Usine de formage et de dimensionnement de tubes

Laminoir à tubes en acier au carbone ERW

Machine de broyage de tubes Compose

Machine de formage à froid

Ligne de refendage de bobines d'acier

Ligne de refendage de bobines d'acier au carbone

Ligne de coupe à longueur de bobines d'acier

Équipements auxiliaires et pièces de rechange

Round to Square Forming and Sizing Section

In ERW tube production, the processus de formage rond à carré 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.

Détails du produit

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Détails du produit

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Description du produit

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

La conception de la ligne proposée est basée sur les spécifications suivantes :

Spécification des matières premières

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Résistance à la traction du matériau	Max 517MPa (75 000 psi max)
Limite d'élasticité du matériau	Max 460 MPa (67 000 psi max)
Diamètre extérieur de la bobine	1200 mm à 2000 mm
ID de la bobine	508mm&610mm (customer order)
Poids de la bobine	Max 7000 kg
Largeur de la bande	Min 240mm, Max520mm
Épaisseur de la bande	Min2.0mm Max6.35mm

Gamme de production

Type de production	▪Tubes ronds ▪Sections creuses carrées et rectangulaires
Tube rond diamètre extérieur	Min 76mm, Max 165mm
Épaisseur du tube rond	Min 2.0mm, Max 6.35mm
Section creuse carrée	Dimensions minimales : 60 x 60 mm, dimensions maximales : 130 x 130 mm
Section creuse rectangulaire	Min 80 x 40 mm, Max 100 x 160 mm
Épaisseur des tubes carrés et rectangulaires	Min2.0mm, Max 5.0mm
Longueur de coupe du tube	Min 6 meter, Max 12 meter

Spécifications de la ligne

Forming Section

Matériau de la tige :	40Cr, HF tempering quenching
Matériau de l'engrenage conique :	20CrMnTi
Support motorisé	7 ensembles
Étau	8 ensembles
Boîte de vitesses	7 ensembles

Sizing Section

Matériau de la tige :	40Cr, revenu HF trempe
Matériau de l'engrenage conique :	20CrMnTi
Support motorisé	5 ensembles
Étau	5 ensembles
Boîte de vitesses	5 ensembles

Déroulement de la chaîne de production

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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