Technical Field
[0001] The present invention relates to a method for producing a seamless pipe.
Background Art
[0002] As a method for producing a seamless pipe, the Mannesmann process is known in which
a seamless pipe is obtained by subjecting a heated round billet to piercing-rolling
with a piercing mill, then to elongation rolling with a mandrel mill, a plug mill
or the like, and further to sizing with a sizing mill to yield the seamless pipe.
[0003] The piercing mill is usually a piercing machine having rolling rolls consisting of
a pair of barrel-shaped or cone-shaped main rolls (also referred to as skew rolls),
guide devices such as a guide shoe, disk rolls, a roller-type guide or the like, and
an inner surface regulating tool referred to as a plug.
[0004] Figure 1 is a schematic view illustrating an example of a skew piercing mill using
cone-shaped skew rolls, and Figure 2 is a schematic view taken in the direction of
A-A in Figure 1. Figure 3 is a view schematically illustrating the shape of the plug.
[0005] As shown in Figure 1, in a piercing mill, for example, a pair of main rolls 1 is
disposed to face each other so as for each of the axial centerlines of the rolls to
form a cross angle of γ in relation to the pass line X-X of the round billet B as
a workpiece. Additionally, as shown in Figure 2, one of the main rolls 1 is disposed
to form a feed angle β in relation to the pass line X-X. The other main roll 1 not
shown in Figure 2 is disposed to face the one of the main rolls 1, with the pass line
X-X interposed therebetween, at the feed angle β in relation to the pass line X-X.
The main rolls 1 to exert spiral movement to the round billet B are directly connected
to driving devices 4 respectively, so as to be rotated about the axial centerlines
of the rolls as the rotational centerlines.
[0006] Also, as shown in Figure 2, a pair of disk rolls 2 is disposed to face each other,
across the pass line with a phase shift of 90° from the pair of main rolls 1. The
pair of disk rolls 2 is rotationally driven in the same direction as the traveling
direction of the workpiece at a predetermined speed, to serve an important role in
making the workpiece round in shape through suppressing the increase of the circumferential
length of the workpiece during wall thickness processing.
[0007] A plug 3 has a bombshell-like shape whose base end is supported by the front end
of a mandrel bar M, and the plug 3 and the mandrel bar M are disposed on the pass
line X-X. As the material for the plug 3, Cr-Ni low alloy steels are usually used,
and an oxide layer is formed on the plug by heat pretreatment in order to enhance
the durability.
[0008] For example, as shown in Figure 3, the plug 3 is mainly composed of a rolling section
31, a reeling section 32 and a relief section 33, and has the maximum diameter of
Pd at the boundary between the reeling section 32 and the relief section 33. The rolling
section 31 mainly plays a role of piercing the solid billet, and the reeling section
32 plays a role of equalizing the wall thickness of the hollow shell and at the same
time a role of smoothing the inner surface of the hollow shell. The reeling section
32 has a half angle θp in relation to the axial center of the plug, namely, the pass
line of the round billet (see Figure 5).
[0009] In a piercing mill constituted as described above, the heated round billet B is fed
rightward on the pass line X-X in the figure, and rolled while the round billet is
being subjected to wall thickness processing with the main rolls 1 and the plug 3
during the passage of the round billet through the gap between the skew rolls. In
this case, the round billet B spirally moves on the pass line X-X, and the axial center
portion of the round billet is pierced with the plug 3 to be converted into a hollow
shell.
[0010] During the piercing-rolling with the piercing mill, the asperities formed on the
inner surface of the hollow shell are flattened out by the inner surface regulating
tools in the lower process such as the plug of the elongator, the bar of the mandrel
mill and the plug of a plug mill, and then the asperities develop into wrinkle flaws
(eruption flaws). In other words, the occurrence of the fine inner surface flaws in
final products is attributed to the properties and conditions (roughness) of the inner
surface of the hollow shell after the piercing with a piercing mill.
[0011] In particular, in the seamless steel pipes undergoing high pressures on the inner
surfaces thereof, such as a fuel injection pipe, the occurrence of fine rice-grain-like
flaws could lead to a serious accident through the blowout of the pipe initiated by
such flaws. When the inner diameter of the pipe is large, it is possible to mechanically
remove the inner surface flaws with a grinder or the like, however, when the inner
diameter of the pipe is small, it is difficult to completely remove the inner surface
flaws. Even if the removal of the inner surface flaws of a pipe having a small inner
diameter is possible, the number of work steps is naturally increased, and problems
from the viewpoint of a product may be left unsolved in such a way that the wall thickness
of the flaw-removed portion is thin.
[0012] For the purpose of solving such problems as described above, the present inventor
has disclosed in Patent Document 1 a method for producing a seamless steel pipe by
using a plug where the scale coated layer of the reeling section is made thinner than
that of the rolling section.
Disclosure of the Invention
Problems to be Solved by the Invention
[0014] According to the invention described in Patent Document 1, the occurrence of rice-grain
shaped eruption can be prevented. However, the removal amount of the scale coated
layer is required to be strictly regulated, and when the control of the coated layer
thickness is not performed properly to make the coated layer thickness too thin, problems
such as the scoring of the reeling section and shortening of the tool life of the
plug may arise.
[0015] The present invention takes as its object the provision of a method for producing
a seamless pipe, capable of improving the properties and conditions of the inner surface
of a hollow shell after piercing-rolling and suppressing the wrinkle flaws of a seamless
pipe.
Means for Solving the Problems
[0016] The present inventor made a diligent study in order to solve such problems as described
above, and consequently has discovered the following findings.
[0017] Figure 4 is a schematic view illustrating an example of the piercing-rolling process
in the cross section perpendicular to the pass line. As shown in Figure 4, in the
piercing-rolling, for example, a workpiece 5 is pressed into the space formed by the
pair of main rolls 1 and the plug 3, and thus the workpiece 5 is subjected to the
wall thickness processing. Thereafter, the outer diameter increase is suppressed at
a half-turned position by the disk rolls 2, and the wall thickness processing is conducted
again by the pair of main rolls 1 and the plug 3. By repeating such operations, a
hole is pierced in the workpiece 5 and at the same time, the wall thickness of the
workpiece 5 is controlled.
[0018] Here, the inner surface of the workpiece 5 having reached the region indicated by
"a" in Figure 4 undergoes the action of a contraction force in the circumferential
direction, and thus wrinkles can occur. Subsequently, when the workpiece 5 spirally
moves to reach the region indicated by "b" in Figure 4, the outer surface of the workpiece
is brought into contact with the main rolls 1. At this time, the workpiece 5 undergoes
the outer diameter processing, and hence the inner surface wrinkles formed in the
region "a" are deepened. Subsequently, when the workpiece 5 reaches the region indicated
by "c" in Figure 4, the inner surface of the workpiece 5 is brought into contact with
the plug 3. At this time, the wrinkles are stretched in the circumferential direction
to develop into fine flaws.
[0019] The present inventor investigated the factors degrading the properties and conditions
of the inner surface of workpieces, and consequently has discovered the following
findings with respect to the occurrence of the piercing troubles such as the roughening
of the inner surface of a pipe and the tail clogging of the workpiece (meaning the
condition in which on completion of piercing-rolling, the workpiece is not yet detached
from the main rolls or the plug remains in the bottom portion of the workpiece).
[0020] (a) With the increase of the number of times R
n of the reeling of the plug, the driving force in the direction of the forward movement
of the workpiece is lowered. Consequently, the speed of the workpiece on completion
of the piercing-rolling is decreased and the piercing troubles such as the tail clogging
tends to occur. However, with the increase of Δθ (= θ
p - θ
r, where θ
r: the half angle between the pass line and the main roll face in the condition where
the feed angle of the main rolls is zero, θ
p: the half angle between the pass line and the reeling section of the plug), the rolling
reduction on the exit side of the gorge is increased, and the interfacial pressure
is increased to minimize the piercing trouble. Consequently, the degree of freedom
(mainly, the degree of freedom of the upper limit) of the number of times R
n of the reeling of the plug is increased.
[0021] (b) With the increase of the number of times R
n of the reeling of the plug, the number of times of the rolling applied to the workpiece
is increased, and hence the roughness of the inner surface of the pierced shell tends
to be reduced. Such roughness reduction effect is enhanced with the increase of Δθ
(= θ
p - θ
r). Consequently, the degree of freedom (mainly, the degree of freedom of the lower
limit) of the number of times R
n of the reeling of the plug is increased.
[0022] (c) With the increase of D
2/D
1, the circumferential speed of the roll on the exit side of the gorge is increased,
and hence the outer diameter expansion in the region indicated by "b" in Figure 4
can be suppressed. Consequently, even when the number of times R
n of the reeling of the plug is decreased, it is also possible to prevent the occurrence
of wrinkles, and the degree of freedom (mainly, the degree of freedom of the lower
limit) of the number of times R
n of the reeling of the plug is increased.
[0023] The above-described θ
r means the half angle (see "θ
r" in Figure 5) between the pass line and the main roll face in the condition where
the feed angle of the main roll is zero, and the above-described θ
p means the half angle (see θ
p" in Figure 5) between the pass line and the reeling section of the plug. It is to
be noted that the number of times R
n of the reeling of the plug is obtained from the following formula:

[0024] In this formula, L
p means the length (mm) of the reeling section, d means the value obtained from the
following formula, and β means the feed angle (°) of the main rolls:

where, d
1 is the outer diameter (mm) of the round billet, and d
2 is the outer diameter of the hollow shell.
[0025] The present invention has been achieved on the basis of such findings as described
above, and involves a method for producing a seamless pipe shown in the following
[1] to [4].
[0026] [1] A method for producing a seamless pipe by using a piercing mill which pierces
and rolls a round billet heated to 1300°C or lower, wherein the piercing mill is composed
of:
a pair of skew rolls disposed to face each other across a pass line;
a pair of guide devices disposed to face each other across the pass line; and
a plug disposed along the pass line, between the pair of the skew rolls and also between
the pair of the guide devices,
wherein the piercing-rolling is performed under the conditions satisfying the following
formulas (1) to (3):



wherein the meanings of the individual symbols in the above-described formulas are
as follows:
θr: The half angle (°) between the pass line and the main roll face in the condition
of the feed angle of the main rolls being zero
θp: The half angle (°) between the pass line and the reeling section of the plug
Rn: The number of times of the reeling of the plug
[0027] [2] A method for producing a seamless pipe by using a piercing mill which pierces
and rolls a round billet heated to 1300°C or lower, wherein the piercing mill is composed
of:
a pair of skew rolls disposed to face each other across a pass line;
a pair of guide devices disposed to face each other across the pass line; and
a plug disposed along the pass line, between the pair of the skew rolls and also between
the pair of the guide devices,
wherein the piercing-rolling is performed under the conditions satisfying the following
formulas (1), (2) and (4):



wherein the meanings of the individual symbols in the above-described formulas are
as follows:
θr: The half angle (°) between the pass line and the main roll face in the condition
of the feed angle of the main rolls being zero
θp: The half angle (°) between the pass line and the reeling section of the plug
Rn: The number of times of the reeling of the plug
[0028] [3] The method for producing a seamless pipe according to [1] or [2], wherein the
piercing-rolling is performed under the conditions further satisfying the following
formula (5):

wherein the meanings of the individual symbols in the above-described formula are
as follows:
D1: The roll diameter (mm) in the gorge portion of the main rolls
D2: The main roll outer diameter (mm) at the position of the maximum-diameter portion
of the plug
Rn: The number of times of the reeling of the plug
[0029] [4] The method for producing a seamless pipe according to [1] or [2], wherein the
piercing-rolling is performed under the conditions further satisfying the following
formula (6):

wherein the meanings of the individual symbols in the above-described formula are
as follows:
D1: The roll diameter (mm) in the gorge portion of the main rolls
D2: The main roll outer diameter (mm) at the position of the maximum-diameter portion
of the plug
Rn: The number of times of the reeling of the plug
[0030] In the present invention, the reeling section means the part satisfying any one of
the following conditions:
- (A) The part in which the wall thickness working ratio obtained from the following
formula is 5% or less:

wherein the meanings of the individual symbols in the formula are as follows:
G1: The distance (mm) between the plug and the roll at the starting position in the
corresponding part of the plug
G2: The distance (mm) between the plug and the roll at the completion position in the
corresponding part of the plug
- (B) The part, in the vicinity of the entrance side, of the maximum-diameter portion
of the plug
- (C) The part in which the face angle difference obtained from the following formula
is 2° or less when the section corresponding to the reeling section has no curvature:

wherein "the starting position in the corresponding part of the plug" means, for example,
the position of the border line between the sections indicated by reference numerals
31 and 32 in Figure 3, and "the completion position in the corresponding part of the
plug" means, for example, the position of the border line between the sections indicated
by reference numerals 32 and 33 in Figure 3.
Advantages of the Invention
[0031] According to the present invention, the properties and conditions of the inner surface
of a hollow shell after piercing-rolling can be improved, and the wrinkle flaws in
a seamless pipe which is obtained by performing elongation rolling and sizing after
piercing-rolling can be prevented.
Brief Description of the Drawings
[0032]
Figure 1 is a schematic view illustrating an example of a skew piercing mill using
cone-shaped skew rolls;
Figure 2 is a schematic view showing a view taken in the direction of A-A in Figure
1;
Figure 3 is a view schematically illustrating the shape of a plug;
Figure 4 is a schematic view illustrating an example of a piercing-rolling process
in a cross section perpendicular to a pass line;
Figure 5 is a schematic view illustrating main rolls and the plug under the conditions
that the feed angle β is zero;
Figure 6 is a graph showing the relation between Δθ and Rn; and
Figure 7 is a graph showing the relation between D2/D1 and Rn.
Description of Symbols
[0033]
- 1
- Main roll
- 2
- Disk roll
- 3
- Plug
- 31
- Rolling section
- 32
- Reeling section
- 33
- Relief section
- 4
- Driving device
- 5
- Workpiece
- B
- Round billet
Best Mode for Carrying Out the Invention
[0034] Existing piercing mills can be employed in the method for producing seamless steel
pipes according to the present invention. In other words, a piercing mill can be used
in which a plug is disposed along a pass line, between a pair of skew rolls and also
between a pair of guide devices, the members in each of these pairs being disposed
to face each other across the pass line, and which has usual guide devices such as
guide shoes, disk rolls or roller-type guides. The shape of the plug is also not particularly
limited. For example, there can be used a plug having a structure which consists of
the rolling section 31, the reeling section 32 and the relief section 33 as shown
in Figure 3 and which has a maximum diameter at the boundary between the reeling section
32 and the relief section 33.
[0035] It is preferable to use disk rolls as the guide device because the disk rolls can
increase the speed of the material in the axial direction. It is also preferable to
use cone-shaped rolls as the main rolls.
[0036] The round billet to be subjected to piercing-rolling is required to be heated to
1300°C or lower. When the temperature of the round billet exceeds 1300°C, inner surface
flaws occur due to the melting of the inner surface of the round billet to degrade
the properties and conditions of the inner surface of the pipe. On the other hand,
the resistance to deformation of the round billet becomes greater with the considerable
decrease of the temperature to make it impossible to perform piercing-rolling or remarkably
shorten the operating lives of the plug and other production facilities. Therefore,
it is preferable to set the temperature of the round billet at 1150°C or higher.
[0037] Here, Δθ defined by the following formula (a) is required to be set at - 1.0 or more:

wherein the meanings of the individual symbols in the above-described formula are
as follows:
θr: The half angle (°) between the pass line and the main roll face in the condition
of the feed angle of the main rolls being zero
θp: The half angle (°) between the pass line and the reeling section of the plug
[0038] Specifically, the inner surface of the hollow shell after piercing-rolling is smoothed
by increasing the number of times R
n of the reeling of the plug; however, depending on the value of the plug face angle
θ
p relative to that of the exit-side face angle θ
r of the main rolls" some problems may occur including the insufficient smoothness
and the failures such as the tail clogging and the unevenness of the wall thickness.
This tendency is enhanced with the decrease of the above-described Δθ, and when Δθ
is less than -1.0, even the increase of the number of times R
n of the reeling of the plug fails in smoothing the inner surface of the hollow shell
after piercing-rolling. Therefore, Δθ is set at -1.0 or more.
[0039] When the number of times R
n of the reeling of the plug is too small, the surface roughness of the inner surface
of the hollow shell after piercing-rolling is high, and when the number of times R
n of the reeling of the plug is too large, the problem of the tail clogging tends to
occur. However, with the increase of Δθ, all these problems hardly occur. This is
because the increase of Δθ pushes up the rolling reduction at the exit side of the
gorge, and hence the interfacial pressure is increased to minimize the piercing trouble.
In other words, the processing with the reeling section can be concentrated in the
second half of the operation, and hence even with the same number of times of the
reeling of the plug, a hollow shell satisfactory in the properties and conditions
of the inner surface can be obtained. Accordingly, the number of times R
n of the reeling of the plug is required to satisfy the relation represented by the
following formula (b) in terms of Δθ. More preferable is the case where the following
formula (b1) is satisfied:

[0040] The number of times R
n of the reeling of the plug preferably further satisfies the following formula (c).
More preferable is the case where the following formula (d) is satisfied:

wherein the meanings of the individual symbols in the above-described formulas are
as follows:
D1: The roll diameter (mm) in the gorge portion of the main rolls
D2: The main roll outer diameter (mm) at the position of the maximum-diameter portion
of the plug
[0041] The inner surface roughness of the hollow shell after piercing-rolling tends to be
affected by the roll diameter at the position on the exit side of the main rolls.
When the main roll outer diameter D
1 at the maximum diameter position of the plug is set to be larger than the gorge portion
diameter D
2 of the main rolls, the compressive strain in the circumferential direction acting
on the inner surface of the workpiece tends to be relaxed, and consequently the suppression
of the wrinkles on the inner surface of the pipe is facilitated. As described above,
the small Δθ value make it difficult to smooth the inner surface of the pipe, however,
by setting the relation between D
2/D
1 and R
n so as to satisfy the conditions represented by the above-described formula (c), the
surface roughness of the inner surface of the pipe can be improved. The surface roughness
of the inner surface of the pipe is further improved by setting the relation between
D
2/D
1 and R
n so as to satisfy the above-described formula (d).
[0042] The method for producing a seamless pipe according to the present invention can be
applied to any pipes such as metal pipes, ordinary steel pipes, low-alloy steel pipes
and high-alloy steel pipes, and is particularly suitable for steel pipes with smooth
inner surfaces which are used for automobile components.
Example 1
[0043] A slab produced by continuous casting from the steel having the chemical composition
shown in Table 1 was subjected to blooming and finished into a round billet of 225φ,
and from the central portion of the round billet, a round billet of 70φ was machined
to prepare a sample material. As the guide device, disk rolls were used; the main
roll shape and the plug shape were varied, and thus piercing-rolling was performed
under the production conditions shown in Table 2 or 3; and the inner surface roughness
(the maximum height Rz defined by JIS-0601) of each of the obtained hollow shells
was measured.
[0044] [Table 1]
Table 1
Chemical composition of the sample material
(in mass%, balance: Fe and impurities) |
C |
Si |
Mn |
P |
S |
Ca |
Nb |
0.20 |
0.35 |
1.35 |
0.012 |
0.01 |
0.001 |
0.04 |
[0045] [Table 2]
Table 2
Heating temperature |
1180°C - 1240°C |
Feed angle β |
7° - 16° |
Gorge diameter D1 of the main rolls |
350φ - 410φ mm |
Exit-side face angle θr of the main rolls |
3°-5.5° |
Roll diameter ratio D2/D1 |
0.9 - 1.3 |
Δθ = θp - θr |
-0.25° - 1.0° |
Hollow shell outer diameter |
70.0 - 75.0 mm |
Hollow shell wall thickness |
4.6 - 10.1 mm |
[0046] [Table 3]
Table 3
Heating temperature |
1180°C - 1240°C |
Feed angle β |
7° - 16° |
Gorge diameter D1 of the main rolls |
350φ - 410φ mm |
Exit-side face angle θr of the main rolls |
3°-5.5° |
Roll diameter ratio D2/D1 |
0.95 - 1.15 |
Δθ= θp - θr |
-1.5° - 1.25° |
Hollow shell outer diameter |
70.0 - 75.0 mm |
Hollow shell wall thickness |
4.6 - 10.1 mm |
[0047] Figure 6 shows the properties and conditions of the inner surface of the hollow shell
produced under the conditions shown in Table 2 with respect to Δθ and R
n, and Figure 7 shows the properties and conditions of the inner surface of the hollow
shell produced under the conditions shown in Table 3 with respect to D
2/D
1 and R
n.
[0048] In Figures 6 and 7, ▲,△ and ○ mean that the inner surface roughness of the hollow
shell is such that Rz > 150 µmm, 100 µmm ≤ Rz ≤ 150 µmm, and Rz < 100 µmm, respectively.
In Figure 6, × means that piercing troubles such as the tail clogging occurred.
[0049] As shown in Figure 6, in the region where Δθ was less than -1.0, the inner surface
roughness Rz of the hollow shell exceeded 150 µmm or piercing trouble occurred. Although
Δθ was -1.0, in the region where R
n exceeded "0.37 × Δθ + 2.67," piercing trouble occurred, and in the region where R
n was less than "-0.37 × Δθ + 1.47," the surface roughness Rz was increased. When the
production conditions were regulated in such a way that R
n fell in the region equal to or larger than "-0.24 × Δθ + 1.73," the surface roughness
Rz was able to be made smaller.
[0050] As shown in Figure 7, in the region where R
n was less than "-1.37 × D
2/D
1 + 2.74," the surface roughness was increased, and in the region where R
n was equal to or larger than "-1.37 × D
2/D
1 + 2.74," the surface roughness was within a satisfactory range. In the region where
R
n was equal to or larger than "-1.25 × D
2/D
1 + 2.88," the surface roughness was able to be further decreased.
Example 2
[0051] A continuous cast material having the chemical composition shown in Table 1 was converted
into round billets of φ191 by blooming, then each of the round billets was subjected
to piercing-rolling under the conditions shown in Table 4 and from each of the round
billets, 100 seamless steel pipes of φ73 in outer diameter and t5.51 in wall thickness
were produced, and the properties and conditions of the inner surface of the obtained
seamless steel pipes were investigated. The results thus obtained are shown in Table
5.
[0052] [Table 4]
Table 4
Heating temperature |
1240°C |
Feed angle β |
6° - 16° |
Gorge diameter D1 of the main rolls |
1400φ mm |
Exit-side face angle θr of the main rolls |
3° - 4° |
Roll diameter ratio D2/D1 |
1.05 - 1.15 |
Δθ = θp - θr |
-1.5°-1.25° |
Number of times Rn of reeling of the plug |
0.8 - 3.5 |
[0053]

[0054] As shown in Table 5, the rates of occurrence of the inner surface flaws were able
to be remarkably reduced in Examples of the present invention compared to those in
Comparative Examples.
Industrial Applicability
[0055] According to the present invention, the properties and conditions of the inner surface
of a hollow shell after piercing-rolling can be improved, and the wrinkle flaws in
a seamless pipe which is obtained by performing elongation rolling and sizing after
piercing-rolling can be prevented.