Molino de conformado y dimensionamiento de tubos

Laminador de tubos de acero al carbono ERW

Máquina de laminación de tubos

Máquina formadora de rollos en frío

Línea de corte longitudinal de bobinas de acero

Línea de corte longitudinal de bobinas de acero al carbono

Línea de corte longitudinal de bobinas de acero

Equipos Auxiliares y Repuestos

Round to Square Forming and Sizing Section

In ERW tube production, the proceso de conformado de redondo a cuadrado 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.

Detalles del producto

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Detalles del producto

Video

Descripción del Producto

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

El diseño de la línea propuesta se basa en la siguiente especificación:

Especificación de materia prima

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Resistencia a la tracción del material	Presión máxima 517 MPa (75.000 psi máx.)
Resistencia a la fluencia del material	Presión máxima 460 MPa (67.000 psi máx.)
Diámetro exterior de la bobina	1200 mm a 2000 mm
Identificación de la bobina	508mm&610mm (customer order)
Peso de la bobina	Máximo 7000 kg
Ancho de la tira	Min 240mm, Max520mm
Espesor de la tira	Min2.0mm Max6.35mm

Gama de producción

Tipo de producción	▪Tubos redondos ▪Secciones huecas cuadradas y rectangulares
Diámetro exterior de tubo redondo	Min 76mm, Max 165mm
Espesor del tubo redondo	Min 2.0mm, Max 6.35mm
Sección hueca cuadrada	Mínimo 60x60 mm, Máximo 130x130 mm
Sección hueca rectangular	Mínimo 80x40 mm, Máximo 100x160 mm
Espesor de tubos cuadrados y rectangulares	Min2.0mm, Max 5.0mm
Longitud de corte del tubo	Min 6 meter, Max 12 meter

Especificación de línea

Forming Section

Material del eje:	40Cr, HF tempering quenching
Material del engranaje cónico:	20CrMnTi
Soporte de transmisión	7 juegos
Soporte inactivo	8 juegos
Caja de cambios	7 juegos

Sizing Section

Material del eje:	40Cr, revenido HF temple
Material del engranaje cónico:	20CrMnTi
Soporte de transmisión	5 juegos
Soporte inactivo	5 juegos
Caja de cambios	5 juegos

El flujo de la línea de producción

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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