Prediction of the fracture due to Mannesmann effect in tube piercing

Mannesmann piercing process is a well-known hot rolling process used for seamless tube production. its special feature is the so-called Mannesmann effect, that is the cavity formation in the center of the cylindrical billet and its propagation along the axis due to stress state caused by the rolls in the early stages of the process. The cavity is then expanded and sized in its internal diameter by an incoming plug. The industrial requirement is to know quite precisely the characteristics of the cavity especially in terms of its location along the billet axis in order to minimize the plug wear and the oxidation of the pierced bar. However, the scientific knowledge about the fracture mechanism leading to the Mannesmann effect is still limited, even if several theories have been proposed; this lack makes the design and optimization of the process through numerical simulations still a challenging task. The aim of this work is then to develop a suitably calibrated FE model of the piercing process in its first stage before the plug arrival, in order to investigate the Mannesmann effect using different damage criteria. Hot tensile tests, capable to reproduce the industrial conditions in terms of temperature, strain rate, and stress states, are carried out to investigate the material workability and to determine the parameters of the damage models on specimens machined from continuous-casting steel billets. The calculated parameters are implemented in the numerical model of the process and a sensitivity analysis to the different criteria is carried out, comparing numerical results with non-plug piercing tests conducted in the industrial plant.