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Tube and Pipe Production Articles
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Selecting speed reducers for roll forming lines - Horsepower isn't the only considerationBecause roll forming can be an aggressive, demanding application, improper use of speed reducers in a roll forming line can be costly. Problems... Publish date: October 14, 2008 |
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Modern flying shear tube cutoff systems - Part II : Die set acceleratorsEditor's Note: This article is Part II in a three-part series about modern flying shear tube cutoff systems. Part I discussed the different... Publish date: August 8, 2006 |
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The regrind process for tube mill tooling - Part II : Machining, inspection, and shippingEditor's Note: This is the second article in a two-part series on regrinding tube mill tooling. Part I discussed the first two steps of the... Publish date: June 13, 2006 |
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When a good tube bends bad - Part II : How to prevent tube from taking a bad turnEditor's Note: This is the second part of a two-part article that examines tube bending defects, possible causes, and suggested remedies. Part I... Publish date: April 11, 2006 |
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Modern flying shear tube cutoff systems - Part I : MainframesThe current generation of flying shear tube cutoff systems is even better-suited for the application than previous versions. With mainframes made... Publish date: April 11, 2006 |
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The regrind process for tube mill tooling - Part I : Inspection and evaluationEditor's Note: This is the first article in a two-part series on regrinding tube mill tooling. Part I discusses the first two steps of the... Publish date: April 11, 2006 |
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Choices in flying cutoff saw blades : Friction versus carbideIf an image is not displayed, click the hyperlinked figure number to view it. Tube and pipe producers are a demanding breed. They have... Publish date: December 2, 2009 |
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Laser-based inspection for laser welding : Two lasers for tube and pipe productionIf an image is not displayed, click the hyperlinked figure number to view it. Advances in laser welding processes for tube and pipe... Publish date: October 20, 2009 |
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Shopping for a new tube mill coolant? : It takes more than comparing price tagsIf an image is not displayed, click the hyperlinked figure number to view it. Warren Buffett is known to have said, "Price is what you... Publish date: September 2, 2009 |
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Rotary straighteners for tube and pipe : An introduction to 6- and 10-roll straightening machinesIf an image is not displayed, click the hyperlinked figure number to view it. Despite great strides in manufacturing processes and... Publish date: September 25, 2009 |
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Looking to improve weld seams? : Try fluxes for tube, pipe productionIf an image is not displayed, click the hyperlinked figure number to view it. Technological improvements often are simple concepts that... Publish date: September 1, 2009 |
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Troubleshooting OCTG threading: Part I : Detecting and working with stress-induced deformationIf an image is not displayed, click the hyperlinked figure number to view it. Read Part II Editor's Note: This article is Part I of a... Publish date: August 5, 2009 |
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Flexibility with smart flying shear upgradesIf an image is not displayed, click the hyperlinked figure number to view it. Tube Cutoff System Flexibility is key to profitable tube... Publish date: April 14, 2009 |
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Selecting speed reducers for roll forming lines : Horsepower isn't the only considerationBecause roll forming can be an aggressive, demanding application, improper use of speed reducers in a roll forming line can be costly. Problems... Publish date: November 11, 2008 |
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Increasing efficiency of HFI tube and pipe mills : Optical system detects material, alignment problemsManufacturing welded tube and pipe efficiently requires controlling several variables. The material type, gauge, edge condition, tooling setup,... Publish date: September 16, 2008 |
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Buy it by the pound, sell it by the foot : Process optimization can help tube, pipe producers cut costs one foot at a timeWith raw material and energy costs soaring and imported tube and pipe flooding the U.S., tube and pipe producers are facing increasing... Publish date: April 15, 2008 |
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Using FEM to compare tube forming processes : Analyzing residual strains, stressesClick to Enlarge Image Three roll forming processes typically used in tube and pipe production are single-radius forming (top), edge forming... Publish date: January 15, 2008 |
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Working with stainless on a budget : Surcharge flood sends some OEMs to high groundTo say the last several years have been chaotic would be an understatement. It started with the bursting of the tech stock bubble in 2000, and... Publish date: December 11, 2007 |
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Reducing conversion cost in a copper tube mill : Lean initiatives, measurable resultsRecent business-sector changes—copper cost increases, globalization, technology advances, and rapidly changing consumer... Publish date: September 11, 2007 |
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Roll forming high-strength materials : Higher strength, more springback, more forming challengesFigure 1 A forming force that exceeds a material's yield strength results in plastic deformation, which holds the metal in the shape to be... Publish date: April 10, 2007 |
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Tube drawing principles : Understanding processes, parameters key to qualityYou might not think that a hypodermic syringe and a large-diameter down-hole tube for oil exploration have much in common, but in fact they do.... Publish date: March 13, 2007 |
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Is your cold pilger mill maintenance on schedule? : Analyzing the need for routine inspections and alignmentsRoutine maintenance inspections are necessary for any cold pilger mill to perform optimally. The number, frequency, and quality of routine... Publish date: November 7, 2006 |
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Aluminum pipe pioneer streamlines tube mill welding : Welding controls bring process under controlHastings Irrigation Pipe Co., Hastings, Neb., blazed a trail in the late 1940s by manufacturing irrigation pipe out of a material that was... Publish date: October 10, 2006 |
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Opening the gate to efficiency : Farm equipment-maker combines new, custom machines to boost productivityDotting the rolling landscape on U.S. 127 in Kentucky, just south of Danville, are a half-dozen small gate manufacturers. As is typical in... Publish date: August 8, 2006 |
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How do you measure success? : Exploring two factors, debunking one mythYou have probably heard it, and you may have lived it. Business is slow, layoffs have left you shorthanded, maintenance is a thing of the past,... Publish date: July 11, 2006 |
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Introducing cold pilger mill technology : An overview of the equipment and the processCold pilgering is a longitudinal cold-rolling process that reduces the diameter and wall thickness of metal tube in one process step. Depending on... Publish date: July 11, 2006 |
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Envelope, please! : Announcing the winner of the caption contestDo you remember this photo that originally appeared in the January/February issue of TPJ on page 10? I asked readers to send me short, glib... Publish date: June 13, 2006 |
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Troubleshooting Guide for CleanersThis guide is part of an article series " Flushing out four-letter words-rust, dirt, and wear; Part II: Removing soils effectively ," by Mike... Publish date: May 15, 2006 |
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Flushing out four-letter words: rust, dirt, and wear : Part I: How to select a rust inhibitorMatching the best lubricant with your applications requires a comprehensive evaluation of your goals, your operation, and how your operation may... Publish date: April 11, 2006 |
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Eliminating problems that cause flaws : Part II: Focus on the materialEditor's Note: This is the second article in a two-part series on eliminating tube or pipe flaws. Part I discussed the steps needed to eliminate... Publish date: April 11, 2006 |
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Home-court advantageTurquoise and tequila aren't the only things coming back from Mexico; some fabricating jobs are working their way back as well. While many... Publish date: April 11, 2006 |
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Modern flying shear tube cutoff systems : Part I: MainframesEditor's Note: This article is Part II in a three-part series about modern flying shear tube cutoff systems. Part I discussed the... Publish date: April 11, 2006 |
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The regrind process for tube mill tooling : Part I: Inspection and evaluationEditor's Note: This is the second article in a two-part series on regrinding tube mill tooling. Part I discussed the first two steps of the... Publish date: April 11, 2006 |
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When a good tube bends bad : Part I: How to Prevent Tube From Taking a Bad TurnEditor's Note: This is the second part of a two-part article that examines tube bending defects, possible causes, and suggested remedies. Part I... Publish date: March 7, 2006 |
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Happy New Year! : Make 2006 better than 2005This sample was cut from a section of welded 16-in.-OD pipe. The interesting pattern was created when a socket head cap screw got rolled... Publish date: January 10, 2006 |
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Cutoff die setup for dimple-free roundsFigure 1 Tube Mill Dimple-free Flying Cutoff Modern tube mills that operate with a dual-shear blade and a flying cutoff system can... Publish date: December 13, 2005 |
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Relief ahead in 2006? : The answer is a two-letter word you don't want to hearAs we approach the end of another year, anticipation builds to see what challenges and changes will emerge. Please observe I'm not... Publish date: December 13, 2005 |
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Scarfing tube and pipe—cut to the quick : Part III: Drawing a bead on improving ID scarf removal and disposalFigure 1 The strand in the top photo did not get cut completely from the tube wall. Removing this strand of scarf with compressed air or... Publish date: October 11, 2005 |
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Tube mill cutoff die setup for square and rectangular profilesModern high-speed tube mills produce square and rectangular tubing very efficiently. They typically reshape square and rectangular tube from a... Publish date: September 13, 2005 |
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Tube and pipe loading: : How one manufacturer made the process less hazardousFigure 1 Editor's Note: Occasionally, thefabricator.com will publish brief features that highlight the successful use of a specific... Publish date: July 12, 2005 |
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Innovative die setup and maintenance methods for tube mill cutoffFigure 1 Tube Mill Cutoff - Left to Right - Single Cut A comprehensive tooling plan that includes setting up and maintaining... Publish date: April 11, 2005 |
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Tension control in tube and pipe production : Getting it right for smooth, steady mill operationOn a tube or pipe mill, the incoming strip is formed by about 24 pairs of tool stands. To help ensure such a line runs smoothly, the strip... Publish date: April 11, 2005 |
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Measuring wall thickness in seamless tube, cast-iron pipe : Lasers meet ultrasonicsControlling the wall thickness during the manufacture of seamless steel tubes and cast-iron pipe is critical in meeting specifications and... Publish date: March 8, 2005 |
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Certifying the quality of your tube and pipeMany testing services are available to ensure the quality of tube and pipe. Laboratories that perform the testing provide certified reports... Publish date: October 12, 2004 |
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MIAB welding of thick-walled pipe ends : Research finds ways to increase pipe thickness while maintaining qualityVarious methods are used for welding pipe, including electric shielded metal arc welding (SMAW), submerged arc welding (SAW), and flash end... Publish date: July 13, 2004 |
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Optimizing your hydraulic cutoff press : Squeezing more out of your tube millIt is accepted that, because tube production is a highly competitive industry, many tube producers stay up nights thinking of ways to... Publish date: June 8, 2004 |
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Troubleshooting OCTG threading: Part II : Insert type impacts finished-surface quality, tool life, chip controlRead Part I Editor's Note: This article, Part II of a two-part series on tube and pipe threading, explores troubleshooting related... Publish date: May 4, 2004 |
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Keeping stainless steels stainless : How important is passivation for SS?Causes of Corrosion Stainless steel's corrosion resistance is due to a thin, chromium-rich, transparent oxide film on the surface1. This... Publish date: May 4, 2004 |
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Managing environmental risk in tube, pipe production : What you need to know about state and federal regulationsEditor's Note: This article is adapted from a presentation made at the TPJ Symposium, March 16-18, 2003, Scottsdale, Ariz. The... Publish date: January 29, 2004 |
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Pulling taffy and producing tube : Proper tension is a key to success for both processesDo you remember going to the county fair and watching candy makers make taffy? As a child I often would watch the whirling motion of the taffy... Publish date: December 11, 2003 |
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Laser tube processing : Ten out-of-the-box techniques save money, spur innovationAlthough many new applications are made possible by modern lasers, laser processing is not entirely new to tube production. Manufacturers... Publish date: November 20, 2003 |
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Six-axis tube laser adds new dimension to job shopNine years ago co-owners Phil Kooima and his father, John, got out of the stamping business and into lasers. They now have seven flatbed... Publish date: November 20, 2003 |
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Plotting for success : Using edge thickness measurements to aid troubleshootingAnother way of looking at this is that we get so tied up in the day-to-day grind that we forget or ignore the deteriorating conditions in the... Publish date: October 23, 2003 |
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An evaluation of two cold pilger die designs : Making tool design recommendations based on tube transitional qualityThe cold pilger process is a common method of finishing seamless stainless steel hollows. Many aspects of the pilgering process influence machine... Publish date: May 30, 2001 |
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Measuring tube as it grows and shrinks : Using girth changes to set up a tube millWe always have some confusion at our house concerning desserts. My wife claims that I like only two kinds of pie: hot and cold. Well, she is... Publish date: August 28, 2003 |
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Minimizing wall thickness variation in seamless tubingReducing the amount of variation, or achieving more wall thickness consistency, can be the difference between meeting a customer's... Publish date: August 28, 2003 |
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Roll form tooling tryout and troubleshooting : Taking a five-step approachThe secret to developing successful roll tooling—whether for tube production or roll forming—and achieving maximum roll... Publish date: May 29, 2003 |
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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... Publish date: May 15, 2003 |
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Solving the mysteries of the fin pass—Part 1 : Uncovering where, why and howFigure 1 Original tubular forms, such as bulrushes, are found in nature. Modern tube isn't an invention-it's merely a copy of a natural... Publish date: April 10, 2003 |
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Don't lose your bearing! : Protect the lifeblood of your tube millThe foreman gives everyone the production schedule, and the last of the big order you were working on before the Friday shutdown is ready to run.... Publish date: February 27, 2003 |
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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... Publish date: April 24, 2001 |
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Boosting efficiency in solid state welders : Improving weld mechanicals can make the differenceHigh-frequency induction (HFI) welding is used widely by the tube producing industry, but a large number of variables need to be controlled... Publish date: September 4, 2001 |
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The process of contoured tubing manufacturing : How tubemakers are meeting demandsFigure 1: Contoured tubing requires more forming passes than conventional tubing. The more complex the shape of the tube, the more... Publish date: February 28, 2002 |
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Optimizing robotic laser cutting of hydroformed tubes : Meeting the challenge of closed-tube cuttingHydroformed and rectangular cross-section tubes have become popular for new truck and sport utility vehicle (SUV) frames, engine cradles,... Publish date: May 15, 2001 |
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Inline gauge control in welded tube production: Reducing conversion lossesIn welded tube production, the conversion of strip to finished tube always produces some loss of raw material. These conversion... Publish date: July 26, 2001 |
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Do your tubes seam good enough? Using eddy current testing to make sureTo use this method, a manufacturer must have, as a minimum, eddy current test electronics, test coils and cabling, and some form of output device... Publish date: August 16, 2001 |
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Presenting coil to a tube mill : Preparation of material for continuous operationMany articles have been written on the different types of entry end equipment for tube and pipe mills. Most of these articles concentrate on the... Publish date: September 4, 2001 |
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Examining tube mill roll tooling, setup, and maintenancePoor tooling setup and mill alignment can be costly, especially when they result in decreased production quality and scrap. Both areas must be... Publish date: September 17, 2001 |
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Taking the troubles out of tube mill tooling: Preventing and solving some common problemsIn today's tube and pipe producing industries, the need to run the tube/pipe mill faster, reduce changeover times, and produce a higher-quality... Publish date: October 11, 2001 |
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Mastering the tool selection process : How to minimize production costs with the proper equipmentEditor's Note: Baicheng Wen is no longer with Roll-Kraft. This article originally appeared in the December 1999 edition of TPJ-The Tube & Pipe... Publish date: October 11, 2001 |
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Comparing single-cut and dimple-free tube mill cutoffs : When to employ each systemThis article covers the application of single-cut and dimple-free cutoff shear technologies as they are applied to contemporary high-speed... Publish date: October 25, 2001 |
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Using existing tooling for new product applications : Evaluating the tooling's capabilities and limitationsFigure 1: This design is typical for the last fin pass for low-carbon steel using high-frequency welding. "In turbulent times, one... Publish date: November 29, 2001 |
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Cutting to the chase : Sawing structural and architectural tubingTube cutoff machines have evolved to integrate end forming and bending capabilities that normally are considered secondary operations.... Publish date: December 13, 2001 |
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Laser welding of stainless pressure tubesThe vast majority of welded stainless steel pressure tubing is produced with the gas tungsten arc welding (GTAW) process. This process... Publish date: July 12, 2001 |
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Maintaining a RF Tube and Pipe Welding Generator : How to find trouble spotsIn the simplest terms, tube and pipe is produced by a mill that rolls flat stock material into a round shape, welds the two edges together,... Publish date: September 4, 2001 |
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Piping in Productivity : Construction company uses orbital welding on underground pipelineA critical requirement of this underground pipeline was to build it directly to the bottling plant. The 8-inch-diameter 304L stainless... Publish date: November 21, 2002 |
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Solving Problems on the Tube MillTube mill operators face a variety of challenges every day in their effort to produce high-quality tubing in a cost-effective and productive way.... Publish date: August 16, 2001 |
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Coil joining criteria for tube and pipe millsA coil end joiner's obvious benefit is that it maintains the continuity of stock flow through the line, preventing rethreading downtime and... Publish date: March 13, 2003 |
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Skelp edge preparation for manufacturing ERW pipeAchieving a quality weld requires starting with good edges. In manufacturing electric-resistance- welded (ERW) pipe and tube, this is... Publish date: May 30, 2001 |
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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. In the simplest terms, a welded... Publish date: May 30, 2001 |
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Achieving faster, more efficient tube mill changeoversA changeover on a tube mill does not mean just changing the tooling. It means changing from running good tube of one size to running good tube of... Publish date: July 26, 2001 |
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Accumulating strip before the mill : An introduction to entry end equipmentFigure 1: Strip can be stored in a deep pit, where it will hang in a loop. In simple terms, a strip processing line consists of a... Publish date: September 4, 2001 |
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Skiving strip edges for tube and pipe producing : New equipment developments address coil preparation challengesEdge treatment of coil strip before it enters a tube and pipe mill, called skiving, is a rapidly advancing technology. Improving the coil edge... Publish date: September 4, 2001 |
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Making seamless tubing with a floating mandrel millEvery six seconds, a single, 32-foot length of oil country tubular goods (OCTG) production tubing used in the exploration and production of oil... Publish date: September 17, 2001 |
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Increasing tube mill welding speed: Examining technology for tube producersIn the manufacture of tubing by continuously roll forming and welding, the cost of the finished product is directly related to the... Publish date: October 25, 2001 |
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Tooling, the key for mill productionOne of the most important lessons any successful tube mill producer learns is that high-quality tooling is mandatory to achieving and sustaining... Publish date: November 29, 2001 |
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Using flowformed titanium alloy seamless tubes in production : Process and material can make good combo for the futureFlowforming is a cold metalworking process for manufacturing seamless tubular and rotationally symmetrical products. In the process, a... Publish date: February 14, 2002 |
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Maintaining and troubleshooting HF welders: A common-sense approach for vacuum tube and solid-state machinesSince the 1960s, the workhorse of the tube and pipe industry has been the high frequency (HF) vacuum tube welder. Recently, an increasing number... Publish date: February 19, 2001 |
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Producing quality ASTM A249 and ASME SA 249 pressure tubesObject Producing quality ASTM A249 and ASME SA249 pressure tubes takes more than just applying a stencil to the product. It requires a... Publish date: March 26, 2001 |
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