Technical Tips for the Tube and Pipe Industry E-Newsletter: January 2012

January 26, 2012 by

This issue includes the following articles:

Setting Up the Fin Section

The primary job of the fin section on any tube or pipe mill is to prepare the edges of the strip (parallel) for welding, and set the body of the tube. The only way this will take place, is if we properly set (work) each and every driven and side pass station in the fin section as per the tooling design and set up chart.

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Symptoms:

We are using hot rolled coils for steel pipe manufacturing. The hot rolled coils are slitted depending upon the pipe diameter and the helix angle calculation. We often encounter edge-like cracking up to 25 mm at slitted edges of hot rolled coils. Edge splitting of slitted coils was also observed.
 
The slitting problem was encountered in hot rolled coils when these are sent for slitting. Edge-like cracking was observed at slitted coils’ edges before welding.
 
Kindly advise what could be the real cause of edge splitting and what remedial measures can be taken?

Medicine:

Normally hot roll product is very easy to slit, and results in very few difficulties, especially in regard to cracking.
 
The first thing to check would be the chemistry of the material itself.
 
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Fabtech Canada 2012 to Include Presentation by Roll-Kraft Vice President of Tube Mill Engineering

January 18, 2012 by

MENTOR, OH – January 2012

Roll-Kraft’s Vice President of Tube Mill Engineering, Robert A. Sladky, will be presenting, “Tube and Pipe Mill Set Up” on Wednesday, March 21st from 10:15AM—12:15PM at Fabtech’s first conference in Canada – Fabtech Canada 2012. The conference will be held March 20-22, 2012 at the Toronto Congress Centre in Toronto, Ontario, Canada.

This presentation is tailored to address and strengthen the “weak links” in the mill operations in regard to proper tube and pipe mill set up.  Problems and solutions will be outlined throughout the presentation in the major sections of forming, welding and sizing sections.

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Roll Forming Equipment and Processes Aid in Response to Growth

December 7, 2011 by

Roll forming equipment and processes have been one of the keys to GRD’s ability to growth over the past few decades. Advances in the roll forming industry prompted the Suwanee Operations team to investigate these changes and pursue the latest technology in the industry. In October of 2010, a decision was made to partner with Roll-Kraft Inc. in Mentor, Ohio to build a new roll forming line for Suwanee Operations. The reasons behind this decision included:

  • Increased production capacity
  • Backup to existing processes
  • Lower cost production tooling

One of the advances in the roll forming industry that allows for lowering the overall tooling cost is the use of “rafted tooling.” Traditionally, a roll form line was built to produce only one part-profile. By mounting the roll tooling on moveable plates or “rafts,” the roll form line is more like a powered punch press with changeable dies. This tooling concept allows the same line to produce multiple parts on the same base with a quick tool change. The new line in Suwanee was tooled for VCS3 frames, VCS3 blades and 530/630 return blades. The changeover time on this line is expected to be 45 minutes or less to switch from one part-profile to another.

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New Trend in Tube and Pipe and Roll Forming Seminars: Plant Consolidation

December 5, 2011 by

MENTOR, OH – December 2011

Roll-Kraft, a leading producer of tooling for the tube & pipe and roll forming industries conducts numerous tube and pipe training seminars and roll forming training seminars throughout the country. Recently, it has seen a new trend emerge as companies look to decrease training costs and improve efficiencies.

According to Robert Sladky, Vice President of Tube Mill Engineering, and Bret Molnar, Senior Technical Advisor for Roll-Kraft, “We are seeing a new trend in conducting seminars. More firms with multiple plants are consolidating their training programs and combining the attendees from multiple plants for their in-house seminars.”

This not only expedites the training of entire teams of personnel, but saves the costs involved in having individual seminars for each plant. It is by far the most efficient plan for these companies.

Such was the case recently for two of Roll-Kraft’s major tube & pipe customers in the East, and in the South. Each customer has multiple plants running smaller mechanical tube mills, as well as larger pipe mills. Management from each location got together and scheduled back-to-back weeks of programs at key locations, which allowed them to split up the attendees from their various plants and still keep production running on their mills.

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Roll-Kraft’s Fabtech 2011 Tube and Pipe Presentation More Than Doubles Previous Attendance

November 22, 2011 by

Summary:

The Roll-Kraft presentation at this year’s Fabtech Technical Conference, entitled, “Tube and Pipe Mill Setup, Tooling Design Evaluation, and Problems and Solutions” drew more than double the attendance of previous years.

MENTOR, OH -  November, 2011

Roll-Kraft’s Robert A. Sladky, Vice President of Tube Mill Engineering and Bret Molnar, Senior Technical Advisor presented, “Tube and Pipe Mill Setup, Tooling Design Evaluation, and Problems and Solutions,” at Fabtech’s Technical Conferences recently held in Chicago. 

This year’s attendance was more than double the previous years of the conferences.  The Technical Conferences are held in conjunction with the annual Fabtech Trade Shows and offer concise, focused learning opportunities for attendees.

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Nebraska Regional Seminar Exceeds Attendees Expectations

November 9, 2011 by

Requested by 75% of Roll-Kraft’s Nebraska customer base, Roll-Kraft organized and conducted a regional seminar on October 27th in Waverly, Nebraska.

    

In addition to customers from Nebraska, many others from surrounding states also attended the program.

The program was presented Robert A. Sladky, Vice President of Tube Mill Engineering.

Below is a sampling of some of the comments from the course attendees:

  • Five months into my job here, it was a great amount of pertinent data. I also think it’s a great refresher training for more experienced operators.
  • It gave me a better understanding of operation and maintenance.
  • Very thorough and informative. Would be beneficial for all mill employees, not just operators.
  • I realized the importance of standards for setup and operation. Maintaining tooling is vital.
  • Being new to welding, this technical information has jump-started my education in this field and gave me several ideas of projects to implement to improve this department. I now have a better understanding of this information and am confident in the reasoning behind the science.

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Roll-Kraft Upgrades Software

November 3, 2011 by

MENTOR, OH – October, 2011

Roll-Kraft has recently upgraded its tube and pipe design and roll forming design software used in engineering custom-made tube and pipe tooling and roll forming tooling. This upgrade will now allow the software to design the bearingless floating flange within the program. The improvement will immediately reduce engineering time by close to 50%. The program will draw up each piece of the bearingless floating flange and produce an assembly drawing. The result will be shorter manufacturing times for the programmers and standardization of the various processes.

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Roll-Kraft Ltd. Adds to Sales Team

October 28, 2011 by

MENTOR, OH – October, 2011

Roll-Kraft, a leading producer of tube and pipe tooling and roll forming tooling, is pleased to announce the addition of Juergen Hack to the staff at Roll-Kraft Ltd. in Ontario, Canada as an Account Manager. Mr. Hack comes to Roll-Kraft from ECO Solutions FT, Inc. His experience there was as Technical Business Development Manager, opening up markets across Canada and in the U.S. through direct sales and agent and distribution networks.

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Roll-Kraft Staffer Named to Fabricators & Manufacturers Association’s Young Professional Council

October 26, 2011 by

MENTOR, OH – October, 2011

Roll-Kraft is pleased to announce that Patrick J. Hopkins has been selected to be a part of the Young Professional Council. This is a group sponsored by the Fabricators & Manufacturers Association (FMA). Their mission is to identify, create, and establish mentoring and networking opportunities to reach potential entrepreneurs, business owners, and those interested in a manufacturing career.

The group provides speakers for manufacturing conferences, local schools, and various other opportunities, to enumerate the advantages and benefits of being involved in the manufacturing community. Often, the group works directly with school guidance counselors to answer questions and challenge America’s youth to investigate the field of manufacturing. Their effort is to dispel the old stereotypes of dirty and dangerous factory workplaces, and expose them to the updated, modern factory floor, with automated systems, and clean working conditions. There are many advantages in pursuing a career in manufacturing these days.

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Roll-Kraft Northern Makes Maintaining Our Tooling Inventory Easier

October 25, 2011 by

To whom it may concern,

Over the past year, I have had the opportunity to obtain the services of Roll-Kraft Northern. I am happy to supply them this testimonial.

Being new to the roll-forming industry, I began my relationship with them with limited knowledge of roll tooling. With the help of Dan Ruiz, the Sales staff, Engineering personnel, and all others involved I have been able to maintain our tooling inventory with relative ease. My ultimate responsibility here is making sure we have quality tooling available to manufacture a quality product. The services I’ve received through quality regrinds, low lead times, and on time deliveries has been exceptional, making this possible.

I would also like to recognize Roll-Kraft, as an entity, for being there as support in troubleshooting some of the issues we may have had on our tube mills other than tooling.

I appreciate Dan Ruiz keeping in touch with me on a regular basis to make sure Roll-Kraft Northern is satisfying our needs and look forward continuing our business relationship for years to come.

Sincerely,
Ron Perttu, Tooling Technician
Tectron Tube
DePere, WI


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