Tube Forming and Sizing Mill

مطحنة أنابيب الفولاذ الكربوني ERW

آلة طحن الأنابيب

آلة تشكيل اللفة الباردة

خط تقطيع لفائف الفولاذ

خط تقطيع لفائف الفولاذ الكربوني

خط قطع لفائف الفولاذ حسب الطول

المعدات المساعدة وقطع الغيار

Round to Square Forming and Sizing Section

In ERW tube production, the عملية تشكيل من دائري إلى مربع is a key technique for manufacturing square and rectangular pipes. It involves reshaping a fully welded round tube into a square or rectangular section through a series of precision sizing and forming rolls under cold forming conditions.

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1. Technical Overview: Round-to-Square Forming Process

Process Flow:

Raw material → Forming → HF Welding → Burr Removal → Cooling → Round-to-Square → Sizing → Flying Saw → Finished Pipe

Key Features and Technical Notes:

Stepwise Deformation: The tube undergoes three stages: pre-forming, transitional forming, and final shaping, progressively transforming the round section into a square.
Cold Bending Principle: The shaping relies on plastic deformation across multiple roll passes to gradually modify the profile.
Precision Control: Equipped with CNC adjustments and inline measuring systems to ensure dimensional accuracy and edge/angle precision.
Flexible Tooling: Only the final forming and sizing rolls need to be replaced for different specifications, allowing fast product changeovers.

Technical Advantages:

High dimensional accuracy and straight edges with clean corners
Centralized weld seam, ensuring better structural performance
Reduced energy consumption and tooling wear compared to direct square forming
Widely used in construction, mechanical frames, furniture tubing, and automotive profiles

2. BASIC DESIGN DATA

يعتمد تصميم الخط المقترح على المواصفات التالية:

مواصفات المواد الخام

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
قوة الشد المادية	الحد الأقصى 517 ميجا باسكال (75000 رطل لكل بوصة مربعة كحد أقصى)
قوة خضوع المواد	الحد الأقصى 460 ميجا باسكال (67000 رطل لكل بوصة مربعة كحد أقصى)
ملف OD	1200 مم إلى 2000 مم
معرف الملف	508mm&610mm (customer order)
وزن الملف	الحد الأقصى 7000 كجم
عرض الشريط	Min 240mm, Max520mm
سمك الشريط	Min2.0mm Max6.35mm

نطاق الإنتاج

نوع الإنتاج	▪أنابيب مستديرة ▪أقسام مجوفة مربعة ومستطيلة
أنبوب دائري بقطر خارجي	Min 76mm, Max 165mm
سمك الأنبوب المستدير	Min 2.0mm, Max 6.35mm
مقطع مربع مجوف	الحد الأدنى 60 × 60 مم، الحد الأقصى 130 × 130 مم
مقطع مجوف مستطيل	الحد الأدنى 80 × 40 مم، الحد الأقصى 100 × 160 مم
سمك الأنبوب المربع والمستطيل	Min2.0mm, Max 5.0mm
طول قطع الأنبوب	Min 6 meter, Max 12 meter

مواصفات الخط

Forming Section

مادة العمود:	40Cr, HF tempering quenching
مادة الترس المخروطي:	20CrMnTi
حامل مدفوع	7 مجموعات
حامل خامل	8 مجموعات
صندوق التروس	7 مجموعات

Sizing Section

مادة العمود:	40Cr، HF تبريد وتلطيف
مادة الترس المخروطي:	20CrMnTi
حامل مدفوع	5 مجموعات
حامل خامل	5 مجموعات
صندوق التروس	5 مجموعات

تدفق خط الإنتاج

Forming section（Flattening unit +Main driving unit +Forming unit +Guide unit +squeeze roller）+ De-burr frame →→Cooling unit →→ Sizing unit and straightener

Forming and Final Sizing Section of ERW Pipe Mill

2. Frequently Asked Questions (FAQ)

Q1: Why choose the round-to-square process instead of direct square forming?
A: The round-to-square method ensures better weld seam alignment, stronger structural integrity, and greater tooling flexibility, especially for mid-to-thick wall and high-strength materials.

Q2: How is the corner quality controlled? What are the common issues?
A: Corners are formed through gradual pressing in multiple roll passes. Issues like cracking, over-rounded corners, or misalignment can be resolved by optimizing roll design and adjusting pressure settings.

Q3: How to prevent weld seam misalignment during forming?
A: Keep the weld seam centered after welding and ensure symmetrical roll forces during forming. Optional weld seam tracking systems can further stabilize seam position.

Q4: Do we need to replace the entire roll set when changing specifications?
A: No. Only the round-to-square and sizing sections need to be changed, significantly reducing downtime and tooling costs.

Q5: What causes edge waviness or "bamboo-like" defects?
A: These are typically due to excessive deformation per pass or improper roll design. Adjusting the deformation rate and optimizing pressure balance in the sizing unit can solve this.

Q6: Is round-to-square suitable for small-size thin-wall tubes?
A: Generally not. Thin-wall small tubes are prone to instability or cracking during transformation. Direct square forming is more appropriate for such sizes.

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Forming & Sizing Section FAQs

Why choose the round-to-square process instead of direct square forming?

The round-to-square method ensures better weld seam alignment, stronger structural integrity, and greater tooling flexibility, especially for mid-to-thick wall and high-strength materials.

How is the corner quality controlled? What are the common issues?

Corners are formed through gradual pressing in multiple roll passes. Issues like cracking, over-rounded corners, or misalignment can be resolved by optimizing roll design and adjusting pressure settings.

How to prevent weld seam misalignment during forming?

Keep the weld seam centered after welding and ensure symmetrical roll forces during forming. Optional weld seam tracking systems can further stabilize seam position.

Do we need to replace the entire roll set when changing specifications?

No. Only the round-to-square and sizing sections need to be changed, significantly reducing downtime and tooling costs.

What causes edge waviness or "bamboo-like" defects?

These are typically due to excessive deformation per pass or improper roll design. Adjusting the deformation rate and optimizing pressure balance in the sizing unit can solve this.

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