous Metallurgy.2010. no. 11, pp. 22-24. (In Russ.).

2. Samusev S.V., Tovmasyan M.A., Hlybov O.S. Shaping of pipe blanks in the edge-bending press of the TESA 1420 pipe-electrowelding line. Steel in Translation. 2014, no. 8, pp. 329-332.

3. Moshnin E.N. Issledovanieplasticheskogo izgiba. Sb. TsNIITmash, kn. 62 [Plastic bending research. Coll. of TSNIITmash. Book 62]. Moscow: Mashgiz, 1954, 458 p. (In Russ.).

4. Moshnin E.N. Gibka i pravka na rotatsioimykh mashinakh [Bending and straightening on rotary machines], Moscow: Mashinostroenie, 1967, 272 p. (In Russ.).

5. Fan Lifeng, Gao Ying, Li Qiang, Xu Hongshen. Quality control on crimping of large diameter welding pipe. Chinese Journal of Mechanical Engineering. 2012, vol. 25, Issue 6, pp. 1264-1273.

6. Tsuru E., Akata J., Shinohara K., Uoshida T. Numerical and experimental evaluation of formability and buckling resistance for high strength steel UOE pipe. Zaiiyo to Prosesu = CAMP ISIJ. 2010, vol. 23. no. 1(2). pp. 297-300."

7. Tomlenov A.D. Mekhanika protsessov obrabotki metallov davlenieni [Mechanics of metal forming processes], Moscow: Mashgiz. 1963. 236 p. (In Russ.).

8. Avitzur B. Metal forming: processes and analysis. New York: McGraw-Hill. 1968. 500 p.

9. Storozhev M.V.. Popov E.A. Teoriya obrabotki metallov dcwleniem. Uchebnik dlya vuzov [Theory of metal forming: Textbook for universities], Moscow: Mashinostroenie. 1971. 424 p. (In Russ.).

10. Ren Qiang. Li Dayong. Zhou Tianxia etc. The simulation of UOE pipe forming by three-dimensional finite element method. Journal of Netshape Forming Engineering. 2011. no. 3(6). pp. 80-84 (in Chin.).

11. Samusev S.V.. Velichko A.A.. Lyuskin A.V.. Andreev Yu.P.. Vorontsov A.N. Calculating methods for the parameters of deformation of pipe billet on the TESA 1420 line of CJSC “IPM”. Izvestiya VUZov. Chernaya metallurgiya = Izvestiya. Ferrous Metallurgy. 2009. no. 5. pp. 36-40. (In Russ.).

12. Matveev Yu.M. Teoreticheskie osncny proizvodstva svamykh trub [Theoretical basics of welded pipes production], Moscow: Metallurgiya. 1967. 167 p. (In Russ.).

13. Malinin N.N. Prikladnaya teoriya plastichnosti i polzuchesti [Applied theory of plasticity and creep], Moscow: Mashmnostroenie 1968. 399 p. (In Russ.).

14. Palumbo G.. Tricarico L. Effect of forming and calibration operations on the final shape of large diameter welded tubes. Journal of Materials Processing Technology’. 2005. vol. 164-165(5). pp. 1098.

15. Raffo J.. Toscano R. G.. Mantovano L.. Dvorkin E. N. Numerical model of UOE steel pipe: forming process and structural behavior. Mecanica Сomputacional. 2007. vol. 26. no. 10. pp. 317-333.

16. Zhigulev G.P.. Samusev S.V.. Fadeev V.A.. Faizulaev F.Kh. Calculation of energy-power parameters of bending process in production of welded pipes for gas pipelines. Izvestiya VUZov. Chernaya metalluigiya = Izvestiya. Ferrous Metallurgy. 2014. vol. 57. no. 7. pp. 39^12. (In Russ.).

17. Shiro Kobayashi. Soo-ik Oh. Taylan Altan. Metal forming and the finite-element method. New York: Oxford University Press. 1989. pp. 145-151.

18. Il'yushin A.A. Trudy. T. 2. Plastichnost' [Proceedings. Vol. 2. Plasticity], Il'yushina E.A.. Korotkina M.R. eds. Moscow: Fizmatlit. 2004. 480 p. (In Russ.).

19. Feodos'ev V.I. Soprotivlenie materialov: uchebnik dlya vuzov [Strength of materials: Textbook for universities], Moscow: Izd-vo MGTU im. N.E. Baumana. 2003. 592 p. (In Russ.).

20. Ren Qiang. Li Dayong. Zhou Tianxia. etc. The simulation of UOE pipe forming by three-dimensional finite element method. Journal of Netshape Forming Engineering. 2011. vol. 3(6). pp. 80-84.

21. Herynk M.D.. Kyriakides S.. Onoufriou A.. Yun H.D. Effects of the UOE/UOC pipe manufacturing processes on pipe collapse pressure. International Journal of Mechanical Sciences. 2007. vol. 49(5). pp. 533-553.