ISSN 0967-0912, Steel in Translation, 2017, Vol. 47, No. 4, pp. 235–240. © Allerton Press, Inc., 2017.

Original Russian Text © V.N. Shinkin, 2017, published in Izvestiya Vysshikh Uchebnykh Zavedenii, Chernaya Metallurgiya, 2017, No. 4, pp. 285–291.

Asymmetric Three-Roller Sheet-Bending Systems

in Steel-Pipe Production
V. N. Shinkin
Moscow Institute of Steel and Alloys, Moscow, Russia
e-mail: shinkin-korolev@yandex.ru
Received March 27, 2017

Abstract⎯Various attachments are used to produce components of particular configurations from metal
sheet. In particular, sheet-bending roller systems may be classified in terms of the number of rollers (two,
three, or four); the type of drive (mechanical, pneumatic, electromechanical, hydraulic); and the roller con-
figuration (symmetric, asymmetric). Three-roller systems are used for the production of cylindrical, oval, and
conical components by bending the metal sheet. They may be employed to manufacture pipes, channels, air-
ways, shells, barrels, and sheathes. The operation of three-roller sheet-bending systems is based on the rota-
tion of rollers in opposite directions, so that the sheet is captured and bent to the specified radius. To facilitate
sheet supply and the release of the products bent into closed circles, the three-roller sheet-bending systems
are combined with a removable front shaft applying a pressure that may be adjusted. In the three-roller sys-
tems, the diameter of the upper roller is about 1.5 times that of the lower rollers. In shaping, the rollers per-
form reversible motion. The upper roller may be raised and lowered to regulate the diameter of the circle pro-
duced. In this approach, extremely small sheet sections remain flat. This problem is eliminated by bending
the ends of the sheet in a press or in a roller mill. In the present work, a mathematical method is proposed for
determining the forces and torques in cold flexure of thick steel sheet on three-roller sheet-bending systems.
The calculations permit the determination of the reaction of the roller supports, the residual stress in the wall
of the steel sheet, the proportion of the plastic deformation over the sheet thickness, and the relative defor-
mation of longitudinal surface fibers of the sheet in flexure as a function of the roller radius, the roller spacing,
the reduction of the sheet by the upper roller, the sheet thickness, the Young’s modulus, the yield point, and
the strengthening modulus of the steel sheet. The results may be used at metallurgical and manufacturing
plants in the production of large-diameter steel pipe for major pipelines.

Keywords: steel sheet, three-roller sheet-bending system, surface curvature of sheet, springback coefficient,
elastoplastic medium, linear strengthening
DOI: 10.3103/S0967091217040106

In the present work, we consider the shaping of
large-diameter pipe from broad thick steel sheet for
major pipelines.
In the production of straight-seam electrowelded
large-diameter steel pipe (diameter 1020, 1220, and
1420 mm) from steel of strength classes K36–K65 and
X42–X80 (wall thickness up to 52 mm, working pres-
sure up to 22.15 MPa), the main operation is shaping
of flat steel sheet into an open cylindrical blank prior
to assembly and welding of the pipe [1–35].
The commonest methods of pipe shaping in Russia
and elsewhere (Germany, China, India) are shaping
into an open cylindrical blank on a roller shaping mill
and a continuous roller mill; shaping on three-roller
sheet-bending systems; shaping of a cylindrical blank
on presses (UOE method); and stepwise shaping by
stamps (dies) on narrow hammer faces (JCOE
method) [18–24].
In the production of large-diameter steel pipe for
major pipelines, the UOE and JCOE methods (SMS
Meer technology) are used at OAO Chelyabinskii
Truboprokatnyi Zavod and AO Vyksunskii Metallur-
gicheskii Zavod; the JCOE method (SMS Meer tech-
nology) is used at ZAO Izhorskii Trubnyi Zavod; con-
tinuous roller shaping is used at AO Volzhskii Trubnyi
Zavod; and three-roller sheet-bending systems are
used at AO Zagorskii Trubnyi Zavod (Haeusler tech-
nology).
To obtain parts of different configuration from
metal sheets, various attachments are used. In partic-
ular, sheet-bending roller systems may be classified in
terms of the number of rollers (two, three, or four); the
type of drive (mechanical, pneumatic, electrome-
chanical, hydraulic); and the roller configuration
(symmetric, asymmetric).
Three-roller systems (Figs. 1–3) are used for the
production of cylindrical, oval, and conical compo-

235
236 SHINKIN

Fig. 1. Three-roller sheet-bending system with hydraulic drive (Haeusler technology).

Fig. 2. Bending of steel sheet in the Haeusler three-roller system.

nents by bending the metal sheet. They may be
employed to manufacture pipes, channels, airways,
shells, barrels, and sheathes [1–6, 18–24, 29–35].
The operation of three-roller sheet-bending sys-
tems is based on the rotation of rollers in opposite
directions, so that the sheet is captured and bent to the
specified radius. To facilitate sheet supply and the
release of the products bent into closed circles, the
three-roller sheet-bending systems are combined with
a removable front shaft applying a pressure that may be
adjusted.
In the three-roller systems, the diameter of the
upper roller is about 1.5 times that of the lower rollers.
In shaping, the rollers perform reversible motion. The
upper roller may be raised and lowered to regulate the
diameter of the circle produced. In this approach,
extremely small sheet sections remain flat. This prob-
lem is eliminated by bending the ends of the sheet in a
press or in a roller mill.
In the present work, a mathematical model is pro-
posed for three-roller sheet-bending systems. Suppose
that t1 is the spacing between the first and second roll-

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 ASYMMETRIC THREE-ROLLER SHEET-BENDING SYSTEMS 237

t1 t2 > t1 t1 t2 = t1

Fig. 3. Bending of steel sheet with asymmetric three-roller sheet-bending systems.

The springback coefficient β of the sheet’s neutral

line with radius of curvature ρ is
Mr2
β ( ρ) = 1 ,
R2
(1 − η)( 2ξ − 1) 2 (ξ + 1)
2 ρ2 where
ρσ y Π + Π co
ξ= ; η = ex .
hE 2E
N1 N3 We now introduce three local rectangular Carte-
ϕ2 sian coordinate systems y–z at the points of sheet–
roller contact. The z axes are tangential to the roller
Fs3 surface and run left to right; the y axes are perpendic-
H2
ular to the z axis and run toward the center of the cor-
ϕ1 Fs1 ϕ3 responding roller. In these systems, the coordinates of
Fs2 the sheet’s longitudinal neutral line (between adjacent
R1 R3 points of sheet–roller contact) are approximated by
N2 cubic polynomials of the form y(z) = aiz2 – biz3
ρ1 ρ3 (Shinkin method), where ai and bi are the coefficients
1 3 of the cubic polynomials in coordinate system i.
We now write equations for the coefficients of the
Mr3
Mr1 cubic polynomials, the curvature, and the radii of cur-
t1 t2 vature of the sheet’s neutral line at points of sheet–
roller contact:
⎯for the first and second rollers
Fig. 4. Forces on the sheet in bending at the rollers.

( )
z 2 = t − R10 sin ϕ1 − R20 sin ϕ 2 cos ϕ1
2
ers; t2 is the spacing between the second and third roll- + [H 2 − R10 (1 − cos ϕ1 ) − R20 (1 − cos ϕ 2 )] sin ϕ1;

( )
ers (t1 + t2 = t); Hi is the reduction of the neutral sur-
face of the steel sheet in roller i; h is the thickness of the y2 = − t − R10 sin ϕ1 − R20 sin ϕ 2 sin ϕ1
steel sheet; Ri is the radius of roller i; Ri0 = Ri + h/2; 2
+ [H 2 − R10 (1 − cos ϕ1 ) − R20 (1 − cos ϕ 2 )] cos ϕ1;
σy and E are the yield point and Young’s modulus;
Πex and Πco are the strengthening moduli of the steel 3 y + tan ( ϕ1 − ϕ 2 ) z 2
a1 = 2 ;
in extension and compression; ρi and εi = 1/ρi are the z 22
radius of curvature and the curvature of the longitudi- 2 y + tan ( ϕ1 − ϕ 2 ) z 2
b1 = 2 ;
nal neutral line of the sheet at its points of contact with z 23
the rollers; ϕi are the angles corresponding to points of
sheet–roller contact (i = 1, 2, 3). This notation is illus- ε12 = 2a1; ρ12 = 1 ;
2a1
trated in Fig. 4.
2a1 − 6b1z 2
ε 21 = ; ρ 21 = 1 ;
ε 21
( )
Suppose that the lower rollers have the same diameter 3/2
⎡1 + 2a z − 3b z 2 ⎤ 2
(R1 = R3) and are at the same height (H1 = H3 = 0 m). ⎢⎣ 1 2 1 2 ⎥⎦

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238 SHINKIN

⎯for the second and third rollers Suppose that Mi is the bending moment of the sheet at

)
points of sheet–roller contact: M1 = 0; M2 = M(ρ2);
(
z 3 = t + R20 sin ϕ 2 − R30 sin ϕ3 cos ϕ 2
2
M3 = 0.
For high-strength steel pipe, Πco ≈ Πex = Π.
− [H 2 − R20 (1 − cos ϕ 2 ) − R30 (1 − cos ϕ3 )] sin ϕ 2;

( )
The extremal residual stress is determined from the
y3 = t + R20 sin ϕ 2 − R30 sin ϕ3 sin ϕ 2 following formulas according to [18–20]
2
+ [H 2 − R20 (1 − cos ϕ 2 ) − R30 (1 − cos ϕ3 )] cos ϕ 2;
σ res = σ y + Π ( ε max − ε y ) − 6 ⎛⎜ M2 ⎞⎟ ;
1

3 y − tan ( ϕ 2 + ϕ3 ) z3 ⎝ bh ⎠
a2 = 3 ; σ ρ
σ 2res = σ y − 12 ⎜⎛ M2 ⎟⎞ y ,
2
z3
2 y − tan ( ϕ 2 + ϕ3 ) z3 ⎝ bh ⎠ Eh
b2 = 3 ;
z3
3
where εy = E/σy.
ε 23 = 2a2; ρ 2 = ρ 23 = 1 ; We now calculate the parameters of the three-roller
2a2 sheet-bending system. Suppose that Ni denotes the
2a2 − 6b2 z3 reaction of the supports for roller i; Mri denotes the
ε 32 = ; ρ 3 = ρ32 = 1 ; rotary torque (transmitted from the gear) for roller i;
ε 32
( )
2 3/2
⎡1 + 2a z − 3b z ⎤ 2 and Fsi = Mri/Ri is the supply force for roller i; i = 1, 2, 3.
⎢⎣ 2 3 2 3 ⎥⎦
The increments in the reactions at the points of
The boundary conditions take the form sheet–roller contact are
ρ12 = ρ1; ρ 21 = −ρ 23; ρ32 = β (ρ 23 ) ρ 23. Δ N 2 = −N 1 cos ( ϕ1 − ϕ 2 ) + Fs1 sin ( ϕ1 − ϕ 2 ) ;
Δ Fs2 = N 1 sin ( ϕ1 − ϕ 2 ) + Fs1 cos ( ϕ1 − ϕ 2 ) .
The proportion of plastic strain over the sheet
thickness in flexure is The normal reactions of the rollers at the points of
sheet–roller contact are
⎧ 2σ y ρ Eh
⎪⎪1 − Eh , if ρ ≤ 2σ ; M 2 − Fs1 y2
N1 = ;
η=⎨ y
z2
⎪0, if ρ > Eh
2σ y
. M − Δ N 2 z3 − ( Fs2 + Δ Fs2 ) y3
⎪⎩ N2 = 2 ;
z3
The strain of the sheet’s longitudinal surface fibers is M + Fs3 [−z3 sin ( ϕ 2 + ϕ3 ) + y3 cos ( ϕ 2 + ϕ3 )]
N3 = 2 .
z3 cos ( ϕ 2 + ϕ3 ) + y3 sin ( ϕ 2 + ϕ3 )
ηif = h .
2ρ The vertical force applied by the upper (second)
roller to the steel sheet is
⎛ ⎞
In plastic flexure of the steel sheet ⎜ ρ < ρ y = hE ⎟ , Fupp = N 2 cos ϕ 2 + Fs2 sin ϕ 2,
⎝ 2σ y ⎠
the bending moment M in the sheet cross section is while the vertical force applied by the lower (first and
[18–24] third) rollers to the steel sheet is

bh 2σ y ⎡ ⎛ σ y ρ ⎞ ⎤ bh ( Π ex + Π co ) Flow = N 1 cos ϕ1 + Fs1 sin ϕ1 + N 3 cos ϕ3 + Fs3 sin ϕ3.

2 3
M (ρ) = ⎢3 − 4 ⎜ ⎟ ⎥ +
12 ⎣⎢ ⎝ Eh ⎠ ⎦⎥ 24ρ Suppose that
⎛ σ ρ ⎞⎤ ⎛ σ ρ ⎞
2
⎡ R1 = 0.340 m, R2 = 0.510 m, R3 =0.340 m,
× ⎢1 − 2 ⎜ y ⎟⎥ ⎜1 + y ⎟ ,
⎣ ⎝ Eh ⎠⎦ ⎝ Eh ⎠ b =1.8 m, h = 0.01 m, E = 2 × 1011 Pa,
σy = 500 × 106 Pa, H2 = 0.131 m, and ρ1 = 2 m.
⎛ ⎞
In elastic flexure of the steel sheet ⎜ ρ ≥ ρ y = hE ⎟ , Then, solving the system of equations, we obtain
⎝ 2σ y ⎠ (Figs. 5 and 6)
the bending moment M in the sheet cross section is
[1–6, 18–20] ρ2 = 0.631 m; ρ3 = 1.216 m; ϕ1 = 26.08°;
ϕ2 = –1.95°; ϕ3 = 26.52°; M2 = 22.889 kN m;
2
N1 = 60.510 kN; N2 = 112.671 kN; N3 = 66.146 kN;
M = bh E .
12ρ Flow ≈ Fupp = 112.583 kN.

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 ASYMMETRIC THREE-ROLLER SHEET-BENDING SYSTEMS 239

7. Belskiy, S.M., Mazur, I.P., Lezhnev, S.N., and

Panin, E.A., A two-zone model of browdening during
rolling, J. Chem. Technol. Metall., 2017, vol. 52, no. 2,
Sheet flexure, m

0.2
pp. 180–185.
8. Belskiy, S., Mazur, I., Lezhnev, S., and Panin, E., Dis-
0 tribution of linear pressure of thin-sheet rolling across
strip width, J. Chem. Technol. Metall., 2016, vol. 51,
no. 4, pp. 371–378.
–0.2 9. Belskiy, S.M., Yankova, S., Chuprov, V.B., Bakhaev, K.V.,
and Stoyakin, A.O., Temperature field of stripes under
0 0.5 1.0 hot rolling, J. Chem. Technol. Metall., 2015, vol. 50,
no. 6, pp. 613–616.
Horizontal axis, m 10. Muhin, U., Koinov, T., Belskij, S., and Makarov, E.,
Application of between-stand cooling in the production
Fig. 5. Sheet flexure between three rollers. of hot-rolled strips, J. Chem. Technol. Metall., 2014,
vol. 49, no. 1, pp. 65–70.
11. Muhin, U., Belskij, S., and Koinov, T., Study on the
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widening in hot rolling of thin sheet, J. Chem. Technol.
Sheet curvature, m–1

Metall., 2014, vol. 49, no. 1, pp. 77–81.

1.5
1.0
0.5
0 0.5
Horizontal axis, m
Fig. 6. Curvature of the sheet’s neutral line on bending by
the rollers.
CONCLUSIONS
An analytical method has been proposed for deter-
mining the reactions of the supports, the bending
moments, and the residual stress in the wall of the steel
sheet during cold flexure on three-roller sheet-bend-
ing systems.
The results may be used at metallurgical plants in
the production of large- or medium-diameter steel
pipe for major oil and gas pipelines.
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Translated by Bernard Gilbert
STEEL IN TRANSLATION Vol. 47 No. 4 2017