In the present research work, a finite element model of the electro-resistance welding pipe forming process chain is developed using the ABAQUS/Explicit software. The forming process, which is composed of 22 tandem roll stations, has been fully modeled in the developed finite element simulation. In order to account for the Bauschinger effect on the pipe material properties as a consequence of the loading and the unloading during the process, a non-linear kinematic hardening model has been utilized in all the proposed finite element simulation models. The constants for the non-linear kinematic hardening model were estimated by means of cyclic experiments on the K55 steel pipe material. In order to properly simulate the electric arc welding (electro-resistance welding) operation, the ABAQUS welding interface has been utilized to account for the joining between the two edges of the formed pipe as well as to assess the influence of the welding-induced temperature field on the residual stresses on the pipe material. The sizing operation, which is the final station of the electro-resistance welding process, has been also accounted in the developed finite element method model and is composed of six tandem rolls. To export and import the results between two different modules, a mapping strategy has been utilized and allowed exporting the element results, in terms of stress, strain, and temperature, and importing them into the following simulation module. Finally, in order to estimate the influence of each process station on the yield strength of the material, a finite element simple tension test simulation has been implemented in ABAQUS/Static, mapping the results of each station on the tensile specimen. This mapping operation allowed to estimate the yield stress of the material after each of the three process stations, a consequence of the residual stresses present in the material, and has been carried out on eight circumferential locations around the pipe, evenly spaced with a 22.5° angle. The model has been validated by comparing the geometrical results, in terms of average pipe diameter and thickness, obtained from the finite element model with those of the relevant industrial production, showing deviations equal to 1.25% and 1.35% (forming) and 1.29% and 1.43% (sizing), respectively, proving the reliability of the proposed process chain analysis simulation. The results will show how the process-induced residual stresses arising on the pipe material make the material yield strength to vary from station to station as well as having different values along the circumferential direction of the pipe.

在本研究工作中，使用ABAQUS / Explicit软件开发了电阻焊管成型工艺链的有限元模型。由22个串联轧辊站组成的成形过程已在开发的有限元模拟中进行了完全建模。为了考虑在过程中由于加载和卸载而对鲍辛格效应的影响，在所有提出的有限元模拟模型中都采用了非线性运动硬化模型。通过对K55钢管材料进行循环实验，估计了非线性运动硬化模型的常数。为了正确模拟电弧焊（电阻焊）的操作，ABAQUS焊接界面已被用于说明所形成管道的两个边缘之间的连接以及评估焊接引起的温度场对管道材料上残余应力的影响。在开发的有限元方法模型中也考虑了上浆操作，它是电阻焊接过程的最后一步，它由六个串联的轧辊组成。为了在两个不同模块之间导出和导入结果，已使用了一种映射策略，并允许导出应力，应变和温度方面的元素结果，并将其导入以下模拟模块中。最后，为了估算每个处理站对材料屈服强度的影响，在ABAQUS / Static中实现了有限元简单的拉伸试验模拟，将每个测站的结果映射到拉伸试样上。该映射操作允许估计三个处理站中每个站之后的材料屈服应力，这是材料中存在残余应力的结果，并且已在管道周围的八个圆周位置上进行了均匀分布，间距为22.5°角度。通过比较从有限元模型获得的平均管径和平均厚度的几何结果与相关工业生产的几何结果进行了验证，该模型的偏差分别为1.25％和1.35％（成形）和1.29％，以及1.43％（调整大小），分别证明了所提出的过程链分析仿真的可靠性。