Journal of Materials Processing Technology 209 (2009) 4850–4856

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Journal of Materials Processing Technology

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Research on strip deformation in the cage roll-forming

process of ERW round pipes
Jinmao Jiang a,∗ , Dayong Li a , Yinghong Peng a , Jianxin Li b
a
School of Mechanical Engineering, Shanghai Jiaotong University, 800 Dongchuan Road, Shanghai 200240, PR China
b
Baoshan Iron & Steel Co. Ltd., Shanghai 201900, PR China

a r t i c l e i n f o a b s t r a c t

Article history: Cage roll forming is an advanced roll-forming technique to manufacture electric resistance welded (ERW)
Received 25 June 2008 round pipes. In the cage roll-forming process, many small rolls are arranged along the outer surface of
Received in revised form 6 January 2009 the deformable strip to bend the strip edge in a more smooth way. Furthermore, these small rolls can be
Accepted 10 January 2009
used for forming pipes of different sizes. Therefore, cage roll forming can reduce roll change time and
improve forming quality, as compared with the conventional step roll forming. However, very few studies
Keywords:
can be found about cage roll forming, due to its complexity, and the industrial practice depends greatly
Cage roll forming
on experience rather than science-based design today. In this work, the whole cage roll-forming process
ERW round pipes
Non-bending area
is simulated with the explicit elastic–plastic finite element method, and the strip deformation during the
Finite element method cage roll-forming process has been investigated in detail. Through the simulation, the “non-bending area”
Longitudinal strain phenomenon is found, and the ranges of the non-bending area at different forming stands are obtained.
In addition, the longitudinal strain at the inside edge and center are predicted, and by comparison, it can
be known that the deformation of the strip edge is usually larger and edge buckling is most likely to occur
at the entry sides of No.1–No.3 fin-pass stands. Finally, the circumferential length, opening distance and
the profiles of the deformed strip are measured on the cage roll-forming mill. There is a good agreement
between the experimental and simulated results.
© 2009 Elsevier B.V. All rights reserved.

1. Introduction
In cold roll-forming processes, metal sheets are progressively
deformed into products with required cross-sectional profiles by a
series of rolls installed at the tandems along the longitudinal direc-
tion. As an economical metal sheet forming technology, cold roll
forming is playing more and more important roles in various indus-
trial fields, and many products are manufactured by it, such as light
gauge section steels, electric welded round pipes and tubes, electric
welded square and rectangular pipes, etc.
At present, there are two main roll-forming processes for pro-
ducing electric resistance welded (ERW) pipes, which are the
conventional step roll forming and cage roll forming. In the con-
ventional step roll-forming process of ERW pipes, a metal sheet is
stepwise bent into round shape using contoured rolls (vertical and
horizontal rolls) mounted on different stands, as shown in Fig. 1.
Because the formed strip is shaped as defined by the contour of rolls,
all the forming rolls have to be changed every time when pipes with
different outer diameters are manufactured, which leads to long
downtime and high roll costs. Moreover, edge buckling and spring
∗ Corresponding author. Fax: +86 21 34206313.
E-mail addresses: void@sjtu.edu.cn, erwok@hotmail.com (J. Jiang).
back are prone to occur during the conventional forming process,
especially as the ratio of the outside diameter to wall thickness (D/t
ratio) increases. In consideration of these problems, the conven-
tional roll-forming mill is changed into the cage roll-forming mill
(Michitoshi et al., 2004).
In the cage roll-forming process of ERW pipes, a metal sheet is
continuously deformed into a round pipe by using a set of small
cage rolls arranged along the outer surface of the steel strip. Those
small cage rolls can realize a bending process by applying the down-
hill forming before the fin-pass stands. As shown in Fig. 2, the cage
roll-forming mill consists of five parts, which are pinch roll unit,
edge-bending stand, pre-forming section, linear forming section
(No.1–No.3 linear forming section) and fin-pass stands (No.1–No.3
fin-pass stand). The pinch roll unit serves for feeding the strip into
the forming mill and for providing main drive forces during pro-
duction. The edge-bending stands are arranged after the pinch roll
stand to bend strip edge on both sides by an upper and a lower
bending roll. The pre-forming section consists of two outer forming
roll groups equipped with 13 non-driven cage rolls, inner forming
tools (upper roll 1–upper roll 4), and a breakdown stand. The linear
forming section serves for further forming of the strip before the
fin-pass stands, and comprises three (No.1–No.3) linear forming
sub-sections (each sub-section consists of two outer forming roll
groups equipped with 10–12 non-driven cage rolls), inner forming

0924-0136/$ – see front matter © 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2009.01.011
 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856
Fig. 1. A conventional roll-forming mill.
tools (upper roll 5–upper roll 8) and the support rolls. The fin-pass
stands are the last roll-forming sections before the shaped metal
sheet welded, and each fin-pass stand comprises an upper roll, a
lower roll, and two side rolls. This cage roll-forming mill is charac-
terized by the feature that it is equipped with several dozen pairs of
cage rolls, which can be used for manufacturing pipes of any sizes
without changing and ensure smooth forming of strip edge. As a
result, the cage roll forming can not only reduce the roll changing
time significantly, but also prevent edge buckling and spring back of
the deformed strip, compared with the conventional roll forming.
Many researchers have done many studies on the conventional
roll-forming process of ERW pipes. Kiuchi (1973) firstly applied a
semi-analytical method (SAM) to simulate the conventional roll-
forming process by defining the deformed surface of the sheet
between two adjacent stands as a set of sinusoidal shape functions,
and an automated design system of roll profiles was developed by
Kiuchi and Koudabashi (1984). Walker and Pick (1990, 1991) per-
formed a general modeling technique by describing the complex
deformed geometry of the skelp with B-splines and a method of
using this geometric description to define the strain state in the
Fig. 2. A cage roll-forming mill.
4851
deformed skelp. Nefussi and Gilormini (1993) described the middle
surface of the deformed strip by using a ‘Coons Patch’, and predicted
the optimal shape and the deformed length of a strip before the first
roll stand. Liu et al. (1996) and Han et al. (2004) developed a finite
strip method (FSM) to analyze the cold roll-forming process of ERW
pipes based on total-Lagrangian method and updated-Lagrangian
method respectively. The above two methods SAM and FSM both
have an advantage of low computational cost, but these two meth-
ods are based on the geometric assumption of the deformation
shape of the strip and neglect the contact between forming rolls
and the strip, which decrease the accuracy of analysis.
In recent years, the finite element method has also been applied
in the analysis of the roll-forming process. Kim and Oh (1999) pre-
sented a computational method based on the three-dimensional
rigid-viscoplastic finite element method to investigate the steel
sheet deformation in the conventional roll-forming process. Hong
et al. (2000) developed a 3D FEM program (SHAPE-RF) for anal-
ysis of the cold roll-forming process of channel and circular tube
sections. In SHAPE-RF, initial geometry was calculated with “gener-
alized” plane-strain assumption, and then the 3D FEM simulation
was started with the initial geometry and boundary conditions.
Kim et al. (2003) established a finite element model of the multi-
pass conventional roll-forming process of ERW pipes, and predicted
the edge shapes of initial strip with second-degree polynomial
regression method. Kiuchi and Wang (1999) developed 2D and
3D elasto-plastic FEM codes based on static implicit and dynamic
explicit methods, and made a comprehensive study on flexible roll-
forming process of ERW pipe. To obtain fundamental knowledge
on cage roll-forming process, Yokoyama et al. (1981) investigated
the deformation behavior of steel sheet as expressed in strain
history, projection trace and forming flowers and methods of
determining forming load at fin-pass rolls and squeeze rolls by
experiments.
Although there have been many researches on the analysis of
roll-forming process by various simulation techniques, most of pre-
vious studies focused on deformation features of metal sheets in the
conventional roll-forming process. Few reports have been found
on the analysis of the cage roll-forming process, except for some
industrial experiment. Due to the quite long forming zone (almost
20 m), great number of forming rolls (approximately 80 rolls), and
complicate contact status between the deformed strip and rolls in
cage roll forming, the computation cost for simulation of the whole
cage roll forming is formidable. Therefore, the dynamic explicit
FEM is selected to simulate the whole cage roll-forming process
of ERW pipes, due to its high efficiency in reducing CPU time, sav-
ing memory and dealing with the contact (Lindgren and Edberg,
1990). The modeling of the cage roll-forming process is proposed
using explicit code LS-DYNA based on 3D elastic–plastic finite ele-
ment method. The work presented here aims to investigate the
deformation characteristics of steel strip in the cage roll-forming
process. In particular, through analyzing the relative curvature of
the deformed strip, the “non-bending area” phenomenon is found
during the cage roll-forming process of ERW pipes, and the ranges
of non-bending area at different forming stands are obtained. In
addition, the distribution of longitudinal strains at inside edge and
center are predicted and the positions most likely subjected to edge
buckling are located. Finally, the circumferential length, opening
distance and cross-section configurations of the deformed strip are
measured and compared with the simulation results.
2. Finite element modeling of the cage roll-forming process
An elastic–plastic finite element model of the cage roll-forming
mill, which is used to produce pipes of 325 mm in outer diame-
ter, has been established. The FE models about pre-forming, linear
forming section, and fin-pass stands are shown in Figs. 3–5 respec-
4852 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856
Fig. 3. The FE model of pre-forming section in the cage roll-forming process.
Fig. 4. The FE model of linear forming section in the cage roll-forming process.
tively. The dimension of the original strip to be formed is 21,000 mm
(length) × 1018 mm (width) × 10.3 mm (thickness). The material is
X-60 steel. In this study, different element types, element sizes,
sheet speed, sheet length, type of velocity boundary conditions have
been tried to get a good balance between the required CPU time
Fig. 5. The FE model of fin-pass stands in the cage roll-forming process.
Fig. 6. Stress–strain curves for X-60 steel.
and the computation accuracy. Only half of the model is used due
to symmetry. The detailed information of the finite element model
of the cage roll-forming process is described as follows.
2.1. Material properties
The elastic modulus (E) and Poisson’s ratio () of X-60 steel are
210 GPa and 0.3, respectively. The stress–strain curve for X-60 is
depicted in Fig. 6. The deformation of all the forming rolls in the
cage roll-forming process of ERW pipes is very tiny as compared
with the shaped steel strip, so all of them are assumed as rigid
bodies.
2.2. Finite element modeling
In the finite element model, eight-node brick elements are used
to generate the mesh for the steel strip, and four-node shell ele-
ments are used to model the roll surfaces. In order to simulate the
inside and outside bending deformation of strip more accurately,
the steel strip is divided into two layers through the thickness. The
whole strip consists of 231,132 nodes and 150,500 brick elements,
and all the forming rolls consist of 278,280 nodes and 269,384 shell
elements. The coulomb’s friction law is used and the frictional coef-
ficient is set to 0.1. For simplicity, all six degrees of freedom of all
of the forming rolls are fixed and the steel strip is pulled with a
certain speed through a series of fixed forming rolls arranged in the
forming direction. A set of nodes at the center of the strip is sub-
jected to a symmetrical condition constraint in the y–z plane, i.e.
no motion is allowed for y translation, x and z rotation. For keeping
a satisfactory precision for simulation, the virtual velocity should
be rationally controlled to ensure that the virtual kinetic energy
of metal sheet should be less than 7% of the total internal energy
(Zhang et al., 2006). As a result, in the final 3D simulation, the vir-
tual velocity of steel strip is set to 12 m/s, which results in its virtual
kinetic energy being 5.8% of the total internal energy.
3. Discussion of simulation results
Through the finite element simulation, the whole cage roll-
forming process of ERW round pipe is investigated.
3.1. Deformation features of steel strip
As shown in Fig. 7, A–A, B–B, C–C and D–D represent the section
shapes at the outlet of pre-forming, No.1–No.3 linear forming sec-
tions; E–E represents the section shape at the No.1 fin-pass stand.
 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856 4853

Fig. 7. Schematic illustration of non-bending area of steel sheet in the different forming positions.

The non-bending areas of steel sheet in different forming positions

can be clearly observed from Fig. 7. The so-called non-bending areas
are those regions on the strip that remain almost straight after
passing through forming rolls. According to Fig. 7, along the form-
ing direction, the non-bending area is always in existence prior to
the No.1 fin-pass stand and eliminated after passing through fin-
pass stands. The reason for having the non-bending area is that
the steel strip is shaped by air-bending before the No.1 fin-pass
stand (as shown in Fig. 8(a)). In air-bending the steel sheet and
forming rolls are under an incomplete contact state, which usually
leads to inadequate bending due to the lack of constraints. As the
deformed strip is passing through the fin-pass stands, it is shaped by
squeeze-bending (shown as Fig. 8(b)), which can greatly strengthen
the constraints. Moreover, in squeeze-bending the shape of the
deformed strip is generally dependent on the geometry of the
forming rolls. Therefore, the non-bending area of the steel strip is
eliminated at the fin-pass rolls.
Through above analysis, it just can be found that the non-
bending area usually occurs at the pre-forming and linear forming
sections, so it is still very necessary to investigate the ranges of the
Fig. 9. Relative curvature of the cross-section of deformed strip at different positions
non-bending area at different forming positions. In the next study, during the pre-forming section.
the non-bending area is indicated by the relative curvature, which
is defined as the ratio of bending radius of the deformed sheet to
deformed strip is 50–72% relative distance from the center of strip
the radius of the final product. Usually the region where relative
during the pre-forming section.
curvature is less than 0.1 can be taken as non-bending area.
Fig. 10 shows the relative curvature of the cross-section of the
In order to get the detailed information of the non-bending area
deformed strip at different positions during the linear forming sec-
during the whole cage roll-forming process, the relative curvature
along transverse profiles of the deformed sheet is calculated at the
typical forming positions. These typical forming positions include
the edge-bending stand (ED), upper roll 2 (R2), upper roll 4 (R4),
outlet of pre-forming section (Prf), outlet of No.1 linear forming
section (Lf1), outlet of No.2 linear forming section (Lf2), outlet of
No.3 linear forming section (Lf3), No.1 fin-pass stand (Fp1), No.2
fin-pass stand (Fp2) and No.3 fin-pass stand (Fp3).
Fig. 9 shows the relative curvature of the cross-section of the
deformed strip at different positions during the pre-forming sec-
tion. As shown in Fig. 9, the range of non-bending area of the

Fig. 10. Relative curvature of the cross-section of deformed strip at different posi-
Fig. 8. Schematic illustration of air-bending and squeeze-bending. tions during the linear forming section.
4854 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856
Fig. 11. Relative curvature of the cross-section of deformed strip at different posi-
tions during the fin-pass stands.
tion. As shown in Fig. 10, during the No.1 and No.2 linear forming
sections the range of non-bending area of the deformed strip is
52–72% relative distance from the center of strip and after the No.3
linear forming section its range is 63–68% relative distance from
the center of strip.
Fig. 11 shows relative curvature of the cross-section of deformed
strip at different positions at the fin-pass stands. As shown in Fig. 11,
the non-bending area of the deformed strip disappears completely
after the No.1 fin-pass stand, which has also been demonstrated in
Fig. 7.
In order to evaluate the contribution of different forming stands
and corresponding bending degree to the deformed strip, the inte-
gral of ‘relative curvature’ with respect to ‘distance from the center
of strip’ at different positions is calculated. Fig. 12 depicts the
integral of relative curvature of the deformed strip cross-section
at different forming positions. During the pre-forming and lin-
ear forming sections, the integral of relative curvature of the
deformed strip cross-section increases linearly and smoothly along
the forming direction; an obvious increment can be observed at
the edge-bending (ED) and No.1 fin-pass (Fp1) stands. The reason
is that the bending deformation at ED and Fp1 stands is very large,
while the deformation at the pre-forming and linear forming sec-
Fig. 12. Integral of relative curvature of the deformed strip cross-section at different
forming positions.
Fig. 13. Longitudinal strain of the deformed strip at inside edge during the entire
cage roll-forming process.
tions is smooth and uniform. In addition, at the last forming stand
(No.3 Fin-pass) the integral of relative curvature of the deformed
strip cross-section reaches about 0.65, which means the bending
deformation of the flat strip has been done 65% after the entire cage
roll-forming process. The remaining 35% deformation will be com-
pleted by squeeze-welding and sizing sections, before the deformed
strip becomes the final product.
3.2. Longitudinal strain
In practice, the most common defect in the cage roll-forming
process of ERW round pipes is edge buckling, which is so-called
“edge wave”. Once the edge elongation is excessive, the edge buck-
ling will occur. Therefore, it is necessary to analyze the longitudinal
strain of the skelp during the cage roll-forming process.
Fig. 13 shows the longitudinal strain of the deformed strip at
inside edge during the entire cage roll-forming process. In the lon-
gitudinal direction, tensile strain at the edge shows a great increase
and the maximum strain is about 1.65% at edge-bending stand. It
means the edge-bending rolls exert a strong bending on the strip
edge, which is helpful to increasing the rigidity and preventing
edge buckling. After edge-bending rolls, small plastic deforma-
tion occurs on the strip edge at the inlet of pre-forming section,
break down stand, the outlet of No.1–No.3 linear forming sec-
tions. In the cage zone, little variation in the longitudinal strain
is observed.
It should be noticed that the edge is subjected to a slight ten-
sile deformation and then a large compressive deformation in the
region from the last cage roll to the entrance of the No.1 fin-pass
stand.
The longitudinal strain at the edge shows a great increase at
the No.1–No.3 fin-pass stands and the maximum strains are about
2.0%, 2.3% and 3.2% respectively, which means that the relative large
deformation of the strip edge occurs at the fin-pass stands. Obvi-
ously, edge buckling is mostly likely to appear at the entry side of
No.1–No.3 fin-pass stands.
Fig. 14 shows the longitudinal strain of the deformed strip at
inside center part during the entire cage roll-forming process. As for
strain at the center part, small plastic deformation occurs after the
No.1 fin-pass stand and the longitudinal strain in the pre-forming
and linear forming sections are less than 0.2%, which indicates that
the longitudinal deformation in the cage zone is small enough to
remain within the elastic scope.
 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856 4855

Fig. 15. Profile comparison at the exit of edge-bending stand.

Fig. 14. Longitudinal strain of the deformed strip at inside center during the entire
cage roll-forming process.

Table 1
Comparisons of measured and simulated results of the circumferential length of
strip.

Measured positions Circumferential length l (mm) l (mm) ıl (%)

Simulated Measured

ED 1026.5 1030.5 4 0.388

Prf 1031.8 1036.2 4.4 0.425
Lf1 1035.5 1039.4 3.9 0.375
Lf2 1037.5 1043.1 5.6 0.537
Lf3 1041.5 1047 5.5 0.525

4. Comparisons with experimental measurements

In order to calibrate the finite element simulation, the circum-

Fig. 16. Profile comparison at the exit of the pre-forming section.
ferential length, opening distance and the section configurations of
the deformed strip have been measured on an industrial cage roll-
forming mill. As shown as in Fig. 7, for convenience, five measured respectively. The corresponding position is located at the exit of
positions have been chosen, which are the exit of edge bending No.2 linear forming section.
(ED), pre-forming section (Prf), linear forming section 1 (Lf1), linear Figs. 15–19 show the comparison of the section configurations
forming section 2 (Lf2) and linear forming section 3 (Lf3), respec- of the deformed strip at the exit of edge bending, pre-forming, No.1
tively. linear forming, No.2 linear forming and No.3 linear forming section
Table 1 shows the measured and simulated results of the circum- respectively. Good agreement is shown between the experimental
ferential length (l) of the deformed strip along the outside surface results and simulation results.
at the different positions. Table 2 shows the measured and simu-
lated results of the opening distance (d) of the deformed strip at
the outside surface at the different positions. As shown in Table 1,
the maximum absolute error (l ) and relative error (ıl ) of the
circumferential length is 5.6 mm and 0.537% respectively. The cor-
responding positions are located at the exit of No.2 linear forming
section. As shown in Table 2, the maximum absolute error (d ) and
relative error (ıd ) of the opening distance is 20.2 mm and 4.514%

Table 2
Comparisons of measured and simulated results of the opening distance of strip.

Measured positions Opening distance d (mm) d (mm) ıd (%)

Simulated Measured

ED 979.1 986.2 7.1 0.720

Prf 778.6 785.5 6.9 0.878
Lf1 572.6 585.8 13.2 2.253
Lf2 427.3 447.5 20.2 4.514
Lf3 184.6 190.3 5.7 2.995 Fig. 17. Profile comparison at the exit of No.1 linear forming.
4856 J. Jiang et al. / Journal of Materials Processing Technology 209 (2009) 4850–4856
Fig. 18. Profile comparison at the exit of No.2 linear forming.
Fig. 19. Profile comparison at the exit of No.3 linear forming.
5. Summary and conclusion
In this paper, the elastic–plastic FEM model about the whole
cage roll-forming ERW pipe mill has been established. The
deformation behavior of steel sheet has been analyzed through
simulation of the forming process. The following conclusions are
drawn:
(1) The steel strip is subjected to an air-bending deformation before
No.1 fin-pass stand in the cage roll-forming process. As a result,
the “non-bending area” phenomenon can be found before No.1
fin-pass stand. After calculating the relative curvature of profiles
of the deformed strip, the ranges of the non-bending area at
different forming positions are obtained, which is instructive to
the design of pass-schedules and roll profiles in the cage roll-
forming process.
(2) By computing the integral of ‘relative curvature’ with respect to
‘distance from the center of strip’ at different positions with the
trapezoidal method, not only the forming contribution of differ-
ent forming stands but also the bending degree of the deformed
strip in different forming sections are predicted. It is helpful
to evaluate the forming capability of different forming sections
and adjust forming parameters more reasonably during the cage
roll-forming process.
(3) Through analyzing the strain distribution of the deformed strip
in the forming direction, the characteristics of longitudinal
deformation at edge and center parts are obtained. At the same
time, the positions most likely subjected to edge buckling have
been located.
(4) The circumferential length, opening distance and the profiles of
the deformed strip have been measured on the Ø325 mm cage
roll-forming mill, and the experimental and simulated results
have a good agreement.
Acknowledgements
The authors would like to acknowledge the financial sup-
port of National Natural Science Foundation of China (Nos.
50634010, 50375095), Shanghai Science & Technology Projects
(Nos. 07XD14016, 06QA14026, 05JC14022), and Program for New
Century Excellent Talents in University (NCET-07-0545).
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