US20150174632A1 - Dual seam electric resistance welded tubes - Google Patents
Dual seam electric resistance welded tubes Download PDFInfo
- Publication number
- US20150174632A1 US20150174632A1 US14/640,074 US201514640074A US2015174632A1 US 20150174632 A1 US20150174632 A1 US 20150174632A1 US 201514640074 A US201514640074 A US 201514640074A US 2015174632 A1 US2015174632 A1 US 2015174632A1
- Authority
- US
- United States
- Prior art keywords
- forming
- tube
- roller pair
- roller
- product
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/08—Making tubes with welded or soldered seams
- B21C37/083—Supply, or operations combined with supply, of strip material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/08—Seam welding not restricted to one of the preceding subgroups
- B23K11/087—Seam welding not restricted to one of the preceding subgroups for rectilinear seams
- B23K11/0873—Seam welding not restricted to one of the preceding subgroups for rectilinear seams of the longitudinal seam of tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/38—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, pack rolling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/08—Making tubes with welded or soldered seams
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/08—Making tubes with welded or soldered seams
- B21C37/0803—Making tubes with welded or soldered seams the tubes having a special shape, e.g. polygonal tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
- B23K11/061—Resistance welding; Severing by resistance heating using roller electrodes for welding rectilinear seams
- B23K11/062—Resistance welding; Severing by resistance heating using roller electrodes for welding rectilinear seams for welding longitudinal seams of tubes
Abstract
A method of continuously forming a dual seam welded tubular product includes the steps of providing two coils of sheet metal material, uncoiling the two coils and forming the material into opposing sections, bringing the two opposing sections together at a convergence angle of less than about 4°; and welding the two seams created between the two opposing sections. An apparatus is configured to bring the sections together at a convergence angle less than about 4° to produce the tubular product. The tubular product may have a diameter greater than 26 inches.
Description
- This application is a division of U.S. patent application Ser. No. 13/098,762, which application claims the priority benefit of U.S. Provisional Application No. 61/329,721 filed on Apr. 30, 2010 entitled “Dual Seam Electric Resistance Welded Tubes”, the entire contents of which are incorporated herein by reference.
- The present invention is directed to methods and apparatuses for forming dual seam welded tubes.
- Electric resistance welding (ERW) refers to a group of welding processes such as spot and upset welding that produce coalescence of faying surfaces where heat to form the weld is generated by the resistance of the welding current through the workpieces. Some factors influencing heat or welding temperatures are the proportions of the workpieces, the electrode materials, electrode geometry, electrode pressing force, weld current and weld time. Small pools of molten metal are formed at the point of greatest electrical resistance (the connecting surfaces) as a high current (100-100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are limited to relatively thin materials and the equipment cost can be high.
- Upset welding relies on two electrodes to apply current to join metal sheets. However, instead of pointed electrodes, contacts or induction coils are used to induce current, making it possible to make long continuous welds.
- Upset welding is mainly used on the seams of tubes and pipes for its ease and accuracy. The resulting weld is extremely durable due to the length of the contact area. A coil of metal sheet is uncoiled to flat, and formed continuously into a tube using forming rolls.
- Tubes formed from metal sheet may be formed with a single seam or with dual seams. Dual seam mills are known where two semi-circular sections are formed separately and then brought together for welding. This process requires some twisting or deformation of the semi-circular sections prior to joining. As shown in prior art
FIG. 1 , welding pressure at the welding point (7) between the two semi-tubes (1, 2) is produced by deflection between the spreaders (3, 4) and the electrode rollers (5, 6). However, excessive bending or twisting will result in an inferior product, particularly as the diameter of tube becomes larger. - There is a need in the art for an improved dual seam welding process, particularly for tubular products of a larger diameter.
- The present invention comprises improved methods and apparatuses for forming a dual seam welded tubular product. In one aspect, the invention comprises a method which forms two half-tubes and welds them together with a low convergence angle, which may be less than about 4°. In another aspect, the invention may comprise an apparatus which has at least one upper forming roller pair, and at least one lower forming roller pair, where the upper and lower roller pairs are interleaved in order to reduce the convergence angle at the welding point.
- In the drawings, like elements are assigned like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. Additionally, each of the embodiments depicted are but one of a number of possible arrangements utilizing the fundamental concepts of the present invention. The drawings are briefly described as follows:
-
FIG. 1 is a schematic depiction of a prior art dual seam forming process. -
FIG. 2 is a cross-sectional view of the “forming flower” produced by one embodiment of the present invention. -
FIGS. 3A (top plan) and 3B (side view) are a schematic depiction of the forming rollers of one embodiment. -
FIG. 4 is a schematic depiction of one embodiment of a dual seam forming apparatus of the present invention. - The invention relates to a method and apparatus of forming a dual seam welded tubular product. When describing the present invention, all terms not defined herein have their common art-recognized meanings. To the extent that the following description is of a specific embodiment or a particular use of the invention, it is intended to be illustrative only, and not limiting of the claimed invention. The following description is intended to cover all alternatives, modifications and equivalents that are included in the spirit and scope of the invention, as defined in the appended claims.
- In general terms, one aspect of the invention comprises a method of continuously forming a dual seam welded tubular product, comprising the steps of:
-
- (a) providing two coils of sheet metal material;
- (b) uncoiling the two coils and forming the material into opposing sections, each having a generally semi-circular cross-section;
- (c) bringing the two opposing sections together at a convergence angle of less than about 4°; and
- (d) electric resistance welding the two seams created between the two opposing sections.
- In another aspect, the invention comprises an apparatus for continuously forming a dual seam welded tubular product from two coils of sheet metal material, comprising:
-
- (a) a first forming roller having an upper concave roller and a lower convex roller, for forming an upper half-tube;
- (b) a second forming roller having a lower concave roller and an upper convex roller, for forming a lower half-tube;
- (c) wherein the first forming roller and the second forming roller are positioned such that a convergence angle of the upper and lower half-tubes is less than about 4°;
- (d) an electric resistance welding device
- The tubular products produced by methods and apparatuses of the present invention are continuously formed from two substantially similar, opposed semi-circular half-tubes. Each half-tube is formed from a length of flat sheet material, typically stored as a coil, which is passed through at least one pair, and preferably multiple pairs of forming rollers. Each pair of forming rollers brings the initially flat material closer to its final semi-circular shape. When viewed in transverse cross-section, the changing shape of material is termed a “forming flower”, as shown in
FIG. 2 . - As shown in
FIG. 3 , the upper coil of sheet material (10) is fed into a first upper forming roller pair (12), consisting of an upper concave roller (12A), and a lower convex roller (12B). The first forming roller pair produces an intermediate shape. In one embodiment, the material then passes through one or more additional forming roller pairs (14A, 14B) to create the final semi-circular shape of the upper half-tube (16). - The lower coil of sheet material is fed through a first lower forming roller pair (22), consisting of a lower concave roller (22A) and an upper convex roller (22B). As with the upper sheet, additional forming roller pairs (24A, 24B) create the final shape of the lower half-tube (26).
- An important element of the present invention is the convergence angle between the upper and lower half-tubes (16, 26). The convergence angle is the angle at which the lower half-tube and the upper half-tube meet at during the forming and welding process. In the prior art, as exemplified in prior art
FIG. 1 , that convergence angle is large, which reduces the quality of the welded seams. In one embodiment of the present invention, the range of the convergence angle is below about 4°, preferably between about 2° to about 4°. Keeping the convergence angle within this range enables the proximity effect to increase the efficiency substantially. The heat affected zone is minimized as only the faying edges are heated. Another benefit to keeping the convergence angle small is a homogenous strain profile around the circumference of the tube. With higher angles, such as those above 4°, the edges being welded are strained excessively as their direction changes abruptly at the welding point (30), causing irregularities in the finished product. - Accordingly, in one embodiment, the apparatus is arranged to minimize the convergence angle. This is accomplished by overlapping or interleaving the upper and lower forming rollers, such that the two half-tubes are formed closer together. As may be seen in
FIGS. 3B and 4 , the lower roller (12B, 14B) of the upper roller pair is substantially horizontally planar with the upper roller (22B, 24B) of the lower roller pair. As a result, the upper roller pair (12) and the lower roller pair (22) must be spaced laterally, but that does not significantly adversely affect the forming process or the final product. In one embodiment, the convergence angle is less than about 4°, and is preferably about 3°. As used herein, the term “about” denotes a possible variance of 10% above or below the stated value and may also reflect imprecision of the available methods of measuring the stated value. - Welding occurs at the welding point (30) using an electric resistance welding device (40), which are well known in the art, and further description thereof is unnecessary. The specific nature of the welding method is not an essential element of the present invention.
- Because the end-product is formed from two coils of material, the tubular product will have a circumference equal to approximately twice the width of the coiled material. The low convergence angle permitted by implementing the present invention allows large diameter product to be produced by the dual seam welding process. In one embodiment, tubular products having diameters in excess of about 26″ may easily be produced. Single seam products have not exceeded 26″ in diameter because of limitations of the width of the coiled sheet material. Larger diameter dual seam products have not been made due to the stresses and inconsistencies produced during the forming process in the prior art.
- The terms “upper”, “lower”, “vertical”, “horizontal” and the like have been used herein in reference to the orientation shown in
FIGS. 3 and 4 . However, those skilled in the art may adapt the methods and apparatuses described and shown herein to shift the orientation of the components shown. In particular, the forming process may be rotated such that the two half-tubes are facing each other horizontally, as opposed to vertically. Alternatively, the material may be fed through the forming rollers and welding device vertically, or at an angle, as opposed to the horizontal orientation shown in the Figures. - As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the scope of the invention claimed herein.
Claims (5)
1. A dual seam welded tubular product, having a diameter greater than about 26 inches comprising a generally semi-circular first half-tube formed from a first coil of sheet metal material, a generally semi-circular second half-tube formed from a second coil of sheet metal material, wherein the first half-tube and the second half-tube are brought together and welded to form a tube with two seams.
2. The product of claim 1 wherein the first half-tube and the second half-tube are brought together at a convergence angle less than about 4°.
3. The product of claim 2 wherein the product is continuously formed using an apparatus comprising:
(a) a first forming roller pair having an outer concave roller and an inner convex roller, for forming the first half-tube from the first coil fed longitudinally through the first forming roller pair;
(b) a second forming roller pair having an outer concave roller and an inner convex roller, for forming the second half-tube from the second coil fed longitudinally through the second forming roller pair;
(c) wherein the inner convex roller of the first forming roller pair and the inner convex roller of the second forming roller pair are overlapped in a longitudinal plane to bring the first and second half-tubes together at the convergence angle; and
(d) an electric resistance welding device for receiving and welding together the first and second half-tubes.
4. The product of claim 3 wherein the convergence angle is between about 2° and about 4°.
5. The product of claim 3 wherein the inner convex roller of the first forming roller pair and the inner convex roller of the second forming roller pair are positioned substantially longitudinally co-planar.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/640,074 US20150174632A1 (en) | 2010-04-30 | 2015-03-06 | Dual seam electric resistance welded tubes |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US32972110P | 2010-04-30 | 2010-04-30 | |
US13/098,762 US8987627B2 (en) | 2010-04-30 | 2011-05-02 | Dual seam electric resistance welded tubes |
US14/640,074 US20150174632A1 (en) | 2010-04-30 | 2015-03-06 | Dual seam electric resistance welded tubes |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/098,762 Division US8987627B2 (en) | 2010-04-30 | 2011-05-02 | Dual seam electric resistance welded tubes |
Publications (1)
Publication Number | Publication Date |
---|---|
US20150174632A1 true US20150174632A1 (en) | 2015-06-25 |
Family
ID=44512363
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/098,762 Active 2032-01-30 US8987627B2 (en) | 2010-04-30 | 2011-05-02 | Dual seam electric resistance welded tubes |
US14/640,074 Abandoned US20150174632A1 (en) | 2010-04-30 | 2015-03-06 | Dual seam electric resistance welded tubes |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/098,762 Active 2032-01-30 US8987627B2 (en) | 2010-04-30 | 2011-05-02 | Dual seam electric resistance welded tubes |
Country Status (4)
Country | Link |
---|---|
US (2) | US8987627B2 (en) |
EP (1) | EP2383065B1 (en) |
CA (1) | CA2738518C (en) |
MX (1) | MX2011004682A (en) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2014001408A1 (en) * | 2012-06-30 | 2014-01-03 | Sms Meer Gmbh | System for stitch welding in the production of seam heat sealed pipes made of sheet panels |
DE102014002360A1 (en) * | 2014-02-18 | 2015-08-20 | Beumer Gmbh & Co. Kg | Transport device with an endless belt-shaped transport element |
US9476203B2 (en) * | 2015-03-06 | 2016-10-25 | John Powers, III | Column/beam maufacturing apparatus and methods |
CN105945517B (en) * | 2016-05-12 | 2018-04-27 | 宝鸡石油钢管有限责任公司 | A kind of continuous velocity tubing string and its manufacture method |
EP3504015A1 (en) | 2016-08-23 | 2019-07-03 | Albert Gaide | Method for producing multi-component cases |
CN112474802A (en) * | 2020-11-19 | 2021-03-12 | 中北大学 | Equipment and method for preparing stainless steel/aluminum/stainless steel laminated composite board |
KR102217666B1 (en) * | 2020-11-20 | 2021-02-19 | 변한호 | Steel pipe manufacturing method using semi-pipe |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3707257A (en) * | 1969-09-08 | 1972-12-26 | Voest Ag | Plant for the selective production of either two one-seam tubes or one two seam-tube |
US20050035094A1 (en) * | 2003-07-03 | 2005-02-17 | Mannesmannrohren-Werke Ag | Method and apparatus for making welded large pipes |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB104689A (en) | 1917-03-08 | 1918-01-31 | Wilhelmus Gerardus Jo Verberne | Improvements in Method of Welding Tubes and the like. |
US2009685A (en) | 1931-09-03 | 1935-07-30 | James V Caputo | Apparatus for welding |
US2502012A (en) * | 1947-05-26 | 1950-03-28 | W R Ames Company | Apparatus and method for continuous manufacture of seamed tubing |
AT169915B (en) * | 1947-12-08 | 1951-12-27 | Alfred Woegerbauer | Continuous electric butt-seam welding process for the production of round or profile tubes and equipment for carrying out this process. |
US2950376A (en) | 1957-04-05 | 1960-08-23 | Wogerbauer Alfred | Method and apparatus for the manufacture of sections |
US3132234A (en) | 1959-12-10 | 1964-05-05 | Wogerbauer Alfred | Process for the continuous manufacture of sections, particularly tubes and hollow sections, and apparatus for carrying out the process |
US3263053A (en) * | 1964-11-27 | 1966-07-26 | American Mach & Foundry | Tube forming apparatus |
AT271829B (en) * | 1966-08-09 | 1969-06-10 | Voest Ag | Folded tube and method and device for the production of foldable tubes |
JPH0698382B2 (en) * | 1988-03-23 | 1994-12-07 | 住友金属工業株式会社 | Hot ERW Pipe Manufacturing Method |
-
2011
- 2011-05-02 CA CA2738518A patent/CA2738518C/en active Active
- 2011-05-02 MX MX2011004682A patent/MX2011004682A/en active IP Right Grant
- 2011-05-02 US US13/098,762 patent/US8987627B2/en active Active
- 2011-05-03 EP EP11275070.8A patent/EP2383065B1/en active Active
-
2015
- 2015-03-06 US US14/640,074 patent/US20150174632A1/en not_active Abandoned
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3707257A (en) * | 1969-09-08 | 1972-12-26 | Voest Ag | Plant for the selective production of either two one-seam tubes or one two seam-tube |
US20050035094A1 (en) * | 2003-07-03 | 2005-02-17 | Mannesmannrohren-Werke Ag | Method and apparatus for making welded large pipes |
Also Published As
Publication number | Publication date |
---|---|
CA2738518C (en) | 2015-12-15 |
MX2011004682A (en) | 2011-10-31 |
CA2738518A1 (en) | 2011-10-30 |
EP2383065B1 (en) | 2020-11-04 |
EP2383065A3 (en) | 2017-06-14 |
US8987627B2 (en) | 2015-03-24 |
EP2383065A2 (en) | 2011-11-02 |
US20110308660A1 (en) | 2011-12-22 |
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Legal Events
Date | Code | Title | Description |
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AS | Assignment |
Owner name: DFI CORPORATION, ALBERTA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BERUBE, ERIC;REEL/FRAME:035099/0319 Effective date: 20110715 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |