The operator will have a better insight into mill adjustments and set-ups that can be used to correct buckling problems. These solutions can be used by both mill operators and design engineers. This understanding has lead to the development of several solutions to eliminate it. By using the finite element method, which predicts the behavior of a material during the forming process, the causes of edge buckling are understood. Due to the number of parameters that can be adjusted, this method is very inefficient and cannot guarantee success. Many times, operators resort to a trial-and-error method of mill adjustment to correct skelp edge buckling problems. In some cases, this problem may become so severe that an unscheduled mill shutdown is required to remove the buckled product and readjust the mill. Skelp edge buckling often causes poor quality welds that lead to degrading, or scraping, of the finished tube or pipe. They often occur when forming tube and pipe with large diameter-to-thickness (d/t) ratios and using high strength/high stiffness materials, such as stainless steel and titanium. Two common forming problems are skelp, or strip, edge buckling and surface marking. By applying this knowledge to tooling design and manufacturing procedures, many forming problems can be eliminated, resulting in the production of high quality tube and pipe product. These advanced designs and techniques are based on a thorough understanding of material deformation during the forming process. In order to be competitive, it is important that manufacturers use high quality tooling, in conjunction with scientific management and operation techniques in the production process. This analysis will help tube and pipe manufacturers understand the causes of edge buckling and to eliminate and prevent its occurrence.Īn increased demand for a wider variety of sizes and shapes in tube and pipe products, along with stringent requirements for high quality, characterizes todays tube and pipe making industry. As a result, the tube or pipe is poorly welded and the product is rejected. Experience has shown that skelp edge buckling can occur during the formation of thin wall tube and pipe (large d/t ratios). The following is an analysis, using the finite element method, of skelp edge buckling in welded tube and pipe roll forming processes.
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