Мелница за обликување и димензионирање цевки

ERW јаглероден челик цевки мелница

Композирај машина за мелница за цевки

Машина за формирање на ладна ролна

Линија за сечење на челични намотки

Јаглероден челик серпентина за сечење линија

Челична калем пресечена до линијата за должина

Помошна опрема и резервни делови

Round to Square Forming and Sizing Section

In ERW tube production, the процес на обликување од тркалезно до квадратно 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.

Детали за производот

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Детали за производот

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Опис на производот

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

Дизајнот на предложената линија се заснова на следната спецификација:

Спецификација на суровина

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Материјална цврстина на истегнување	Макс. 517MPa (макс. 75.000 psi)
Јачина на истегнување на материјалот	Макс. 460MPa (макс. 67.000 psi)
Калем ОД	1200 мм до 2000 мм
ИД на калем	508mm&610mm (customer order)
Тежина на серпентина	Макс. 7000 кг
Ширина на лента	Min 240mm, Max520mm
Дебелина на лента	Min2.0mm Max6.35mm

Опсег на производство

Вид на производство	▪ Тркалезни цевки ▪Квадратни и правоаголни шупливи пресеци
Тркалезна цевка со надворешен дијаметар	Min 76mm, Max 165mm
Дебелина на тркалезната цевка	Min 2.0mm, Max 6.35mm
Квадратен шуплив дел	Мин. 60x60 мм, макс. 130x130 мм
Правоаголен шуплив дел	Мин. 80x40mm, макс. 100X160mm
Квадратна и правоаголна дебелина на цевката	Min2.0mm, Max 5.0mm
Должина на сечењето на цевката	Min 6 meter, Max 12 meter

Спецификација на линијата

Forming Section

Материјал на вратилото:	40Cr, HF tempering quenching
Материјал на конусен запчаник:	20CrMnTi
Погонски држач	7 сета
мирување	8 сета
Менувачка кутија	7 сета

Sizing Section

Материјал на вратилото:	40Cr, HF калење при гаснење
Материјал на конусен запчаник:	20CrMnTi
Погонски држач	5 сета
мирување	5 сета
Менувачка кутија	5 сета

Текот на производствената линија

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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