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Common problems and solutions for burr removal in roll forming equipment (1)

Common problems and solutions for burr removal in roll forming equipment (1)

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  • Release time:2023-10-24 11:30
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【概要描述】Internal burrs often appear when roll forming equipment is used to make pipes, and there will also be many problems in removing internal burrs. We explain and deal with common problems in removing burrs from welded pipes.

Common problems and solutions for burr removal in roll forming equipment (1)

【概要描述】Internal burrs often appear when roll forming equipment is used to make pipes, and there will also be many problems in removing internal burrs. We explain and deal with common problems in removing burrs from welded pipes.

  • Sort:Information
  • Auth:
  • Source:
  • Release time:2023-10-24 11:30
  • Pvs:
Detail

Internal burrs often appear when roll forming equipment is used to make pipes, and there will also be many problems in removing internal burrs. We explain and deal with common problems in removing burrs from welded pipes.

 

Roll forming equipment

 

There are 9 common problems in removing internal burrs with roll forming equipment: ① The output power is too large. ②Welded weld bead. ③ The inner burr ring knife breaks down. ④ The residual height of the inner burr exceeds the standard. ⑤ The weld is in the shape of a peach. ⑥The cutter bar cannot be lifted up and the burr cannot be scraped. ⑦ Internal burr scraping is periodic, scale-like and spiral-like. ⑧ Internal burr scraping deviation. ⑨ Other problems and solutions. According to these 9 kinds of common problems, we will explain to you the common problems of internal burr removal: the output power is too large and the welding seam is welded.

 

Excessive output power:

Due to the limited diameter of the small diameter HFW welded pipe itself, the built-in cutter bar will limit the cross-sectional area of the magnetic rod, resulting in low welding speed and excessive output power.

 

Solution:

(1) Try to choose a magnet rod with a larger diameter when space allows;

(2) The end of the magnet bar is aligned with the center of the squeeze roller;

(3) The gap between the magnet bar and the tube should be as small as possible, and controlled within 5-15mm;

(4) Choose a magnetic rod with a high Curie point temperature;

(5) Using an external magnetic rod;

(6) The magnetic bar increases the pressure of the cooling water and reduces the temperature;

(7) Reasonably choose the length of the magnetic rod and the number of turns of the induction coil (usually 2 to 5 turns);

(8) Select the opening angle reasonably, the smaller the opening angle, the stronger the proximity effect and skin effect;

(9) Reasonably select the distance between the induction coil and the center of the extrusion roller (the closer the better), the smaller the gap between the induction coil and the tube, the better, the best is 5-8 mm;

(10) Reasonably select the frequency of solid-state high frequency; do not pour cooling water directly to the weld; the weld is preferably cooled by inert gas.

 

Roll forming equipment

 

Welded weld bead:

When roll forming equipment is used to produce steel pipes with a wall thickness of 6-14 mm, due to the low welding speed and slow melting of the strip section, the phenomenon that the edge of the strip is melted first and the middle is not melted, resulting in a step temperature, which makes the strip melt. The high-temperature molten metal at the sharp corners of the steel edge flows to the center of the squeezing roller at the end of the magnet bar to instantly generate a weld flash.

 

Solution:

(1) Increase the cooling water pressure of the magnetic rod by 1 MPa, and wash away the welding tumor at the end of the magnetic rod;

(2) Add a horizontal compressed air pipe to the end of the magnetic rod to blow the welding tumor;

(3) The end of the magnet bar should not be placed in the center of the squeeze roller, and the placement position should be moved back by 20-30 mm;

(4) After the unit is running, after the vehicle speed and welding temperature are stabilized, the tool bar is raised to remove internal burrs;

(5) Use semi-melting welding to reduce the generation of molten metal slag;

(6) Using solid-state high-frequency and low-frequency welding, it can provide stable frequency and output power;

(7) Properly increasing the opening angle, that is, widening the width of the guide plate, reducing the fusion of the molten metal in front of the center of the extrusion roller, and making the strip steel converge in the extrusion roller;

(8) Appropriately increase the gap between the magnetic rod and the tube, and keep it at 15-20 mm;

(9) It can increase the welding speed, reduce the metal spatter, and avoid the generation of welding flashes.

 

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Disadvantages of Stainless Steel Electrolytic Tubes:
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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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Advantages of Stainless Steel Electrolytic Tubes:
1. Corrosion Resistance: Stainless steel electrolytic tubes have excellent resistance to corrosion, which makes them ideal for use in harsh environments, including acid and alkaline conditions.
2. Durability: They are highly durable and can withstand high temperatures and pressures, making them long-lasting and reliable.
3. Hygienic Properties: Stainless steel is easy to clean and maintain, making it suitable for applications that require strict hygiene standards, such as in the food and pharmaceutical industries.
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6. Aesthetic Appeal: They have a shiny and attractive appearance, which is beneficial for applications where aesthetics are important.

Disadvantages of Stainless Steel Electrolytic Tubes:
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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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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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Cooling: Cooling systems protect the laser and the workpiece from overheating during the cutting process.

4.Quality Monitoring Real-time Monitoring: Advanced machines use cameras and sensors to monitor the cutting process in real time, checking for defects and ensuring quality.
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.
Unloading: The finished pieces are then unloaded, either manually or using an automated system, and prepared for the next stage of processing or delivery.

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.

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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Analysis of the workflow of a laser tube cutting machine:

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.
Initial Calibration: The machine checks the initial position of the tube using sensors and adjusts accordingly. This step ensures the accuracy of the cuts.

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.

4.Quality Monitoring Real-time Monitoring: Advanced machines use cameras and sensors to monitor the cutting process in real time, checking for defects and ensuring quality.
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.
Unloading: The finished pieces are then unloaded, either manually or using an automated system, and prepared for the next stage of processing or delivery.

6.Post-processing (if necessary)
Deburring: Some cut tubes might require deburring to remove sharp edges.
Cleaning: The workpieces could require cleaning to remove any residual material or dirt.

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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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
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Automation: Automated systems may reduce labor costs but require initial investment and maintenance.
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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.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com

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