Factors affecting the opening angle of the used roll forming machine and the adjustment principle
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【概要描述】In the production of welded pipes on used roll forming machine, the opening angle is one of the most sensitive welding elements. The size of the opening angle directly affects the welding heat, welding speed and weld strength, and involves a wide range of aspects. As can be seen from the figure below, there are at least 7 direct factors affecting the opening angle.
Factors affecting the opening angle of the used roll forming machine and the adjustment principle
【概要描述】In the production of welded pipes on used roll forming machine, the opening angle is one of the most sensitive welding elements. The size of the opening angle directly affects the welding heat, welding speed and weld strength, and involves a wide range of aspects. As can be seen from the figure below, there are at least 7 direct factors affecting the opening angle.
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Factors that affect the opening angle
In the production of welded pipes on used roll forming machine, the opening angle is one of the most sensitive welding elements. The size of the opening angle directly affects the welding heat, welding speed and weld strength, and involves a wide range of aspects. As can be seen from the figure below, there are at least 7 direct factors affecting the opening angle.
(1) Squeeze roll hole radius. According to the welded pipe production process, the radius of the extrusion roll pass is always smaller than the radius R of the open cylindrical tube to be welded. In this way, different extrusion roll passes (R1≠R2) produce different first force points on the edge of the tube blank. , see Figure 2,
This affects the position and opening angle of the edge of the tube blank. In the figure, the smaller the pass radius of the extrusion roller, the earlier the pass force point B will exert force on the tube blank, and the unilateral advance S is determined by R, R1 and R2:
At the same time, since the force-applying point of the extrusion roller hole type R2 is advanced by S mm, the opening angle is reduced from α to α´, then according to the formula:
The opening angle α´ affected by R2 is:
Obviously, α>α´
When the opening angle becomes smaller, the actual apex of the edge of the heating tube blank will inevitably be advanced, and defects such as over-burning and weld perforation are likely to occur. For the same type of tube, the opening angle will decrease sharply as the radius of the extrusion roller hole becomes smaller, causing the actual confluence point of the edge of the tube blank to move forward, that is, away from the center line of the extrusion roller, and run a series of used roll forming machine. Welding process parameters such as extrusion force, input heat, resistor position, welding speed, etc. have an important impact.
For example: to produce φ50mm tube on 50 units, let R=26.11mm, R1=25.5mm, R2=25.3mm, α=2°~6°, b=6mm, S=0.84mm is calculated. Therefore, the opening angle is reduced to α'=1.73°~5.19°, which is reduced by 13.5%.
(2) The outer diameter of the squeeze roller. Welded pipes of the same specification, different outer diameters of extrusion rollers, and the first force point of the hole pattern to the pipe blank are different. In Figure 2, the extrusion roller with a larger outer diameter touches the tube blank earlier by A1A2 (edge) and a1a2 (bottom diameter) than the extrusion roller with a smaller outer diameter, which in turn affects the opening angle and the position of the actual meeting point.
(3) Thickness b of guide ring. The thickness of the guide ring is proportional to the tangent of the opening angle, the thicker the ring, the larger the opening angle; conversely, the thinner the ring, the smaller the opening angle.
(4) The tube blank springs back. According to Figure 1, the tube blank has high strength and hardness, and the edge of the tube blank rebounds greatly in the elastic deformation zone, and the opening of the tube blank will exceed the thickness of the roll ring, resulting in an actual opening angle that is larger than the theoretical opening angle.
(5) The height of the tube blank entering the extrusion roller. Since the size of the open tube is larger than the size of the pass of the squeeze roll, when the guide roll and the squeeze roll are adjusted according to the horizontal rolling bottom line, the edge of the tube blank is higher than the upper edge of the pass of the squeeze roll, which leads to the upper edge of the pass of the squeeze roll. The pressure point is pressed to the edge of the tube blank in advance, and thus the opening angle is reduced; the higher the pressure, the more obvious the reduction.
(6) The wall thickness of the tube blank. Thick-walled tubes plus deformation blind areas can easily form inner and outer opening angles with the same size but different apex (convergence) positions. According to the principle of proximity effect of high-frequency current, the temperature near the inner opening angle of the tube must be higher than the outer opening. The temperature at the corner makes the welded pipe unable to be welded normally.
(7) Roll gap. Including the guide roll and the squeeze roll gap all affect the opening angle to varying degrees.
Adjustment principle of opening angle
The following 4 basic principles should be followed when adjusting the opening angle of the used roll forming machine
(1) The principle of wall thickness. It means that the opening angle should be reduced as much as possible when producing thick-walled pipes, and the opening angle should be appropriately increased when producing thin-walled pipes.
(2) The principle of nature.That is, after the natural wear of the guide ring and the hole pattern, the guide roller is pressed down in stages, so that the opening angle will be reduced accordingly; after the new guide ring is replaced, the opening angle should be restored to the original state.
(3) The principle of micro deformation. Theoretically, the guide rollers do not undertake the task of deformation; however, from the practical needs of stabilizing the opening angle, it is necessary for the guide rollers to undertake the slight deformation that is limited to the control of springback.
(4) The principle of efficiency. In order to improve the power utilization efficiency and production efficiency, the opening angle must be adjusted as small as possible when the process conditions allow.
More News
Time of issue : 2024-11-06
Analysis of Double-Head Uncoiler Introduction:
A double-head uncoiler is a crucial piece of equipment in metal processing industries. It is primarily used to feed metal coils into roll forming machines, cut-to-length lines, or slitting lines. The double-head design allows for continuous operation by enabling one coil to be loaded and prepared while the other coil is being processed.
Key Components:
1.Mandrels:The double-head uncoiler features two mandrels, each designed to hold and unwind a coil of metal. These mandrels are typically hydraulic or motor-driven to control the unwinding process.
2.Coil Carriages:These assist in loading and unloading coils onto the mandrels. Coil carriages help to position the coils correctly and securely.
3.Hydraulic System:This system is used to expand the mandrel to grip the inner diameter of the coil securely.
4.Control System:The electronic control system automates the switching between coils and ensures synchronization with the subsequent processing line.
5.Brake System:To control the speed of uncoiling and ensure smooth feeding into the processing line, a braking system (mechanical or pneumatic) is integrated.
Operation:
1.Loading:One coil is loaded onto a mandrel with the assistance of a coil carriage. The hydraulic system secures the coil.
2.Preparation:While one coil is being processed, the second coil can be prepared on the other mandrel.
3.Uncoiling:The control system manages the unwinding process, adjusting speed and tension to match the requirements of downstream equipment.
4.Switching Coils:Once the first coil is nearly depleted, the system can seamlessly switch to the second coil, ensuring continuous operation without stopping the line.
Advantages:
1.Continuous Operation:Allows for non-stop processing as one coil can be prepared while the other is being used.
2.Increased Efficiency:Reduces downtime and increases overall productivity in the metal processing line.
3.Improved Safety:Automated systems reduce the need for manual handling of heavy metal coils.
4.Precise Control:Advanced control systems provide precise management of coil unwinding, contributing to product quality and consistency.
Applications:
Double-head uncoilers are widely used in industries such as:
- Steel production and processing- Automotive manufacturing- Construction material production- Electrical appliance manufacturing Conclusion:
Double-head uncoilers are essential in facilitating efficient and continuous production processes in various metalworking industries. Their automation and robust design contribute significantly to operational efficiency, safety, and overall productivity.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Analysis of Double-Head Uncoiler Introduction:
A double-head uncoiler is a crucial piece of equipment in metal processing industries. It is primarily used to feed metal coils into roll forming machines, cut-to-length lines, or slitting lines. The double-head design allows for continuous operation by enabling one coil to be loaded and prepared while the other coil is being processed.
Key Components:
1.Mandrels:The double-head uncoiler features two mandrels, each designed to hold and unwind a coil of metal. These mandrels are typically hydraulic or motor-driven to control the unwinding process.
2.Coil Carriages:These assist in loading and unloading coils onto the mandrels. Coil carriages help to position the coils correctly and securely.
3.Hydraulic System:This system is used to expand the mandrel to grip the inner diameter of the coil securely.
4.Control System:The electronic control system automates the switching between coils and ensures synchronization with the subsequent processing line.
5.Brake System:To control the speed of uncoiling and ensure smooth feeding into the processing line, a braking system (mechanical or pneumatic) is integrated.
Operation:
1.Loading:One coil is loaded onto a mandrel with the assistance of a coil carriage. The hydraulic system secures the coil.
2.Preparation:While one coil is being processed, the second coil can be prepared on the other mandrel.
3.Uncoiling:The control system manages the unwinding process, adjusting speed and tension to match the requirements of downstream equipment.
4.Switching Coils:Once the first coil is nearly depleted, the system can seamlessly switch to the second coil, ensuring continuous operation without stopping the line.
Advantages:
1.Continuous Operation:Allows for non-stop processing as one coil can be prepared while the other is being used.
2.Increased Efficiency:Reduces downtime and increases overall productivity in the metal processing line.
3.Improved Safety:Automated systems reduce the need for manual handling of heavy metal coils.
4.Precise Control:Advanced control systems provide precise management of coil unwinding, contributing to product quality and consistency.
Applications:
Double-head uncoilers are widely used in industries such as:
- Steel production and processing- Automotive manufacturing- Construction material production- Electrical appliance manufacturing Conclusion:
Double-head uncoilers are essential in facilitating efficient and continuous production processes in various metalworking industries. Their automation and robust design contribute significantly to operational efficiency, safety, and overall productivity.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Time of issue : 2024-11-04
1.Working Principle:
High-frequency quenching equipment utilizes induction heating, where alternating electromagnetic fields generate heat within the metal workpiece.
The frequency of the alternating current is typically between100 kHz and500 kHz, which effectively heats the surface rapidly while keeping the core relatively cool.
2.Components:
Power Supply:Generates the high-frequency current necessary for induction heating.
Induction Coil:The coil is designed to fit around or near the workpiece, creating a magnetic field that induces eddy currents on its surface.
Cooling System:Typically, a coolant (such as water or oil) is sprayed or immersed to rapidly cool the heated metal surface.
Control System:Manages the operation, regulating the frequency, heating time, and cooling process to achieve desired material properties.
3.Advantages:
Precision:High control over the heating parameters allows for localized hardening of specific areas without affecting the entire workpiece.
Efficiency:Fast heating and cooling cycles reduce overall processing time.
Consistency:Achieves uniform hardening across the treated surface, improving the reliability and performance of components.
Energy Savings:Induction heating is highly energy-efficient, converting electrical energy directly into heat within the material.
4.Applications:
Automotive Industry:Used to harden components like gears, crankshafts, camshafts, and drive shafts.
Aerospace:Treats critical parts such as turbine blades and landing gear components.
Tool and Die Making:Enhanced hardness and durability of tools such as cutting tools, punches, and dies.
Machine Parts:Hardening of various machine parts, including spindles, rollers, and bearings.
5.Maintenance and Safety:
Regular inspection and maintenance of the induction coil, power supply, and cooling system are essential to ensure optimal performance and longevity.
Safety precautions must be taken to protect operators from high temperatures, electrical hazards, and coolant exposure.
6.Technological Advancements:
Modern high-frequency quenching equipment often incorporates advanced control systems with real-time monitoring and automation features.
Integration with computer numerical control (CNC) systems allows for precise and repeatable processing of complex geometries.
In conclusion, high-frequency quenching equipment plays a crucial role in the modern manufacturing industry by enhancing the durability and performance of metal components. Understanding its working principles, advantages, and applications can help businesses select the right equipment and optimize their heat treatment processes.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
1.Working Principle:
High-frequency quenching equipment utilizes induction heating, where alternating electromagnetic fields generate heat within the metal workpiece.
The frequency of the alternating current is typically between100 kHz and500 kHz, which effectively heats the surface rapidly while keeping the core relatively cool.
2.Components:
Power Supply:Generates the high-frequency current necessary for induction heating.
Induction Coil:The coil is designed to fit around or near the workpiece, creating a magnetic field that induces eddy currents on its surface.
Cooling System:Typically, a coolant (such as water or oil) is sprayed or immersed to rapidly cool the heated metal surface.
Control System:Manages the operation, regulating the frequency, heating time, and cooling process to achieve desired material properties.
3.Advantages:
Precision:High control over the heating parameters allows for localized hardening of specific areas without affecting the entire workpiece.
Efficiency:Fast heating and cooling cycles reduce overall processing time.
Consistency:Achieves uniform hardening across the treated surface, improving the reliability and performance of components.
Energy Savings:Induction heating is highly energy-efficient, converting electrical energy directly into heat within the material.
4.Applications:
Automotive Industry:Used to harden components like gears, crankshafts, camshafts, and drive shafts.
Aerospace:Treats critical parts such as turbine blades and landing gear components.
Tool and Die Making:Enhanced hardness and durability of tools such as cutting tools, punches, and dies.
Machine Parts:Hardening of various machine parts, including spindles, rollers, and bearings.
5.Maintenance and Safety:
Regular inspection and maintenance of the induction coil, power supply, and cooling system are essential to ensure optimal performance and longevity.
Safety precautions must be taken to protect operators from high temperatures, electrical hazards, and coolant exposure.
6.Technological Advancements:
Modern high-frequency quenching equipment often incorporates advanced control systems with real-time monitoring and automation features.
Integration with computer numerical control (CNC) systems allows for precise and repeatable processing of complex geometries.
In conclusion, high-frequency quenching equipment plays a crucial role in the modern manufacturing industry by enhancing the durability and performance of metal components. Understanding its working principles, advantages, and applications can help businesses select the right equipment and optimize their heat treatment processes.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Time of issue : 2024-11-02
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.
4. Strength: These tubes have high mechanical strength and can endure significant amounts of stress without deforming.
5. Recyclability: Stainless steel is recyclable, which makes these tubes environmentally friendly.
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:
1. Cost: Stainless steel electrolytic tubes are generally more expensive than tubes made from other materials.
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.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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.
4. Strength: These tubes have high mechanical strength and can endure significant amounts of stress without deforming.
5. Recyclability: Stainless steel is recyclable, which makes these tubes environmentally friendly.
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:
1. Cost: Stainless steel electrolytic tubes are generally more expensive than tubes made from other materials.
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.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Time of issue : 2024-10-31
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.
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.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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.
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.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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