The roundness of the reducer should not exceed 1% of the outer diameter at each end, with an allowable deviation of ±3 mm. The materials used for reducers include SY/T5037, GB/T9711, GB/T8163, ASTM A106/A53 GRB, API 5L, APT5CT, ASTM A105, ASTM A234, ASTM A106, DIN standards, and can be customized based on customer specifications.
A reducer, also known as a size head, is a pipe component designed to connect pipes of different diameters. It is commonly manufactured using processes such as reduction pressing, diameter expansion pressing, or a combination of both. For certain sizes and configurations, press forming is also applicable.
Reduced Diameter / Expanded Diameter Forming
In the reduced diameter forming process, a tube blank with the same diameter as the larger end of the reducer is placed into a mold. The metal is then pressed axially, causing it to flow along the cavity and shrink to form the smaller end. Depending on the size and complexity of the reducer, this may involve one pressing operation or multiple stages. The diagram below illustrates the concentric reducer's reduced diameter forming method.
For expanded diameter forming, a tube blank with a smaller diameter than the larger end of the reducer is used. The inner diameter of the blank is expanded using a die to achieve the desired size. This method is particularly useful when the reduction ratio is too large to be achieved through simple shrinking. In some cases, a combination of expanding and reducing is employed based on material properties and forming 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 change. Cold pressing is typically preferred under normal conditions, but hot pressing is often necessary when dealing with severe work hardening, thick-walled tubes, or alloy steels.
Stamping Process
Besides using steel pipes as raw materials, parts of the reducer can also be manufactured through stamping. The die design is based on the internal dimensions of the reducer. After blanking, the steel sheet is punched and formed using a die to create the final shape. This method is especially suitable for producing partial sections of reducers where precision and efficiency are key.
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