Mulliri për Formimin dhe Përcaktimin e Madhësive të Tubave

Mulliri i tubave të çelikut të karbonit ERW

Kompozimi i Makinerive të Mullirit me Tuba

Makinë për formimin e rrotullave të ftohtë

Linja e prerjes së spirales së çelikut

Linja e prerjes së spirales së çelikut të karbonit

Spirale çeliku e prerë në vijën e gjatësisë

Pajisje ndihmëse dhe pjesë këmbimi

Round to Square Forming and Sizing Section

In ERW tube production, the procesi i formimit nga rrumbullakët në katror 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.

Detajet e produktit

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Detajet e produktit

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Përshkrimi i produktit

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

Dizajni i linjës së propozuar bazohet në specifikimet e mëposhtme:

Specifikimi i lëndës së parë

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Rezistenca e materialit në tërheqje	Maks 517MPa (maks 75,000 psi)
Rezistenca e Materialit në Rrjedhje	Maks 460MPa (maks 67,000 psi)
Bobina OD	1200 mm deri në 2000 mm
ID e spirales	508mm&610mm (customer order)
Pesha e spirales	Maksimumi 7000 kg
Gjerësia e shiritit	Min 240mm, Max520mm
Trashësia e shiritit	Min2.0mm Max6.35mm

Gama e prodhimit

Lloji i prodhimit	▪Tuba të rrumbullakëta ▪Seksione të zbrazëta katrore dhe drejtkëndore
Tub i rrumbullakët me diametër OD	Min 76mm, Max 165mm
Trashësia e tubit të rrumbullakët	Min 2.0mm, Max 6.35mm
Seksioni i zbrazët katror	Min 60x60 mm, Maks 130x130 mm
Seksion i zbrazët drejtkëndor	Min 80x40mm, Maks 100X160mm
Trashësia e tubit katror dhe drejtkëndor	Min2.0mm, Max 5.0mm
Gjatësia e prerjes së tubit	Min 6 meter, Max 12 meter

Specifikimi i linjës

Forming Section

Materiali i boshtit:	40Cr, HF tempering quenching
Materiali i ingranazhit të pjerrët:	20CrMnTi
Qëndrim i shtyrë	7 sete
Qëndrim i papunë	8 sete
Kuti ingranazhesh	7 sete

Sizing Section

Materiali i boshtit:	40Cr, HF shuarje me kalitje
Materiali i ingranazhit të pjerrët:	20CrMnTi
Qëndrim i shtyrë	5 sete
Qëndrim i papunë	5 sete
Kuti ingranazhesh	5 sete

Rrjedha e Linjës së Prodhimit

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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