チューブ成形およびサイジングミル

ERW炭素鋼チューブミル

チューブミルマシン構成

冷間ロール成形機

スチールコイルスリッターライン

炭素鋼コイルスリッターライン

長さに合わせて切断された鋼コイル

補助装置およびスペアパーツ

Round to Square Forming and Sizing Section

In ERW tube production, the 丸型から角型への成形工程 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.

製品詳細

今すぐお問い合わせ

製品詳細

ビデオ

製品説明

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

提案されたラインの設計は、次の仕様に基づいています。

原材料仕様

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
材料の引張強度	最大517MPa（最大75,000psi）
材料降伏強度	最大460MPa（最大67,000psi）
コイル外径	1200mmから2000mm
コイルID	508mm&610mm (customer order)
コイル重量	最大7000kg
ストリップ幅	Min 240mm, Max520mm
ストリップ厚さ	Min2.0mm Max6.35mm

生産範囲

生産タイプ	▪丸管 ▪正方形および長方形の中空セクション
丸管外径	Min 76mm, Max 165mm
丸管の厚さ	Min 2.0mm, Max 6.35mm
角中空断面	最小60x60mm、最大130x130mm
長方形中空断面	最小80x40mm、最大100x160mm
正方形および長方形のチューブの厚さ	Min2.0mm, Max 5.0mm
チューブカット長さ	Min 6 meter, Max 12 meter

ライン仕様

Forming Section

シャフト材質:	40Cr, HF tempering quenching
ベベルギアの材質：	20CrMnTi
駆動スタンド	7セット
アイドルスタンド	8セット
ギアボックス	7セット

Sizing Section

シャフト材質:	40Cr、HF焼戻し焼入れ
ベベルギアの材質：	20CrMnTi
駆動スタンド	5セット
アイドルスタンド	5セット
ギアボックス	5セット

生産ラインの流れ

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.

お問い合わせ

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

* 名前

* 電子メール

電話

*メッセージ

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.

関連ニュース

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

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.

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.

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.

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.

2026-04-09 16:15:19

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

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.

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.

メッセージを送信

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!