There are huge tube-rolling units where large amounts of seamless metal pipes as well as tubing, are produced specially with the help of rolling process. Now when we say seamless pipes or tubing, we mean by-products, which do not have longitudinal or any spiral-welded seams. There is a huge demand for such kind of pipes in manufacturing automobiles, tractors, industrial boilers, and air craft.
In fact besides these major applications, there are some industrial applications such as tools in machine building industry, in the process of petroleum extraction, even chemical industries need tubings and rolled pipes and last but not the least public works.
With the help of Tube Rolling process, we can make two types of rolled pipes:
1.Hot Rolled Pipe
2.Cold Rolled Pipe
However, the cold rolled pipe is first hot rolled and then cold rolled to complete its production.
This process of tube rolling needs high-quality tube tools to get the job done. Tubing Expander tool is one of the most important devices, whichare inevitable in rolling process. Tube Expanding is no less than an art. It needs reducing a particular tube wall by pressurizing or compressing the outer diameter of the tube against a fixed metal container such as rolling tubes into any form of tube sheets, tube drums, ferrules or maybe flanges.
In real life applications, construction of heat exchangers, industrial boilers, and popularly used surface condenser tubes is mainly made up of copper, steel, good quality stainless steel and last but not the least cast iron with few exceptions such as the use of strong titanium metal in manufacturing ultra high pressure resisting vessel applications. For added safety and to assure a proper tube joint, this tube wall must be reduced only till a predetermined percentage. This percentage depend directly upon the material of which the tube is constructed.
Let us see the process of tube rolling and understand the operations:
• 1st Operation: It is basically known as piercing. A longitudinal opening is made purposefully in the round bar to construct a thick walled pipe also known as the shell.
• 2ndOperation: This process is termed as plug rolling. In this step, the pierced bar or billet in 1st operation is elongated to make its wall thin and reduce its thickness upto desired dimensions for finishing the pipe of custom size.
Both operations are performed in one heating. Rolling is currently the most widely used forming process and can closely monitor and control all the final products.
Besides expander tool, the process also needs Ring Rolls. They are made up of spheroidized graphite biotitic and pearlitic matrix or at times, alloy cast steel base is used.
Hence, we have understood the importance of tube rolling for industries and how often, they need to apply extra forces for excellent rolling completion. In metalworking jobs, rolling is like a rolling a dough. It has a metal forming process in which all the stock of metal is passed through different rolls, which may reduce the thickness and thus make the thickness uniform.
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