Mismatch Defect in ERW Steel Tubes: September 2014
Mismatch Defect in ERW Steel Tubes: September 2014
Mismatch Defect in ERW Steel Tubes: September 2014
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Mismatch defects in
ERW steel tubes
By Abhishek Bhartim, engineer, Caparo Engineering India Limited and Sitaram Bainsla, intern, Caparo Engineering India Limited
2.2 Over storage in the floop (accumulator) – Over storage 2.5 Position of guide rolls – Arrangement of the guided rolls
in the accumulator is also a cause of slit edge waviness or is required to be correct. If the position of the guided rolls is
camber. In the accumulator the slit is bent in the “U” shape incorrect then un-centred slit can enter in the mill, another
so if the storage in the accumulator is more than desired potential reason for the mismatch defect.
there will be instances of bending or edge waviness. This
camber present in the skelp again leads to the mismatch
defect.
2.3 Work done by the break down passes – The breakdown 2.6 Weld rolls configuration – The configuration of the weld/
passes are the most important rolls in the tube mill. They are squeeze rolls must be appropriate. The pressure applied by
responsible for imparting the initial profile to the skelp. We the squeeze out roll must be the same. If the applied load is
know that for the same diameter (OD) of ERW tubes, more not equal then it can be a reason for the mismatch.
width of the skelp is required in thin gauge tubes than in thick
gauge tubes. Hence, if the same breakdown passes are used
for both kinds of tubes, there will be instances of untouched
and un-worked portions in the skelp, which might further
behave erratically. The problem will be compounded if other
defects such as skelp waviness or unaligned movements are
present.
The term universal chuck also refers to this type. These chucks
are best suited to grip circular or hexagonal cross-sections
when very fast, reasonably accurate (±0.005" [0.125mm] TIR)
centring is desired.
3.1 Variation in the vee length and vee angle – Vee angle is
the angle between slit edges and the squeeze out rolls, and
vee length is distance between weld roll centre line and HF
Skin effect
coil.
(b) Open Seam. When the vee angle is too big, the strip
edges might not get sufficient weld heat. The edges
usually show a blue heat tint suggesting that some heat
was input. However, the edge face remains flat and
smooth, showing no signs of having been molten.
5 References
a. Roll Forming Handbook (edited by George T. Halmos), 2006
b. Common HF welding defects, Robert K Nichols, PE, Thermatool
Corp
c. http://en.wikipedia.org/wiki/Chuck_(engineering)#Self-centering
d. Optimizing Efficiency in HF Tube Welding Processes, John
Wright, Electronic Heating Equipment, Inc
Caparo – India
Number 46, Near Chennai Trade Centre,
Mount Poonamallee Road, Chennai, TN 600089, India
Website: www.caparo.com