Pipe production varies depending on the material of manufacture, the intended purpose of the product, diameter, profile, method of connection and other technological factors. Consider the features of the release of these products and their brief characteristics.
Classification
Steel products are classified as obsolete pipes for equipping water supply and other systems. They are susceptible to corrosion and therefore require a protective coating. Zinc is often used as it, which affects the increase in the price of products.
Cast iron analogues are more resistant to rust, but not as durable. They are distinguished by their large mass and require special reliable fastening during installation. Of these structures, water, heating and sewer systems are equipped.
Plastic pipes have become very popular. The combination of metal and plastic allows to achieve excellent quality indicators. To make a water supply system from such elements is not at all difficult. The disadvantages of products include poor thermal stability and the possibility of leaks at the docking sites.
Plastic pipes include several types of polymer products. These include: low / high pressure polyethylene (HDPE, LDPE) and crosslinked polymer modifications. They have a small mass, durable, resistant to corrosion. Between themselves, the species differ in characteristics and properties, however, they have a common production technology.
Copper pipes are the most expensive option. The material is characterized by high technical parameters, resistance to moisture, temperature extremes. Due to their appearance, such products can become a real decoration of the interior.
Profile pipe production
We begin the review with the features of the production of the products in question by cold deformation. Equipment for manufacturing is a compact machine consisting of a set of rollers through which a pipe is passed. Such devices differ in power and throughput. On the most powerful units, it is possible to produce pipes not only welded, but also seamless.
On devices for the production of profile modifications, predominantly non-responsible products are manufactured. Such designs are suitable for the furniture industry, as well as the production of decorative elements. The materials under consideration are in demand at various enterprises, but are not suitable for installation where an increased reliability indicator is required.
Full technological cycle
The pipe production line using this technology is based on the use of special sheet metal in rolls (strip). It is supplied directly from metallurgical plants. The thickness of the workpieces may vary, which makes it possible to produce structures of the necessary reliability for various purposes.
Since the strip is larger than the width required in the first step, it is cut into pieces of the desired size. The material is processed on a special slitting machine. The output is a tape with a width of 50 millimeters, which are welded into one continuous element.
The resulting workpiece is wound on a drum, which ensures the continuity of the process. The tape is fed to a molding mill equipped with several tanks in which the creation of a circular endless part is performed. At this stage, cold steel without heating is predominantly used.
The main stages of manufacturing a shaped pipe
The above manipulations lead to the formation of a workpiece with an open seam. The pipe is passed through a welding unit in which welding is performed using high-frequency currents. During the process, the edges of the product are compressed by rollers, and the melt is extruded from the inner and outer parts. The resulting burr is removed immediately with a cutter.
Further production of pipes using this technology involves cooling the workpiece by exposure to a special emulsion solution. Profiling a part includes the following steps:
- Processing of the pipe on the rollers, which allows to achieve the same cross section along the entire length of the structure.
- Next, the pipe from four positions is processed by other rollers, after which the finished profile product with a square or round cross section is obtained.
- To obtain an oval design, additional finishing on the second rollers is not required.
At the finishing stage, profile blanks are cut to the specified dimensions with the desired profile.
Quality control
Finished products undergo the final control procedure. There are two main parameters for the analysis:
- A visual inspection is carried out by a specialist, which makes it possible to detect defects caused by wear of the rollers or their failure.
- Inspection by a flaw detector. It allows you to identify possible problems in the finished product, not visible to the eye.
In order to level the internal stresses that appear in the steel after deformation, the finished pipes at all stages of manufacture must be heated and then naturally cooled in air.
Plastic pipe production
Products from this material are used in the industrial sector and in the private sector. In the manufacture of polyethylene elements, special machines are used - extruders. They are divided into disk, screw and combined models. Most often in the production of pipes, screw devices of various designs are used. In such an extruder, the main part is the screw. The principle of operation of the machine can be compared with the functionality of a mechanical meat grinder. Units can be equipped with one or several working elements.
Disk counterparts are divided into single or multi-disk modifications. The extruder works by moving raw materials with special elements that provide adhesion. The main advantage of this machine is its good mixing of polymer granules. The disadvantages include low pressure in the working area, which makes it impossible to obtain products with high reliability parameters and the correct geometric shape.
Combined (worm-disk) extruders include models equipped with both nodes. Used in the processing of polymers with reduced elasticity and viscosity.
Equipment
The plastic pipe production line includes the following elements:
- Extruder
- Automatic feed hopper for plastic granules.
- Dryer.
- Automated production stage controller.
- Dies of removable type.
- Pulling device.
- Vacuum moulder and calibrator.
- Automatic cooling system with water bath.
- Conveyor belt.
- Cutting device with a cutter.
- Device for automatic stacking of the finished product.
Technology
HDPE pipe production involves the use of extrusion (ejection) technology. It consists in homogenization, controlled softening and plasticization of the feed in the extruder. Next, the formation of the finished product using a die, subsequent cooling and final calibration are performed.
Any polymer pipe factory is equipped with an extruder receiving hopper. Granular raw materials are loaded into it. Then the polymer enters the working cylinder equipped with heating elements. Granules from the loading area are moved to the hotter compartments of the tank, the raw materials are melted, homogenized, and the melt is fed to the forming head (die).
Final stages
The working head determines the shape of the finished product and its quality characteristics. A technological feature is that when the melt is fed, the die has a fixed temperature value.
Depending on the designs of the heads, heating elements of a flat or cartridge type are used. Bypassing the external matrix and the shaping mandrel, the pipe takes the form of a finished product. During the calibration process, the part enters the vacuum bath, where the final formation takes place. This is done by pressure, which presses the workpiece against the calibration tool. Then the products are cooled and fed to a conveyor equipped with pneumatic track clamps. At the finishing stage of the production of polypropylene pipes, standard cutting is performed using cutters or a circular saw.
Own manufacture
Having decided to establish a private line for the production of plastic pipes, first of all, it is necessary to consider what the level of product quality will be. If the products are aimed at furniture companies and small construction companies, a compact machine is quite suitable, which provides output for accessories, fences, fences and other non-essential structures.
To organize a line for the production of polymer elements, the necessary set of devices is presented above. The following is a list of equipment for the production of profile pipes from round analogues:
- Installation for profile bending.
- A line for producing blanks from round pipes.
- Automated welding unit.
- Device for cutting finished products.
Consumer Reviews
Users note the strength and reliability of modern pipes if they are manufactured by a bona fide manufacturer. The advantages of profile steel products include high strength, designed for special operating conditions, as well as the reliability of the joints. Among the minuses are high weight, complexity of processing and transportation, and susceptibility to corrosion.
Plastic analogues delight users with their low weight, flexibility, wide scope, environmental friendliness. Among the disadvantages of such pipes is the susceptibility to deformation from heating or mechanical stress.