Edge Wave and Instability During Tube Forming
Every tube defect starts at the forming section. Edge wave, strip camber and uneven bending force the strip into the weld off-center, producing oval, wavy or split tube. Mills that cannot feed flat, stable strip waste material on every coil change.
Why Forming Produces Edge Wave
Strip that enters the forming section with coil-set or camber bends unevenly, and a single-radius pass concentrates deformation at the edge. Without progressive shaping across rough and finish stands, the edge buckles before welding and the seam arrives misaligned.
The ZY20 Roll Forming Tube Mill Solution
A 7-roll precision leveler removes coil-set and feeds the strip flat, creating a stable start for every pass.
Double-radius pass design on a bottom-line horizontal roller basis shapes the strip gently, while 5-stand rough plus 3-stand finish forming complete the round progressively without edge wave.
Overload-protected horizontal stands and 42CrMo hardened shafts keep the pass stable, so the strip reaches the weld centered and ready for full fusion.
Technical Specifications of the ZY20 Tube Mill
| Parameter | Specification |
|---|
| Tube outside diameter | φ10–26 mm |
| Wall thickness | 0.4–1.5 mm |
| Rated production speed | up to 90 m/min |
| Raw material | HR / CR low-carbon steel, galvanized steel |
| HF welder power | 100 kW solid-state |
| Forming stands | 5 rough + 3 finish |
| Sizing stands | 6 horizontal + 6 vertical |
| Leveling rolls | 7-roll precision leveler |
| Cut length / precision | 4–8 m, ±3 mm |
| Coolant flow | ≥10 t/h spray + overflow pool |
| Roll shaft material | 42CrMo quenched & tempered + HF hardened |
Complete Continuous Production Process
Every ZY20 runs one continuous flow from coil to finished cut tube. An uncoiler feeds strip through a 7-roll precision leveler that removes coil-set, then double-radius forming shapes it in 5 rough and 3 finish stands without edge wave. A 100 kW solid-state HF welder fuses the seam under squeeze pressure with a dedicated seam guide, and an automatic outside-burr unit clears the bead immediately. ≥10 t/h spray plus overflow-pool cooling locks the shape, the 6-horizontal + 6-vertical sizing train sets the diameter, and a 4-roll Turk head straightens the tube before the microcomputer flying saw cuts 4–8m lengths to ±3mm. Overload-protected stands and 42CrMo hardened shafts keep the whole line stable over long runs.
Where the ZY20 Roll Forming Tube Mill Is Applied
Precision, furniture and structural tube where stable forming and flat strip entry determine weld quality and final roundness.
How to Select a Roll Forming Tube Mill
Check the leveler roll count and pass design first — the ZY20 uses 7-roll leveling and double-radius forming. Match OD and wall to φ10-26mm / 0.4-1.5mm, and confirm stand configuration for your profile.
Installation, Support and After-Sales
The ZY20 ships as a turnkey package with layout and foundation drawings so you can prepare the site before delivery. Engineer-led on-site installation and commissioning bring the line to rated output, with operator training to hand over a running mill. A one-year warranty with spare-parts support protects the investment, and because the line accepts HR, CR and galvanized coil, you can adapt to changing material costs and market demand without re-tooling.
Frequently Asked Questions About the ZY20 Roll Forming Tube Mill
How does the ZY20 prevent edge wave?
A 7-roll leveler plus double-radius pass and 5+3 stand forming shape the strip progressively.
What is the forming stand layout?
5 rough stands + 3 finish stands complete the round in controlled stages.
Why double-radius passes?
They distribute bending across the strip instead of concentrating it at the edge.
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