Otimização de um processo de fabricação de tubos laminados com auxílio de ferramentas computacionais

Abstract

This work refers to a welded pipe rolling line through an analytical approach using a numerical simulation aimed at modernizing the tube manufacturing lines of the Aperam site installed in Ancerville, France. The main objective was to improve the final quality of the tubes produced by the site based on two assumptions: the surface quality (visual conditions of the inner and outer surfaces of the tube) and the mechanical properties of the tube (transverse plastic deformation and yield strength) at the end of the rolling process. An improvement study was adopted for two tube rolling lines used in the Ancerville site: Laser 27 and TIG 3. Initially, an analysis of the current state of these two lines was performed in order to find the defects that would be targets in the process optimization. After this first step, it was observed that the TIG 3 line presented a large number of superficial and geometric defects and, consequently, several elements to be improved. Thus, a numerical simulation of the TIG 3 line was launched in order to be able to compare the results of the simulations with the empirical data collected during the analysis of the current metal strip. The correlation between the simulation and the current process allowed us to understand the origins of surface defects. Considering both the defects found in the first two stages of conformation and its influence on the rest of the manufacturing process, it was decided to perform an optimization study of these two roll forming stages. After an in-depth analysis, an action plan was proposed aiming to correct, mitigate or even eliminate the defects found. With a defined action plan, the reconceptual stage of the first two TIG 3 roll forming steps began. After implementing all the modifications, some simulations with this new conception were made and the results obtained were discussed in order to evaluate whether the action plan was effective or not.