Трубоформовочный и калибровочный стан

Трубный завод ERW из углеродистой стали

Состав трубопрокатной машины

Машина для холодной прокатки

Линия продольной резки рулонной стали

Линия продольной резки рулонной углеродистой стали

Линия поперечной резки рулонной стали

Вспомогательное оборудование и запасные части

Round to Square Forming and Sizing Section

In ERW tube production, the процесс формовки круглого сечения в квадратное 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.

Подробная информация о продукте

Свяжитесь сейчас

Подробная информация о продукте

Видео

Описание продукта

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

Проектирование предлагаемой линии основано на следующей спецификации:

Спецификация сырья

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Прочность материала на растяжение	Макс. 517 МПа (макс. 75 000 фунтов на кв. дюйм)
Предел текучести материала	Макс. 460 МПа (макс. 67 000 фунтов на кв. дюйм)
Внешний диаметр катушки	1200 мм до 2000 мм
Идентификатор катушки	508mm&610mm (customer order)
Вес катушки	Макс. 7000 кг
Ширина полосы	Min 240mm, Max520mm
Толщина полосы	Min2.0mm Max6.35mm

Ассортимент продукции

Вид производства	▪Круглые трубы ▪Квадратные и прямоугольные полые профили
Внешний диаметр круглой трубы	Min 76mm, Max 165mm
Толщина круглой трубы	Min 2.0mm, Max 6.35mm
Квадратное полое сечение	Мин. 60x60 мм, макс. 130x130 мм
Прямоугольное полое сечение	Мин. 80x40 мм, макс. 100x160 мм
Толщина квадратной и прямоугольной трубы	Min2.0mm, Max 5.0mm
Длина отрезка трубы	Min 6 meter, Max 12 meter

Спецификация линии

Forming Section

Материал вала:	40Cr, HF tempering quenching
Материал конической шестерни:	20CrMnTi
Приводной стенд	7 комплектов
простаивать	8 комплектов
Коробка передач	7 комплектов

Sizing Section

Материал вала:	40Cr,HF отпуск закалка
Материал конической шестерни:	20CrMnTi
Приводной стенд	5 комплектов
простаивать	5 комплектов
Коробка передач	5 комплектов

Поток производственной линии

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.

Свяжитесь с нами

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

* Имя

* Электронная почта

Телефон

*Сообщение

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.

Сопутствующие товары

3 Inch Pipe Straightening Machine for ERW Tube Mill

Посмотреть больше

Garage Door Strut Roll Forming Machine

Посмотреть больше

ERW Tube and Pipe Welding Impeder – High Efficiency Ferrite Core | AIS MACHINERY

Посмотреть больше

Automatic Steel Pipe Oiling & Painting Line | ERW Pipe Coating Equipment Manufacturer – AIS MACHINERY

Посмотреть больше

Impeder for ERW Tube and Pipe Welding

Посмотреть больше

Auto Stacking and Strapping Machine for Hex Steel Tubes

Посмотреть больше

Warehouse Pallet Rack Roll Forming Machine

Посмотреть больше

Solar Panel Frame Roll Forming Machine (Carbon Steel Type)

Посмотреть больше

Связанные новости

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

Посмотреть больше

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.

Посмотреть больше

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.

Посмотреть больше

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.

Посмотреть больше

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.

Посмотреть больше

2026-04-09 16:15:19

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

Посмотреть больше

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.

Посмотреть больше

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.

Посмотреть больше

Отправить сообщение

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!