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On-line heat treatment weld process and air cooling length of used roll forming machine

On-line heat treatment weld process and air cooling length of used roll forming machine

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  • Release time:2022-05-10 11:30
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【概要描述】There are three types of welding seam processes for online heat treatment of used roll forming machine: annealing, normalizing and quenching + tempering. Manufacturers only need to choose the corresponding process according to the pipe products and customer needs.

On-line heat treatment weld process and air cooling length of used roll forming machine

【概要描述】There are three types of welding seam processes for online heat treatment of used roll forming machine: annealing, normalizing and quenching + tempering. Manufacturers only need to choose the corresponding process according to the pipe products and customer needs.

  • Sort:Information
  • Auth:
  • Source:
  • Release time:2022-05-10 11:30
  • Pvs:
Detail

There are three types of welding seam processes for online heat treatment of used roll forming machine: annealing, normalizing and quenching + tempering. Manufacturers only need to choose the corresponding process according to the pipe products and customer needs.

 

Annealed (A)

The function of on-line annealing of welds is to reduce the hardness of welds and heat-affected zones, improve plasticity, refine grains, and eliminate residual stress.

The commonly used annealing process is: heating the weld and the heat-affected zone to 640~680°C, then air-cooling to about 350°C, and then cooling to room temperature by spraying water or bathing.

 

Normalizing (N)

The purpose of normalizing is to eliminate the coarse grains in the weld area, refine and uniform the weld structure, and improve the mechanical properties of the used roll forming machine weld.

The process route is: after heating the weld area to 30~50°C above the Ac3 line, that is, 920°C~950°C, air-cooled to 350°C, and then forcedly cooled with coolant.

 

Remarks: Heat treatment Ac3 is a temperature code, A stands for critical point, c stands for heating. Different carbon content steel grades and different alloying element content steel grades have different heat treatment Ac3. On the iron-carbon phase diagram, people name the temperature of 230°C (Curie point of cementite) as A0, 727°C as A1 (PSK line of iron-carbon phase diagram), and 770°C (iron-carbon phase diagram) for the convenience of application. The Curie point of the element body, the magnetic transition point) is A2, 727~912°C is A3 (GS line of the iron-carbon phase diagram), and 1394~1495°C is A4 (the NJ line above the iron-carbon phase diagram)

 

Used roll forming machine

 

Quenching + Tempering (Q+T)

The function is to reduce the hardness of the weld area, improve the plasticity and toughness, reduce the internal stress, and obtain good comprehensive mechanical properties.

The heat treatment process is as follows: after heating the weld area to the normalizing temperature, spray water for quenching, then heat it to the tempering temperature (540 ~ 650°C), and then start to add water for forced cooling after air cooling to 350°C.

 

The latter two heat treatment processes are mostly used for high-grade steel oil and gas pipes, as well as high-grade welded pipes according to process requirements.

 

Air cooling length

After the welding seam is heated by medium frequency induction, the air cooling speed should not be too fast, otherwise it will affect the structure and performance of the welding seam area. From the point of view of heat treatment, a longer holding time is conducive to the homogenization of alloy elements and the homogenization of the weld structure, and the comprehensive mechanical properties such as plasticity and toughness of the weld area are also better. However, due to the constraints of the process layout and the economy of the plant land, it is impossible to keep the air-cooling section very long, which requires an analysis of the factors affecting the air-cooling effect, and a balance point between the two to ensure the welding after heat treatment. The joint has good comprehensive mechanical properties and can use the site more economically. At present, the air cooling length of the used roll forming machine is mostly selected between 50 and 60m. From the perspective of production practice, it can basically meet the needs of normal production of welded pipes and on-line heat treatment of welded seams.

 

Another way to determine the air cooling length L is to determine the air cooling length according to the following formula according to the type of heat treatment, welding speed and air cooling speed, etc.

 

Used roll forming machine

Formula:

L——the length of air cooling required after heat treatment of the weld, m;

v——the welding speed of the unit, M/min;

△T——The difference between the heat treatment temperature of the weld and the final cooling temperature, °C;

Vc - cooling rate, °C/s.

 

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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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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.
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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.
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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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
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Workflow Analysis of a Laser Tube Cutting Machine

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

2.Positioning Alignment: The tube is aligned and secured in place to ensure precise cutting. This can be achieved through mechanical clamps or automated systems that adjust the position based on pre-programmed parameters.
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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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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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
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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

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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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