Pyramidal three-roll bending has the advantage of simple configuration and is widely used in manufacture. However, the bent shape has two planar zones near the front and rear ends. This paper proposes the modeling of the mecano-welding process which provides improved circularity of the bent shape. This process includes three sub-processes: the first sub-process is the roll bending from a plate with cylindrical rolls, the second sub-process which is the gas metal arc-welding process used to join the gap of the bent tubular section, and the third sub-process is the rerun roll bending of the welded shape. Results of the simulation of the first two sub-processes under the well-known ANSYS and ANSYS/LS-DYNA environment are reported. The bent shape after the first roll bending, the distributions of the temperature and residual stress after the welding are illustrated.

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