Tube Forming and Sizing Mill

ERW karbonli po'lat quvur tegirmoni

Tube tegirmon mashinasini tuzish

Sovuq rulonni shakllantirish mashinasi

Po'lat bobinni kesish liniyasi

Karbonli po'latdan yasalgan rulonni kesish liniyasi

Uzunlikdagi chiziqqa kesilgan po'lat rulon

Yordamchi uskunalar va ehtiyot qismlar

Round to Square Forming and Sizing Section

In ERW tube production, the dumaloqdan kvadratga shakllantirish jarayoni 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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Video

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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

Taklif etilayotgan liniyaning dizayni quyidagi spetsifikatsiyalarga asoslanadi:

Xom ashyo spetsifikatsiyasi

Raw Material Feeding	CR bright tube with oiled, Galvanized steel, HR coil
Materialning kuchlanish kuchi	Maks 517MPa (maksimal 75 000 psi)
Materialning chiqish kuchi	Maks 460MPa (maksimal 67000 psi)
Bobin OD	1200 mm dan 2000 mm gacha
Bobin identifikatori	508mm&610mm (customer order)
Bobinning og'irligi	Maksimal 7000 kg
Chiziq kengligi	Min 240mm, Max520mm
Chiziq qalinligi	Min2.0mm Max6.35mm

Ishlab chiqarish diapazoni

Ishlab chiqarish turi	▪Dumaloq quvurlar ▪Kvadrat va to'rtburchaklar bo'shliq bo'laklar
Dumaloq quvur OD	Min 76mm, Max 165mm
Dumaloq trubaning qalinligi	Min 2.0mm, Max 6.35mm
Kvadrat ichi bo'sh qism	Minimal 60x60mm, Maks 130x130mm
To'rtburchaklar ichi bo'sh qism	Minimal 80x40mm, Maks 100X160mm
Kvadrat va to'rtburchaklar Quvur qalinligi	Min2.0mm, Max 5.0mm
Quvurni kesish uzunligi	Min 6 meter, Max 12 meter

Chiziq spetsifikatsiyasi

Forming Section

Mil materiali:	40Cr, HF tempering quenching
Konik tishli tishli material:	20CrMnTi
Boshqariladigan stend	7 to'plam
Ishsiz stend	8 to'plam
Vites qutisi	7 to'plam

Sizing Section

Mil materiali:	40Cr, HF temperli söndürme
Konik tishli tishli material:	20CrMnTi
Boshqariladigan stend	5 to'plam
Ishsiz stend	5 to'plam
Vites qutisi	5 to'plam

Ishlab chiqarish liniyasining oqimi

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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