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ORGANIZER;CN=ESTAD 2023:mailto:info@metec-estad.com
LOCATION:Room 28
SUMMARY:Technological developments in process design of tube and pipe roll forming
DESCRIPTION:The latest requests for ERW pipe mills were characterized by challenging conditions: the product range is more and more extended to pipes with extreme wall thickness and higher yield strength. At the same time, dimensional tolerances for pipes and profiles become stricter. Moreover, mill owners ask for technological support regarding easy and fast dimensional changeover in combination with traceability of process parameters and product quality. 
To comply with these demands machine and process design are transferred to a digital twin, which allows the designer to find the best mill configuration for revamped and new-planed mills. In combination with the mill automation the digital twin enables the operating personnel to find optimum settings in short time, taking in account induced deformation throughout the whole mill. This is big advantage for production, as the online model helps realizing the influence of the individual forming steps on the final quality. This saves valuable time and material, especially when dealing with a big variety of profile dimensions and pre-material conditions. 
In the first step towards the “digital twin” the complete pipe forming sequence was mapped as a parametric analytical calculation model, calibrated by FEA and practical experiences. Taking into account the interaction between stand usage, roll design and load limits, the model evaluates the optimum combination with regard to metal forming and economic aspects.  
Moreover, reliable initial setting values for the well-established “X-Pact® Quicksetting” system are calculated to accelerate commissioning new products or material grades. But also a process feedback is visualized online to indicate process limits and/or design limits. Up to now, the pre-forming section (lineal forming or breakdown forming) as well as forming section (fin-pass) and sizing/profiling have been added to the digital modelling approach. 
In future, a systematic process feedback enables a (self-)learning model to the point of a 
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DTSTART:20230615T102000
DTEND:20230615T104000
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