The roundness of the reducer should not exceed 1% of the outer diameter at the corresponding end, with an allowable deviation of ±3 mm. The materials used for the reducer include SY/T5037, GB/T9711, GB/T8163, ASTM A106/A53 GRB, API 5L, API 5CT, ASTM A105, ASTM A234, ASTM A106, DIN standards, and can also be customized based on customer requirements.
A reducer, also known as a size head, is a type of pipe used to change the diameter of a pipeline. It is typically manufactured using methods such as reduction pressing, diameter expansion pressing, or a combination of both. For specific sizes and configurations, press forming may also be applied depending on the design and material properties.
Reduced Diameter / Expanded Diameter Forming
The reduced diameter forming process involves placing a tube blank with the same diameter as the larger end of the reducer into a forming mold. The metal is then pressed axially, causing it to flow along the cavity and shrink in diameter to form the desired shape. Depending on the size of the reducer, this process may involve one pressing operation or multiple steps. The image below illustrates the reduced diameter forming of a concentric reducer.
For expanded diameter forming, a tube blank with a smaller diameter than the large end of the reducer is used. The inner diameter of the blank is expanded using an internal die to achieve the required size. This method is particularly useful when the reduction ratio is too high to be achieved through simple diameter reduction. In some cases, a combination of expansion and reduction techniques is employed based on material properties and product requirements.
During the deformation process—whether reducing or expanding—the choice between cold pressing and hot pressing depends on the material type and the degree of diameter reduction. Cold pressing is generally preferred for most applications, but hot pressing is often used when dealing with severe work hardening, thick-walled pipes, or alloy steel materials that require additional flexibility during forming.
Stamping Process
While steel pipes are commonly used as raw materials for producing reducers, another method involves stamping. In this process, the die is designed based on the inner dimensions of the reducer. A steel sheet is punched and formed using a die to create the desired shape. This technique is especially effective for producing partial diameter sections of the reducer where full pipe extrusion may not be practical.
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