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Calculation of tube blank width for tube making by used roll forming machine

Calculation of tube blank width for tube making by used roll forming machine

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  • Release time:2023-04-27 11:30
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【概要描述】The calculation of the width of the tube blank of the used roll forming machine is based on the allowance of the welded pipe, the allowance of sizing and the allowance of forming.

Calculation of tube blank width for tube making by used roll forming machine

【概要描述】The calculation of the width of the tube blank of the used roll forming machine is based on the allowance of the welded pipe, the allowance of sizing and the allowance of forming.

  • Sort:Information
  • Auth:
  • Source:
  • Release time:2023-04-27 11:30
  • Pvs:
Detail

The calculation of the width of the tube blank of the used roll forming machine is based on the allowance of the welded pipe, the allowance of sizing and the allowance of forming.

 

Used roll forming machine

 

Welding allowance

The welded tube blank is formed into a cylinder and then enters the induction coil. Due to the skin effect and proximity effect of the current, the edge of the tube blank is heated to a semi-melted or molten state. Under the pressure of the squeeze roller, the molten metal at the two edges crystallizes together. to achieve the purpose of welding.

In order to weld firmly, during the extrusion process, a small amount of molten metal is squeezed out of the weld to form burrs attached to the upper and lower sides of the weld.

If the negligible factor in engineering, the oxidation of the edge of the tube blank during the welding process is excluded, the amount of extruded metal can be regarded as the welding allowance.

 

Sizing allowance

After welding into a tube, the roundness and diameter of the steel pipe are different from the standard requirements, and the diameter reduction and rounding process must be carried out to make the outer diameter of the steel pipe meet the standard requirements. Therefore, it is necessary to leave a certain reduction and finishing allowance on the width of the strip, that is, the sizing allowance.

 

Forming allowance

During the forming process of the steel pipe, the outer wall of the pipe blank has been strictly limited in a certain shape of the roll groove. The inner wall of the tube blank is less and less restricted as the edge of the tube blank rises, and it is not restricted after it is rolled into a cylindrical shape. In the process of completing the inward bending deformation of the tube blank under this condition, there is a slight thickening phenomenon, thus making the tube blank narrow. In order to offset the narrowing of the tube blank due to the thickening, it is necessary to add a certain allowance to the width of the strip, that is, the forming allowance.

 

The tube blank is constantly stretched throughout the forming process of the used roll forming machine, which also narrows the strip. Under normal conditions, the stretch will not exceed the elastic limit of the steel. This can be proved from the obvious yield point in the elongation test of the low carbon steel finished pipe. Therefore, the amount of narrowing caused by stretching will basically disappear as the tube blank is rolled into a cylinder. Therefore, this factor can be ignored when considering the forming allowance.

 

Used roll forming machine

 

By measuring the thickness of the welded pipe blank and the wall thickness of the finished pipe, it is easy to obtain the wall thickness increase during the production of the welded pipe.

 

The increase in the thickness of the finished tube compared to the blank tube is not solely caused by the forming process. The reducing and finishing process of the sizing process will cause a slight thickening of the pipe wall while drawing the steel pipe to elongate it. Therefore, the increase in the wall thickness of the finished pipe is the sum of the increase in the wall thickness during the forming process and the increase in the wall thickness during the sizing process.

 

The empirical formulas commonly used by manufacturers in calculating the width of blanks are as follows. However, the selection range of the relevant coefficients in these formulas is large, and the calculation is more complicated.

At present, the commonly used empirical formulas for calculating the width of blanks mainly include the following:

 

Formula 1: Blank width = π (finished tube outer diameter + sizing allowance - blank thickness) + welding and forming allowance coefficient × blank thickness

In the formula, the sizing allowance is taken as a coefficient of 0.7~1.5mm.

The welding and forming allowance coefficient is 0.5~2.5mm. The thinner the tube wall, the larger the diameter and the lower the carbon content, the larger the value. Or determined according to production experience.

This formula is applicable to welded pipes whose outer diameter is less than or equal to 114mm.

 

Formula 2: Blank width = π (finished tube outer diameter - blank thickness) + forming allowance + welding allowance + sizing allowance

This formula applies to the circular deformation method.

The values of forming allowance, welding allowance and sizing allowance are shown in the table below.

 

Used roll forming machine

 

Used roll forming machine

 

Used roll forming machine

 

Formula 3: Blank width = (Finished tube outer diameter - Blank thickness) × 1.046~1.05

The selection of the range of 1.046~1.05 in the formula needs to be determined according to production experience. When the outer diameter of the finished pipe is greater than 40mm, the coefficient is 1.04~1.045; when the outer diameter of the finished pipe is smaller or equal to 40mm, the coefficient is 1.046~1.05. This formula applies to thin-walled tubes.

 

Two empirical formulas with simple calculation methods and reliable results are recommended here.

 

Formula 1: Blank width = π (finished tube outer diameter - blank thickness) + 3mm

 

The scope of application of this formula: straight seam welded pipes with a thickness between 0.7 and 2 and an outer diameter below φ50.

In the formula, π (the outer diameter of the finished pipe - the thickness of the billet) refers to the width of the theoretical non-deformation layer during the forming process of the steel pipe. This is a necessary basic dimension in the calculation of the blank width of the straight seam welded pipe. The constant 3mm refers to the sum of the required allowance for the steel pipe in the process of forming, welding and sizing.

 

Formula 2: Blank width = π (finished tube outer diameter - tube blank thickness) + (0.438 tube blank thickness) + (0.035 finished tube outer diameter) + 2.07

 

This formula has no restrictions on the use of used roll forming machine.

 

Our company has many brands and wide resources, there is always one suitable for you. You only need to inform us of your pipe manufacturing needs, and our company will provide you with used welded pipe equipment that really suits your needs. Welcome new and old customers to come to consult and order.

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2. Weight: They can be heavier compared to alternative materials like aluminum or plastic, which may be a disadvantage in some applications.
3. Work Hardening: Stainless steel has a tendency to work harden, which can make machining and forming operations more difficult.
4. Thermal Conductivity: Stainless steel has relatively low thermal conductivity compared to other metals like copper, which can be a limitation in certain applications requiring efficient heat transfer.

Overall, the selection of stainless steel electrolytic tubes depends on the specific requirements of the application, balancing their benefits with their drawbacks.
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6.Post-processing (if necessary)
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7. Inspection Dimensional Inspection: Quality control checks the dimensions of the cut pieces to ensure they match the required specifications.
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SummaryThe laser tube cutting machine's workflow involves several steps that ensure precision, efficiency, and quality. From loading the raw tubes to cutting, monitoring, and final inspection, each stage is crucial for delivering a high-quality product. Automated systems enhance the speed and accuracy of these processes, making laser tube cutting an efficient method for manufacturing tubular components.

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Workflow Analysis of a Laser Tube Cutting Machine

1.Loading Automated Loading: High-end laser tube cutting machines often feature automated loading systems that can handle multiple tubes at once, which increases efficiency.
Manual Loading: Some systems require manual loading, particularly in smaller or less automated setups.

2.Positioning Alignment: The tube is aligned and secured in place to ensure precise cutting. This can be achieved through mechanical clamps or automated systems that adjust the position based on pre-programmed parameters.
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3.Cutting Laser Generation: The laser source generates a high-intensity beam focused on the tube.
Movement System: CNC (Computer Numerical Control) systems guide the laser along the programmed path to cut the tube according to the desired specifications.
Cooling: Cooling systems protect the laser and the workpiece from overheating during the cutting process.

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Feedback Loop: Errors detected are communicated back to the control system, which can make real-time adjustments to the cutting parameters.

5.Sorting and Unloading Automated Sorting: After cutting, sections of the tube are sorted automatically based on their size, shape, or another criterion.
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6.Post-processing (if necessary)
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7. Inspection Dimensional Inspection: Quality control checks the dimensions of the cut pieces to ensure they match the required specifications.
Surface Inspection: The surface quality is also inspected to ensure there are no defects or damages that might affect the product's functionality or appearance.

8. Packaging and Shipping Packaging: The finished tubes are packaged to prevent damage during transportation.
Shipping: The packaged tubes are then prepared for shipping to the customer or for further processing.

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4.Operational Time
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Idle Time: Machines may consume energy even when not actively cutting, depending on the design and standby modes.
5.Maintenance and Consumables
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Assist Gases: Gases like oxygen, nitrogen, or compressed air are used in the cutting process and add to operating expenses.
6.Labor Costs
Operational Efficiency: Skilled operators can optimize machine performance, reducing waste and downtime.
Automation: Automated systems may reduce labor costs but require initial investment and maintenance.
7.Capital Depreciation
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4.Operational Time
Utilization Rate: How often and for how long the machine is operated directly impacts total energy consumption.
Idle Time: Machines may consume energy even when not actively cutting, depending on the design and standby modes.
5.Maintenance and Consumables
Lens and Mirrors: Regular maintenance and replacement of optical components are necessary, adding to operational costs.
Assist Gases: Gases like oxygen, nitrogen, or compressed air are used in the cutting process and add to operating expenses.
6.Labor Costs
Operational Efficiency: Skilled operators can optimize machine performance, reducing waste and downtime.
Automation: Automated systems may reduce labor costs but require initial investment and maintenance.
7.Capital Depreciation
Machine Depreciation: Over the machine’s lifespan, depreciation costs contribute to overall operating costs. Higher initial investment means higher depreciation.
These calculations can be adjusted based on actual usage, efficiency, and local energy prices.

ConclusionThe energy consumption and operating costs of a laser tube cutting machine depend on multiple factors, including the type of laser, machine efficiency, material being cut, operational time, and maintenance requirements. By optimizing each of these factors, it’s possible to manage and reduce the overall operating costs effectively.
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Laser tube cutting machines are intricate systems designed to cut metal tubes with high precision using laser technology:

1.Laser Source:This is the core component that generates the laser beam used for cutting. It can be of different types, such as CO2, fiber, or Nd:YAG lasers, each providing varying power levels and suitable for different materials and thicknesses.
2.Beam Delivery System: This system directs the laser beam from the laser source to the cutting head. It usually consists of mirrors and lenses ensuring the beam remains focused and consistent in power and quality.
3.Cutting Head:Includes a focusing lens, a nozzle, and sometimes a height sensor. The focusing lens concentrates the laser beam to a fine point for precise cutting. The nozzle directs assist gases (like oxygen or nitrogen) towards the cutting point, helping to clear molten material and enhance cutting quality.
4.Assist Gas System: Supplies gases (usually oxygen, nitrogen, or compressed air) required for the cutting process. Different gases are used based on the material being cut to achieve optimal cutting quality and speed.
5.Chuck and Rotary Axis: Holds and rotates the tube to position it accurately under the laser beam. These chucks can be adjusted to accommodate different tube sizes and shapes, ensuring secure and precise handling.
6.CNC Control System: The brain of the operation, this computer numerical control system runs the software that guides the laser cutting process. It handles the movement of the cutting head, the rotation of the chuck, and the application of assist gases per the programmed design.
7.Material Handling System: Includes loading and unloading mechanisms that manage the tubes before and after cutting. Automated systems can greatly enhance productivity by reducing manual intervention.
8.Cooling System: Maintains the temperature of the laser source and other critical components to ensure they operate efficiently and avoid overheating.
9.Exhaust and Filtration System: Removes fumes and particulates generated during the cutting process, ensuring a clean working environment and protecting sensitive components from contamination.
10.Safety Features: Includes protective barriers, interlock switches, and emergency stop buttons to ensure operator safety during machine operation.

Each of these components must function optimally and in harmony to achieve precise and efficient tube cutting with minimal wastage and high-quality outputs.
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Laser tube cutting machines are intricate systems designed to cut metal tubes with high precision using laser technology:

1.Laser Source:This is the core component that generates the laser beam used for cutting. It can be of different types, such as CO2, fiber, or Nd:YAG lasers, each providing varying power levels and suitable for different materials and thicknesses.
2.Beam Delivery System: This system directs the laser beam from the laser source to the cutting head. It usually consists of mirrors and lenses ensuring the beam remains focused and consistent in power and quality.
3.Cutting Head:Includes a focusing lens, a nozzle, and sometimes a height sensor. The focusing lens concentrates the laser beam to a fine point for precise cutting. The nozzle directs assist gases (like oxygen or nitrogen) towards the cutting point, helping to clear molten material and enhance cutting quality.
4.Assist Gas System: Supplies gases (usually oxygen, nitrogen, or compressed air) required for the cutting process. Different gases are used based on the material being cut to achieve optimal cutting quality and speed.
5.Chuck and Rotary Axis: Holds and rotates the tube to position it accurately under the laser beam. These chucks can be adjusted to accommodate different tube sizes and shapes, ensuring secure and precise handling.
6.CNC Control System: The brain of the operation, this computer numerical control system runs the software that guides the laser cutting process. It handles the movement of the cutting head, the rotation of the chuck, and the application of assist gases per the programmed design.
7.Material Handling System: Includes loading and unloading mechanisms that manage the tubes before and after cutting. Automated systems can greatly enhance productivity by reducing manual intervention.
8.Cooling System: Maintains the temperature of the laser source and other critical components to ensure they operate efficiently and avoid overheating.
9.Exhaust and Filtration System: Removes fumes and particulates generated during the cutting process, ensuring a clean working environment and protecting sensitive components from contamination.
10.Safety Features: Includes protective barriers, interlock switches, and emergency stop buttons to ensure operator safety during machine operation.

Each of these components must function optimally and in harmony to achieve precise and efficient tube cutting with minimal wastage and high-quality outputs.
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