Simulation of Mannesmann piercing process by the three-dimensional rigid-plastic finite-element method

Simulation of the Mannesmann piercing process is performed for the first time by the three-dimensional rigid-plastic finite-element method. Firstly, a method of analysis is proposed for the steady-state formulation in the case that the sides of the finite elements cannot be made to coincide with the streamline of the material flow. Secondly, the simulation of the Mannesmann piercing process is performed under the variation of rolling conditions such as the feed angle, the minimum roll gap, the maximum plug diameter, the plug advance and the guide shoe diameter, and the effects of the rolling conditions on various rolling properties such as the outer diameter, the inner diameter, the roll force, the mandrel force, the equivalent strain distribution and the equivalent strain rate distribution are demonstrated. Finally, the results of the analysis are compared with the results of an experiment using Plasticine. The dimension in the rolling condition of the experiment is scaled to one-third of the dimension in the rolling condition in an actual Mannesmann piercing process. The analytical results agree with the experimental results and the validity of the method of analysis is confirmed.