Name: 無縫鋼管制造 (Seamless steel pipe manufacturing)
Uploaded: 2025-03-24T07:49:33.000Z
Duration: 8 min 36 s

Seamless steel pipes are commonly utilized for transportation of fluids like water, natural gas, waste, and air.

無縫鋼管通常用於輸送水、天然氣、廢物和空氣等流體。

It is frequently needed in various high-pressure, highly corrosive settings such as in the oil and gas, power generation, and pharmaceutical industries.

在各種高壓、高腐蝕性環境中，如石油和天然氣、發電和製藥行業中，經常需要使用這種設備。

To satisfy the requirements of the preceding applications, seamless steel pipes are produced using three different methods which are the Manusman plug mill process, the mandrel mill process, and the extrusion process.

為滿足上述應用要求，無縫鋼管的生產採用了三種不同的方法，即馬努斯曼塞軋機工藝、芯軸軋機工藝和擠壓工藝。

In this video, the Manusman plug mill process is explained.

在這段視頻中，我們將介紹馬努斯曼塞碾工藝。

By this method, seamless steel pipes are produced from a continuously cast billet weighing up to seven tons.

通過這種方法，無縫鋼管是從重達 7 噸的連鑄坯中生產出來的。

Seamless steel pipes with a wide range of diameters and wall thicknesses can be manufactured from these billets.

用這些鋼坯可以生產出各種直徑和壁厚的無縫鋼管。

The production procedure of the hot operation starts with the steel billets being placed in a rotary hearth furnace, where they are heated to a rolling temperature of 1,250 to 1,300 degrees Celsius over up to nine hours.

熱操作的生產程序首先是將鋼坯放入轉底爐，經過長達九個小時的加熱，使其達到 1250 至 1300 攝氏度的軋製溫度。

When exiting from the rotary hearth furnace, the surface of the billet is covered with scales which must be removed by high-pressure water.

從轉底爐出來時，鋼坯表面覆蓋著鱗片，必須用高壓水清除。

The steel billets, brought to rolling temperature, are placed into a round die and transformed into a hollow shell using a vertical 2,000-ton piercing press using a cylindrical mandrel up to 400 millimeters in diameter.

達到軋製溫度的鋼坯被放入圓模中，然後通過使用直徑達 400 毫米的圓柱心軸的 2,000 噸垂直穿孔壓力機將其轉化為空心殼體。

This process, known as upsetting, involves elongating the hollow shell while maintaining nearly the same outer diameter.

這一過程被稱為鐓粗，包括拉長空心殼體，同時保持幾乎相同的外徑。

From the piercing press, the hollow shell goes to the cross-rolling mill.

從穿孔壓力機出來的空心殼體進入交叉軋機。

Initially, the remaining bottom from the piercing press is pierced with a force of about 3,200 kilonewtons.

最初，穿孔壓力機的剩餘底部被約 3 200 千牛頓的力穿孔。

After that, the hollow is inserted into the rolling mill, where it is captured by the rolls in a spiral movement over the mandrel, forming a thick-walled hollow shell.

然後，空心坯料被放入軋機，在軋機中，軋輥在心軸上以螺旋運動捕捉空心坯料，形成厚壁空心殼體。

The cross-rolling mill consists of two specially profiled work rolls driven in the same rotational direction.

橫輥軋機由兩個以相同旋轉方向驅動的特製工作輥組成。

Their axes are inclined by about three degrees against the horizontal rolling axis.

它們的軸與水準滾動軸傾斜約三度。

In the middle of the roll gap is an internal tool, a mandrel supported by a rod against an external abutment.

在輥隙中間有一個內部工具，即一個由杆支撐的心軸，心軸與外部基臺相抵。

The wall thickness of the hollow shell is reduced and equalized, and the outer diameter is adjusted as needed.

空心殼體的壁厚被減小和均衡，外徑則根據需要進行調整。

Material elongation is about 150 to 200 percent, with a cross-sectional reduction of about 33 to 50 percent.

材料伸長率約為 150%至 200%，橫截面縮小約 33%至 50%。

After the rolling process is completed, the scale formed on the surface is blown off with pressurized water.

軋製過程結束後，用加壓水將表面形成的水垢吹掉。

After that, the thick-walled hollow shell is rolled into the final pipe using the pilger mill.

然後，使用皮爾格軋機將厚壁中空殼體軋製成最終管材。

The rolling tools in the pilger process comprise two ring dies and a cylindrical rolling mandrel whose diameter matches the inner diameter of the hollow shell.

皮爾格工藝中的軋製工具包括兩個環形模具和一個圓柱形軋製芯軸，其直徑與空心殼體的內徑相匹配。

The lubricated mandrel is located inside the hollow shell in a fixed position and rotated by the mandrel thrust block.

潤滑心軸位於空心殼體內的固定位置，並通過心軸止推塊旋轉。

The mandrel itself is tapered in the rolling direction.

芯棒本身在軋製方向上呈錐形。

The dies have matching grooves on their circumferences.

模具的圓周上有相匹配的凹槽。

The machine provides the mill's saddles with oscillating motion to generate the ring die's oscillating rotary motion.

該機器為軋機鞍座提供擺動運動，以產生環模的擺動旋轉運動。

During the forward and backward strokes, an external compression force is applied on the shell walls resulting in a reduction of the hollow shell wall thickness in the same way as a rolling pin rolls out pastry.

在前進和後退的過程中，外部壓縮力作用在殼壁上，導致中空殼壁厚度減小，就像擀麵杖擀麵皮一樣。

This process involves at least two passes over each material particle.

這一過程中，每個材料顆粒至少要經過兩道工序。

A large number of small forming passes helps to ensure a constant wall thickness and nearly homogeneous material characteristics in the rolled pipe.

大量的小成型道次有助於確保軋製管材的壁厚恆定和材料特性接近均勻。

This process results in stretching the hollow shell into the with elongation reaching up to 12 times the hollow shell length and a cross-sectional reduction of 80 to 90 percent.

這一工藝的結果是將中空殼體拉伸到中空殼體內，伸長率可達中空殼體長度的 12 倍，橫截面縮小了 80% 至 90%。

After rolling, the finished pipe is removed from the pilger mandrel.

軋製完成後，將成品管從皮爾格芯軸上取下。

The mandrels must be replaced and cooled after each pipe due to the high temperature exposure.

由於暴露在高溫下，每根管道完成後都必須更換和冷卻芯模。

Additionally, for changes in the wall thickness of the final product necessitate the use of new of corresponding diameters.

此外，如果最終產品的壁厚發生變化，就必須使用相應直徑的新材料。

Immediately after the pilger mill, a saw cuts off the remaining hollow shell's end.

在皮爾格磨機之後，立即用鋸子鋸掉剩餘的空殼末端。

Known as the pilger head, it is often unevenly deformed front end of the pipe.

它被稱為皮爾格頭，通常是管道前端的不均勻變形。

After that, the pipe is reheated to a uniform temperature of approximately 900 to 940 degrees Celsius in a natural gas-fired walking beam furnace for further processing.

然後，在天然氣燃燒的步進梁爐中將管材重新加熱到約 900 至 940 攝氏度的均勻溫度，以便進一步加工。

In the stretch-reducing mill, the final outer diameter is produced.

在拉伸減徑軋機中，生產出最終外徑。

This mill consists of three stands in a two-roll arrangement, with the rolls forming a closed caliber and offset by 90 degrees in the rolling direction.

該軋機由三個機架組成，採用雙輥佈置，軋輥形成閉合口徑，在軋製方向上偏移 90 度。

After cooling, the finished pipes go to the straightening stage, where they are straightened on a roll straightening machine.

冷卻後，成品管道進入矯直階段，在輥式矯直機上進行矯直。

Depending on the application, the pilger pipe undergoes additional processing steps or specific inspections.

根據不同的應用，皮爾格管還需要經過其他加工步驟或特定的檢查。

At the cutting stage, pipes are cut to the desired length according to customer specifications.

在切割階段，管道會根據客戶的規格要求切割成所需的長度。

On the cutting bench, the pipes are cut perpendicularly to the pipe axis, achieving a clean, burfree-cut surface.

在切割臺上，管道垂直於管道軸線切割，從而獲得乾淨、無毛刺的切割表面。

All pipes undergo thorough visual inspection here, with minor imperfections being ground out.

在這裡，所有管道都要經過徹底的目視檢查，細小的瑕疵都會被打磨掉。

Here, two surface treatment methods are available.

Machining removes surface defects, especially for medium and high-alloy materials.

機械加工可去除表面缺陷，尤其適用於中高合金材料。

This is done to ensure a flawless surface and does not change the dimensional tolerances.

這樣做是為了確保表面無瑕疵，並且不會改變尺寸公差。

Additionally, pipes are processed by external grinding according to requirements.

此外，還可根據要求對管道進行外部打磨處理。

This involves processing the pipes in an automatic machine with up to seven grinding wheels of different grains and a finishing polish belt.

這包括在一臺自動機器上用多達七個不同顆粒的砂輪和一條拋光帶對管道進行加工。

When required, tubes can be shaped with ends upset according to standards where the pipe's ends are heated to forging temperature with induction heaters and are then upset to the required contour.

如有需要，可根據標準對管材進行端部鐓粗成型，即用感應加熱器將管材端部加熱到鍛造溫度，然後鐓粗成所需的輪廓。

The forging is done by using either a mechanical or a mechanical hydraulic press.

鍛造是通過機械壓力機或機械液壓機完成的。

Moreover, pipe's ends can be threaded with different types of threads as required by the gas and oil industry.

此外，管道兩端還可根據天然氣和石油行業的要求，安裝不同類型的螺紋。

Threading is normally performed using CNC threading machines.

通常使用數控穿孔機進行穿孔。

In some cases, seamless pipes undergo a heat treatment cycle to increase their hardness and strength.

在某些情況下，無縫鋼管需要經過熱處理，以提高硬度和強度。

This is done by heating the pipes to a temperature where their microstructure changes.

具體做法是將管道加熱到微觀結構發生變化的溫度。

This enables the pipe to be hardened by rapid cooling in the quenching process.

這樣就能在淬火過程中通過快速冷卻使管材硬化。

The pipes are then tempered to the desired strength level in a tempering furnace.

然後在回火爐中將鋼管回火至所需的強度水準。

After finishing the pipes, they have to be inspected non-destructively using the electromagnetic test and the pipe ends are then inspected using ultraviolet magnetic particles.

管道完工後，必須使用電磁測試對其進行非破壞性檢查，然後使用紫外線磁粉對管道末端進行檢查。

During the electromagnetic inspection, the wall thickness is measured by phased array ultrasonic method.

在電磁檢測過程中，採用相控陣超音波法測量壁厚。

Moreover, ultrasonic testing is used to check pipes for longitudinal and transverse defects and ensure wall thickness compliance.

此外，超音波檢測還用於檢查管道的縱向和橫向缺陷，並確保壁厚符合要求。

Finally, before shipping to the customer, pipes are individually marked with material grade, order number, and other details to identify the pipe.

最後，在運送給客戶之前，管材會被單獨標記上材料等級、訂單號和其他詳細信息，以便識別管材。

The destination of each pipe is also marked.

Then the pipes are strapped together in bundles and prepared for shipping.

然後將管道捆紮成捆，準備裝運。

Here, the production of seamless pipes is explained.

這裡將對無縫鋼管的生產進行說明。

If you enjoyed this video, please like, subscribe, and share it with others who might find it interesting.

如果您喜歡這段視頻，請點贊、訂閱並與其他可能感興趣的人分享。

Drop a comment below if you have any questions or suggestions for future videos.

如果您對今後的視頻有任何問題或建議，請在下方留言。

Stay tuned for more Industrial Insights, and we'll see you in the next video!

敬請期待更多 "工業洞察"，我們下期視頻再見！