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①. Mold materials can be chosen from Taiwan SKD11, domestic Cr12MoV, copper alloy, and other materials.
Production molds are vacuum heat-treated, and their hardness reaches HRC 60 or even more.
(This depends on the material and whether it's India.) High-precision CNC machining is employed.
②. Processing technology:
mold Sawing → forging → rough machining → CNC precision machining → heattreatment → grinding → linear engraving → CNC precision turning → inspection → packaging →warehousing
1. Core Functions and Roles
Forming: The straight edges of the steel strip are raised by bending the sides gradually and smoothly almost forming an open, circular tube ready for welding (O-shape).
Closing and Extrusion: The open tube is closed right before the welding point so that the two edges are perfectly in contact (I-shape). Also, suitable extrusion pressure is applied to make sure the weld is of high quality (especially for high-frequency contact welding or induction welding mechanisms).
Sizing and Straightening: Subsequent to welding, the tube, which is heated and thus dimensionally unstable, is carefully aligned to ensure accurate tube dimensions for diameter, roundness, and straightness.
Controlling Weld Quality: The degree of forming and closing correctness has a direct influence on weld misalignment, welding load, and it is the first challenge in judging weld quality.
2. Main Components and Structure (Classified by Process Section)
Generally, the rolling mill die system in a welded pipe production line is made up of the main parts listed below:
A. Forming Section Rolls (Rough Forming Section)
Location: To the front of the production line, past the welding point.
The forming section rolls are normally made up of 5-10 (or more) horizontally and vertically alternating rolls in total.
Design Principle: Uses the bending deformation method. During the bending process, the radius of the strip pass is getting smaller each time the pass is repeated, while the angle at which the strip edge is "lifted" increases with each pass, thus the cross-section changes first from flat to flared, then to U-shaped, and finally to an open O-shape.
Teacher: The W-bending method is very well-known, which is basically a super talented roll profile figuring that the main purpose is the lateral extension of the strip edge during bending, reducing the edge stretching and preventing bulging or wrinkling.
Characteristics: Many rolls with the continuous pass changes; mainly facing bending stress.
B. Closing/Extrusion Section Rolls
Location: Directly preceding the weld spot (most commonly the last forming roll).
Function: It is usually a pair of precision-machined flat rolls or rolls with small guide grooves.
Their main purpose is to press the open O-shaped tube together; thus, the two sides are perfectly aligned and in contact to form an "I" shape. Besides this, this pair of rolls also gives the basic force of extrusion for welding.
Key Requirements: Perfectly smooth, flush fitting of the two edges, without any vertical misalignment requires extremely centering accuracy and thus, rigidity of the rolls.
C. Sizing Rolls
Location: Immediately following welding (after stripper has removed the slag).
Composition: Usually comprises 3-5 main horizontal roll stands, with the vertical rolls assisting each stand.
Function: After welding, the tube is at a very high temperature, and its dimensions are unstable. The sizing rolls have a perfectly circular hole, and the inner diameter of this hole is the desired outer diameter of the finished tube.
During the cooling phase, a tube is passed through these progressively smaller holes to achieve:
1. The outside diameter of the tube is very accurate and stays the same along the length.
2. The shape of the section is a perfect circle.
3. Getting rid of the small deformation and stress caused by the welding.
Characteristics: The hole is a perfect circle; the rolls are subjected to high radial pressure, so they have to be highly wear-resistant and be very stable in their dimensions.
D. Straightening Rolls (Optional, or on an offline straightener)
Function: It works by making the long tube flat along its length. This involves the removal of any bending (sickle bend) along the length of the tube, thus the tube becomes straight.
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The rolling mill mold is a complex "guiding and shaping" system in a welded pipe production line. It is different from the "compression forming" concept of the traditional rolling mills, as it focuses more on continuous, progressive bending guidance and accurate dimensional control. The level of its design, manufacture, and maintenance directly impacts the weld quality, dimensional accuracy, production efficiency, and material utilization of the welded pipe; it is considered the most technologically advanced core component of the welded pipe production line. A good welded pipe mold design can effectively minimize the edge stretching and residual stress to a great extent, thus resulting in the production of higher-quality and stronger welded pipes.
Our Advantages
Established: 2020
Core Expertise: Experience of more than 20 years in the field of welded pipe equipment.
Factory Size: Production base and warehouse covered with more than 20,000 square meters, equipped with modern facilities.
Technical Team: The company is equipped with a team of over 20 professional technicians continuously devoted to R&D and innovation.
Core Products: Precision-welded pipe production lines, welding leveling equipment, bright solution equipment,
weld seam tracking systems, intelligent control systems, finishing rolling pipe bright solution equipment,
rotary annealing equipment, etc.
R&D Strength: Has more than 30 national patents and keeps getting new patent authorizations.
Certifications: The company is recognized as a national high-tech enterprise and is certified with the ISO9001 quality management system, thus complying with the quality standard during the entire process from design to service.
Partners: The company’s strong commitment to quality and excellence has won the trust of many tier-1 corporate clients such as Juli, Wujin, Sanhua, Plymouth (USA), and Binner (India).
Market Coverage: The equipment is sold worldwide, exported to several countries and regions in Asia,
the Americas, and Oceania, besides the Chinese market.
FAQ
Q1: Do you own the factory?
A1: Yes, we are a manufacturer from China, and our factory is in Yunfu, Guangdong, China.
You are welcome to visit us.
Q2: Do your goods have an ISO9001 or CE certificate ?
A2: Yes, all our goods have an ISO certificate. All machines are of high quality.
Q3: How about the warranty?
A3: We offer our customers a one-year quality warranty for all our products, and during the warranty period, spare parts replacement will be free. Moreover, we give lifelong technical support and other assistance.
Q4: How about the payment terms and delivery time?
A4: Small machine payment term: 100% closed before shipment by T/T/Western Union/Cash.
Big machines and big amount payment: 40% deposit, 60% before shipment.
(We will do the entire process and prepare all documents for the customer's confirmation)
You can pay through T/T, L/C, Western Union, or other ways.
Machine delivery time is within 45-90 working days.
Q5: Which countries are your products exported to?
A5: Our products have always had a global presence, and they come with the necessary certifications.
