Factors and various influences to ensure the quality of used HFW pipe equipments welded pipe products(2)
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【概要描述】In the process of producing welded pipes with used HFW pipe equipments, how to ensure that the product quality meets the requirements of technical standards and the needs of customers, it is necessary to analyze the factors affecting product quality in the production process of steel pipes.
Factors and various influences to ensure the quality of used HFW pipe equipments welded pipe products(2)
【概要描述】In the process of producing welded pipes with used HFW pipe equipments, how to ensure that the product quality meets the requirements of technical standards and the needs of customers, it is necessary to analyze the factors affecting product quality in the production process of steel pipes.
- Sort:Information
- Auth:
- Source:
- Release time:2023-02-22 11:30
- Pvs:
In the process of producing welded pipes with used HFW pipe equipments, how to ensure that the product quality meets the requirements of technical standards and the needs of customers, it is necessary to analyze the factors affecting product quality in the production process of steel pipes.
Through the statistics of unqualified products of a Φ76mm high-frequency welded steel pipe unit in a certain month, it is believed that the factors affecting the quality of steel pipe products in the production process include raw materials, welding process, roll adjustment, roll material, equipment failure, production environment and other reasons . seven aspects. Among them, raw materials account for 32.44%, welding process accounts for 24.85%, roll adjustment accounts for 22.72%, and the three together account for 80.01%, which are the main links. The four factors, such as roll material, equipment failure, production environment and other reasons, account for 19.99% of the impact on the quality of steel pipe products, which are relatively minor links. Therefore, in the process of steel pipe production, the three links of raw materials, welding process and roll adjustment should be controlled.
Control of Welding Seam Gap of Steel Pipe
After the steel strip enters the used HFW pipe equipments and is formed by the forming roller and the guide roller is oriented, a circular steel pipe blank with an opening gap is formed. Both ends of the welded joint remain flush. If the weld gap is controlled too large, the weld will be poorly welded and cause unfusion or cracking; if the weld gap is controlled too small, the weld will be burned due to excessive heat, and the molten metal will splash, which will affect the welding quality of the weld.
Adjustment of the position of the high frequency induction coil
The induction coil should be placed on the same center line as the steel pipe, and the distance between the front end of the induction coil and the center line of the extrusion roller should be as close as possible to the specification of the steel pipe without burning the extrusion roller. If the induction coil is far from the squeeze roller, the effective heating time will be longer and the heat affected zone will be wide, which will reduce the strength of the steel pipe weld or not penetrate it; otherwise, the induction coil will easily burn the squeeze roller.
Control of Impedance Position
Impedance is one or a group of special magnetic rods for welded pipes. The cross-sectional area of the impedance should usually not be less than 70% of the cross-sectional area of the inner diameter of the steel pipe. Proximity effect is produced, and the eddy current heat is concentrated near the edge of the tube blank weld, so that the edge of the tube blank is heated to the welding temperature. The resistor should be placed in the heating section of the V-shaped area, and the front end should be at the center of the squeeze roller, so that its centerline is consistent with the centerline of the tube. If the position of the resistor is not well placed, the welding speed and welding quality of the welded pipe will be affected, and the steel pipe will be cracked.
High frequency welding process parameters - control of input heat
The heat input by the high-frequency power supply to the welded part of the steel pipe is called the input heat. When converting electrical energy into heat energy, the formula for the input heat is: Q=KI2 Rt (1) In the formula, Q—the heat input to the tube blank; K—energy conversion efficiency; I—welding current; R—circuit impedance; t—heating time.
Heating time: t=Lv (2), where L—the center distance from the front end of the induction coil or the electrode head to the squeeze roller; v—the welding speed.
When the heat input by the high frequency is insufficient and the welding speed is too fast, the edge of the heated pipe body cannot reach the welding temperature, and the steel still maintains its solid structure and cannot be welded, forming unfused or incompletely welded cracks; When the high-frequency input heat is too large and the welding speed is too slow, the edge of the heated pipe body exceeds the welding temperature, which is prone to overheating or even overburning, which will break down the weld and cause metal splashes to form shrinkage cavities. It can be seen from formulas (1) and (2) that the amount of high-frequency input heat can be controlled by adjusting the high-frequency welding current (voltage) or the welding speed, so that the weld of the steel pipe needs to be penetrated without being damaged. Weld through to obtain steel pipes with excellent welding quality.
When changing the steel pipe specifications, the entire set of rolls is generally replaced.
The method of roll adjustment is: use steel wire to draw a center line from the entrance to the exit of the used HFW pipe equipments, and adjust it so that the hole patterns of each frame are on a center line, and the bottom line of the forming meets the technical requirements. After changing the roll specifications, first make a comprehensive adjustment to the forming roll, guide roll, squeeze roll and sizing roll, and then focus on the adjustment of the closed hole pattern, guide roll and squeeze roll of the forming roll.
The function of the guide roller is to control the direction of the pipe seam of the steel pipe and the height of the bottom line of the pipe blank, ease the edge extension, control the rebound of the edge of the pipe blank, and ensure that the pipe seam is straight and not twisted into the extrusion roller. During the welding process, it is easy to cause welding defects such as torsion, lap welding and edge waves of the steel pipe seam.
The squeeze roller is the key equipment of the used HFW pipe equipments. Its function is to complete the pressure welding of the pipe body whose edge is heated to the welding temperature under the action of the extrusion force of the squeeze roller. In the production process, it is necessary to control the size of the opening angle of the extrusion roll. When the extrusion force is too small, the strength of the weld metal will decrease, and cracks will occur after being stressed; when the extrusion force is too large, the welding strength will be reduced, and the amount of external burrs will increase, which is likely to cause welding defects such as lap welding.
In the process of slow start of the used HFW pipe equipments, pay close attention to the rotation of the rolls in various parts, and adjust the rolls at any time to ensure that the welding quality and process dimensions of the welded pipe meet the specified requirements.
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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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