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Combined Experimental and Simulation-Based Approach for Optimizing Roll Forming of Pipes for Hydrogen Infrastructure

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Abstract:

Roll forming pipes for hydrogen infrastructure poses particular challenges for process design, especially with regard to geometric accuracy and the avoidance of forming defects that could compromise the integrity of the pipelines. Geometric accuracy is crucial to ensure uniform pressure distribution within the pipe. Conventional trial-and-error approaches to developing roll flower designs are time-consuming and cost-intensive, especially when working with high-strength steel grades. This work presents an integrated methodology for roll forming of monolithic sheet by incorporating real-world machine stiffness and experimental anisotropy. A finite element model was developed for S235 and S355 steels, validated through three-point bending and Digital Image Correlation (DIC). While database-derived models (JMatPro) underestimated yield stress by up to 30%, the experimental model precisely predicted strain distributions (error < 2%). A central novelty is the integration of in-situ 3D laser scans of the roll forming mill under load, allowing the simulation to account for elastic machine deflection. This enables the prediction of process-induced residual stresses, which are critical for the long-term integrity of pipelines against hydrogen-induced cracking.

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Periodical:

Key Engineering Materials (Volume 1050)

Pages:

235-247

DOI:

https://doi.org/10.4028/p-SA56ki

Citation:

Cite this paper

Online since:

April 2026

Authors:

Murli Manohar Pandey*, Anja Rautenstrauch, Andreas Kunke, Till Clausmeyer

Keywords:

FEM Simulation, Modeling, Pipe, Roll Forming

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Creative Commons CC BY 4.0

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* - Corresponding Author

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