Professional Documents
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Introduction
Tube expansion is the art of reducing tube wall by compressing the OD of the tube against a fix container.
Tube
Tube
Before
Tube sheet
After
Tube
Tube sheet
4. Hydro / Mechanical:
This system makes use of mechanical expander but the self feed of mandrel is replaced by positive hydraulic feed using a separate hydraulic circuit apart from the electric drive used for rotation of mandrel.
When the expansion length for the product is more then the roller length of the tube expander, more than one stage of expansion has to performed. That type of expansion is called as Pilgrim technique of expansion. Cont....
% Thinning calculation
Percentage thinning = (Do - Di) - (d - Di w) 2S Where, Di w = Average tube inside diameter after rolling Di = Average tube inside diameter before rolling Do = Average tube OD before rolling d = Average hole diameter S = Do - Di 2 Percentage thinning shall be in the range of 3-6%
Check on RCBs
Visual examination of tube surfaces Length of rolling on each tube Pull out test for all the tubes. Pull is between 764 - 1530 kg. % thinning between 3 - 6 %
Operator Qualification
The person who are engaged for qualifying machine is automatically qualified for performing on the job. For other 10 nos. tubes hole to be rolled and following is the test required on that. % thinning of that rolled tube within limit. Pull out test on all tube Out of 10 tubes 2 tube ID to be sectioning for scratch free expansion.
Record of expansion
Following record to be kept for expansion of tubes No. of tube rolled (with location R x C) for each shift, day, operator,equipment and settings. Correlation of RCBs with the tube locations, equipment and operator. Melt and heat no. of tube and block. Report of % thinning and surface inspection of 1% tubes in the tube sheet. Pull out test and % thinning results of RCBs Certificate of checking of length of expansion and termination from secondary side . Non conformance list
Cont...
Inspection :
Check all tube end for free from lubricants. Remove all plugs and with ball test check for free passage.