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Articles tagged with "tube"
Results: 130
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Increasing productivity on your cutoff saw: Considerations when sawing round and square tubingAll of the components of a tube cutting job—the workpiece, the blade, the saw, and the cutting fluid included—have to work together optimally to maximize your productivity.
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Putting a spark into cutting productivity: Exploring the friction alternativeThere are many ways to cut sheet, plate, tubing, and structural shapes, ranging from a hand hacksaw to power shears and lasers.
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Making the cut: ArrayArray
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Boatmaker finds new saw for trailer production: Circular cold saw meets compound miter cut, setup requirementsAt its factory in Vonore, Tenn., MasterCraft builds boats and trailers in adjacent bays. It offers the option of a trailer with every ski boat it sells.
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Take the old with the new - Selecting saw blades with new technologies in mindNew methods for cutting tube and pipe have been introduced to welding shops in the last few years—methods designed not only to cut metal, but also to cut costs.
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Tube Hydroforming Design Flexibility—Part I |
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The basic elements of tubular hydroformingMany factors come into play when attempting to execute a production hydroforming operation, among them material selection, friction and lubricants, tube bending and preforming, and equipment. Many companies in the automotive sector are experiencing great success with the process, which can reduce weight, overall costs, and the number of parts per vehicle.
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Hydroforming with end feedingThe list of applications for hydroforming with end feeding is growing all the time. Maybe you should check into how this technology could benefit your operation.
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Predicting failure in hydroforming prevent aluminum tubes: Strain variables require sophisticated analysisThis article discusses an approach to predicting failure in hydroforming prebent aluminum tubes. While strains are well researched for stamping sheet, this type of knowledge is lacking for hydroforming tubular components. Because the strains are different—prebent hydroformed tubular parts experience stress in the axial direction during bending, then in the circumferential direction during hydroforming—new methods for predicting failures are necessary. Researching these methods adds to the knowledge base of hydroforming, helping the technology gain further acceptance in manfacturing.
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Hydroforming provides Rx for medical pumps: Fabriator adds economy to other benefits of titaniumThis article relates how a Florida-based company used hydroforming to produce titanium housings for implantable pumps for a Massachusetts-based manufacturer.
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Tube Hydroforming Design Flexibility—Part II |
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Hydroforming a new front automotive structure: How new methods can rise to old challengesHydroforming the parts in a vehicle structure can be of immense benefit on several counts, as a review of a recent project at the author's company can attest.
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Material property variations in tubes used for hydroforming: Using the hydraulic bulge test to determine formabilityAs tubular hydroforming becomes a competitive process for the mass production of automotive parts, a tube's material properties must be consistent. To predict variations in material properties, many tube producers use the uniaxial tensile test. Because the specimens for the tensile test are collected before a tube is bent and welded, they are not always accurate. To predict variations in tube property accurately, it should be tested under a biaxial state of stress.
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Hydroforming on a budgetYou can use several strategies for starting a hydroforming operation on a limited budget. Review your alternatives for selecting a press, fluid intensification system, and developing the tooling necessary for your operation before you take the plunge.
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Fill'er Up: Using hydroforming to manufacture one-piece gas tank filler tubesHydroforming is gaining ground in the manufacture of many automotive components,such as pillars, frame rails, and engine cradles. Automakers are finding hydroforming advantageous for forming many smaller parts also. The process is useful for manufacturing an automobile fuel filler tube, which is the expanded portion of a fuel filler assembly where a fuel nozzle is inserted.
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Tube Hydroforming Design Flexibility—Part III |
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Dealing with internal pressure in free hydraulic bulging: Predicting results with FEAFor hydraulic tube bulging, direct pressure control is the most commonly used process. Pressure control allows engineers to determine the correct capacity hydraulic system and, more importantly, prevent tube rupture. However, inflow control, or control of the volume of fluid inside the tube, theoretically could be another viable hydroforming process. Finite element analysis has shown that inflow control could allow engineers to more accurately predict deformation behavior and therefore enhance the hydroforming process.
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Examining the effects of push assist on the formability of aluminum tubesIt is well-known that tube has become an important material for hydroforming hollow components. The increasing complexity of product structures, particularly in the automotive industry, often requires one or more forming operations before a tube actually is hydroformed. Prebending is one of these forming processes used to prepare tubes for the so-called prebent tube hydroforming.
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Tier 1 supplier builds four-stage competitive strategyF & P Manufacturing Inc., a tier-one automotive components supplier, focused on four areas when it developed a hydroforming line for manufacturing Honda Accord engine cradles. These areas were eliminating end scrap, decoupling the bending machines from the manufacturing line, reducing cycle time, and palletizing parts.
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A survey of presses for hydroforming tubes, extrusions: Presses, accessories offer options for hydroformersHydroforming is one of the most important fields in production manufacturing. In recent years many single presses, groups of presses, and entire production plants for internal high-pressure (IHP) hydroforming of tubes and extrusions have been installed, especially in the Americas and in Europe. The driving force behind this development has been the efficient production of automotive parts.
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Tube Hydroforming Design Flexibility—Part V |
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Developments in hydroforming: International conference highlights new equipment, industry trendsCommentary from the people interviewed at the International Conference on Hydroforming (Oct. 2003) indicate that trends include an increasing interest in forming aluminum and other lightweight materials; more use of tailored tubes; and that sheet hydroforming is expected to grow faster than tube hydroforming.
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Part feature developments in hydroforming products: Hydroforming continues to make automotive inroadsTube hydroforming technology continues to develop in ways that improve part utility, economy, or process robustness. Auto parts that have recently been produced by hydroforming include roof rails, radiator enclosures, a front-end structural module, and roof rails.
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Hydroforming tapered engineered tubes: Are they more formable than uniform-thickness tubes?Hydroforming often results in localized thinning. Using engineered tubes--tubes that have a thicker wall where the tube is most prone to thinning--can result in a stronger finished component.
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Tube Hydroforming Design Flexibility—Part VI |
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Tube Hydroforming Design Flexibility—Part VIII: Dimensional StabilityWhether they are producing automobiles or hydroforming press parts, designers, manufacturers, and assembly personnel are very concerned about dimensional stability. Surfaces and holes must be located in a specified range and smaller is better. Concern escalates as the drive to improve quality and reduce build tolerances and problems increases.
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Straining to understand bending?: Regression analysis predicts springback’s magnitude, variationBefore you can hydroform tube, you bend it. Then it springs back. You can compensate by overbending it, but first you have to predict the amount of springback.
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Metallurgical aspects of tube production: Understanding the science, improving the manufacturingSmall-diameter tubing plays a crucial role in many markets, including aerospace, nuclear, medical, and industrial. From coronary stents to hydraulic aircraft controls, each application has unique requirements. To meet the requirements of customers in these industries, well-designed processing steps and adequate control are critical.
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Using laser shock peening to increase pilger die life: Case-hardening for reducing toolsDuring pilgering, the dies endure extreme amounts of stress. Shot peening is a conventional, economic process for hardening the tooling, but its benefits are limited. Supplementing shot peening with laser shock peening where the stress is highest can help to extend the service life of the tools.
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Putting a few end forming basics to workWhether maintaining or changing the OD, knowing the basics of end forming—especially friction and lubrication—can help achieve a successful result.
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Evaluating the Danger of Loud Noises in Tube and Pipe Shops: How OSHA's Rules Protect Your EmployeesIn work environments that generate noise that exceed 85 dB or with impact noises exceeding 140dB, such as found in tube and pipe, OSHA requires a hearing conservation program.
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Achieving cost-effective environmental compliance: How outsourcing waste management can helpThis article provides information on waste management, with specific focus on outsourcing. Topics include determining waste generator status, waste identification and minimization, safety training for employees, and "green" products.
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Learning to adapt: Fabricator adapts to changing manufacturing environmentProduction Cutting Services opened for business in 1985 as a service
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Supply chain collaborates on bending project: Planning, cooperation keep project on schedule despite short time frameFaced with a daunting bending contract and a short timeframe, Rick Williams of Rockford Process Control (RPC) sought cooperation from a tubing supplier, bending machine manufacturer, and a tooling supplier at the beginning of the project. The information exchange enabled RPC and its supply chain partners to develop a process, deliver a bender, and engineer and manufacture tooling without the benefit of tubing samples.
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All eyes on Dusseldorf: TUBE® expo hints at things to comeThe timing of the previous TUBE expo in Dusseldorf was nearly perfect. The industrialized economies were growing, oil was around $100 per barrel, and capacity utilization was healthy across the board. A few signs indicated trouble ahead, but it was a successful expo nonetheless. Now it is time for the 2010 show, and again the timing is good. Most of the industrialized countries have rebounded from the biggest financial crisis in 80 years, and many economists expect 2010 to be a big improvement over 2009. In addition, the tradeshow organizer has reported increased registration compared with the previous expo, and the TUBE exhibition space is sold out.
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Don't underestimate India: TPA tours the country that could overtake U.S. by 2050TPA recently hosted a tour of eight tube and pipe producers and fabricators throughout India. Although the country is not advanced, this tour and a recent report by Goldman Sachs reveal where it stands and where it is likely to go in the near future. Its capabilities are modernizing and Goldman Sachs expects its economy to overtake the U.S. economy by 2050.
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Troubleshooting your stamping operationA common thread runs through all effective troubleshooting approaches: the skill of observation. Learn to use it to your advantage.
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Using NDT systems to monitor welded tube production: Two methods are better than oneThis article discusses the capabilities and limitations of the two most common online tube monitoring test methods -- eddy current and ultrasonic. It discusses the types of flaws that each is capable of detecting, and shows photographs of three typical flaws -- one that was detected by ultrasonic, one by eddy current, and one by both. It concludes by showing that both methods should be used to provide the most comprehensive testing of welded tube.
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Technology modernizes CMMs: Hardware, software progress to enhance these shop toolsCoordinate measuring machines have progressed since their inception in the 1970s.
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Rockwell hardness and Brinell testing of tube and pipe: Special factors merit attention to ensure proper resultsThe article discusses special considerations that must be kept in mind when hardness testing tube and pipe. Rockwell and Brinell are covered. Special considerations include surface finish, wall thickness, deflection, and internal supports.
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Monitoring the quality of welded tube and pipeAn eddy current flaw detection system is suitable for detecting discontinuities in tube and pipe during the production process. Understanding about eddy current system principles and this technology's capabilities and limiatations can help tube and pipe producers learn how to use such a system.
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Do you use checking jigs and fixtures?: An ounce of prevention is worth a pound of cureHow do you check tube fabrications to ensure they meet quality standards? Do you ship parts without checking them and hope that the next time the phone rings it isn't a prelude to a tirade from a disgruntled customer? Or do you check finished parts only to realize that your scrap rate is too high and wish you had checked them at earlier stages of the manufacturing process?
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Error-free tube fabrication: Electronic sensing devices provide an ounce of preventionManufacturing processes are prone to variances, resulting in manufactured products that do not conform to specifications. Dozens of types of electronic sensors and measurement systems are available that fabricators can use to verify that their products are not defective. Understanding what types of sensors are available and how they work are the first two steps in implementing electronic sensing devices for quality control.
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A primer on titanium tube and pipe: Applications abound for this versatile metalThis article discusses titanium—how it is processed; the types and grades of pure titanium and alloys that are available; and applications for titanium tube and pipe. Discusses manufacturing and testing titanium tube and pipe to ASTM standards for specific applications.
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Forming exhaust components with an alternative lubricant: Manufacturer cleans up with gelSwitching from an oil-based lubricant to a water-based gel lubricant helped an exhaust-system components manufacturer, Zeuna Starker, reduce costs and cycle time. After studying several types of lubricants, the company chose a water-based gel that was less prone to spilling onto the floor and did not produce smoke during the welding process. The company reaped benefits in decreased housekeeping and disposal costs, and found that it did not need to wash the lubricant residue from semifinished parts before welding.
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Reviewing forming, expansion, and bending applications for welded tubeTube used in production processes that form a part by expanding or bending the tube
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Focusing on tube cutting lasers: Tube fabricators, producers see the lightState-of-the-art laser technology for cutting metal tubes includes capabilities for cutoff, beveling, and cutting an infinite variety of shapes such as holes, slots, and notches. In this article, manufacturers of laser cutting equipment discuss the state of advancements such as automated loading and unloading of parts; simplified programming; automatedinspection of finished parts; and lights-out operation.
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CPR for your old CNC bender: Before you junk it, try rebuildingIn the 1980s, when CNC machinery evolved, tube fabricators made the transition from manually forming each part to allowing a machine to form the parts unassisted. Now in the age of Windows®-based computers and brushless electric servo drives, these machines can seem like relics. But don't take them to the scrap heap just yet.
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Quenching and tempering of welded carbon steel tubulars: Minimal process variations to obtain a uniform productThe quenching and tempering of tubes include a number of variables that can have a profound effect on the process and the finished product.
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Using precision abrasive wheel technology: Narrow niche, small parts, tight tolerancesPrecision abrasive wheel cutting is a small but important niche in the abrasive cutting field. It can be used to cut many types of parts, including metal rods, tubes, extruded shapes, and even wire. It is most useful in operations characterized by small parts, hard-to-cut materials, and tight tolerances.
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Heating P91 boiler pipe: Induction heating gives contractor faster, more consistent resultsIn the power piping industry, turnaround time on a boiler pipe project typically is from 20 to 36 weeks. But J.F. Ahern Co. (JFA), Fond du Lac, Wis., a company ranked as one of the Midwest's top 10 mechanical contractors according to the May 2002 Contractor magazine, isn't typical. Neither were the results JFA achieved when it switched to induction technology for pipe preheating.
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Expanding Their Reach: Expandable Casing Pipe Helps Oil Companies Drill to New DepthsExpandable-casing pipe is being used by some aggressive OCTG players, causing oil companies to look at deep water and land based wells in a whole new light.
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Comparing materials for high-temperature steam piping: The use of X20 and P91 in power stationsOf all the materials used for high-temperature steam piping, X20 (12 percent chromium, 1 percent molybdenum, 1/4 percent vanadium) and P91 (9 percent chromium, 1 percent molybdenum, 1/4 percent vanadium) stand out because of their very high creep rupture properties, even at elevated temperatures.
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Say 'no!' to burrs, dimples: Competitors, customers drive finishing requirementsAs tube mill speeds increase, tube end cut quality suffers. Meanwhile, customer requirements for end cut quality continually increase. Tube producers are turning to dedimpling and deburring machines to enhance tube cut quality and improve worker safety.
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The basics of roll form tooling design: Understanding tube forming's not-so-distant cousinYou can successfully roll-form a profile more than one way. In fact, many roll form designers take different approaches to design and development. Also, because the roll forming process has a seeming limitless capacity to produce complex profiles with just as many variables, many roll form designs are one-of-a-kind; therefore, theory can go only so far.
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Specifying the sulfur content of 316L stainless steel for orbital welding: Weldability versus surface finishThe widespread use of autogenous (fusion) orbital gas tungsten arc welding (GTAW) in the high-purity semiconductor and biopharmaceutical industries, combined with modern steel refining technology, has made it both desirable and practical to supply type 316L stainless steel with a restricted range of elemental sulfur.
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Making the connection: Substituting tube end forms for machined connectorsHundreds of types of machined end connectors are used to transmit fluid in fabricated tube and hose assemblies. In recent years manufacturers and end users of these connectors have been developing new methods and processes that eliminate machined connectors and the associated joining operation. Eliminating connectors and joining operations can help save both money and time.
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The anatomy of a monster truckIt drives right over nearly every obstacle in its path and splits nearly every eardrum in its vicinity. It's supercharged, oversized, and extraordinary. It stands more than 10 feet tall, develops more than 1,500 horsepower, and can leap over a 727 jet airliner in a single bound.
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Coating fabricating toolingTube fabricators all over the country are starting to see some major benefits from new coating technology. Many coatings-both those that are time-proven and new ones just hitting the market-can provide many benefits for many tube fabrication processes, including extended tooling life, better finished parts, and less stress on machinery.
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Producing holes in tubing: Comparing the piercing and punching methodsNeed to put a hole in a tube? This article provides an overview of tube punching and tube piercing, exploring the different variations of each method and comparing the two methods on cost, safety, and flexibility.
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Inspecting welds on complex tube forms: Manual eddy current optionsMany manufacturers are familiar with using eddy current systems to inspect their sheet and tubular products. Eddy current testing (ECT) is a nondestructive electromagnetic test that offers a rapid examination to detect surface-breaking flaws or cracks. It can be applied easily to straight sections of both seamless and welded tubing. Tests can be performed online as part of the manufacturing process or offline as part of a supplier or customer quality assurance check.
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Batter up! Turning an aluminum tube into a baseball batThe roar of the crowd, the shouts of the umpire, the crack of the bat hitting the ball—these are the unmistakable sounds of a baseball game. Over the last few decades, however, one of those sounds has changed; now the bat tends to make a ping that resonates when it hits the ball. It's the sound of aluminum rather than wood making contact with the ball.
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Automotive motives - Tips for cutting per-piece prices for automotive customersToday's automotive industry is more competitive than ever. To compete with the European, Mexican, and Asian markets, the U.S. market must become more aggressive in finding ways to cut costs.
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Waste not, want not: ArrayArray
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The little-known life of the scarfing tool: Focusing on a small device to see the bigger pictureWho cares about scarfing tools? There are more important things in life. When the beauty pageant contestant is asked what problem she would like to solve, she's more likely to answer "I'd like to establish world peace" than "I wish I could find ways to help scarfing tools last longer."
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Designing an off-road sport truckThe main component in any off-road sport vehicle is the frame. Frames for mass-produced vehicles usually are stamped and welded. These are suitable for most drivers' needs, but for intense off-road driving and competitions, a sturdier frame is necessary.
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Pour me a mandrel: Bending tubes, pipes, and other forms with low-melting-point alloysTo reduce weight and cost for all types of products, design engineers often specify tubes and pipes with thinner walls instead of the previously used heavier-walled tubes and pipes. Shorter tube or pipe lengths also achieve the same objectives, but usually they require sharper or more complex bends. These designs make the tube bender's task more difficult.
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Zero to sixty in the blink of an eyeThe engine roars to life, and Bruce Van Sant inches the motorcycle forward, stopping about 25 feet from the starting line. Alan Geetings, crew member of the Van Sant racing team, sprays the asphalt with water. Bruce revs up the engine. The engine's torque breaks the rear tire's grip on the asphalt and it spins furiously. The air is suddenly filled with a cloud of smoke and the smell of burning rubber. After heating the tire, Bruce approaches the starting line.
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Selecting a welding frequency: Research on the optimal frequency for tube productionEarly power supplies for contact and induction welding for tube production, which were introduced in the 1950s, operated at 300 to 400 kHz. Modern power supplied, introduced in the 1990s, are variable from 200 to 400 kHz. While using any frequency in this range can produce acceptable welds for most applications, finite element analysis can be helpful for finding the optimal frequency for a particular gauge and material.
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Is your bend good enough?: Standards for hot and cold bendingBending tube or pipe so the finished product conforms to one of two bending standards can help to reduce rejects and improve relations between fabricators and their customers. The standards can facilitate the use of bending terms, and promote an understanding of bending tolerances and acceptable defects before starting a bending project.
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Bending and handling tube: Tailoring equipment to an applicationThree main types of tube bending equipment are dedicated, CNC, and automated bending cells. Understanding the advantages of each is crucial to deciding which type to purchase.
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Tips for welding preparation: How machine, materials, and tool bits affect the resultsThe increasing use of advanced equipment and applications (such as orbital welding for high-purity systems) requires better weld preparation. A thorough understanding of equipment, tool bits, and materials—including advanced alloys—helps to achieve better end prep.
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Lean times call for mean tactics—Part 1: A tube bender’s tools of the tradeRon Stange looks back on his 50 years in the tube-bending industry and provides his insight on the one thing tube bender operators must know to be successful: Ironclad rules for successful bending do not exist. Tube bender operators must start with guidelines and incorporate their own experience to be successful.
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Thinking about an equipment upgrade?: Laser systems offer flexibility from prototyping to productionProducts change, and so do manufacturing methods used to make products. In the tube and pipe industry, however, manufacturing changes have been few and infrequent over the past few decades.
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Welding zirconium and zirconium alloys: ArrayArray
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Selecting a tube cutting process: Methods and applications, pros and consTube fabricators use a variety of methods—sawing, lathe cutting, rotary cutting, supported shear cutting, dual-blade shear cutting, and laser cutting—to cut tubing from mill lengths into shorter pieces for use in final fabrication. No single method is optimal for cutting the broad range of tubular materials and tubular shapes produced by this industry.
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Managing rotary-draw tube bending: Best practices minimize variation and downtimeEditor's Note: This article is adapted from a conference presentation made by the author at a previous TPJ Symposium.
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The basics of rotary cutting: Finding the right machine type and optionsThe rotary cutting process rotates a tube or pipe and cuts it with a rotating blade. Because it is a chipless cutting method, it does not waste any material and reduces or eliminates subsequent deburring and cleaning operations. Although it can be used on any metal, it is not suitable for every application. The cutting action produces a slight chamfer on the end of the workpiece, so it is not useful for applications that require a square end. Machine types include manual and pneumatic. Accessories include cutter block assemblies that support the workpiece during the cut; length gauges for repeatable cut lengths; and feed systems that store and feed the material into the cutting machine.
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Making the cut: ArrayArray
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Fact or Friction?: Understanding lubricant types is key to best selectionArray
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Titanium trends: Energy demand, titanium demand grow hand-in-handElectricity demand grew an average of 15,000 megawatts per year from 1995 to 2006, and this trend will undoubtedly continue. The Energy Information Administration predicts that meeting future demands will require the equivalent of more than 20 new 500-MW power plants per year over the next 20 years or so. A critical component in power plant construction is titanium tubing, which is favored for its high strength and corrosion resistance.
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Focusing on bent tubing: Making measurements using photogrammetryMeasuring the bends and straight sections of a bent tube can be tricky and time-consuming, especially if the tube has a large number of bends in several directions. Photogrammetry, also known as optical measurement, uses a booth equipped with several digital cameras to make a digital image of the part, allowing fast, easy measurements.
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Manufacturing motorcycle mufflers: Fabricator finds improvement with rotary swagingArray
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Shaping profits with a mandrel extractor: The basics of mandrel extractors and their applicationsArray
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Welding zirconium and zirconium alloys Part II: Part II: Welding technique, procedures, and quality testingLike welding of other metals, welding zirconium successfully depends on correct application of electrical characteristics, wire feed, interpass cleaning, preheating, and heat input. Understanding the resulting surface color is key in knowing whether the weld was performed successfully or if it requires repair.
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Making the cut - Understanding rotary cutoff blades and extending blade lifeThe rotary cutting process rotates a tube or pipe and cuts it with a rotating blade. The blades are beveled to various angles and produce a chamfered end on the workpiece. Selecting the right bevel angle is the key in getting an optimal combination of end finish and production rate. Proper alignment and clearance, the use of a lubricant, frequent inspections, and proper sharpening are the keys to long blade life.
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Manufacturing motorcycle mufflers - Fabricator finds improvement with rotary swagingArray
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Making a workhorse run: Getting the best performance from a vertical compression bender |
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No need for annealing: Tube benders find success with unannealed material |
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Producing quality ASTM A249 and ASME SA 249 pressure tubesDetails are everything when you're manufacturing stainless steel pipe to exacting specifications.
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Increasing tube mill welding speed: Examining technology for tube producersThis article reviews processes that were technological advances in tube welding years ago but still have a bearing on how tube producers do their jobs today.
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Accumulating strip before the mill: An introduction to entry end equipment |
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Exploring the welded tube making process: The basics for fabricatorsThis article is aimed not at tube producers, but at fabricators of tubing, to provide an overview of the process.
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Skelp edge preparation for manufacturing ERW pipePreparing the edge of a metal strip properly before it enters an electric resistance welding tube mill makes a huge difference in the quality of the final product. Make sure your prep methods match your quality requirements.
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Maintaining a RF Tube and Pipe Welding Generator: How to find trouble spotsThis article separates the RF generator into seven major subassemblies and then gives tips for finding and preventing problems in each subassembly.
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Mastering the tool selection process: How to minimize production costs with the proper equipmentNeed a tutorial on how to select the proper tube mill tooling for all kinds of jobs? Getting the right tools in place for a particular product can make a world of difference in the final product.
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Presenting coil to a tube mill: Preparation of material for continuous operationTubemakers looking to improve operations at the front of the mill should consider factors such as coil preparation before feeding it into the tube mill—end joining, removal of overthickness, burr up/down condition, and accumulation.
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Boosting efficiency in solid state welders: Improving weld mechanicals can make the differenceThis article, reprinted from the January/February 1999 issue of TPJ-The Tube & Pipe Journal, is based on excerpts from Thermatool Corp.'s "High Frequency Pipe & Tube Welding Manual."
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Automated tube welding of heat exchangers: Converting from a manual process allows one company to increase production, expand projectsHarris Thermal Transfer Products, Newberg, Oregon, is an American Society of Mechanical Engineers (ASME)-code shop that focuses mainly on the production of shell and tube heat exchangers.
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Solving the mysteries of the fin pass—Part 1: Uncovering where, why and howThe fin pass was not the first time your father gave you five bucks for your allowance. The fin passes are those forming passes that immediately follow the breakdown or initial forming stages on a tube mill. Their role is paramount in the successful final presentation of the formed tubular section to the welding process.
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Solving the mysteries of the fin pass—Part 2Editor's Note: This article is the second part of a two-part series about fin passes. Part I, which appeared in the March issue, discussed their location, what they do, and how they do it. Part II focuses on troubleshooting.
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Minimizing wall thickness variation in seamless tubingAll mechanical steel tubing has some amount of wall thickness variation. Wall variation in welded tubing results from the strip manufacturing and tube welding processes. Seamless tube, which is created from a hot billet of solid steel, has wall variation that results from tooling wear, bearing and shaft variation, and normal hot-process variation. The wall thickness in seamless tubing varies in the cross section and along the tube's length.
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Measuring tube as it grows and shrinks: Using girth changes to set up a tube mill |
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Six-axis tube laser adds new dimension to job shopSince its founding in 1988 as a stamping job shop, the Kooima Co.'s equipment and services have evolved to meet the changing demands of its customers—always with the goal of providing them with one-stop shopping for all their primary metal fabricating needs.
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Laser tube processing: Ten out-of-the-box techniques save money, spur innovationThe introduction of lasers to the manufacturing process has changed the fabrication of tubing. Today, many manual processes can be replaced with laser processing techniques. Using the flexibility afforded by lasers, a bundle of raw tubing can be loaded into a laser tube cutter; parts can be cut with high accuracy, quality, and speed; and then finished parts from the machine can be sent directly to the final assembly.
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Pulling taffy and producing tube: Proper tension is a key to success for both processes |
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Keeping stainless steels stainless: How important is passivation for SS?Stainless steels are inherently resistant to surface attack in mildly corrosive environments. However, when corrosion does occur, it can result in the formation of pits on the surface or within crevices of the part. Why does this situation develop, and what can be done to prevent catastrophic failure?
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Troubleshooting OCTG threading: Part II: Insert type impacts finished-surface quality, tool life, chip control |
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Optimizing your hydraulic cutoff press: Squeezing more out of your tube mill |
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MIAB welding of thick-walled pipe ends: Research finds ways to increase pipe thickness while maintaining quality |
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Certifying the quality of your tube and pipeIn a perfect world, quality assurance and certification of materials would not be issues. In the tube and pipe industry, however, flawless raw materials and finished goods are not givens.
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Tension control in tube and pipe production: Getting it right for smooth, steady mill operation |
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Innovative die setup and maintenance methods for tube mill cutoff |
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Tube and pipe loading:: How one manufacturer made the process less hazardousThis article discusses the hazards associated with manually loading and unloading tube and pipe. It describes one company's solution to making the process less hazardous.
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Tube mill cutoff die setup for square and rectangular profilesWhen properly selected and utilized, single-cut die sets can produce top-quality cut ends on square and rectangular tubing. This article discusses the criteria for selecting and using the die sets to achieve the best results.
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Cutoff die setup for dimple-free roundsWith the right equipment and proper setup, tube mills can produce dimple-free round tubing efficiently. A multistep process using a two shear blade makes a dimple-free cut, and an inline brush end finisher can be used to remove the ever-present clearance burrs, if needed
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Modern flying shear tube cutoff systems: ArrayArray
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Troubleshooting Guide for CleanersRust, 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.
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Rotary straighteners for tube and pipe: An introduction to 6- and 10-roll straightening machinesAlthough six-roll straightening machines were the industry standard for decades, 10-roll machines provide twice as many bending moments and therefore turn out straighter, rounder tube.
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Shopping for a new tube mill coolant?: It takes more than comparing price tagsMany mill coolants are available today. Understanding the factors that drive selection and management of these fluids can help to minimize the costs of their use in welded tube production.
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Choices in flying cutoff saw blades: Friction versus carbideFriction saws are the conventional cutoff machines for tube and pipe mills. Drawbacks include hazards (noise and risk of breakage) and burrs they tend to generate. Tungsten-carbide-tipped (TCT) blades, which require more sophisticated sawing machines, run slower and safer, cut cleaner, and are less prone to breakage.
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Modern flying shear tube cutoff systems - Part I: MainframesModern 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.
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Modern flying shear tube cutoff systems - Part II: Die set acceleratorsThis article, Part II of a three-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.
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Using AC for Al: How alternating current is employed in orbital GTAW |
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TIG for titanium tubing: Success hinges on filler metal selection, cleanness, gas coverageAlthough titanium has a reputation for being difficult to weld, it doesn't have to be problematic. Paying close attention to filler metal selection, cleanness, and use of the shielding gas are three steps to successful GTAW on titanium tube and pipe.
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Trends in offshore energy: Training, technology help overcome skill shortageThe welding industry is known for a persistent shortage of skilled workers, and the energy sector is no exception; meanwhile, offshore welding is getting more rigorous. The easiest-to-find oil sources were discovered long ago; with each passing year, energy companies go into harsher environments (deeper waters) to find petroleum and natural gas. Drilling into deeper waters means dealing with higher pressures and colder temperatures, and many companies have been switching too high-strength pipe, which tends to be more difficult to weld than common pipe.
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Robots and dials and knobs—oh my!: GMAW power sources have evolved over timeIn the late 1950s, the U.S. Navy wanted to find a way to join heavy aluminum structural sections used to fabricate motor torpedo boat hulls.
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Simulating a robotic workcell: Taking the guesswork out of automationNot so long ago, setting up a robotic work cell was a trail-and-error affair. However, advances in simulation technology allow manufacturers to visualize a robotic work cell and sort out any problems before setting up the cell. Simulating the work cell's function helps to ensure the cell will yield the desired results and helps prevent costly mistakes and re-engineering.
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Don't throw away your profit margin |
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Examining electric resistance weld nuggets in tube and pipe: Using the microscope to study weld characteristicsAn in-depth examination of electric resistance welding nuggets as a quality control step in the manufacturing of high-strength tube and pipe used for pressure applications
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