Tube Forming and Sizing Mill

ERW көміртекті болат құбыр диірмені

Түтік диірмен машинасын құрастыру

Суық орамды қалыптау машинасы

Болат орамды кесу сызығы

Көміртекті болаттан жасалған катушкаларды кесу сызығы

Ұзындыққа кесілген болат катушкалар

Көмекші жабдықтар мен қосалқы бөлшектер

Round to Square Forming and Sizing Section

In ERW tube production, the дөңгелектен шаршыға дейін қалыптастыру процесі 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.

Өнім мәліметтері

Қазір хабарласыңыз

Өнім мәліметтері

Бейне

Өнім сипаттамасы

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

Ұсынылған желіні жобалау келесі спецификацияға негізделген:

Шикізаттың спецификациясы

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Материалдың созылу күші	Макс 517 МПа (макс. 75 000 psi)
Материалдың шығымдылығы	Макс 460 МПа (макс 67 000 psi)
Орам OD	1200 мм-ден 2000 мм-ге дейін
Катушка идентификаторы	508mm&610mm (customer order)
Орамның салмағы	Ең көбі 7000 кг
Жолақ ені	Min 240mm, Max520mm
Жолақ қалыңдығы	Min2.0mm Max6.35mm

Өндіріс ауқымы

Өндіріс түрі	▪Дөңгелек түтіктер ▪Төртбұрышты және төртбұрышты қуыс қималар
Дөңгелек түтік OD	Min 76mm, Max 165mm
Дөңгелек түтік қалыңдығы	Min 2.0mm, Max 6.35mm
Шаршы қуыс бөлім	Мин 60x60мм, макс 130x130мм
Тік бұрышты қуыс қима	Мин 80x40мм, Макс 100X160мм
Шаршы және тіктөртбұрыш түтік қалыңдығы	Min2.0mm, Max 5.0mm
Түтіктің кесілген ұзындығы	Min 6 meter, Max 12 meter

Сызық сипаттамасы

Forming Section

Білік материалы:	40Cr, HF tempering quenching
Конусты беріліс материалы:	20CrMnTi
Жетекші стенд	7 жиынтық
Бос стенд	8 жиынтық
Беріліс қорабы	7 жиынтық

Sizing Section

Білік материалы:	40Cr,HF шынықтырумен сөндіру
Конусты беріліс материалы:	20CrMnTi
Жетекші стенд	5 жиынтық
Бос стенд	5 жиынтық
Беріліс қорабы	5 жиынтық

Өндіріс желісінің ағымы

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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