Collapse performance enhancement in the sizing process of ERW pipes produced using edge, double radii, and reverse bending methods

The rising demand for offshore transportation of oil, gas, and derivatives necessitates high-performing pipeline infrastructure. Electric resistance welded pipes, manufactured through cold-forming processes, have become a cornerstone for offshore pipeline systems. This study employs sequential numerical simulations in ABAQUS to model the pipe-forming process and predict collapse pressures—a pivotal design parameter for offshore pipelines. Three forming methods were modeled: reverse bending forming, double radii forming, and edge forming, with roller geometries tailored to each technique. The constitutive model integrated cyclic tension-compression loading, incorporating the Bauschinger effect and strain hardening for precise material representation. The impact of the sizing stage in the pipe manufacturing was analyzed through different sizing ratios and the thickness-to-diameter ratio. Results demonstrated that higher sizing ratios uniformly enhance collapse pressure regardless of the forming method, particularly in pipes with larger t/D values. Among the forming methods, reverse bending forming consistently produced pipes with superior collapse performance. Parametric studies further explored the influence of ovality and stress history on collapse pressure enhancement across sizing ratios.