Laminatoio per la formatura e la calibrazione dei tubi

Laminatoio per tubi in acciaio al carbonio ERW

Macchina per laminazione tubi Compose

Macchina per la formatura a freddo

Linea di taglio a nastro in acciaio

Linea di taglio a nastro per bobine di acciaio al carbonio

Bobina di acciaio tagliata a misura

Attrezzature ausiliarie e pezzi di ricambio

Round to Square Forming and Sizing Section

In ERW tube production, the processo di formatura da tondo a quadrato 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.

Dettagli del prodotto

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Dettagli del prodotto

Video

Descrizione del prodotto

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 progettazione della linea proposta si basa sulle seguenti specifiche:

Specifiche della materia prima

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Resistenza alla trazione del materiale	Max 517 MPa (75.000 psi max)
Resistenza allo snervamento del materiale	Max 460 MPa (67.000 psi max)
Diametro esterno della bobina	da 1200 mm a 2000 mm
ID bobina	508mm&610mm (customer order)
Peso della bobina	Massimo 7000 kg
Larghezza della striscia	Min 240mm, Max520mm
Spessore della striscia	Min2.0mm Max6.35mm

Gamma di produzione

Tipo di produzione	▪Tubi tondi ▪Sezioni cave quadrate e rettangolari
Tubo tondo OD	Min 76mm, Max 165mm
Spessore del tubo tondo	Min 2.0mm, Max 6.35mm
Sezione cava quadrata	Min 60x60mm, Max 130x130mm
Sezione cava rettangolare	Minimo 80x40mm, Massimo 100X160mm
Spessore del tubo quadrato e rettangolare	Min2.0mm, Max 5.0mm
Lunghezza del taglio del tubo	Min 6 meter, Max 12 meter

Specifiche della linea

Forming Section

Materiale dell'albero:	40Cr, HF tempering quenching
Materiale dell'ingranaggio conico:	20CrMnTi
Supporto guidato	7 set
Supporto inattivo	8 set
Scatola del cambio	7 set

Sizing Section

Materiale dell'albero:	40Cr, tempra con rinvenimento HF
Materiale dell'ingranaggio conico:	20CrMnTi
Supporto guidato	5 set
Supporto inattivo	5 set
Scatola del cambio	5 set

Il flusso della linea di produzione

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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