Investigation and Simulation of the Mannesmann Effect in QForm

The Mannesmann effect (ME) was first identified in the production of seamless tubes through helical or continuous rolling, named after the German engineers Mannesmann, who invented the first such process in 1886. This effect describes the formation of axial cavities in workpieces and forgings subjected to radial compression due to secondary tensile stresses developing in the material’s center. The ME presents significant challenges in processes such as cross-wedge rolling (CWR), gear processing, and rotary forging of round workpieces. This study investigates ME using finite element (FE) analysis in QForm. By analyzing velocity vectors and FE mesh structures, the research proposes improvements for more accurate stress distribution modeling. A modified damage assessment formula based on Lemaitre’s law is implemented for better predictive capabilities. Experimental modeling results are discussed, emphasizing the effect of geometric parameters on damage criteria. The conclusions provide recommendations for optimizing industrial metal forming processes. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2025.