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The method of adjusting the r angle of the directly forming to square pipe mill when making pipes

The method of adjusting the r angle of the directly forming to square pipe mill when making pipes

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  • Release time:2022-08-14 11:30
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【概要描述】When the square tube is manufactured by the directly forming to square pipe mill, the r-angle symmetry and the same size of the square tube are important conditions to measure the external beauty of the square tube, and it also affects the subsequent assembly requirements of the finished tube tooling.

The method of adjusting the r angle of the directly forming to square pipe mill when making pipes

【概要描述】When the square tube is manufactured by the directly forming to square pipe mill, the r-angle symmetry and the same size of the square tube are important conditions to measure the external beauty of the square tube, and it also affects the subsequent assembly requirements of the finished tube tooling.

  • Sort:Information
  • Auth:
  • Source:
  • Release time:2022-08-14 11:30
  • Pvs:
Detail

When the square tube is manufactured by the directly forming to square pipe mill, the r-angle symmetry and the same size of the square tube are important conditions to measure the external beauty of the square tube, and it also affects the subsequent assembly requirements of the finished tube tooling.

 

To According to international standards, if there is no special requirement, the r angle of the finished pipe should be adjusted according to 1.5t (wall thickness). However, in actual production, the four r angles are often unequal. Some customers will require the r angle to be greater than 1.5 or less than 1.5 wall thickness according to the use of the finished pipe. Therefore, the manufacturer is required to effectively control the r angle according to the process requirements to meet different needs.

 

When using the directly forming to square pipe mill to manufacture square rectangular pipes, there are three adjustments for the r angle greater than 1.5 or less than 1.5 wall thickness.

 

Adjustment of r<1.5t

(1) Increase the bandwidth and reduce the r angle. According to the calculation formula of the material width of the circular variable square tube:

 

Directly forming to square pipe mill

 

In the formula, for a specific welded pipe, A, B, t and △ are fixed values. To make r smaller, the most direct way is to increase C. After the width of the tube blank is widened, the increase will make the round tube larger before the square is rounded, and more material will fill the gap at the corner of the rectangular tube pass. The more the filler, the sharper the corner.

 

Adjustment of r>1.5t

The adjustment method is opposite to the above-mentioned situation.

 

r angle symmetry adjustment

Judging from the practice of manufacturing square rectangular tubes with directly forming to square pipe mill, the difficulty of controlling the r angle of the square rectangular tube is not simply whether it is large or small, but whether it is symmetrical. The symmetry of the r angle, in addition to adjustment, is also closely related to the hole design.

 

There are three design methods for the angle r when designing the rectangular tube pass.

(1) Specific r-angle hole type. The characteristic of the obliquely specific r-angle pass is: each roll pass is composed of five arcs, that is, two main deformation arcs and three r arcs are connected by tangent, and the pass is gradually designed to be a specific The r angle.

The only advantage of this pass is the high accuracy of the r-angle, and the four corners are easy to be symmetrical and equal, but this is also its fatal shortcoming-a set of rolls can only produce the only rectangular tube with the r-angle shape. Unless the customer has special regulations and requirements for the r angle, such a design is generally not made.

 

(2) Sharp-angle hole type. The characteristic is that the hole-shaped arc intersects the arc. The advantage of this type of pass is strong adaptability. The same pass can meet the requirements of different customers for different fillets. By controlling the width of the tube blank and proper on-site adjustment, it can completely ensure that the four corners of the rectangular tube are within a certain accuracy range. Symmetry is equal. However, this requires relatively high requirements for the commissioning personnel. If the adjustment is improper, even a hole with a specific r-angle may produce a rectangular tube with asymmetrical four corners.

 

(3) No angle hole type. The characteristic is that the hole pattern lines do not intersect, and the r-angle does not exist. For example, the hole pattern for the universal arch deformed rectangular tube and the hole pattern that uses the Turkish head method to participate in the deformation. This type of hole pattern is actually the inheritance and development of the sharp-angled hole pattern.

 

There are four basic forms and adjustments for the unqualified r angle when making square rectangular tubes with directly forming to square pipe mill:

(1) The adjustment of the lateral r angle of the rectangular tube that does not meet the standard.

 

 

Directly forming to square pipe mill

 

As shown in the first case in the above figure, r2 and r4 are too large for the obliquely exiting square tube. The main adjustment measures are:

Properly loosen the vertical roller, and at the same time properly press down the flat roller (whether or not the last flat roller is also pressed depends on the tolerance). When the tolerance is in place, loosen the first few vertical rollers a little to keep the last flat vertical roller basically stationary . It is also possible to separately press down one or two flat rollers with little change in r angle after passing through the flat roller hole type according to the specific situation. If r2 and r4 are too small, reverse adjustment is performed.

 

(2) Adjust the vertical angle r of the rectangular tube that does not meet the standard.

Directly forming to square pipe mill

In the second case of the above figure, the oblique rectangular tube r1 and r3 are too large. The guiding ideology of the disposal method is to relax the flat roll and gather the vertical roll as the basic adjustment method, and directly roll the small roll gap with the edge of the vertical roll pass. Angle r1 and r3. The purpose of relaxing the flat roll is to increase the upper and lower dimensions of the tube blank to facilitate the rolling of the vertical roll pass edge to reduce r1 and r3; the second is to achieve a relative reduction of r1 and r3 by increasing r2 and r4; the third is to reduce r1 for the vertical roll And r3 prepare more materials.

 

(3) Adjust the angle r on the lateral side of the rectangular tube that does not meet the standard.

 

Directly forming to square pipe mill

 

If r4 is too large (as shown in the figure above), after observing and analyzing the specific situation, you can try to make the following adjustments:

① properly press down the flat roll on the side of r4, and directly roll the small r4;

② You can also move the penultimate first and second vertical rollers a little in the direction of r4. This action actually forces the angle of r4 to drill into the gap of the flat roller on the side of r4, thereby aggravating the rolling of the edge of the side pass to the angle of r4. Braking force, reduce r4.

 

(4) The adjustment of the upper (lower) angle r of the rectangular tube is not up to the standard.

 

 

Directly forming to square pipe mill

 

If r1 is too large (as in the fourth case in the above figure), on the basis of fully observing and analyzing the current situation of the sizing roller, the following adjustments can be made:

①Appropriately narrow the upper roll gap of the vertical roll to increase the rolling force at the r1 corner of the rectangular tube at the upper edge of the vertical roll pass, thereby reducing r1;

②Appropriately lower the penultimate vertical roll. This action is actually to increase the rolling force at the angle r1 of the rectangular tube at the upper edge of the vertical roll pass and reduce r1.

③Raise the upper roller. If the r1 of the nth to the vertical roller is too large, the n-1th flat roller can be properly raised.

 


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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.

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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.

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6.Post-processing (if necessary)
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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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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.

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