Optimization of the Processes of Forming and Welding of Large-Diameter Pipes with the Help of Mathematic Simulation

We propose the procedures whose realization in the form of algorithms and mathematical models developed on the basis of the finite-element method (FEM) enables one to compute the boundaries of the zone of deformation and the width and radius of the billets formed in the pressing equipment depending on the depth of lowering of the upper punch in each step for the edge-bending (EBP) and step forming (SFP) presses followed by the additional shaping of splined pipes, welding in an assembly welding mill, and calibration in the expander and to get finished profiles of the pipes with diameters of up to 1420 mm and with the required geometric dimensions without defects and according to the regulatory documents. The application of the developed “ZV JCO” software enables one to compute the effective parameters of adjustment of pressing tools, to reduce the time required to compile the technological maps by 4–6 times (down to 20 min), and hence, to optimize the processes of forming and welding of large-diameter pipes.