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Learn about the solutions for thick-wall pipe forming of directly forming to square pipe mill(1)

Learn about the solutions for thick-wall pipe forming of directly forming to square pipe mill(1)

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  • Release time:2022-08-19 11:30
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【概要描述】In the welded pipe industry, people generally regard welded pipes with a ratio of wall thickness to outside diameter of 12%≤t/D≤18% as thick-walled pipes. Regarding the forming difficulties of thick-walled pipes with directly forming to square pipe mill, they clearly propose Solutions such as the edge double-semi-warp forming hole shape.

Learn about the solutions for thick-wall pipe forming of directly forming to square pipe mill(1)

【概要描述】In the welded pipe industry, people generally regard welded pipes with a ratio of wall thickness to outside diameter of 12%≤t/D≤18% as thick-walled pipes. Regarding the forming difficulties of thick-walled pipes with directly forming to square pipe mill, they clearly propose Solutions such as the edge double-semi-warp forming hole shape.

  • Sort:Information
  • Auth:
  • Source:
  • Release time:2022-08-19 11:30
  • Pvs:
Detail

In the welded pipe industry, people generally regard welded pipes with a ratio of wall thickness to outside diameter of 12%≤t/D≤18% as thick-walled pipes. Regarding the forming difficulties of thick-walled pipes with directly forming to square pipe mill, they clearly propose Solutions such as the edge double-semi-warp forming hole shape.

 

Difficulties in processing technology of thick-walled pipe deformation:

There are three processing technology problems for thick-walled welded pipe forming with the directly forming to square pipe mill: 1、The large bending springback. 2、The actual deformation blind zone is wide. 3、The large difference between the inner and outer circumferences.

 

Directly forming to square pipe mill

 

Bending resilience is large:

The tube blank will produce two kinds of deformation, elastic deformation and plastic deformation, in the process of bending the tube blank from a straight condition into a cylindrical shape. In addition, it is inevitable to produce springback, the key is how much. Thick-walled pipes have large deformation resistance and much springback, resulting in insufficient pipe blank deformation.

 

Affected by the mechanical properties of the tube blank, the wall-to-diameter ratio (t/D), the main parameters of the pass, the characteristics of the machine and equipment, the actual operation error, etc., the springback regularity is very different, so it is difficult to accurately predict and analyze the springback amount. Give precise springback compensation. At this stage, there are roughly two commonly used methods for characterizing springback:

 

①Actual measurement characterizatio. According to the evaluation of the chord length difference △b before and after springback at the same point on the edge of the deformed tube blank and the two index values ​​of the semi-longitude difference △R before and after springback at the bending position, it is characterized by referring to the formula to calculate the following: specific accurate measurement of the characterization value is more intuitive , The most widely used

 

Directly forming to square pipe mill

 

②Function representation. According to the basic theory of bending neutralization layer and the basic theory of metal elastoplastic deformation, the correlation between the deformation of the deformed tube before and after springback can be calculated. Refer to the formula to calculate the following:

 

Directly forming to square pipe mill

 

The theoretical significance of the second calculation formula is that according to the deformation half-warp of the tube blank after springback, the yield strength of the tube blank, the thickness of the tube blank, the springback angle and the metal modulus, the required pass bending deformation radius R can be directly calculated. In turn, the adverse effects of springback on the formed tube are eliminated.

 

Deformation blind zone width

Deformation dead zone, also known as deformation dead zone, means that in the process of tube blank deformation, no matter how it deforms, there is no way to deform at the edge of the tube blank and the area whose width is equal to the thickness of the tube blank. In fact, a part of the road sections adjacent to the deformation blind zone of the basic theory also belong to the range of the deformation blind zone. The existence of the deformation blind zone has its inevitable trend.

 

①There is an inevitable trend of deformation blind zone. The bending and deformation of the edge of the tube blank can be analyzed and studied with reference to the basic theory of bending stiffness. When a billet with a thickness of t has to bend and deform a billet with a length of L under the action of the forming and rolling force P, the positioning point of the section of the billet will definitely cause a vertical displacement y, that is, the billet will bend and deform. Calculate the bending deformation radius of the tube blank. When forming a thick-walled pipe of Φ60mm X 6mm, the calculation results show that in order to produce a bending deformation of only 0.001cm in the width of the thickness area (0.6cm), a forming force of 48kN is required. This is for welded pipe forming equipment. It is impossible to provide; what's more, according to the welding pipe forming process, the closer to the edge of the tube blank, the smaller the specific forming force acting on the tube blank, which in turn causes the specific deformation blind zone to be wider.

 

In addition, from the perspective of the specific deformation effect, a bending deformation of 0.001 cm should be completed in a length of 0.6 cm, and the bending radius R is equal to 30 cm. The arc length of 0.6 cm is the same as a straight line on an arc with a half meridian of 30 cm.

 

②Comparison of deformation blind zone. Both thick-walled pipes and thin-walled pipes have deformation blind zones; only thick-walled pipes' deformation blind zones account for a higher proportion of the total width of the tube blank. Taking Φ60mm X 3mm and Φ60mm X 6mm as examples, their blind zone width ratios of 2t /B (%) are 3.24% and 6.89%, respectively, and the latter is twice that of the previous one. Therefore, according to the calculation formula of the total opening width of the deformation blind zone, the total width of the trench on both sides of the wall thickness can be obtained as 0.64mm (tube inner diameter r2=27.87mm) and 2.79mm (tube inner diameter r2=25.08mm), the latter being 4.36 times of the former, the influence of such a wide groove on the thick-walled pipe of thedirectly forming to square pipe mill on the weld strength is obvious.

 

Large difference in diameter between inside and outside

Still taking the Φ60mm X 6mm thick-walled pipe as an example, the difference between the inner and outer circumferences is 37.68mm, while the difference between the inner and outer circumferences of the Φ60mm X 3mm standard wall thickness pipe is only 18.84mm. A pipe with a large circumference difference represents a large amount of internal axial stress accumulated in the formed tube. The process of compressing the inner layer and stretching the outer layer requires a lot of deformation work, and its increased deformation resistance has an impact on the unit. Both the drag output power and the rigidity of the unit have special requirements. After welding, the large amount of compressive stress accumulated on the inner side of the neutral layer of the pipeline always tries to open the weld; in addition, the large amount of tensile stress accumulated on the outer side of the neutral layer is always pulling the weld, trying to get rid of the weld. In addition, the actual effects of these two stresses on the welding seam are the same, with superimposing effects. These accumulated stresses in thick-wall welded pipes cause serious stress corrosion damage to the weld seam, and have great potential safety hazards, which must be solved by the welded pipe forming process.

 

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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.
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

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Analyzing  advantages and disadvantages of stainless steel electrolytic tube

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.
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Analyzing of the workflow of a laser tube cutting machine
Analyzing of the workflow of a laser tube cutting machine
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.

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
Detail
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.

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

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Analyzing the energy consumption and operating costs of a laser tube cutting machine involves examining several key factors
Analyzing the energy consumption and operating costs of a laser tube cutting machine involves examining several key factors
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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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.
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 Laser tube cutting machines components
Analysis Laser tube cutting machines components
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

JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Detail
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

JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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