Analysis of Roll Wear in Reshaping Using Finite Element Simulation

Reshaping process is a widely used method for producing tubes with non-circular cross sections. Owing to the friction between pipe and rolls, initial round pipe moves forward and consequently, it gradually formed into square or rectangular one. In practice, geometric profile of the rolls will be changed after a while. These changes would be detrimental the production of faultless products. Therefore, in this paper the reshaping process is studied considering wear phenomena on the rolls. This study is a co-operation with a related industry at which square tubes are produced using reshaping process. In order to investigate the production line, considering industrial datasheets, the process is modeled by means of a commercial FEM package, ABAQUSExplicit. The reshaping process is simulated as a 3D model and subsequently the sustainable regions to wear are investigated. The influences of significant parameters such as material and thickness of strip, as well as friction coefficient on the worn area, are studied. At the end, the FEM reults are comprised with the experiments reults and a good consistency between them is seen.