Pipe Mills is essential to the fabricating of piping and pipelines. Pipe Mills consists of two machines: the roller mill and the bending machine. Roller Mills is using to manufacture pipes of any possible configuration, whether using spiral or linear types. And, on the other hand, the bending machines are used to manufacture pipes and other forms of cables.
Pipe Mills in a general run includes two separate machines: the casting or press mill and the welding or die cutting machine. Pipe casting is done on a large scale at the industrial plant while die cutting is done in smaller scale in the factories. In both the cases, production is centralized and automation is key. Pipe Mills makes use of different kinds of equipment such as rollers, cutters, press brakes and hydraulic presses. However, with the advent of computer software, automation has become more efficient. This results in considerable cost savings and hence, in turn, increases profitability.
Preventive Maintenance A preventive maintenance program for pipe mills must include both machine-driven as well as machine-assisted maintenance procedures. Both have their own advantages and disadvantages. Machine-driven methods are generally characterized by a high level of operator involvement. This results in less preventive maintenance effort and in the long term, it may result in increased machine downtime. On the other hand, machine-assisted methods help reduce operator workload and allow timely detection of potential problems, which in turn can help solve them before they result in costly failures.
There are a number of measures that help in improving machine efficiency. For instance, pre-tension springs and dampers are generally used for maintaining smooth pipe runs. Sustained tensions help reduce friction and heat buildup. Another measure is the use of baffles, which direct trapped air into certain areas of the tube mills. Air turbulence is known to improve pump performance. Lastly, preventing lubrication of the moving parts of the mill by means of oil-water separators is another measure adopted by pipe mill operators.
Welded Tube Milling A major advantage of tube mills is that they are able to fabricate pipes from diverse varieties of materials. However, despite their flexibility, tube mills need regular attention and upkeep to ensure efficiency. Cleaning the inlet and outlet of the machines is one of the most important tasks. Cleaning the inlet and outlet is also essential for ensuring that welds are consistent.
Ultrasonic Welding Pipe Milling: The use of ultrasonic welding has increased over the years. It has now become widely accepted at all stages of manufacturing, including pipe making and pipe welding. The process involves the heating of an arc (a strong electric current) to melt the welding rods and metals, and then the high frequency sound waves generated by the vibrating irons hits the metals, which creates a heat weld. The high frequency of the irons used in the process results in faster and more consistent welds, which is why this method is now commonly used for welding tubes.