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โรงงานผลิตท่อเหล็กกล้าคาร์บอน ERW

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Round to Square Forming and Sizing Section

In ERW tube production, the กระบวนการขึ้นรูปกลมเป็นสี่เหลี่ยม 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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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

การออกแบบสายที่เสนอจะอิงตามข้อกำหนดต่อไปนี้:

ข้อมูลจำเพาะของวัตถุดิบ

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
ความแข็งแรงแรงดึงของวัสดุ	สูงสุด 517MPa (สูงสุด 75,000 psi)
ความแข็งแรงของวัสดุ	สูงสุด 460MPa (สูงสุด 67,000 psi)
คอยล์ OD	1200 มม. ถึง 2000 มม.
รหัสคอยล์	508mm&610mm (customer order)
น้ำหนักคอยล์	สูงสุด 7000 กก.
ความกว้างของแถบ	Min 240mm, Max520mm
ความหนาของแถบ	Min2.0mm Max6.35mm

ช่วงการผลิต

ประเภทการผลิต	▪ท่อกลม ▪ส่วนกลวงสี่เหลี่ยมจัตุรัสและสี่เหลี่ยมผืนผ้า
ท่อกลม OD	Min 76mm, Max 165mm
ความหนาของท่อกลม	Min 2.0mm, Max 6.35mm
โครงสี่เหลี่ยมกลวง	ขั้นต่ำ 60x60 มม. สูงสุด 130x130 มม.
หน้าตัดกลวงทรงสี่เหลี่ยมผืนผ้า	ขั้นต่ำ 80x40 มม. สูงสุด 100X160 มม.
ความหนาของท่อสี่เหลี่ยมและสี่เหลี่ยมผืนผ้า	Min2.0mm, Max 5.0mm
ความยาวตัดท่อ	Min 6 meter, Max 12 meter

ข้อมูลจำเพาะของสาย

Forming Section

วัสดุเพลา:	40Cr, HF tempering quenching
วัสดุของเฟืองเอียง:	20CrMnTi
ยืนขับเคลื่อน	7 ชุด
สแตนด์ว่าง	8 ชุด
กล่องเกียร์	7 ชุด

Sizing Section

วัสดุเพลา:	การชุบแข็ง 40Cr,HF
วัสดุของเฟืองเอียง:	20CrMnTi
ยืนขับเคลื่อน	5 ชุด
สแตนด์ว่าง	5 ชุด
กล่องเกียร์	5 ชุด

การไหลของสายการผลิต

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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