Abstract The cage roll forming process improves the flexibility of electrical resistance welding (ERW) pipes manufacturing by employing several groups of cage rolls, but poses great challenge to flower design and roll positioning, since the flower pattern and rolls’ positions are no longer one-to-one correlated as in conventional roll forming processes. In the present work, a forming flower design method for cage roll forming of ERW pipes is proposed, considering the transversal bending characteristics of the sheet metal, especially the existence of “non-bending area”. Furthermore, based on kinematic analysis of the cage roll frame, a roll positioning method is put forward by implementing flower pattern and enforcing the geometric constraint condition between rolls and the steel strip. The proposed flower pattern design and roll positioning methods are demonstrated by the cage roll forming of two ERW pipes. The forming processes by using the newly designed parameters and old experience based parameters are compared. The proposed method provides a science based process design method for cage roll forming processes. To the best of our knowledge, the present work is the first effort on developing flower pattern and roll positioning design methods for the cage roll forming process of ERW pipes.

中文翻译：

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ERW管笼式滚压成型工艺的花型及滚压定位设计

摘要 笼辊成型工艺通过采用多组笼辊提高了电阻焊（ERW）管制造的灵活性，但对花型设计和辊定位提出了很大的挑战，因为花型和辊的位置不再是单一的。与传统辊轧成型工艺中的相关性。在目前的工作中，考虑到金属板的横向弯曲特性，特别是“非弯曲区域”的存在，提出了一种用于ERW管笼滚成形的成形花设计方法。在此基础上，基于笼式辊架的运动学分析，提出了一种通过实施花卉图案并强制轧辊与钢带之间的几何约束条件的轧辊定位方法。通过两根 ERW 管的笼式滚压成型来演示所提出的花卉图案设计和滚压定位方法。比较了使用新设计参数和旧经验参数的成形过程。所提出的方法为保持架滚压成型工艺提供了一种基于科学的工艺设计方法。据我们所知，目前的工作是第一次为 ERW 管的笼式滚压成型工艺开发花型和滚压定位设计方法。