Special Section Tube Mills

Shijiazhuang Faith Machinery Co.,Ltd introduces its Special Section Tube Mills, engineered to form tubes with non-standard cross-sections such as rectangular, oval, elliptical, and customized multi-bend profiles. These mills serve architectural, automotive, and industrial applications where conventional round tubing does not meet functional or aesthetic requirements.

Line Configuration and Forming Process
The Special Section Tube Mill begins with a decoiler and entry tension-leveling unit, which ensures strip flatness before forming. A sequence of precision roll stands progressively shapes the strip into the desired profile. Each stand is fitted with upper and lower forming rolls whose contours correspond to the target cross-section. Roll gaps and stand spacing are calculated via finite element analysis to minimize springback and maintain consistent wall thickness.

Welding and Post-Forming Operations
After the final forming stand, the tube passes through a high-frequency induction welding head. Edge heating parameters—frequency, current, and coil geometry—are optimized for each profile to achieve uniform weld penetration without distortion. A scarfing unit removes both internal and external weld beads, preserving the geometric integrity of complex sections. Downstream sizing stands apply gentle calibration to correct minor deviations in wall thickness and outer dimensions.

Customization and Tooling Adaptability
Special Section Tube Mills are designed for rapid tooling changes. Pre-aligned roll cassette systems allow technicians to swap forming rolls within hours rather than days. Roll cassettes carry identification codes matched to stored PLC recipes, so that forming parameters—roll position, welding head power settings, and conveyor speeds—are automatically loaded. This flexibility supports short production runs and just-in-time manufacturing for customized profiles.

Control Systems and Quality Assurance
A centralized PLC network coordinates decoiler speed, roll stand servo positions, welding power, and downstream handling. Laser micrometers monitor outer dimensions after sizing, feeding real-time data to the automatic gauge control (AGC) system. Non-destructive testing (NDT) units—such as ultrasonic flaw detectors—inspect the weld seam for internal defects. Any non-conforming sections are diverted automatically, ensuring that only tubes meeting geometric and structural criteria proceed to packaging.

Support and Maintenance
Shijiazhuang Faith’s service package includes on-site commissioning, operator training, and preventive maintenance schedules. Roll cassettes and welding coil spares are stocked for rapid replacement. Remote diagnostics capabilities allow engineers to review machine trends and advise on parameter adjustments without a site visit. Through this comprehensive support, Special Section Tube Mills maintain consistent production of complex-shaped tubing to meet evolving market demands.