On the modelling of complex 3D bulk metal forming processes via the pseudo-concentrations technique. Application to the simulation of the Mannesmann piercing process

The modelling of complex 3D metal forming processes using the flow formulation, implemented via the pseudo-concentrations technique, requires the development of robust computational strategies for dealing with the velocity and pseudo-concentration boundary conditions in the zone where the blank– tools contact is developed. A new algorithm, designed to fulfil those requirements, is presented in this paper. The Mannesmann piercing process is a metal forming operation used in industry for manufacturing metal seamless pipes. The results of the Mannesmann process finite element simulation are particularly dependent on the accuracy and stability of the algorithm used to describe the contact boundary conditions between the forming tools and the blank. The validation of the finite element model is performed by comparing the numerical predictions obtained using the new algorithm with the results of industrial tests