Prediction and design of edge shape of initial strip for thick tube roll forming using finite element method

Increasing demands for electric resistance welded pipes of high quality with thick wall require close investigations in edge deformation by slitting, strip deformation during break down forming, and difference of circumferential length. In order to obtain good quality of a welding zone, it is necessary to predict the edge shape of the initial strip. The modeling of the multi-pass thick tube roll forming process with rigid–plastic finite element method and the edge shape prediction of an initial strip with second-degree polynomial regression method are presented in this paper. Edge shapes of initial strip have been analyzed by the finite element method and designed by the regression method to satisfy the requirements at target fin pass. It is concluded that the proposed edge design method results in optimal edge shapes satisfying the design requirements.