September 11, 2007 | By David Liddle
Sorting through the myriad quality programs and manufacturing trends—total quality management, Six Sigma, lean manufacturing—can be a daunting challenge. Knowing which strategies to use and how to use them can deliver big results in a copper tube production facility.
April 10, 2007 | By Baicheng Wen
The use of high-strength materials is growing, and roll forming engineers and tooling designers who want to form this material successfully need to arm themselves with knowledge about these materials, their capabilities, and the limitations. Knowledge gained from press brake bending operations is useful in predicting how these metals will form on a roll forming line.
March 13, 2007 | By Laurence Shaheen
Five tube drawing methods are sinking, rod drawing, floating plug drawing, tethered plug drawing, and fixed plug drawing. Choosing the right method or combination of methods for a particular application requires understanding the characteristics of each. Tube producers also have a choice of feedstock: seamless or welded tube. Likewise, choosing the right one is a matter of understanding the differences.
November 7, 2006 | By Glen Stapleton
Glen Stapleton relies on his experience in troubleshooting for more than 30 years to discuss the most pressing pilger mill maintenance issues—causes, cures, and tips to prevent breakdowns and get the machines up and running again when they do fail.
October 10, 2006 | By Eric Lundin
When Hastings Irrigation Pipe Co., a manufacturer of aluminum pipe, needed to replace its decades-old welding power supplies, it looked for units that could weld a variety of thicknesses at fast welding speeds. What it found were power supplies that allowed the company to run its mills faster and save money in several ways.
September 15, 2006 | By Mike Pelham
Dirt, rust, and wear, cost tube producers and fabricators millions of dollars annually, and they can be the bane of tube processes. Analyzing the criteria for selecting the lubricants can help you select the best lubricant extend tool life and improve bends.
August 8, 2006 | By John Pavelec
Modern flying shear tube cutoff systems comprise state-of-the-art mainframes, tools, and controllers. This article, Part I of a three-part series, discusses the different types of mainframes, their capabilities, and construction. It describes and includes images of the construction process from start to finish.
August 8, 2006 | By Stephanie Vaughan
Since 1945 family-owned and -operated Tarter Gate has grown in staff and sales as it has changed the design of its products. To keep up with sales, continue growing the company, and absorb as many rising costs as possible — particularly in steel and fuel prices — the company uses custom machines and new technologies to its advantage.
August 8, 2006 | By John Pavelec
This article, Part II of a two-part series, discusses the different types of die set accelerators found in flying shear tube cutoff systems. It presents an overview of earlier accelerator technologies still in use today—cam link, assisted lift target, and air/oil units. It also discusses three common closed-loop die set accelerators that represent newer technology—hydraulic servo valve, servomotor belt, and servomotor rack and pinion.
July 11, 2006 | By Oliver Strehlau
The cold mill pilgering process uses ring dies and a tapered mandrel to reduce tube cross sections by up to 90 percent. Because the process relies on large number of small forming steps, the result is tube or pipe that has nearly homogenous material characteristics. It is suitable for every metal.
July 11, 2006 | By W.B. "Bud" Graham
Contrary to common opinion, a high production rate is not the key to success in making tube. Attempting to low-ball the price — while cutting corners in maintenance and upgrades -- is a poor strategy in this industry. Columnist Bud Graham provides four production scenarios that compare various rates of capacity utilization and line speed and how these affect profitability.
June 13, 2006 | By Chris Miller
Although most tube and pipe producers don't get too involved in the regrind process, it is crucial—reconditioning roll tooling can extend its useful life by 15 or 20 times. The regrind process reduces the producer's overall out-of-pocket tooling expenses, while helping to ensure the tooling continues to produce a consistent-quality product at the required speeds. A better understanding of the process, especially familiarity with the types of flaws that reconditioning can and cannot resolve, can go a long way toward a better working relationship between a tube and pipe producer and its regrind contractor.
June 13, 2006 | By W.B. "Bud" Graham
Bud Graham revisits his January/February column on problems that plague tube mills (or nearly any manufacturing company, for that matter) and shares some reader feedback. Also, he provides the runners-up and winner of a caption contest for a photo that also appeared in the January/February issue.
May 15, 2006 | By Mike Pelham
Rust, wear, and dirt cost tube fabricators and producers millions of dollars annually, and they can be the bane of tube processes. Analyzing the criteria for selecting the lubricant, cleaner, and rust preventative can help provide maximum protection.
April 11, 2006 | By W.B. "Bud" Graham
Problematic material? Yes, bad coil is out there. It could be mislabeled; the yield strength could vary from one part of the coil to another; it might have damaged edges; and so on. In the second part of this two-part series, columnist Bud Graham discusses steel coil, how its characteristics can vary, and how these variations can result in substandard tube.