튜브 성형 및 사이징 밀

ERW 탄소강 튜브 밀

튜브 밀 기계 구성

콜드롤 성형기

스틸 코일 슬리팅 라인

탄소강 코일 슬리팅 라인

길이에 맞춰 절단된 강철 코일 라인

보조 장비 및 예비 부품

Round to Square Forming and Sizing Section

In ERW tube production, the 원형에서 정사각형으로 성형하는 공정 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.

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제품 세부 정보

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제품 설명

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

제안된 노선의 설계는 다음 사양을 기반으로 합니다.

원자재 사양

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
재료 인장 강도	최대 517MPa(최대 75,000psi)
재료 항복 강도	최대 460MPa(최대 67,000psi)
코일 외경	1200mm에서 2000mm까지
코일 ID	508mm&610mm (customer order)
코일 무게	최대 7000kg
스트립 폭	Min 240mm, Max520mm
스트립 두께	Min2.0mm Max6.35mm

생산 범위

생산 유형	▪원형 튜브 ▪정사각형 및 직사각형 중공 단면
원형 튜브 외경	Min 76mm, Max 165mm
원형 튜브 두께	Min 2.0mm, Max 6.35mm
정사각형 중공 단면	최소 60x60mm, 최대 130x130mm
직사각형 중공 단면	최소 80x40mm, 최대 100x160mm
정사각형 및 직사각형 튜브 두께	Min2.0mm, Max 5.0mm
튜브 절단 길이	Min 6 meter, Max 12 meter

라인 사양

Forming Section

샤프트 소재:	40Cr, HF tempering quenching
베벨기어의 재료:	20CrMnTi
구동 스탠드	7세트
아이들 스탠드	8세트
기어박스	7세트

Sizing Section

샤프트 소재:	40Cr,HF 템퍼링 담금질
베벨기어의 재료:	20CrMnTi
구동 스탠드	5세트
아이들 스탠드	5세트
기어박스	5세트

생산 라인의 흐름

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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