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A square steel pipe is reshaped from a welded round pipe by roll forming. We investigated the effect of the roll diameter on the cross-sectional size of the square steel pipe by experimentation and three-dimensional finite element (FE) simulation. When the diameters of the top and bottom roll pairs are larger than those of the pair of side rolls, the cross section width of the formed pipe is less than the height. To equilibrate them, we perform finish forming at the final stage. Furthermore, the width of corner part of the formed pipe is greater than its height. The difference between these two sizes of width and height of the corner part in the final product is greater than those at upstream stands and increases with the ratio of the diameter of top and bottom roll pairs to that of side roll pairs. Offset the smaller roll pairs upstream makes the pipe square. Such offset is effective for producing pipes with equal width and height at the corner.

Effects of Roll Diameter and Offset on Sectional Shape of Square Steel Pipe Processed by Roll Forming