WO2023007925A1 - 鋼管の真円度予測方法、鋼管の真円度制御方法、鋼管の製造方法、鋼管の真円度予測モデルの生成方法、及び鋼管の真円度予測装置 - Google Patents
鋼管の真円度予測方法、鋼管の真円度制御方法、鋼管の製造方法、鋼管の真円度予測モデルの生成方法、及び鋼管の真円度予測装置 Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
- B21D5/015—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments for making tubes
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/08—Tube expanders
- B21D39/20—Tube expanders with mandrels, e.g. expandable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/01—Bending sheet metal along straight lines, e.g. to form simple curves between rams and anvils or abutments
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- G05—CONTROLLING; REGULATING
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- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
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- G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
Definitions
- the present invention provides a steel pipe circularity prediction method for predicting the circularity of a steel pipe after a pipe expansion process in a steel pipe manufacturing process using a press bending method, a steel pipe circularity control method, a steel pipe manufacturing method, and a steel pipe circularity prediction method.
- the present invention relates to a roundness prediction model generation method and a steel pipe roundness prediction device.
- a steel plate having a predetermined length, width, and thickness is press-formed into a U-shape and then press-formed into an O-shape.
- a technique for manufacturing a steel pipe (so-called UOE steel pipe) is widely used in which the butt portions are welded to form a steel pipe, and the diameter is increased (so-called pipe expansion) to improve roundness.
- pipe expansion a technique for manufacturing a steel pipe
- a large press pressure is required in the process of pressing steel plates into U-shapes and O-shapes, so it is necessary to use large-scale press machines.
- the pipe expansion device is equipped with a plurality of pipe expansion tools having curved surfaces obtained by dividing a circular arc into a plurality of parts, and by bringing the curved surfaces of the pipe expansion tools into contact with the inner surface of the steel pipe, expands the steel pipe and adjusts the shape of the steel pipe. Used.
- the number of three-point bending presses improves the roundness of the steel pipe after the pipe expanding process, but it takes a long time to form the steel pipe into a U-shaped cross section.
- the number of three-point bending presses is reduced, the cross-sectional shape of the steel pipe becomes closer to a polygonal shape, and there is a problem that it is difficult to obtain a circular shape. Therefore, the number of three-point bending presses (for example, 5 to 13 times for a steel pipe with a diameter of 1200 mm) is determined empirically according to the size of the steel pipe.
- many proposals have been conventionally made regarding methods of setting the conditions.
- Patent Document 1 discloses a method for performing the three-point bending press with as few times as possible, in which a plurality of tube expanding tools arranged in the circumferential direction of a tube expanding device are deformed by the three-point bending press. A method for expanding a tube by bringing it into contact with an undeformed portion that is not deformed is described.
- Patent Document 3 describes a manufacturing method for efficiently manufacturing a steel pipe with high roundness without requiring an excessive pressing force in a press bending process. describes a method of providing a lightly worked portion with a very slight curvature compared to other regions, or providing an unworked portion where bending is omitted.
- a pressing force is applied to a portion at a predetermined distance from the center of the lightly processed portion or the unprocessed portion without restraining the lightly processed portion or the unprocessed portion. It is stated that Note that an O press device is usually used in the seam gap reduction process performed after the press bending process.
- JP 2012-170977 A Japanese Patent No. 5541432 Japanese Patent No. 6015997
- the method described in Patent Document 1 is a method for improving the roundness of the steel pipe after the pipe expansion process by associating the pressing position of the three-point bending press with the pressing position of the tube expansion tool.
- the steel pipe manufacturing process includes a plurality of processes such as an end bending process, a press bending process, a seam gap reducing process, a welding process, and a pipe expanding process.
- the method described in Patent Document 1 does not consider the influence of operating conditions in other processes on the roundness of the steel pipe after the pipe expansion process, so the roundness of the steel pipe after the pipe expansion process is not necessarily improved. may not be possible.
- the curvature radius of the outer peripheral surface of the punch used in the three-point bending press, which is the operating condition of the press bending process, and the tube expanding tool, which is the operating condition of the tube expanding process. is a method for improving the roundness of the steel pipe after the pipe expansion process by making the radius of curvature of the outer peripheral surface of the pipe satisfy a predetermined relational expression.
- the method described in Patent Document 2 has the problem that the influence of processes other than the press bending process, such as the seam gap reduction process, cannot be considered.
- the steel pipe manufacturing process includes multiple processes as described above, there is a problem that the lead time until the steel plate is manufactured is long and the manufacturing cost increases.
- the seam gap reducing process may be omitted, and the steel pipe manufacturing process may include an end bending process, a press bending process, a welding process, and a pipe expanding process.
- the seam gap reduction process is omitted, it is assumed that the roundness of the steel pipe after the pipe expansion process will deteriorate. It is necessary to improve the roundness of the steel pipe.
- the present invention has been made to solve the above problems, and the present invention is a steel pipe roundness prediction that can accurately predict the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps.
- An object of the present invention is to provide a method and a roundness prediction device.
- Another object of the present invention is to provide a steel pipe roundness control method capable of accurately controlling the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps.
- Another object of the present invention is to provide a steel pipe manufacturing method capable of manufacturing a steel pipe having a desired roundness with a high yield.
- Another object of the present invention is to provide a steel pipe roundness capable of generating a roundness prediction model for accurately predicting the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps.
- An object of the present invention is to provide a method for generating a prediction model.
- the steel pipe roundness prediction method includes an end bending process in which the ends of the steel plate in the width direction are bent, and the steel plate subjected to the end bending process is formed into an open pipe by pressing a plurality of times with a punch. Predict the roundness of the steel pipe after the pipe expansion step in the steel pipe manufacturing process including the press bending step for processing and the pipe expansion step for forming the steel pipe in which the ends of the open pipe are joined by pipe expansion.
- a method for predicting the roundness of a steel pipe wherein one or more operating parameters selected from the operating parameters of the end bending process and one or more operating parameters selected from the operating parameters of the press bending process are used as input data. and predicting the roundness of the steel pipe after the pipe expansion process by using a roundness prediction model learned by machine learning, wherein the roundness information of the steel pipe after the pipe expansion process is used as output data. .
- the roundness prediction model preferably includes, as the input data, one or more parameters selected from the attribute information of the steel plate.
- the roundness prediction model preferably includes, as the input data, a pipe expansion rate selected from the operation parameters of the pipe expansion process.
- the operating parameters of the edge bending process may include one or more parameters of edge bending width, C press force, and clamp gripping force.
- the operation parameters of the press bending process preferably include the press position information and press reduction amount at which the punch used in the press bending process presses the steel sheet, and the number of times of pressing performed through the press bending process.
- a steel pipe roundness control method uses the steel pipe roundness prediction method according to the present invention to start a process to be reset selected from a plurality of forming processes constituting the steel pipe manufacturing process. one or more operations selected from at least the operation parameters of the process to be reset so that the circularity of the steel pipe after the pipe expansion process is predicted and the circularity of the steel pipe after the pipe expansion process is reduced.
- a steel pipe manufacturing method includes a step of manufacturing a steel pipe using the steel pipe roundness control method according to the present invention.
- a method for generating a roundness prediction model for a steel pipe according to the present invention includes an end bending process in which the ends of a steel plate in the width direction are subjected to end bending, and a steel plate subjected to end bending by pressing a plurality of times with a punch is opened.
- the roundness of the steel pipe after the pipe expansion process in the steel pipe manufacturing process including the press bending process for forming into a pipe and the pipe expansion process for forming the steel pipe in which the ends of the open pipe are joined together by pipe expansion.
- the input performance data may include one or more parameters selected from the attribute information of the steel plate.
- machine learning it is preferable to use machine learning selected from neural networks, decision tree learning, random forests, and support vector regression.
- a steel pipe roundness prediction apparatus includes an end bending step of bending the ends of a steel plate in the width direction, and forming the steel plate subjected to the end bending by pressing a plurality of times with a punch into an open pipe. Predict the roundness of the steel pipe after the pipe expansion step in the steel pipe manufacturing process including the press bending step for processing and the pipe expansion step for forming the steel pipe in which the ends of the open pipe are joined by pipe expansion.
- a steel pipe roundness predicting device wherein one or more operational parameters selected from the operational parameters of the end bending process and one or more operational parameters selected from the operational parameters of the press bending process are acquired.
- a parameter acquisition unit including as input data one or more operation parameters selected from the operation parameters of the end bending process and one or more operation parameters selected from the operation parameters of the press bending process;
- the roundness prediction model learned by machine learning uses the roundness information of the steel pipe as output data, the steel pipe after the pipe expansion process and a roundness prediction unit for predicting the roundness information of.
- a terminal device having an input unit that acquires input information based on a user's operation and a display unit that displays the roundness information, and the operation parameter acquisition unit is based on the input information acquired by the input unit. to update some or all of the acquired operational parameters, and the display section may display the circularity information of the steel pipe predicted by the circularity prediction section using the updated operational parameters.
- the steel pipe roundness prediction method and the roundness prediction apparatus it is possible to accurately predict the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps.
- the steel pipe roundness control method of the present invention it is possible to accurately control the roundness of the steel pipe after the pipe expansion step in the steel pipe manufacturing process comprising a plurality of steps.
- a steel pipe having a desired roundness can be manufactured with a high yield.
- the roundness of a steel pipe can be accurately predicted after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps. degree prediction model can be generated.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe that is one embodiment of the present invention.
- FIG. 2 is a perspective view showing the overall configuration of the C press device.
- FIG. 3 is a cross-sectional view showing the configuration of the press mechanism.
- FIG. 4 is a diagram showing an example of a process of forming a molded body having a U-shaped cross section using a press bender.
- FIG. 5 is a diagram showing an example of a process of forming a molded body having a U-shaped cross section using a press bender.
- FIG. 6 is a diagram showing a configuration example of a tube expansion device.
- FIG. 7 is a diagram showing a configuration example of an apparatus for measuring the outer diameter shape of a steel pipe.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe that is one embodiment of the present invention.
- FIG. 2 is a perspective view showing the overall configuration of the C press device.
- FIG. 3 is a cross-section
- FIG. 8 is a diagram showing a method of generating a roundness prediction model, which is an embodiment of the present invention.
- FIG. 9 is a diagram showing an example of a change in the relationship between the amount of press reduction in the press bending process and the roundness of the steel pipe after the pipe expansion process due to changes in the operating conditions in the end bending process.
- FIG. 10 is a diagram showing an example of a press reduction position and a press reduction amount for each number of times of reduction.
- FIG. 11 is a diagram showing a method for controlling the roundness of a steel pipe according to one embodiment of the present invention.
- FIG. 12 is a diagram showing the configuration of a steel pipe roundness prediction apparatus that is an embodiment of the present invention.
- FIG. 1 is a diagram showing a manufacturing process of a steel pipe that is one embodiment of the present invention.
- a thick steel plate manufactured by a thick plate rolling process which is a pre-process of the steel pipe manufacturing process, is used as a raw material steel plate.
- the thick steel plate typically has a yield stress of 245 to 1050 MPa, a tensile strength of 415 to 1145 MPa, a thickness of 6.4 to 50.8 mm, a width of 1200 to 4500 mm, and a length of 10 to 18 m.
- the width direction end portions of the thick steel plate are preliminarily ground into a chamfered shape called groove. This is to prevent overheating of the outer surface corner portions of the widthwise end portions in the subsequent welding process, thereby stabilizing the welding strength. Further, since the width of the thick steel plate affects the outer diameter after forming into a steel pipe, it is adjusted within a predetermined range in consideration of the deformation history in subsequent processes.
- an end bending process is performed to bend the ends of the steel plate in the width direction.
- the end bending process is performed by a C press machine, and performs end bending (also referred to as crimping) on width direction ends of the steel plate.
- the C press device includes a pair of upper and lower dies and a pair of upper and lower clamps that hold the central portion of the steel plate in the width direction. Since the length of the mold is shorter than the length of the steel plate, the end bending process is repeated while sequentially feeding the steel plate in the longitudinal direction. Such end bending is performed on both ends in the width direction of the steel plate.
- the operation parameters for specifying the processing conditions are the end bending width, which is the length at which the mold contacts the steel plate from the width direction end toward the width direction center, the gripping force of the clamp, Examples include the feed amount, feed direction, and number of feeds of the die when the end bending is repeated in the longitudinal direction of the steel sheet.
- the subsequent press bending process is a process in which the steel plate is processed into a molded body with a U-shaped cross section by performing three-point bending press with a punch multiple times using a press bending device.
- a seam gap reduction process is often performed to reduce the seam gap of the U-shaped molded product using an O-press, followed by a manufacturing process for forming an open pipe.
- the seam gap reduction process is omitted, and the welding process is performed on the compact having a U-shaped cross section for which the press bending process has been completed.
- the U-shaped cross-section formed body obtained by the press bending process is also referred to as an open tube.
- the subsequent welding step is a step of joining the ends by constraining the seam gaps formed at the ends of the open pipe so that the ends are in contact with each other.
- the subsequent pipe expansion step is a step of expanding the steel pipe by bringing the curved surfaces of the pipe expansion tools into contact with the inner surface of the steel pipe using a pipe expansion device equipped with a plurality of pipe expansion tools having curved surfaces obtained by dividing a circular arc into a plurality of parts. .
- Steel pipes manufactured in this manner are inspected in an inspection process to determine whether or not their qualities such as material quality, appearance, and dimensions satisfy predetermined specifications, and are then shipped as products.
- the inspection process includes a roundness measuring process for measuring the roundness of the steel pipe.
- the end bending process, the press bending process, and the pipe expansion process are referred to as "forming processes”. These steps are common as steps for imparting plastic deformation to the steel plate to control the dimensions and shape of the steel pipe.
- forming processes are common as steps for imparting plastic deformation to the steel plate to control the dimensions and shape of the steel pipe.
- FIG. 2 is a perspective view showing the overall configuration of the C press device.
- the C press device 30 includes a conveying mechanism 31 that conveys the steel sheet S in the conveying direction along the longitudinal direction thereof, and one width direction end of the steel sheet S with the conveying direction downstream side of the steel sheet S as the front.
- a press mechanism 32A that bends Sc to a predetermined curvature
- a press mechanism 32B that bends the other widthwise end portion Sd to a predetermined curvature
- a gap adjusting mechanism (not shown) for adjusting the gap between the mechanisms 32A and 32B is provided.
- the conveying mechanism 31 is composed of a plurality of rotationally driven conveying rolls 31a arranged before and after the press mechanisms 32A and 32B, respectively.
- symbol Sa in a figure has shown the front-end
- FIG. 3(a) shows a widthwise cross section of the press mechanism 32A for bending one widthwise end Sc of the steel sheet S, viewed from the upstream side in the conveying direction of the steel sheet S toward the downstream side in the conveying direction.
- the press mechanism 32A and the press mechanism 32B are symmetrical and have the same configuration.
- the press mechanisms 32A and 32B include an upper die 33 and a lower die 34 as a pair of dies arranged opposite to each other in the vertical direction, and the lower die 34 together with the tool holder 35 are pushed up (in the direction approaching the upper die 33). ) and a hydraulic cylinder 36 as a mold moving means for clamping the mold with a predetermined press force (C press force).
- the press mechanisms 32A and 32B include a clamp mechanism 37 that releasably grips the steel plate S inside the upper mold 33 and the lower mold 34 in the width direction.
- the longitudinal length of the steel plate S of the upper mold 33 and the lower mold 34 is usually shorter than the length of the steel plate S.
- the end bending process is performed a plurality of times while the steel plate S is intermittently fed in the longitudinal direction by the conveying mechanism 31 (see FIG. 2).
- the lower mold 34 that contacts the outer surfaces in the bending direction of the width direction ends Sc and Sd of the steel sheet S to be subjected to the end bending has a pressing surface 34 a that faces the upper mold 33 .
- the upper mold 33 has a convex molding surface 33a facing the pressing surface 34a and having a radius of curvature corresponding to the inner diameter of the steel pipe to be manufactured.
- the pressing surface 34a has a concave surface shape that approaches the upper mold 33 toward the width direction outer side.
- the pressing surface 34a of the lower mold 34 is concavely curved, it may be a surface that approaches the upper mold 33 toward the outside in the width direction, and may be an inclined flat surface.
- an appropriate shape is designed according to the thickness, outer diameter, etc. of the steel plate S, and may be appropriately selected and used according to the target material. .
- FIG. 3(b) is a cross-sectional view in the width direction of the press mechanism 32A at the same position as in FIG.
- the lower mold 34 is pushed up by a hydraulic cylinder 36 , and the widthwise end Sc of the steel plate S is bent into a shape along the arc-shaped molding surface 33 a of the upper mold 33 .
- the width of the end bending process (width of end bending) varies depending on the width of the steel sheet S, but is generally about 100 to 400 mm.
- FIG. 4 is a diagram showing an example of a process of forming a molded body having a U-shaped cross section using a press bender.
- reference numeral 1 indicates a die arranged in a conveying path of the steel sheet S. As shown in FIG. The die 1 is composed of a pair of left and right rod-like members 1a and 1b that support the steel plate S at two points along the conveying direction. ing.
- Reference numeral 2 denotes a punch that can move toward and away from the die 1 .
- the punch 2 includes a punch tip 2a having a downward convex working surface that directly contacts the steel plate S and presses the steel plate S into a concave shape, and a punch support that is connected to the back surface of the punch tip 2a and supports the punch tip 2a. a body 2b; The maximum width of the punch tip 2a and the width (thickness) of the punch support 2b are usually equal.
- arrows attached to the steel plate S and the punch 2 indicate moving directions of the steel plate S and the punch 2 in each process.
- the gap between the ends is called a "seam gap”.
- the operating parameters that determine the operating conditions in the press bending process include the number of presses, press position information, press reduction amount, lower die interval, punch curvature, and the like.
- the number of presses refers to the total number of times the steel plate is pressed in the width direction by a three-point bending press. As the number of times of pressing increases, the U-shaped cross-section formed body becomes a smooth curved shape, and the roundness of the steel pipe after the pipe expanding process is improved.
- the press position information refers to the position in the width direction of the steel plate to be pressed by the punch. Specifically, it can be specified by the distance from one widthwise end of the steel plate or the distance based on the widthwise central portion of the steel plate.
- the press position information is preferably handled as data linked to the number of presses (in order from the first press to the N-th press).
- the amount of press reduction refers to the amount of pressing of the punch 2 at each pressing position.
- the amount of press reduction is defined by the amount by which the lower end surface of the punch tip 2a protrudes downward from the line connecting the points on the uppermost surface of the die 1 shown in FIG.
- the pressing amount of the punch tip portion 2a can be set to a different value for each pressing, it is preferable to handle the number of times of pressing and the pressing reduction amount as data that is associated with each other. Therefore, the operating conditions in the press bending process are specified by 1 to N data sets, where N is the number of presses, and the number of presses, press position information, and press reduction amount are set as a set of data sets.
- the lower die interval is the interval between the pair of left and right rod-shaped members 1a and 1b shown in FIG. 4, and is a parameter represented by ⁇ D in the figure.
- ⁇ D the curvature of the steel plate locally changes even for the same amount of press reduction, which affects the roundness of the steel pipe after the pipe expansion process. Therefore, it is preferable to use the lower die interval set according to the size of the steel pipe to be formed as an operating parameter in the press bending process. Further, in the case where the lower die interval is changed each time the punch is pressed, data associated with the number of presses may be used as the operation parameter.
- the punch curvature is the curvature of the tip of the punch that presses. As the punch curvature increases, the local curvature imparted to the steel plate during the three-point bending press increases, affecting the roundness of the steel pipe after the pipe expansion process. However, it is difficult to change the punch curvature for each press when forming a single steel plate. preferable.
- the seam gap reduction step using an O press device or the like when the seam gap reduction step using an O press device or the like is omitted after performing the press bending step, the seam gap of the formed body tends to increase, and as a result, the roundness after the tube expanding step is reduced. It tends to get worse. Therefore, compared to the case of using the seam gap reduction process, the amount of press reduction at the widthwise central portion of the steel sheet S is often set larger. However, if the amount of press reduction at the widthwise central portion of the steel sheet S is too large, the widthwise end portions of the formed body will come into contact with the punch support 2b, which may result in an upper limit of the amount of pressure reduction.
- the formed body S1 having a U-shaped cross section formed by the press bending process is then butted against each other at the seam gap end faces and welded by a welding machine (joining means) to form a steel pipe.
- a welding machine for example, a machine composed of three types of welding machines, ie, a tack welding machine, an inner surface welding machine, and an outer surface welding machine, is applied.
- the tack welding machine continuously brings the abutting surfaces into close contact with each other with cage rolls in an appropriate positional relationship, and welds the contact portion over the entire length in the pipe axial direction.
- the tacked pipe is welded from the inner surface of the butt portion (submerged arc welding) by an inner surface welder, and further welded from the outer surface of the butt portion by an outer surface welder (submerged arc welding).
- FIGS. 6A to 6C are diagrams showing configuration examples of the tube expansion device.
- the tube expansion device includes a plurality of tube expansion dies 16 having curved surfaces obtained by dividing a circular arc into a plurality of parts along the circumferential direction of a tapered outer peripheral surface 17 .
- a steel pipe movement device is used to move the steel pipe P, thereby moving the pipe expansion die 16 to the pipe expansion start position.
- the pull rod 18 is retracted from the tube expansion start position to perform the first tube expansion process.
- the pipe expansion dies 16 that are in sliding contact with the tapered outer peripheral surface 17 are displaced in the radial direction by the wedge action, and the steel pipe P is expanded.
- the unevenness of the cross-sectional shape of the steel pipe P is reduced, and the cross-sectional shape of the steel pipe P becomes close to a perfect circle.
- the pull rod 18 is advanced to the tube expansion start position, and the expansion die 16 is returned to the inside in the axial vertical direction by the release mechanism. move further.
- the above operation is repeated.
- the first pipe expansion process can be performed over the entire length of the steel pipe P by the pitch of the pipe expansion die 16 .
- the operating parameters that determine the operating conditions of the tube expansion process include the tube expansion rate, the number of tube expansion dies, and the tube expansion die diameter.
- the expansion ratio is the ratio of the difference between the outer diameter after expansion and the outer diameter before expansion to the outer diameter before expansion.
- the outer diameter before and after expansion can be calculated by measuring the circumference of the steel pipe.
- the expansion ratio can be adjusted by adjusting the stroke amount when expanding the expansion die in the radial direction.
- the number of pipe expansion dies refers to the number of parts that come into contact with steel pipes arranged in the circumferential direction during pipe expansion.
- the tube expansion die diameter is the curvature of the portion of each tube expansion die that contacts the steel pipe.
- the operation parameter that can easily adjust the roundness after the tube expansion process is the expansion rate.
- the tube expansion rate increases, the curvature of the region in contact with the tube expansion die over the entire circumference is imparted evenly according to the tube expansion die R, thereby improving the roundness.
- the greater the number of pipe expansion dies the more the steel pipe can be prevented from localized variations in curvature in the circumferential direction, so that the steel pipe has better roundness after the pipe expansion process.
- the expansion ratio is too large, the compressive yield strength of the steel pipe product may decrease due to the Bauschinger effect.
- the expansion rate is set so that the roundness of the steel pipe falls within a predetermined value at an expansion rate smaller than the preset upper limit of the expansion rate.
- ⁇ Roundness measurement process In the final inspection process of the steel pipe manufacturing process, the quality of the steel pipe is inspected and the roundness of the steel pipe is measured.
- the roundness measured in the roundness measuring process is an index representing the degree of deviation from the perfect circle of the outer diameter shape of the steel pipe. Normally, the closer the circularity is to zero, the closer the cross-sectional shape of the steel pipe is to a perfect circle.
- the roundness is calculated based on the outer diameter information of the steel pipe measured by a roundness measuring machine.
- the roundness is Dmax- Dmin can be defined.
- the larger the number of equal divisions the smaller the unevenness in the steel pipe after the pipe expansion process becomes a numerical index, which is preferable.
- the longitudinal position of the steel pipe whose roundness is measured can be arbitrarily selected.
- the roundness may be measured near the ends in the longitudinal direction of the steel pipe, or the roundness at the central portion in the longitudinal direction of the steel pipe may be measured.
- the roundness does not necessarily have to be based on the difference between the maximum diameter and the minimum diameter.
- An equivalent temporary perfect circle (diameter) having the same area as the inner area of the curve is calculated from a figure representing the outer diameter shape of the steel pipe in a continuous diagram, and the steel pipe is measured based on the temporary perfect circle. It may be defined as an image representing the outer diameter shape and the shifted area.
- the following method can be used.
- an arm 20 that can rotate 360 degrees around the approximate center axis of the steel pipe P, displacement gauges 21a and 21b attached to the tip of the arm 20, and rotation of the arm 20
- displacement gauges 21a and 21b detect the rotation center of the arm 20 and the outer circumference of the steel pipe P for each minute angular unit of rotation of the arm 20. The distance to the measurement point is measured, and the outer diameter shape of the steel pipe P is specified based on this measured value.
- a rotating arm 25 that rotates about the central axis of the steel pipe P, and a mount (not shown) provided on the end side of the rotating arm 25 so as to be movable in the radial direction of the steel pipe P. and a pair of pressure rollers 26a and 26b that contact the outer and inner surfaces of the ends of the steel pipe P and rotate along with the rotation of the rotating arm 25, and a base that presses the pressure rollers 26a and 26b against the outer and inner surfaces of the steel pipe P.
- the outer diameter of the steel pipe is determined based on the amount of radial movement of the frame and the pressing positions of the pressing rollers 26a and 26b by each pressing air cylinder. Identify the shape.
- the prediction accuracy is verified by comparing the roundness prediction result by the roundness prediction model described later with the roundness measurement value obtained in the above inspection process. be able to. Therefore, it is possible to improve the prediction accuracy by adding the actual value of the prediction error to the prediction result of the roundness prediction model, which will be described later.
- FIG. 8 is a diagram showing a method of generating a roundness prediction model, which is an embodiment of the present invention.
- the roundness prediction model generation unit 100 in the figure generates actual data of the attribute information of the steel plate used as the material, operational performance data of the end bending process, operational performance data of the press bending process, and the roundness of the steel pipe after the pipe expansion process. is collected, and a roundness prediction model M is generated by machine learning.
- the performance data of the steel plate attribute information is sent from the host computer 110 to the roundness prediction model generation unit 100 .
- the data may be sent to the roundness prediction model generator 100 by measuring attribute information of the steel sheet before starting forming in the end bending process and inputting the result from a terminal or the like.
- the operation performance data of the end bending process, the operation performance data of the press bending process, and the roundness performance data after the tube expansion process are each sent to the roundness prediction model generation unit 100, and the manufacturing number, product number, etc. are linked as data for each target material specified by and stored in the database 100a.
- the database 100a may be supplemented with operation performance data of the tube expansion process.
- the number of performance data accumulated in the database 100a as described above is at least 10 or more, preferably 100 or more, and more preferably 1000 or more. This is because the accuracy of predicting the roundness after the tube expanding process improves as the number of data serving as the basis of the machine learning model increases.
- the machine learning unit 100b uses at least one or more operation result data selected from the operation result data of the end bending process and the operation result data of the press bending process. Machine learning using one or more performance data selected from the performance data as input performance data and the output performance data of the roundness of the steel pipe after the pipe expansion process in the steel pipe manufacturing process using the input performance data.
- a roundness prediction model M is generated. Further, if necessary, one or more performance data selected from the performance data of the attribute information of the steel plate and one or more performance data selected from the operation performance data of the pipe expansion process may be added to the input performance data. good.
- Machine learning uses well-known machine learning methods, such as a neural network, for example. Other techniques include decision tree learning, random forest, support vector regression, and the like. Also, an ensemble model combining a plurality of models may be used. Furthermore, as the roundness prediction model M, it is determined whether or not the roundness is within a predetermined allowable range of roundness instead of the roundness value, and the result is binarized as pass/fail. A machine learning model may be generated using the data as output performance data. At that time, a classification model such as the k-nearest neighbor method or logistic regression can be used. Note that the database 100a can accumulate operation performance data as needed, and update the roundness prediction model M periodically (for example, once a month). Thereby, the prediction accuracy of the roundness prediction model M is improved.
- the roundness prediction model M of the steel pipe after the pipe expansion process generated as described above has the following characteristics.
- bending deformation is applied to the ends of the steel plate in the width direction by means of a mold, which affects the roundness of the steel pipe after the pipe expansion process in the vicinity of the welded portion of the steel pipe. This is because when bending deformation is applied to a steel plate by a three-point bending press as in the press bending process, it is difficult to apply a bending moment to the ends in the width direction. This is because it is difficult to reduce.
- the press bending process is a process in which bending deformation is applied multiple times along the width direction of the steel sheet, it affects the circumferential curvature distribution of the open pipe. As a result, the circularity of the steel pipe after the pipe expansion process is affected in the entire circumferential direction of the steel pipe.
- the position where the bending deformation is applied in the width direction of the steel sheet is different, it is preferable to predict the roundness of the steel pipe after the pipe expanding process by combining the operating conditions of both.
- the attribute information of the steel sheet for example, the yield stress and the thickness of the steel sheet are subject to a certain amount of variation when manufacturing the steel sheet as the raw material. It affects the curvature of the steel plate when pushing the punch in the three-point bending press in the press bending process and the curvature after unloading. Therefore, by using the attribute information of these steel plates as input parameters for the roundness prediction model M of the steel pipe after the pipe expansion process, it is possible to consider the influence of the yield stress, plate thickness, etc. on the roundness.
- FIG. 9 shows that when manufacturing a steel pipe with an outer diameter of 30 inches and a pipe thickness of 44.5 mm, the number of times of pressing in the press bending process is set to 9, and the end bending widths in the end bending process are 180 mm, 200 mm, In the case of 220 mm, the result of measuring the roundness of the steel pipe after the pipe expansion process (setting the operating conditions for the same pipe expansion process) by changing the press reduction amount during the press reduction in the first pass in the press bending process. is.
- FIG. 9 shows the results of changing the reduction amount (first pass reduction amount) at the time of initial (first) pressing while keeping other operating conditions in the press bending process constant.
- the roundness of the steel pipe after the pipe expansion process differs depending on the end bending width, which is an operation parameter in the end bending process, and the first pass reduction amount, which is an operation parameter in the press bending process.
- the width of the end bending process in the end bending process will affect the performance of the press bending process. It is necessary to appropriately change the first pass reduction amount. This causes variation in the attribute information of the steel sheet, and even if the operating conditions of the end bending process are the same, the deformation state (curvature) of the steel sheet after the end bending process may differ.
- ⁇ Attribute information of steel plate> When using the attribute information of the steel plate as the raw material for the input of the roundness prediction model, the yield stress, tensile strength, longitudinal elastic modulus, thickness, thickness distribution in the plate surface, thickness direction of the steel plate Any parameter that affects the roundness of the steel pipe after the expansion process can be used, such as yield stress distribution, degree of Bauschinger effect, and surface roughness.
- the factors that affect the springback at the ends of the steel plate in the width direction in the end bending process and the factors that affect the deformation state and springback of the steel plate due to the three-point bending press in the press bending process are indicators. preferred.
- the yield stress of the steel sheet, the distribution of the yield stress in the thickness direction of the steel sheet, and the thickness of the steel sheet directly affect the state of stress and strain in the three-point bending press.
- tensile strength affects the state of stress during bending deformation.
- the Bauschinger effect influences the yield stress and subsequent work hardening behavior when the load due to bending deformation is reversed, and influences the stress state during bending deformation.
- the modulus of longitudinal elasticity of the steel sheet affects the springback behavior after bending.
- the plate thickness distribution in the plate surface affects the roundness of the steel pipe after the pipe expansion step by generating the bending curvature distribution in the press bending process.
- yield stress is particularly preferable to use yield stress, representative plate thickness, plate thickness distribution information, and representative plate width.
- yield stress is particularly preferable to use yield stress, representative plate thickness, plate thickness distribution information, and representative plate width.
- the yield stress is information that can be obtained from a tensile test of a small test piece for quality assurance taken from a thick steel plate as a material, and a representative value within the surface of the steel plate as a material can be used.
- the representative plate thickness is a plate thickness that represents the plate thickness in the plane of the steel plate that is the material. You may use the average value of plate thickness. Furthermore, the average value of the plate thickness in the entire surface of the steel plate may be obtained and used as the representative plate thickness.
- the plate thickness distribution information refers to information representing the plate thickness distribution in the width direction of the steel plate. A typical example is a steel crown.
- the crown represents the difference between the widthwise central portion of the steel plate and the plate thickness at a position a predetermined distance (for example, 100 mm, 150 mm, etc. is used) away from the widthwise end portion of the steel plate.
- the plate thickness distribution information is not limited to this, and the plate thickness distribution information may be a coefficient of an approximation formula in which the plate thickness distribution in the width direction is approximated by a second-order or higher function.
- Such representative plate thickness and plate thickness distribution information may be obtained from data measured by a plate thickness gauge during rolling in the plate rolling process, or may be data measured in the plate inspection process.
- the representative sheet width is the representative value for the width of the steel sheet that is the material.
- the width of the steel plate used as the material may fluctuate, which affects the accuracy of the outer diameter of the steel pipe used as the product.
- the width at any position in the longitudinal direction of the steel sheet can be used, or the average value of the widths in the longitudinal direction may be used. In that case, it is preferable to actually measure the width of the steel sheet before the end bending process and use the measured value.
- parameters specifying the shape of the molding surface 33a of the upper mold 33 used in the C press device 30 and the shape of the pressing surface 34a of the lower mold 34 can be used as operation parameters. can.
- the end bending width in the end bending process (the width to which the end bending is performed), the feeding amount of the steel plate, the feeding direction, the number of times of feeding, the pushing force (C press force), and the gripping force by the clamping mechanism 37 are used as operation parameters. good too. This is because these are factors that can affect the deformation of the ends of the steel sheet in the width direction in the end bending process.
- the shape formed by the molding surface 33a of the upper mold 33 may be given in the form of a continuous arc having a plurality of radii of curvature or may be given by an involute curve or the like.
- Parameters can be used to specify the shape.
- the cross-sectional shape can be specified by using the coefficients of the first and second terms of the parabola passing through the origin. It can be an operational parameter of the bending process.
- a plurality of molds are owned and used by appropriately exchanging them as the shape formed by the molding surface 33a of the upper mold 33.
- a die control number for identifying the die used in the end bending process may be used as an operation parameter for the end bending process.
- the operational parameters of the press bending process are used as inputs to the roundness prediction model.
- the operation parameters of the press bending process include the number of presses of the three-point bending press described above, press position information, press reduction amount, lower die interval, punch curvature, etc., local bending curvature of the steel plate, and those steel plates Various parameters can be used that affect the distribution in the width direction. In particular, it is preferable to use information including all of the press position information and press reduction amount where the punch presses the steel plate, and the number of times of press performed through the press bending process. The method shown in FIG. 10 can be exemplified for including all of these pieces of information.
- the press reduction position is information representing the distance from the reference width direction end of the steel sheet, and this is used as the press reduction position information.
- the amount of press reduction is described corresponding to each press reduction position, and such "number of times of reduction", "press reduction position", and "press reduction amount” can be a set of data.
- the operating parameters of the press bending process are specified by 16 sets of data and 10 sets of data for 16 times and 10 times of pressing, respectively.
- such a data set is used as an input for the roundness prediction model in the following form.
- the press reduction position and the amount of press reduction when performing the press reduction at the position closest to the end at one end of the steel plate, and the most at the other end of the steel plate A press reduction position and a press reduction amount when performing press reduction at a position near the end can be used.
- the press reduction amount at one end of the steel plate is increased, the curvature at the portion corresponding to about 1 o'clock and the portion corresponding to about 11 o'clock in the steel pipe shown in FIG.
- As a molded body with a letter-shaped cross section it has a horizontally long shape as a whole.
- the press reduction position is to the end of the steel sheet, the lower the position of the seam gap portion becomes, and the formed body having a U-shaped cross section has a horizontally elongated shape as a whole.
- the steel pipe formed into an open pipe and subjected to the welding process and the pipe expansion process also retains a horizontally elongated shape as a whole, which affects the roundness.
- the punch curvature during press reduction, the total number of press reductions, and the interval between the lower dies during press reduction also affect the circularity of the steel pipe.
- the prediction accuracy of the roundness prediction model can be further improved. For example, based on the assumed maximum number of times of pressing, when rolling is performed, the data of the pressing position and the amount of pressing are stored according to the number of times of rolling. Then, the press reduction position and the press reduction amount in subsequent press workings in which no reduction is performed are set to zero. For example, in the example shown in FIGS. 10(a) and 10(b), assuming that the maximum number of presses is 16, if the number of presses is 10, the data for the 11th to 16th presses are assumed to be zero. , are the inputs for the roundness prediction model.
- the number of times of pressing, the position of press reduction, and the amount of press reduction are necessary information for controlling the press bending device as operation performance data in the press bending process, so the set values set by the host computer are used. be able to.
- the measurement result may be used as the operation result data.
- the expansion rate can be used as the operational parameter of the tube expansion process.
- the larger the expansion rate the more the steel pipe roundness after the expansion process is improved, but the upper limit of the expansion rate is limited from the viewpoint of the compressive yield strength as a steel pipe product, so a value within that range is used.
- the tube expansion rate is information necessary for controlling the tube expansion device, and a set value set by a host computer can be used.
- the average outer diameter of the entire circumference is measured by a measuring device such as a shape dimension meter, and the average expansion ratio calculated from the amount of change from the outer diameter calculated from the width of the steel plate before processing is operated. It is good also as performance data. Furthermore, in the tube expansion process, if a tube expansion rate measuring device is provided, the measurement result may be used as the operation performance data. In addition to the expansion ratio, the number of expansion dies and the diameter of the expansion dies may also be used as operational parameters for the expansion process.
- a method for predicting the roundness of a steel pipe after a pipe expansion process using the roundness prediction model generated as described above is used as follows. That is, by using this method, an end bending step of forming the width direction end portion of the steel plate into an end bent shape, a press bending step of forming an open pipe by pressing a plurality of times with a punch, and an open pipe end portion. It is possible to verify whether or not manufacturing conditions in each process are appropriate in a steel pipe manufacturing process including a pipe expanding process in which steel pipes joined together are formed by pipe expansion. The operating conditions in the end bending process and press bending process have a complex effect on the circularity of the steel pipe after the pipe expansion process. Become.
- the operating conditions of the end bending process and the press bending process can be optimized in advance so that the roundness of the steel pipe product falls within a predetermined range. .
- a process to be reset is selected from among a plurality of forming processes that constitute the steel pipe manufacturing process. Then, before starting the process to be reset, the roundness prediction model M is used to predict the roundness of the steel pipe after the pipe expansion process. Subsequently, one or more operation parameters selected from at least the operation parameters of the process to be reset, or forming downstream of the process to be reset so that the roundness of the steel pipe after the pipe expansion process becomes small. One or more operational parameters selected from the operational parameters of the processing steps are reset.
- the multiple forming processes that constitute the steel pipe manufacturing process refer to the end bending process, the press bending process, and the pipe expanding process that apply plastic deformation to the steel plate to process the steel pipe into a predetermined shape.
- An arbitrary process is selected from these molding processes as the process to be reset.
- the circularity prediction model M of the steel pipe is used to predict the circularity of the steel pipe after the pipe expansion process.
- the actual data is used as the roundness It can be used as an input for the prediction model M.
- the setting value set in advance in the host computer or the like is used as the input for the roundness prediction model M of the steel pipe. In this way, it is possible to predict the roundness of the steel pipe after the pipe expansion process for the target material.
- the roundness predicted as the roundness of the steel pipe after the pipe expansion process falls within the roundness allowed as a product.
- the operation parameter to be reset may be the operation parameter in the reset target process or the operation parameter in the molding process downstream of the reset target process.
- operation parameters for the forming process suitable for changing the roundness of the steel pipe after the tube expansion process may be selected.
- both the operation parameter in the reset target process and the operation parameter in any molding process downstream of the reset target process may be reset. This is because when there is a large difference between the predicted roundness and the roundness allowed as a product, the roundness of the steel pipe after the pipe expansion process can be effectively changed.
- Table 1 specifically shows cases of molding processes selected as reset target processes and corresponding molding processes for which operation parameters can be reset.
- the end bending process is selected as the process to be reset.
- the roundness of the steel pipe after the pipe expanding process is predicted using the set values of the operation parameters in the forming process including the press bending process. If the predicted roundness is large, any operating parameters in each forming process of end bending, press bending, and tube expansion can be reset. Operation parameters to be reset may be not only the operation parameters of the end bending process but also the operation parameters of other forming processes.
- actual data including measured values etc. related to the attribute information of the steel plate is obtained before the start of the end bending process, which is the process to be reset. can be used as input.
- case 2 the process to be reset and the operation parameters to be reset can be selected based on the same concept as case 1.
- case 3 is a case where the tube expansion process is set as the process to be reset.
- the roundness prediction model M is used to predict the roundness of the steel pipe after the tube expansion process before starting the tube expansion process.
- operational record data in at least the end bending process and the press bending process.
- the expansion ratio is used as the operation parameter for the expansion process to be reset.
- the amount of change from the initial set value of the tube expansion rate to be reset may be set based on knowledge based on experience.
- the input of the roundness prediction model M includes the expansion rate of the pipe expansion process
- the re-set expansion rate value is used as the input of the roundness prediction model M, and the steel pipe after the pipe expansion process
- the suitability of the conditions to be reset may be determined by predicting the roundness.
- FIG. 11 a method for controlling the roundness of a steel pipe, which is one embodiment of the present invention, will be described.
- the example shown in FIG. 11 is a case in which the press bending process is selected as the process to be reset, the end bending process is completed, and the end C-shaped formed body is transferred for the press bending process.
- the operational result data in the end bending process is sent to the operational condition resetting section 120 .
- Operation performance data may be sent via a network from a control computer provided for each process that controls each molding process. However, the information may be sent from the control computer for each forming process to the host computer 110 that controls the steel pipe manufacturing process, and then sent from the host computer 110 to the operating condition resetting unit 120 .
- the operating condition resetting section 120 performance data regarding the attribute information of the steel sheet is sent from the host computer 110 as necessary.
- the set values are set by the operating condition reset unit from the control computer of each process. 120.
- the set values of the operating parameters for the press bending process and the tube expanding process are stored in the host computer 110 , they may be sent from the host computer 110 to the operating condition resetting section 120 .
- the host computer 110 sends the operating condition resetting unit 120 a circularity target value that is determined according to the specifications of the steel pipe as a product.
- the operating condition resetting unit 120 uses the roundness prediction model M online to predict the roundness of the steel pipe after the pipe expansion process from this information, and calculates the predicted roundness (roundness prediction value) and Compare with the target roundness (roundness target value). Then, when the predicted roundness value is smaller than the target roundness value, the operating condition resetting unit 120 does not change the setting values of the operating conditions for the press bending process and the tube expanding process, and performs the rest of the forming process. determine the operating conditions of the steel pipes. On the other hand, when the predicted roundness is larger than the roundness target value, the operating condition resetting unit 120 resets at least the operating conditions for the press bending process or the operating conditions for the tube expanding process.
- the press reduction amount, the number of times of pressing, and the like in the press bending process may be increased once or twice or more, and the lower die interval ⁇ D may be reset.
- the tube expansion rate of the tube expansion process can be reset.
- both the press reduction amount and the tube expansion rate in the press bending process can be reset.
- the operating condition resetting unit 120 performs roundness prediction again using the operating parameters reset in this way as the input data of the roundness prediction model M, and the predicted roundness is correct.
- the reset values of the operating conditions for the press bending process and the tube expanding process may be determined by confirming whether or not the circularity is smaller than the target circularity value.
- the reset operating conditions for the press bending process and the tube expanding process are sent to the respective control computers and used as the operating conditions for the press bending process and the tube expanding process.
- the pipe expansion process is performed again for the steel pipe that has been formed into an open pipe and welded.
- Roundness control of the steel pipe after the pipe expansion process which is the process to be reset, may be executed. This is because the accuracy of predicting the roundness of the steel pipe is further improved when the operational record data of the press bending process is obtained.
- the roundness is predicted in consideration of the influence on the roundness due to the interaction between the end bending process and the press bending process. Since the model M is used, it is possible to set appropriate operating conditions for improving the circularity of the steel pipe after the pipe expansion process, and to manufacture a steel pipe with a high degree of circularity. In addition, it is possible to achieve highly accurate roundness control that reflects variations in the attribute information of the steel plate that is the material.
- FIG. 12 is a diagram showing the configuration of a steel pipe roundness prediction device that is an embodiment of the present invention.
- a steel pipe roundness prediction apparatus 160 according to an embodiment of the present invention includes an operation parameter acquisition unit 161, a storage unit 162, a roundness prediction unit 163, and an output unit 164. .
- the operational parameter acquisition unit 161 has an arbitrary interface that can acquire the roundness prediction model M generated by the machine learning unit from the roundness prediction model generation unit 100, for example.
- the operational parameter acquisition unit 161 may include a communication interface for acquiring the roundness prediction model M from the roundness prediction model generation unit 100 .
- the operational parameter acquisition unit 161 may receive the roundness prediction model M from the machine learning unit 100b using a predetermined communication protocol.
- the operating parameter acquisition unit 161 acquires the operating conditions of the molding equipment (equipment for executing the molding process) from, for example, a control computer or a host computer provided in the equipment used in each molding process.
- the operational parameter acquisition unit 161 may include a communication interface for acquiring operational conditions.
- the operational parameter acquisition unit 161 may acquire input information based on a user's operation.
- the steel pipe roundness prediction apparatus 160 further includes an input unit including one or more input interfaces for detecting user input and acquiring input information based on user operation.
- the input unit include, but are not limited to, physical keys, capacitance keys, a touch screen provided integrally with the display of the output unit, a microphone for receiving voice input, and the like.
- the input unit receives input of operating conditions for the roundness prediction model M acquired from the roundness prediction model generation unit 100 by the operation parameter acquisition unit 161 .
- the storage unit 162 includes at least one semiconductor memory, at least one magnetic memory, at least one optical memory, or a combination of at least two of these.
- the storage unit 162 functions, for example, as a main storage device, an auxiliary storage device, or a cache memory.
- the storage unit 162 stores arbitrary information used for the operation of the steel pipe roundness prediction device 160 .
- the storage unit 162 stores, for example, the roundness prediction model M acquired from the roundness prediction model generation unit 100 by the operation parameter acquisition unit 161, the operating conditions acquired from the host computer by the operation parameter acquisition unit 161, and the steel pipe trueness. Circularity information predicted by the circularity prediction device 160 is stored.
- the storage unit 162 may store system programs, application programs, and the like.
- the roundness prediction unit 163 includes one or more processors.
- the processor is a general-purpose processor or a dedicated processor specialized for specific processing, but is not limited to these.
- the roundness prediction unit 163 is communicably connected to each component constituting the steel pipe roundness prediction device 160 and controls the overall operation of the steel pipe roundness prediction device 160 .
- the roundness prediction unit 163 can be any general-purpose electronic device such as a PC (Personal Computer) or a smart phone, for example.
- the roundness prediction unit 163 is not limited to these, and may be one or a plurality of server devices that can communicate with each other, or may be another electronic device dedicated to the steel pipe roundness prediction device 160. good.
- the roundness prediction unit 163 uses the operating conditions acquired via the operation parameter acquisition unit 161 and the roundness prediction model M acquired from the roundness prediction model generation unit 100 to predict the roundness information of the steel pipe. Calculate
- the output unit 164 outputs the predicted value of the roundness information of the steel pipe calculated by the roundness prediction unit 163 to a device for setting the operating conditions of the forming equipment.
- the output unit 164 may include one or more output interfaces for outputting information and notifying the user.
- the output interface is, for example, a display.
- the display is, for example, an LCD or an organic EL display.
- the output unit 164 outputs data obtained by the operation of the steel pipe roundness prediction device 160 .
- the output unit 164 may be connected to the steel pipe roundness prediction device 160 as an external output device instead of being provided in the steel pipe roundness prediction device 160 .
- any method such as USB, HDMI (registered trademark), or Bluetooth (registered trademark) can be used.
- the output unit 164 may be a display that outputs information as video or a speaker that outputs information as audio, but is not limited to these.
- the output unit 164 presents the predicted value of the roundness information calculated by the roundness prediction unit 163 to the user. The user can appropriately set the operating conditions of the molding equipment based on the predicted roundness value presented by the output unit 164 .
- a more preferable form of the steel pipe roundness prediction device 160 after the pipe expansion process as described above is that the input unit 165 acquires input information based on the user's operation, and the roundness prediction unit 163 calculates the roundness It is a terminal device such as a tablet terminal having a display unit 166 that displays predicted values of information. This acquires input information based on the user's operation from the input unit 165, and updates some or all of the operation parameters of the forming processing equipment that have already been input to the steel pipe roundness prediction device 160 based on the acquired input information. It is something to do.
- the operator uses the terminal device to obtain the operation parameter acquisition unit 161 to accept an operation to correct a part of the operation parameters of the forming processing equipment input to 161 .
- the operating parameter acquisition unit 161 retains the initial input data for the operating parameters of the molding facility that are not corrected and input from the terminal device, and changes only the operating parameters that have been corrected and input. do.
- the operation parameter acquisition unit 161 generates new input data for the roundness prediction model M, and the roundness prediction unit 163 calculates the prediction value of the roundness information based on the input data.
- the calculated predicted value of the roundness information is displayed on the display unit 166 of the terminal device through the output unit 164 .
- the person in charge of operation of the molding equipment or the person in charge of the factory can immediately confirm the predicted value of the roundness information when the operation parameters of the molding equipment are changed, and quickly change to the appropriate operating conditions. can be done.
- a steel plate for line pipes (API grade X60), which has a thickness of 31.0 to 31.4 mm and a width of 2751 mm by processing (preliminary processing) the width edges of the raw steel plate, is used.
- a steel pipe having a diameter of 36 inches after the pipe expansion process was manufactured through an end bending process, a press bending process, a welding process, and a pipe expansion process.
- steel pipes having various roundnesses were obtained by adjusting the operating conditions of the end bending process and the press bending process.
- the amount of press reduction at each press reduction position was changed within a range of ⁇ 3 mm based on the value of 50 mm as a reference for each steel sheet to be formed. Then, the open pipe formed by the press bending process was sent to the welding process without going through the seam gap reduction process. Further, in the pipe expansion process, steel pipes were manufactured with the pipe expansion rate fixed at 1.2%, and the roundness of the steel pipes after the pipe expansion process was measured.
- Roundness measurement is performed by measuring the outer diameter of the steel pipe at 1080 points in the circumferential direction with a roundness measuring machine in the inspection process, and the difference between the maximum diameter Dmax and the minimum diameter Dmin of them is the roundness. bottom.
- a roundness prediction model was generated at the stage when 500 pieces of performance data obtained as described above were accumulated in the database.
- the roundness prediction model generated in this manner was installed in the system shown in FIG. 11 as an online model.
- the press bending process was selected as a process to be reset. At this time, the target roundness of the steel pipe is set to 10 mm, and the roundness of the steel pipe after the pipe expansion process is predicted before the process to be reset.
- a steel pipe roundness prediction method and a roundness prediction apparatus that can accurately predict the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps. can be done. Further, according to the present invention, it is possible to provide a steel pipe roundness control method capable of accurately controlling the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps. Moreover, according to the present invention, it is possible to provide a steel pipe manufacturing method capable of manufacturing a steel pipe having a desired roundness with a high yield.
- a steel pipe roundness prediction model capable of generating a roundness prediction model for accurately predicting the roundness of a steel pipe after a pipe expansion step in a steel pipe manufacturing process comprising a plurality of steps. can provide a method for generating
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Abstract
Description
図1は、本発明の一実施形態である鋼管の製造工程を示す図である。図1に示すように、本発明の一実施形態である鋼管の製造工程では、素材となる鋼板として、鋼管の製造工程の前工程である厚板圧延工程によって製造される厚鋼板が用いられる。ここで、厚鋼板は、降伏応力245~1050MPa、引張強度415~1145MPa、板厚6.4~50.8mm、板幅1200~4500mm、及び長さ10~18mのものが代表的である。また、厚鋼板の幅方向端部は開先と呼ばれる面取り状の形状に予め研削される。これは、後の溶接工程において、幅方向端部の外面コーナー部の過加熱を防止して溶接強度を安定化させるためである。また、厚鋼板の幅は、鋼管に成形された後の外径に影響するため、後の工程における変形履歴を考慮して所定範囲に調整される。
端曲げ加工を行うCプレス装置について、図2,図3を用いて詳細に説明する。図2は、Cプレス装置の全体構成を示す斜視図である。図2に示すように、Cプレス装置30は、鋼板Sをその長手方向に沿う方向を搬送方向として搬送する搬送機構31と、鋼板Sの搬送方向下流側を前方として、一方の幅方向端部Scを所定の曲率に曲げ加工するプレス機構32Aと、他方の幅方向端部Sdを所定の曲率に曲げ加工するプレス機構32Bと、端曲げ加工を施す鋼板Sの幅に応じて、左右のプレス機構32A,32B間の間隔を調整する図示しない間隔調整機構と、を備えている。搬送機構31は、プレス機構32A、32Bの前後にそれぞれ配置された複数の回転駆動される搬送ロール31aからなる。なお、図中の符号Saは鋼板Sの先端部(長手方向前方端部)を示している。
図4は、プレスベンド装置を用いてU字状断面の成形体を成形する工程の一例を示す図である。図中、符号1は、鋼板Sの搬送経路内に配置されたダイを示している。ダイ1は、鋼板Sをその搬送方向に沿って2箇所で支持する左右一対の棒状部材1a,1bから構成されており、成形すべき鋼管のサイズに応じてその間隔ΔDが変更できるようになっている。また、符号2は、ダイ1に近接及び離隔する向きに移動可能なパンチを示している。パンチ2は、鋼板Sに直接接して鋼板Sを凹形状に押圧する下向き凸状の加工面を有するパンチ先端部2aと、パンチ先端部2aの背面に繋がり、パンチ先端部2aを支持するパンチ支持体2bと、を備えている。なお、通常、パンチ先端部2aの最大幅とパンチ支持体2bの幅(厚さ)とは等しくなっている。
プレスベンド工程により成形加工されたU字状断面の成形体S1は、その後、シームギャップ部の端面を相互に突合せ、溶接機(接合手段)により溶接して鋼管とする。溶接機(接合手段)としては、例えば仮付溶接機、内面溶接機、及び外面溶接機という3種類の溶接機で構成されるものを適用する。これらの溶接機において、仮付け溶接機は、ケージロールにより突き合せた面を適切な位置関係で連続的に密着させ、密着部をその管軸方向全長にわたって溶接する。次に、仮付けされた管は、内面溶接機により突き合せ部の内面から溶接(サブマージアーク溶接)され、さらに、外面溶接機により突き合せ部の外面から溶接(サブマージアーク溶接)される。
シームギャップ部を溶接された鋼管については、鋼管の内部に拡管装置を挿入して鋼管の直径を拡大(いわゆる拡管)する。図6(a)~(c)は、拡管装置の構成例を示す図である。図6(a)に示すように、拡管装置は、円弧を複数に分割した曲面を有する複数個の拡管ダイス16をテーパー外周面17の周方向に沿って備えている。拡管装置を利用して鋼管を拡管する際には、図6(b),(c)に示すように、まず、鋼管移動装置を用いて鋼管Pを移動することにより拡管ダイス16を拡管開始位置に合わせ、プルロッド18を拡管開始位置から後退させることによって1回目の拡管処理を行う。これにより、楔作用によってテーパー外周面17に摺接した拡管ダイス16のそれぞれが放射方向に変位し、鋼管Pが拡管される。そして、鋼管Pの断面形状の凹凸が小さくなり、鋼管Pの断面形状は真円形状に近くなる。次に、プルロッド18を拡管開始位置まで前進させ、リリース機構によって拡管ダイス16を軸垂直方向の内側に復帰させてから、拡管ダイス16のピッチ(軸方向の長さ)に応じた量だけ鋼管Pを更に移動させる。そして、拡管ダイス16を新たな拡管位置に合わせてから前記の動作を繰り返し行う。これにより、拡管ダイス16のピッチ分ずつ1回目の拡管処理を鋼管Pの全長にわたって行うことができる。
鋼管の製造工程の最後となる検査工程では、鋼管の品質検査が行われ、鋼管の真円度が測定される。真円度測定工程において測定される真円度とは、鋼管の外径形状について、真円からのズレの程度を表す指標である。通常は、真円度がゼロに近いほど、鋼管の断面形状が完全な円に近い形状であることを示す。真円度は、真円度測定機によって計測された鋼管の外直径情報に基づいて算出される。例えば任意の管長位置で管を周方向に等分して対向する位置での外直径を計測し、それらのうちの最大径と最少径をそれぞれDmax、Dminとした場合、真円度はDmax-Dminで定義することができる。このとき、等分する数が多いほど、拡管工程後の鋼管における小さな凹凸も数値化した指標となり好ましい。具体的には4~36000等分した情報を用いるのが良い。より好ましくは360等分以上である。
図8は、本発明の一実施形態である真円度予測モデルの生成方法を示す図である。図中の真円度予測モデル生成部100は、素材となる鋼板の属性情報の実績データ、端曲げ工程の操業実績データ、プレスベンド工程の操業実績データ、及び拡管工程後の鋼管の真円度の実績データを収集し、機械学習により真円度予測モデルMを生成するものである。
素材となる鋼板の属性情報を真円度予測モデルの入力に用いる場合には、鋼板の降伏応力、引張強度、縦弾性係数、板厚、板面内の板厚分布、鋼板の板厚方向の降伏応力の分布、バウシンガー効果の程度、及び表面粗さ等、拡管工程後の鋼管の真円度に影響を及ぼす任意のパラメータを用いることができる。特に、端曲げ工程における鋼板の幅方向端部でのスプリングバックに影響を与える因子や、プレスベンド工程における3点曲げプレスによる鋼板の変形状態やスプリングバックに影響を与える因子を指標とするのが好適である。
端曲げ工程の操業パラメータには、Cプレス装置30で使用する上金型33の成形面33aがなす形状や下金型34の押圧面34aがなす形状を特定するパラメータを操業パラメータとして用いることができる。また、端曲げ工程における端曲げ加工幅(端曲げ成形を施す幅)、鋼板の送り量、送り方向、送り回数、押し上げ力(Cプレス力)、クランプ機構37による把持力を操業パラメータとして用いてもよい。これらは、端曲げ工程における鋼板の幅方向端部の変形に影響を与え得る因子だからである。
本実施形態では、プレスベンド工程の操業パラメータを真円度予測モデルの入力に用いる。プレスベンド工程の操業パラメータとしては、上記に記載した3点曲げプレスのプレス回数、プレス位置情報、プレス圧下量、下ダイ間隔、及びパンチ曲率等、鋼板の局所的な曲げ曲率と、それらの鋼板の幅方向の分布に影響を与える各種パラメータを用いることができる。特に、パンチが鋼板を押圧するプレス位置情報とプレス圧下量、プレスベンド工程を通じて行うプレス回数の全てを含む情報を用いるのが好ましい。これらの情報を全て含むとは、図10に示す方法が例示できる。図10(a),(b)はそれぞれ、同一の幅の鋼板に対してプレス回数16回と10回としてパンチの押圧行った場合のプレス圧下位置とプレス圧下量の例を示している。このとき、プレス圧下位置は、鋼板の基準とする幅方向端部からの距離を表す情報であり、これをプレス圧下位置情報として用いる。一方、各プレス圧下位置に対応して、プレス圧下量が記載されており、このような「圧下回数」、「プレス圧下位置」、「プレス圧下量」が一組のデータとすることができる。図10(a),(b)に示す例では、プレス回数16回と10回で、それぞれ16組、10組のデータにより、プレスベンド工程の操業パラメータが特定される。
上述した操業パラメータの他、拡管工程の操業パラメータを真円度予測モデルの入力に用いる場合には、拡管率を拡管工程の操業パラメータとして用いることができる。拡管率が大きいほど、拡管工程後の鋼管の真円度は向上するが、鋼管製品としての圧縮降伏強度の観点から拡管率の上限値が制限されるため、その範囲内での値を用いる。このとき、拡管率は、拡管装置を制御するために必要な情報であり、上位計算機で設定された設定値を用いることができる。また、拡管を行った後に形状寸法計等の測定装置によって全周の平均外径を測定し、加工前の鋼板の幅から計算される外径との変化量によって計算される平均拡管率を操業実績データとしてもよい。さらに、拡管工程において、拡管率の計測装置を備えている場合には、その測定結果を操業実績データとしてもよい。なお、拡管工程の操業パラメータとしては、拡管率の他、拡管ダイス枚数、拡管ダイス径を用いてもよい。
以上のようにして生成した真円度予測モデルを用いた拡管工程後の鋼管の真円度予測方法は以下のように用いられる。すなわち、この方法を用いることにより、鋼板の幅方向端部を端曲げ形状に成形加工する端曲げ工程、パンチによる複数回の押圧によりオープン管に成形加工するプレスベンド工程と、オープン管の端部同士を接合した鋼管に対して拡管による成形加工を行う拡管工程と、を含む鋼管の製造工程において、それぞれの工程における製造条件が適正かどうかの検証を行うことができる。端曲げ工程やプレスベンド工程の操業条件は、拡管工程後の鋼管の真円度に対して複雑に影響するものであり、それらの要因が製品の真円度に対する影響を定量的に評価できることになる。また、素材となる鋼板の属性情報のばらつきの実態を踏まえて、鋼管製品の真円度のばらつきを予測することができ、そのような素材のばらつきを考慮した端曲げ工程やプレスベンド工程の操業条件の変更を行うことができる。すなわち、素材の属性情報に一定のばらつきがあっても、鋼管製品の真円度が所定の範囲内に収まるように端曲げ工程やプレスベンド工程の操業条件の適正化を事前に行うことができる。
表1及び図11を参照して、本発明の一実施形態である真円度制御方法について説明する。
次に、図12を参照して、本発明の一実施形態である鋼管の真円度予測装置について説明する。
1a,1b 棒状部材
2 パンチ
2a パンチ先端部
2b パンチ支持体
16 拡管ダイス
17 テーパー外周面
18 プルロッド
20 アーム
21a,21b 変位計
22 回転角度検出器
25 回転アーム
26a,26b 押圧ローラ
30 Cプレス装置
31 搬送機構
31a 搬送ロール
32A,32B プレス機構
33 上金型
33a 成形面
34 下金型
34a 押圧面
36 油圧シリンダ
37 クランプ機構
100 真円度予測モデル生成部
100a データベース
100b 機械学習部
110 上位計算機
120 操業条件再設定部
160 鋼管の真円度予測装置
161 操業パラメータ取得部
162 記憶部
163 真円度予測部
164 出力部
165 入力部
166 表示部
G シームギャップ部
M 真円度予測モデル
P 鋼管
R1,R2 領域
S 鋼板
S1 成形体
Claims (12)
- 鋼板の幅方向端部に端曲げ加工を施す端曲げ工程と、パンチによる複数回の押圧により端曲げ加工が施された鋼板をオープン管に成形加工するプレスベンド工程、及び前記オープン管の端部同士を接合した鋼管に対して拡管による成形加工を行う拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する鋼管の真円度予測方法であって、
前記端曲げ工程の操業パラメータから選択した1又は2以上の操業パラメータ及び前記プレスベンド工程の操業パラメータから選択した1又は2以上の操業パラメータを入力データとして含み、前記拡管工程後の鋼管の真円度情報を出力データとする、機械学習により学習された真円度予測モデルを用いて、前記拡管工程後の鋼管の真円度を予測するステップを含む、鋼管の真円度予測方法。 - 前記真円度予測モデルは、前記入力データとして、前記鋼板の属性情報から選択した1又は2以上のパラメータを含む、請求項1に記載の鋼管の真円度予測方法。
- 前記真円度予測モデルは、前記入力データとして、前記拡管工程の操業パラメータから選択した拡管率を含む、請求項1又は2に記載の鋼管の真円度予測方法。
- 前記端曲げ工程の操業パラメータは、端曲げ加工幅、Cプレス力、及びクランプ把持力のうちの1又は2以上のパラメータを含む、請求項1~3のうち、いずれか1項に記載の鋼管の真円度予測方法。
- 前記プレスベンド工程の操業パラメータは、前記プレスベンド工程に用いるパンチが鋼板を押圧するプレス位置情報及びプレス圧下量と共に、前記プレスベンド工程を通じて行うプレス回数を含む、請求項1~4のうち、いずれか1項に記載の鋼管の真円度予測方法。
- 請求項1~5のうち、いずれか1項に記載の鋼管の真円度予測方法を用いて、前記鋼管の製造工程を構成する複数の成形加工工程から選択した再設定対象工程の開始前に、前記拡管工程後の鋼管の真円度を予測し、拡管工程後の鋼管の真円度が小さくなるように、少なくとも前記再設定対象工程の操業パラメータから選択した1又は2以上の操業パラメータ、又は、前記再設定対象工程よりも下流側の成形加工工程の操業パラメータから選択した1又は2以上の操業パラメータを再設定するステップを含む、鋼管の真円度制御方法。
- 請求項6に記載の鋼管の真円度制御方法を用いて鋼管を製造するステップを含む、鋼管の製造方法。
- 鋼板の幅方向端部に端曲げ加工を施す端曲げ工程と、パンチによる複数回の押圧により端曲げ加工が施された鋼板をオープン管に成形加工するプレスベンド工程、及び前記オープン管の端部同士を接合した鋼管に対して拡管による成形加工を行う拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する真円度予測モデルを生成する鋼管の真円度予測モデルの生成方法であって、
前記端曲げ工程の操業実績データから選択した1又は2以上の操業実績データ及び前記プレスベンド工程の操業実績データから選択した1又は2以上の操業実績データを入力実績データ、該入力実績データを用いた鋼管の製造工程での前記拡管工程後の鋼管の真円度の実績データを出力実績データとした、複数の学習用データを取得し、取得した複数の学習用データを用いた機械学習によって真円度予測モデルを生成するステップを含む、鋼管の真円度予測モデルの生成方法。 - 前記入力実績データは、前記鋼板の属性情報から選択した1又は2以上のパラメータを含む、請求項8に記載の鋼管の真円度予測モデルの生成方法。
- 前記機械学習として、ニューラルネットワーク、決定木学習、ランダムフォレスト、及びサポートベクター回帰から選択した機械学習を用いる、請求項8又は9に記載した鋼管の真円度予測モデルの生成方法。
- 鋼板の幅方向端部に端曲げ加工を施す端曲げ工程と、パンチによる複数回の押圧により端曲げ加工が施された鋼板をオープン管に成形加工するプレスベンド工程、及び前記オープン管の端部同士を接合した鋼管に対して拡管による成形加工を行う拡管工程を含む鋼管の製造工程における、前記拡管工程後の鋼管の真円度を予測する鋼管の真円度予測装置であって、
前記端曲げ工程の操業パラメータから選択した1又は2以上の操業パラメータ及び前記プレスベンド工程の操業パラメータから選択した1又は2以上の操業パラメータを取得する操業パラメータ取得部と、
前記端曲げ工程の操業パラメータから選択した1又は2以上の操業パラメータ及び前記プレスベンド工程の操業パラメータから選択した1又は2以上の操業パラメータを入力データとして含み、前記拡管工程後の鋼管の真円度情報を出力データとする、機械学習により学習された真円度予測モデルに対して、前記操業パラメータ取得部が取得した操業パラメータを入力することにより、前記拡管工程後の鋼管の真円度情報を予測する真円度予測部と、
を備える、鋼管の真円度予測装置。 - ユーザの操作に基づく入力情報を取得する入力部と、前記真円度情報を表示する表示部と、を有する端末装置を備え、
前記操業パラメータ取得部は、前記入力部が取得した入力情報に基づいて、取得した操業パラメータの一部又は全部を更新し、
前記表示部は、前記更新された操業パラメータを用いて前記真円度予測部が予測した前記鋼管の真円度情報を表示する、請求項11に記載の鋼管の真円度予測装置。
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JP2012170977A (ja) * | 2011-02-21 | 2012-09-10 | Jfe Steel Corp | 鋼管の製造方法 |
JP2012241274A (ja) * | 2011-05-24 | 2012-12-10 | Jfe Steel Corp | 耐圧潰性および耐サワー性に優れた高強度ラインパイプおよびその製造方法 |
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JP2012137813A (ja) * | 2010-12-24 | 2012-07-19 | Nippon Steel Corp | 品質予測装置、品質予測方法、プログラムおよびコンピュータ読み取り可能な記録媒体 |
JP2012170977A (ja) * | 2011-02-21 | 2012-09-10 | Jfe Steel Corp | 鋼管の製造方法 |
JP2012241274A (ja) * | 2011-05-24 | 2012-12-10 | Jfe Steel Corp | 耐圧潰性および耐サワー性に優れた高強度ラインパイプおよびその製造方法 |
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