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Thin wall tube forming with used roll forming machine

Thin wall tube forming with used roll forming machine

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  • Release time:2022-05-21 11:30
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【概要描述】The difference between the thin-walled welded pipe and the thick-walled pipe forming difficulty of the used roll forming machine is that the difficulty of thin-walled pipe forming is that the edges of the tube blank have too much longitudinal extension during the forming process, which is easy to produce forming bulges.

Thin wall tube forming with used roll forming machine

【概要描述】The difference between the thin-walled welded pipe and the thick-walled pipe forming difficulty of the used roll forming machine is that the difficulty of thin-walled pipe forming is that the edges of the tube blank have too much longitudinal extension during the forming process, which is easy to produce forming bulges.

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  • Source:
  • Release time:2022-05-21 11:30
  • Pvs:
Detail

The difference between the thin-walled welded pipe and the thick-walled pipe forming difficulty of the used roll forming machine is that the difficulty of thin-walled pipe forming is that the edges of the tube blank have too much longitudinal extension during the forming process, which is easy to produce forming bulges.

 

Thin-walled pipes theoretically refer to a type of welded pipe with a wall-diameter ratio of less than 2%; in practice, welded pipes with a wall thickness of less than 0.6 mm are also called absolute thin-walled pipes. The difficulty of thin-walled tube forming is that the rigidity of the tube blank is low, and the edge is easily unstable, which leads to the failure of forming.

 

Forming Instability

As mentioned above, there are two main forms of instability in thin-walled tube forming, one is wave, the other is bulge. In a sense, the process of forming thin-walled tubes is the process of inhibiting the formation of bulges.

 

However, in general, even thin-walled pipes do not necessarily have bulges. Taking the adjustment operation as an example, the same thin-walled tube, on the same used roll forming machine production line, uses the same set of forming rolls and the same tube blank raw material, different operators, sometimes the adjustment results are quite different. This shows at least two points. First, the welding pipe debugging operation has a vivid effect in suppressing the bulge, which should be paid great attention to; second, there are many reasons for the bulge, but the formation mechanism is not complicated.

 

Used roll forming machine

 

The formation mechanism of the bulge

(1)Too much plastic extension of the edge. According to the welding tube forming theory, in the process of forming the flat tube blank into an open tube to be welded, a point on the edge gradually rises as the tube blank advances, and at the same time moves closer to the rolling center plane. The movement trajectory of this point has a theoretical minimum value Lmin. Lmin can only be temporarily longer than the bottom of the tube blank by △L in a certain area of the forming. Length (traditionally zero). However, the forming bottom line and rolling center line formed by the roll pass cannot actually be an absolute straight line, as well as the influence of the springback of the tube blank, the roll pass, and the operation adjustment. In fact, the plastic extension of the edge of the tube blank in the process of welded pipe forming is inevitable, which is an objective existence, which can be fully proved from the deformation of the first pass and its edge elongation.

 

(2) In the later stage of forming, the edge tension of the tube blank decreases sharply. The state of the longitudinal edge of the tube blank is determined by the properties of the tensile force and the restoring force: when the previous tensile force is within the elastic limit, the restoring force is the forwarding form of the previous tensile force, and together with the tensile force constitute a pair of balance forces necessary for forming, the tube blank The edge is acted by this pair of balancing forces, so that the edge will not easily shake and jump, that is, there will be no waves or bulges; when the previous tension exceeds the tension required for the longitudinal extension of the tube blank or due to other process reasons, operation reasons, raw material reasons When the tensile force exceeds the elastic limit, the edge will deform plastically. Moreover, if no new longitudinal tension is added, the nature of the restoring force has essentially been transformed into longitudinal compressive stress, and the edge of the tube blank will become unstable under the action of longitudinal compressive stress, and the edge will wave and even form a bulge.

 

It can be seen that the formation mechanism of the thin-walled tube bulge of the used roll forming machine is: during the forming process of the tube blank, the edge is affected by various factors and the elastoplastic extension occurs, and the bulge will occur when the edge does not have sufficient longitudinal tension; Longitudinal plastic extension and loss of longitudinal tensile stress are the internal and external causes of bulge, and both are indispensable. If plastic elongation occurs, but there is a sufficiently large longitudinal tensile stress on the edge, bulging will not occur; similarly, if there is no longitudinal plastic extension on the edge, even if there is not enough tensile stress, bulging will not be formed. This understanding is an important achievement in the development of welded pipe forming theory, and is also the theoretical basis for various advanced forming equipment, advanced forming processes and advanced forming adjustment methods.

 

Used roll forming machine

 

Features of forming drums

The relationship between forming waves and forming drums

Waves are a type of drum kits, they are both different and related. First of all, the wavelength of the wave is much longer than that of the bulge. The wavelength of the formed bulge of the small-diameter welded pipe is generally not more than 20mm, and the wavelength of the wave is usually several times the wavelength of the bulge. Secondly, the waves are usually softer and do not have obvious bulges; and the bulge either has no, or has a sudden edge, and suddenly bulges; the peak of the wave is smaller than that of the bulge, and the peak of the bulge is as small as a few millimeters, as many as ten millimeters, or even more. high. Finally, from the perspective of hazard, the wave usually turns into a small shaking of the edge, sometimes it is not obvious, it is a soft defect that is better to solve, and it is not a big problem if it is not solved for the time being; and every bulge, even a small bulge, will cause weld seams Lap welding and leakage welding cannot be ignored and must be solved.

 

Of course, waves and drums are closely related, and there is a logical relationship between them. There are always waves first, and then bulging; waves are the precursor to bulging, giving birth to bulging; however. Waves do not necessarily all form bulge, and bulge is an inevitable product of wave development to a certain extent. Conversely, as long as there are bulges, there must be waves. This "blood relationship" between waves and bulging tells us that to prevent and eliminate bulging, we should start with preventing and eliminating waves. At the same time, once it is found that there are waves on the edge of the formed tube blank, measures should be taken as soon as possible, and do not wait until the bulge appears before adjusting.

 

Features of drum kits

(1) Morphological features. A common feature of formed drums is that they always bulge outwards. The reason why the bulge is only convex outward and not concave inward is determined by the direction of the transverse deformation of the formed tube blank and the rebound trend after transverse deformation.

(2) Occurrence segment features. The vast majority of bulging occurs in the fine forming section, which is related to the fact that after the formed tube blank enters the fine forming section, the longitudinal extension of its edge is greatly reduced, or even converted to compression; in other words, the tube blank is generated and accumulated in the rough forming section. The edges extend longitudinally, so that the fine-formed section cannot be fully absorbed, and is "excess" during the forced isometric process of the fine-formed section. It can be seen that although the bulge is manifested in the fine forming section, the root cause is in the rough forming section.

 

These characteristics of the bulge point out the direction for eliminating and suppressing the bulge: first, focus on the rough forming section, starting from the hole type, material and adjustment, so that the edge of the tube blank extends as little as possible. Secondly, we should try to strengthen the control force on the outside of the edge of the tube blank in the finishing section (recommended from the deformation angle greater than 180°). This is also one of the reasons why when talking about the thin-walled tube forming and bulging prevention of used roll forming machine, it is always emphasized to increase the reduction amount of the closed-hole type upper roller. Because the pass near the guide ring of the upper roll of the closed pass is the most direct rolling force applied to the edge of the tube blank from the outside of the edge of the tube blank, and it is this force that partially eliminates and suppresses the bulge.

 

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Analyzing of Double head uncoiler
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Time of issue : 2024-11-06
Analysis of a double-head uncoiler:

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.

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Analysis of a double-head uncoiler:

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:
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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.
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High-Frequency Quenching Equipment AnalysisHigh-frequency quenching equipment is advanced machinery used in the heat treatment of metals to improve their hardness and wear resistance. This method involves heating the surface of a workpiece to a very high temperature using high-frequency electric currents, followed by rapid cooling (quenching). The process effectively enhances the mechanical properties of the metal components, making them suitable for high-stress applications. Here are some key points to analyze high-frequency quenching equipment:

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.
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Analyzing  advantages and disadvantages of stainless steel electrolytic tube
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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Detail
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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