Rohrform- und Kalibriermühle

ERW-Rohrwerk aus Kohlenstoffstahl

Rohrmühlenmaschine Zusammensetzung

Kaltwalzformmaschine

Spaltanlage für Stahlcoils

Spaltanlage für Kohlenstoffstahl-Coils

Auf Länge geschnittene Stahlspulenlinie

Zusatzgeräte und Ersatzteile

Round to Square Forming and Sizing Section

In ERW tube production, the Rund-zu-Quadrat-Umformungsprozess 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.

Produktdetails

Kontaktieren Sie mich jetzt

Produktdetails

Video

Produktbeschreibung

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

Der Entwurf der vorgeschlagenen Linie basiert auf folgenden Spezifikationen:

Rohstoffspezifikation

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Zugfestigkeit des Materials	Maximal 517 MPa (75.000 psi max.)
Streckgrenze des Materials	Maximal 460 MPa (67.000 psi maximal)
Spulenaußendurchmesser	1200 mm bis 2000 mm
Spulen-ID	508mm&610mm (customer order)
Spulengewicht	Max. 7000 kg
Streifenbreite	Min 240mm, Max520mm
Streifendicke	Min2.0mm Max6.35mm

Produktionsspektrum

Art der Produktion	▪Rundrohre ▪Quadratische und rechteckige Hohlprofile
Rundrohr-Außendurchmesser	Min 76mm, Max 165mm
Wandstärke von Rundrohren	Min 2.0mm, Max 6.35mm
Quadratisches Hohlprofil	Mindestens 60 x 60 mm, maximal 130 x 130 mm
Rechteckiges Hohlprofil	Mindestens 80 x 40 mm, maximal 100 x 160 mm
Wandstärke von Vierkant- und Rechteckrohren	Min2.0mm, Max 5.0mm
Rohrschnittlänge	Min 6 meter, Max 12 meter

Linienspezifikation

Forming Section

Wellenmaterial:	40Cr, HF tempering quenching
Werkstoff des Kegelrads:	20CrMnTi
Getriebestand	7 Sets
Leerlaufstand	8 Sets
Getriebe	7 Sets

Sizing Section

Wellenmaterial:	40Cr,HF Anlassen Abschrecken
Werkstoff des Kegelrads:	20CrMnTi
Getriebestand	5 Sets
Leerlaufstand	5 Sets
Getriebe	5 Sets

Der Ablauf der Produktionslinie

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.

Schreiben Sie uns

If you are interested in our products, you can choose to leave your information here, and we will be in touch with you shortly.

* Name

* E-Mail

Telefon

*Nachricht

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.

Verwandte Produkte

3 Inch Pipe Straightening Machine for ERW Tube Mill

damit mehr

Garage Door Strut Roll Forming Machine

damit mehr

ERW Tube and Pipe Welding Impeder – High Efficiency Ferrite Core | AIS MACHINERY

damit mehr

Automatic Steel Pipe Oiling & Painting Line | ERW Pipe Coating Equipment Manufacturer – AIS MACHINERY

damit mehr

Impeder for ERW Tube and Pipe Welding

damit mehr

Auto Stacking and Strapping Machine for Hex Steel Tubes

damit mehr

Warehouse Pallet Rack Roll Forming Machine

damit mehr

Solar Panel Frame Roll Forming Machine (Carbon Steel Type)

damit mehr

Verwandte Nachrichten

2026-04-18 03:20:20

AIS Machinery Showcases Advanced Tube Solutions at Tube & Wire Düsseldorf 2026

Tube & Wire Düsseldorf 2026, one of the most influential exhibitions in the global tube and wire industry, held biennially in Düsseldorf, Germany

damit mehr

2027-04-17 00:00:00

Southeast Asia Client Visits Our Factory | Customized Tube Mill Solution Delivered

A Southeast Asia client visited our ERW tube mill factory to inspect production lines and discuss a customized tube mill solution. Impressed by our machine quality, welding performance, and engineering support, the client confirmed strong cooperation intentions. Discover how our ERW tube mill solutions improve efficiency, precision, and long-term production reliability.

damit mehr

2026-04-16 02:35:12

Professional Cold Roll Forming Machine Factory for Production

In the modern industrial landscape, the precision of metal shaping is the cornerstone of quality manufacturing. Partnering with a professional cold roll forming machine factory is essential for businesses looking to optimize their production lines, reduce material waste, and ensure high-dimensional accuracy. Whether you are producing C-channels, square tubes, or custom profiles, the choice of machinery determines your competitive edge in the market. This guide will explore the critical factors in selecting a factory and the technical advantages of advanced roll forming technology to help you make an informed investment.

damit mehr

2026-04-15 10:37:55

Flat Bar Production Line for Steel Coils: How It Works & Why It Matters

Looking for a flat bar production line? Learn how it turns steel coils into ready-to-use flat bars with precise length and high straightness. Compare it with slitting lines and get the best solution for your steel processing needs.

damit mehr

2026-04-14 00:00:00

Looking for a Milling Saw for ERW Tube Mill? Here’s What You Need to Know

Looking for a high-performance milling saw for your ERW tube mill? Upgrade to burr-free, high-precision pipe cutting with advanced flying saw technology. Improve efficiency, reduce rework, and meet export standards for carbon steel, stainless steel, and API pipes. Contact us today for expert solutions and competitive pricing tailored to your production needs.

damit mehr

2026-04-09 16:15:19

5-Inch (127mm) ERW Tube Making Machine Delivered with Heavy-Duty Design and Advanced Quick Change System

damit mehr

2027-04-07 00:00:00

Metal Embossing Machine: Turn Flat Sheets into High-Value Textured Products

Discover how a metal embossing machine transforms flat steel, stainless steel, and aluminum sheets into high-value textured products. Learn about its working principle, key components, and applications. Ideal for decorative and industrial use, embossing machines improve both appearance and performance. Explore complete embossing line solutions and find the right machine for your production needs.

damit mehr

2026-04-04 20:37:18

Automatic Double Side Uncoiler with Hydraulic Expansion and Auto Rotation for Steel Coil Processing

The Automatic Double Side Uncoiler is a high-efficiency solution designed for modern steel coil processing lines, including tube mills, roll forming machines, and slitting lines. With a maximum capacity of 4 tons per side, this machine ensures stable and continuous coil feeding while reducing downtime during coil change.

damit mehr

Eine Nachricht senden

Dear customer, thank you for your attention! We provide high-quality machinery and equipment and look forward to your orders. Please inform us of your needs and we will respond quickly!