Numerical Simulation and Experimental Confirmation of a Bimetallic Pipe Forming Process

Area of Science:

• Materials Science
• Mechanical Engineering
• Corrosion Engineering

Background:

• Bimetallic pipes offer a balance of mechanical strength, corrosion resistance, and cost-effectiveness for oil and gas transport.
• The JCO forming process, while common, introduces complexities in stress distribution and potential imperfections.
• Residual tensile stresses in pipes can significantly accelerate corrosion failure, impacting service life.

Purpose of the Study:

• To simulate and analyze the stress distribution during the JCO forming of 2205/X65 bimetallic pipes.
• To validate simulation models using experimental data, including digital image correlation (DIC).
• To investigate the influence of forming process parameters on stress development in bimetallic pipes.

Main Methods:

• Three-dimensional (3D) finite element method (FEM) simulations were employed to model the pre-bending and JCO forming stages.
• Digital image correlation (DIC) experiments were used to validate the accuracy of the 3D FEM model.
• A two-dimensional (2D) model was developed to study bimetallic plate bending and interfacial stress characteristics.

Main Results:

• The study successfully simulated the JCO forming process, providing detailed stress distribution data for the 2205/X65 bimetallic pipe.
• Simulation results were validated against experimental DIC measurements and the opening width of the formed pipe billet.
• Analysis revealed key factors influencing stress generation during the forming process.

Conclusions:

• The FEM simulation approach is effective for analyzing the complex stress states in JCO-formed bimetallic pipes.
• Understanding and controlling residual stresses are critical for enhancing the durability and safety of bimetallic pipelines.
• The study provides valuable data for optimizing the manufacturing process of bimetallic pipes for demanding applications.