Research on Heating Temperatures and Sizes of Hot Forming of Pipe Caps (Part One)
Posted: 05/24/2021 11:39:45 Hits: 27
Abstract
Using DEFORM-3D finite element forming analysis software to conduct a numerical simulation on the hot forming of the pipe cap, and the optimal heating temperature and size of the hot forming of the pipe cap were obtained. The research results have a certain guiding effect on the design and manufacture of caps.
Pipe caps are widely used in petroleum, chemical, and power station pipelines. The quality of pipe caps will directly affect the integrity and safety of the entire pipeline system. With continuous applications of high-pressure, large-diameter and long-distance pipelines, the mechanical performance requirements for pipe caps and other pipe fittings are getting higher and higher. DEFORM-3D finite element forming analysis software is used to simulate the heating temperature and size of hot forming of the pipe cap and obtain the best heating temperature and size of hot forming of the pipe cap, providing a basis for solving the problems in the hot forming process and actual production of the pipe cap.
1. Establishment of a numerical simulation model for hot forming of pipe caps
1.1 The simulation object
The simulation object is a pipe cap of φ1219 mm x 34 mm, as shown in Figure 1. The outer diameter is 1219 mm, wall thickness 34 mm, total length 381 mm, and length of the shoulder 81 mm.
Figure 1 The pipe cap
1.2 Models of molds and materials
The three-dimensional modeling software Pro/E is used to design the mold and the material, and the three-dimensional solid modeling is carried out; it is transformed into the stl file format required by the numerical simulation software De-form-3D. The three-dimensional structure of pipe cap materials of φ1219 mmx34 mm, upper molds and lower molds are shown in Figure 2.
(a) Materials (b) Upper molds (c) Lower molds
Figure 2 The material and die of pipe caps
1.3 Performance parameters
The deformation resistance of a material within a certain temperature range is an important basis for determining the forming process and selecting forming equipment. Deformation resistance of materials is one of the main factors affecting simulation accuracy. The computer system of the dynamic material thermal simulation testing machine automatically collects true stress, strain, pressure, displacement, temperature, time, and other data, establishes a simulated material model, and draws a material stress-strain curve based on these data, as shown in Figure 1. The material used in this simulation is X804. In the numerical simulation of the hot press forming of the pipe cap, the required calculation parameters are shown in Table 1.
Table 1 Basic parameters in the numerical simulation
Using DEFORM-3D finite element forming analysis software to conduct a numerical simulation on the hot forming of the pipe cap, and the optimal heating temperature and size of the hot forming of the pipe cap were obtained. The research results have a certain guiding effect on the design and manufacture of caps.
Pipe caps are widely used in petroleum, chemical, and power station pipelines. The quality of pipe caps will directly affect the integrity and safety of the entire pipeline system. With continuous applications of high-pressure, large-diameter and long-distance pipelines, the mechanical performance requirements for pipe caps and other pipe fittings are getting higher and higher. DEFORM-3D finite element forming analysis software is used to simulate the heating temperature and size of hot forming of the pipe cap and obtain the best heating temperature and size of hot forming of the pipe cap, providing a basis for solving the problems in the hot forming process and actual production of the pipe cap.
1. Establishment of a numerical simulation model for hot forming of pipe caps
1.1 The simulation object
The simulation object is a pipe cap of φ1219 mm x 34 mm, as shown in Figure 1. The outer diameter is 1219 mm, wall thickness 34 mm, total length 381 mm, and length of the shoulder 81 mm.
Figure 1 The pipe cap
1.2 Models of molds and materials
The three-dimensional modeling software Pro/E is used to design the mold and the material, and the three-dimensional solid modeling is carried out; it is transformed into the stl file format required by the numerical simulation software De-form-3D. The three-dimensional structure of pipe cap materials of φ1219 mmx34 mm, upper molds and lower molds are shown in Figure 2.
(a) Materials (b) Upper molds (c) Lower molds
Figure 2 The material and die of pipe caps
1.3 Performance parameters
The deformation resistance of a material within a certain temperature range is an important basis for determining the forming process and selecting forming equipment. Deformation resistance of materials is one of the main factors affecting simulation accuracy. The computer system of the dynamic material thermal simulation testing machine automatically collects true stress, strain, pressure, displacement, temperature, time, and other data, establishes a simulated material model, and draws a material stress-strain curve based on these data, as shown in Figure 1. The material used in this simulation is X804. In the numerical simulation of the hot press forming of the pipe cap, the required calculation parameters are shown in Table 1.
Table 1 Basic parameters in the numerical simulation
| Parameters of numerical simulation | Numerical values |
| Thermal conductivity of the workpiece /(W.m-1.K-1) | 35.5 |
| Mass heat capacity of the workpiece /(J.kg-1.K-1) | 6.1073 |
| Heat transfer coefficient of contact between molds and workpieces /(N.s-1.mm-1.K-1) |
0.5 |
| Mold temperature/℃ | 20 |
| Friction coefficient | 0.3 |
| Main mold speeds/(mm.s-1) | 10 |
| Ambient temperatures/℃ | 20 |
| Moving speeds of upper molds/(mm.s-1) | 10 |
2. Determination of the heating temperature of the material
In the hot forming process, the selection of the heating temperature of the material is very important. If the temperature is too low, the deformation resistance of the material is great, which will reduce the service life of the mold. If the temperature is too high, the surface quality of the formed workpiece will decrease, and the temperature of the mold will also increase in the hot forming process, which will also cause a decrease in the service life of the mold. Before hot forming, the metal must be heated to a certain temperature. As the heating temperature increases, the ultimate strength of the material decreases, while the plasticity index increases. Therefore, in order to reduce the deformation resistance, the highest hot forming temperature is the best on the condition that the metal is not overheated. However, in actual experiments and production, the heating temperature of the metal is affected by the actual production conditions. The unreasonably high forming temperature not only fails to reduce the deformation resistance, but also causes a waste of energy. The heating temperature of the metal will directly affect whether the required shape can be obtained after the deformation of the metal. Therefore, the heating temperature of the metal directly affects the success of the experiment and production.
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