In the field of tube production research is regularly conducted to gain knowledge and optimise the process parameters, a necessity resulting from the strong competition and fast evolution of the market. The aim of this work is to design and to improve an FEM model able to correctly define the parameters affecting the hole formation and propagation during the rotary tube piercing process (Mannesmann process). The software used to perform the simulations was a commercial FEM code, namely Deform 3D. In particular the three-dimensional model developed is able to calculate stress and deformation distributions into the round bar. A high degree of interesting information is obtained from the simulations performed and the most important results are shown in this article. Pietra SpA Company, a partner in this research, has supplied the technological data introduced in the simulation model. A comparison between the experimental and FEM results shows that the FEM software (12 is able to correctly represent the phenomena, so it is possible to use it to optimise the production process of rotary tube piercing.
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