Млин для формування та калібрування труб

ERW Трубний завод з вуглецевої сталі

Трубопрокатний верстат Compose

Машина для холодного прокату

Лінія розрізання рулонної сталі

Лінія розрізання рулонів вуглецевої сталі

Лінія розрізання сталевих рулонів

Допоміжне Обладнання І Запчастини

Round to Square Forming and Sizing Section

In ERW tube production, the процес формування з круглого на квадратний 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

Конструкція запропонованої лінії базується на наступних специфікаціях:

Специфікація сировини

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Міцність матеріалу на розтяг	Макс. 517 МПа (макс. 75 000 фунтів на квадратний дюйм)
Межа плинності матеріалу	Макс. 460 МПа (макс. 67 000 фунтів на квадратний дюйм)
Котушка OD	від 1200 мм до 2000 мм
ID котушки	508mm&610mm (customer order)
Вага котушки	Макс. 7000 кг
Ширина смуги	Min 240mm, Max520mm
Товщина смуги	Min2.0mm Max6.35mm

Асортимент продукції

Вид виробництва	▪Круглі труби ▪Квадратні та прямокутні порожнисті профілі
Зовнішній діаметр круглої труби	Min 76mm, Max 165mm
Товщина круглої труби	Min 2.0mm, Max 6.35mm
Квадратний порожнистий перетин	Мін. 60x60 мм, Макс. 130x130 мм
Прямокутний порожнистий перетин	Мін. 80x40 мм, Макс. 100X160 мм
Товщина квадратної та прямокутної труби	Min2.0mm, Max 5.0mm
Довжина відрізу труби	Min 6 meter, Max 12 meter

Специфікація лінії

Forming Section

Матеріал вала:	40Cr, HF tempering quenching
Матеріал конічної шестерні:	20CrMnTi
Привідний стенд	7 сетів
Холостий стенд	8 сетів
Коробка передач	7 сетів

Sizing Section

Матеріал вала:	40Cr, HF відпуск, гартування
Матеріал конічної шестерні:	20CrMnTi
Привідний стенд	5 сетів
Холостий стенд	5 сетів
Коробка передач	5 сетів

Потік виробничої лінії

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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