This paper proposes a novel method for determining the initial strip width for thick-walled steel pipes in roll forming. The method introduces three criteria to define the minimum initial width, maximum initial width, and a refined selection within the specified range. An industrial roll forming line is simulated using the commercial finite element software Abaqus. The accuracy of the finite element model is validated by comparing its results with measurements from the production line. Subsequently, the appropriate initial strip width is determined for producing pipes from St37 steel, with an external diameter of 219.1 mm and thicknesses of 6, 10 and 14 mm. This determination is based on criteria defined for circumferential reduction, edge buckling and relative curvature of the strip deforming at the fin-pass forming stage. The results demonstrate that a thicker pipe requires a lower initial width but a higher reduction ratio in the fin-pass station. In conclusion, the proposed method shows great potential for use in the pipe industry.
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