Numerical and Experimental Analysis of Forming Rectangular Copper Pipes by Successive Rolling of Round Pipe Filled With Bismuth

Because of their wide application in industries requiring high pressure and temperature, manufacturing square and rectangular pipes have attracted more attention than ever before. There are various methods such as extrusion, tensile and stress for manufacturing square pipes. Another method on which studies have focused in recent years is the re-forming of round pipes in order to turn them into square or rectangular ones. The methods suggested in these researches are all applicable for the manufacture of square pipes without the possibility of manufacturing rectangular pipes. The method introduced in this paper consists of filling the pipe with bismuth and rolling it in three successive stages. In this research, first, the intended process is simulated in Abaqus software, and then a real sample is manufactured by an experimental test. The manufactured sample is checked with regard to its dimensions and is compared with the results obtained from the simulation. The results of the study show that the method of filling the pipe with bismuth and moving it through three rollers is an appropriate method for the manufacture of thin-walled pipes with rectangular cross-section.