In the core fields of global heavy industry—such as offshore oil and gas development, nuclear power plant construction, and large-scale infrastructure engineering—processing ultra-large-diameter, thick-walled pipes demands equipment that integrates extreme power, micron-level precision, and rugged durability. The 380 pipe end forming machine stands as the industry’s flagship solution, engineered to handle pipes up to 380 mm in outer diameter and adapt to diverse high-strength materials. Designed for sectors spanning petrochemicals, marine engineering, and renewable energy, this ultra-heavy-duty equipment redefines the boundaries of pipe processing by delivering seamless, leak-tight connections and complex forming operations that comply with international standards like JB/T 12088 and ISO 9001.

What is a 380 Pipe end forming machine?

A 380 pipe end forming machine is a specialized ultra-heavy-duty industrial tool designed to reshape, finish, and modify the ends of metal pipes and tubes, distinguished by its “380” designation and exceptional performance capabilities. The “380” primarily refers to the machine’s maximum processing outer diameter—up to 380 mm—setting it apart from smaller 260 or 350-series models that handle narrower pipes. It also signifies ultra-high forming force and compatibility with extra-thick-walled materials, making it the preferred choice for scenarios that exceed the limits of conventional heavy-duty machines.

This equipment integrates advanced hydraulic power systems, high-precision CNC controls, and rugged tooling to automate a full range of forming operations. Key processes include expanding, shrinking, flaring, bulging, upsetting, sealing, chamfering, and beveling—with specialized capabilities for single V, double V, J, and U-type bevels critical for high-strength welding. 

Unlike traditional methods such as welding or threading, it forms pipe ends directly to create seamless, one-piece connections that are 30% stronger and more leak-resistant, a vital advantage in high-pressure, high-temperature, or corrosive environments.

Built with reinforced I-beam frames and heavy-duty casting structures, the 380 pipe end forming machine supports a wide range of materials including carbon steel, stainless steel, alloy steel, titanium, and exotic alloys like Inconel. It caters to both high-volume mass production and custom small-batch work, with options for manual, semi-automatic, or fully automatic operation—including integration with robotic loading/unloading systems for continuous production. Advanced models feature a 180-degree rotating carriage for efficient two-end processing, completing forming on both pipe ends without reloading, while explosion-proof configurations are available for flammable and explosive workplaces like petrochemical plants.

Compliant with industry standards such as JB/T 12088.1-2014 and JB/T 12088.2-2014, the machine meets strict design, safety, and precision criteria. Its structural design emphasizes stability and durability, with key components like the and clamping system engineered to withstand extreme forming forces without deformation. The integrated touchscreen HMI enables intuitive operation, supporting both Chinese and English interfaces for global usability.

Core Working Principles of the 380 Pipe End Forming Machine

The 380 pipe end forming machine’s exceptional performance stems from synchronized mechanical, hydraulic, and electrical systems, optimized for ultra-heavy-duty processing while maintaining micron-level precision. Based on industry-recognized working principles and standard operating procedures, the fundamental process follows five key stages:

1. Material Preparation and Loading

The process begins with pipe preparation—cutting to the required length and deburring to remove surface imperfections that could compromise forming quality. Given the large diameter and heavy weight of the pipes, the machine is equipped with hydraulic elevating devices and automatic conveyors or robotic arms to assist with positioning. This reduces operator fatigue and ensures accurate alignment with the forming dies.

Many models support multi-station processing, enabling sequential operations like cutting, chamfering, and flaring in a single pass. The feeding system adjusts to pipe lengths ranging from 100 mm to 1000 mm, with customizable options for longer workpieces. For high-volume production, fully automatic loading/unloading systems integrate with factory logistics lines to achieve 24/7 continuous operation.

2. Precision Positioning

Accurate positioning is critical for uniform results, especially with ultra-large-diameter pipes where minor misalignment can lead to defective connections. The machine uses automatic self-centering 3-jaw or 4-jaw chucks and hydraulic backstops to set the exact segment of the pipe to be formed. The self-centering function ensures the pipe is perfectly aligned with the forming dies, eliminating dimensional variations across batches.

Advanced models integrate linear encoders and optical rulers for real-time position monitoring, maintaining ±0.05 mm accuracy even at the 380 mm diameter limit. This precision complies with JB/T 12088.3 and ensures consistent forming quality for critical applications like nuclear power piping.

3. Secure Clamping

Once positioned, the pipe is clamped firmly to prevent slippage during high-force forming. The clamping system features reinforced jaws driven by high-pressure hydraulic cylinders, applying adjustable force ranging from 15-30 KG/CM². This adjustability allows the machine to handle both delicate titanium pipes and thick-walled stainless steel pipes with equal stability.

A pressure-locking mechanism ensures the clamp remains secure throughout the forming process, preventing deformation or misalignment even under maximum forming force. The clamping system also incorporates dust-proof devices to protect and moving parts, extending service life in harsh industrial environments. Compliance with GB 17120 safety standards ensures the clamping mechanism has overload protection to avoid equipment damage.

4. Ultra-High-Force Forming

The forming stage is powered by a heavy-duty hydraulic system delivering up to 600 tons of thrust—enough to reshape thick-walled pipes and high-strength alloys without compromising structural integrity. Under CNC control, precision split dies exert uniform pressure on the pipe end to execute customizable operations:

Expanding: Enlarging the diameter to create connections or fit over components, ideal for pipeline assembly.

Shrinking: Reducing the diameter for tight fittings in high-pressure systems, such as oil and gas pipelines.

Flaring: Forming tapered, leak-tight ends for hydraulic or pneumatic connections, critical for LNG transport systems and ship hydraulic lines.

Beveling: Creating single V,double V,J,or U-type bevels for welding preparation—processing a 380 mm diameter, 25 mm thick stainless steel pipe in just 3-5 minutes.

Bulging/upsetting: Forming raised sections or tenon-and-mortise connections for structural reinforcement, suitable for wind power jacket assembly.

The forming speed is adjustable via flow control valves, with cycle times ranging from 8–40 seconds depending on operation complexity. Some models feature a rotary cum push-type design that adds die rotation for smoother forming and improved surface finish, while cold forming technology preserves the pipe’s material properties. The hydraulic system’s maximum is controlled below 60℃ to ensure stable performance during continuous operation.

5. Mold Release and Unloading

After forming is complete, the hydraulic system retracts the dies and releases the clamp. The finished pipe is unloaded manually or via automatic conveyors. The 180-degree rotating carriage on select models enables quick flipping for two-end processing, cutting cycle time in half. Quick-change die systems reduce setup time by 40%, allowing operators to switch between forming operations in minutes.

The machine’s integrated cooling system and oil temperature monitoring prevent overheating, ensuring consistent performance in 24/7 production environments. Post-forming, the pipe ends feature smooth, burr-free surfaces that meet welding and assembly requirements, eliminating the need for secondary processing.

Key Advantages of the 380 Pipe End Forming Machine

Compared to smaller pipe end forming machines and traditional processing methods, the 380 pipe end forming machine offers unique advantages that drive efficiency, cost savings, and reliability in ultra-heavy-duty applications:

1 Ultra-Large-Diameter Processing Capacity

The machine’s ability to handle pipes up to 380 mm in diameter fills a critical gap in industrial manufacturing. It processes ultra-large-diameter pipes that smaller 260/350-series machines can’t accommodate, eliminating the need for manual processing or multiple equipment passes. This capability is essential for industries like offshore oil and gas, nuclear power, and wind energy that rely on large-scale piping systems.

2. Superior Precision and Consistency

Equipped with CNC controls, self-centering chucks, and linear encoders, the 380 pipe end forming machine delivers ±0.05 mm – ±0.1 mm forming accuracy. This consistency eliminates variability from manual processing, reducing scrap rates from 3% to 0.5% for high-volume producers. The uniform pressure distribution from split dies ensures smooth, burr-free finishes that meet strict international standards like JB/T 12088.3 and ISO 9001.

3. Enhanced Production Efficiency

The machine’s automation and multi-station capabilities significantly boost throughput. Heavy-duty models process up to 600 simple-formed pipes per hour, while complex beveling operations are completed 5x faster than manual methods. The 180-degree rotating carriage enables two-end processing without reloading, cutting cycle times in half for long pipe runs. Quick-change tooling and programmable presets reduce setup time by 40%, minimizing downtime between jobs.

4. Versatility Across Materials and Environments

The 380 pipe end forming machine supports a wide range of materials—from lightweight aluminum to heavy-duty Inconel and titanium—and executes multiple forming operations with interchangeable dies. It adapts to diverse production environments, from factory floors to on-site construction sites, with portable and explosion-proof options available for flammable, explosive, or narrow-space applications. Custom die options allow for specialized shapes like concave, convex, square, and tapered ends, meeting unique project requirements.

5. Stronger, Leak-Tight Connections for Extreme Conditions

By forming pipe ends directly, the machine creates seamless, one-piece connections with no weak points. These connections resist leaks even in extreme conditions—high pressure, low temperature, and corrosive environments—critical for industries like LNG transport and nuclear power. For offshore platforms, this reduces the risk of fatigue cracks and environmental damage, while in wind energy applications, tenon-and-mortise connections enable quick on-site assembly.

6. Significant Cost Savings

The machine delivers substantial cost reductions in multiple ways:

Material savings: Eliminates the need for fittings, reducing material costs by 15–20% and welding joints by 40%.

Labor savings: Automates tasks that would require 3–4 workers, cutting labor costs by up to 60% and reducing labor intensity.

Energy efficiency: Hydraulic systems with integrated oil manifolds reduce power consumption by 10–15% compared to older models.

Reduced downtime: Predictive maintenance alerts and durable construction minimize unplanned downtime by 25%, while quick tool changes boost overall equipment efficiency.

7. Safety Compliance and User-Friendliness

Intuitive touchscreen interfaces with programmable presets simplify setup, even for operators with limited technical expertise. Manual override functions allow adjustments for custom jobs, balancing automation with flexibility. Safety features—including emergency stops, protective enclosures, and explosion-proof designs—comply with global industrial standards like GB 17120 and CE, minimizing accident risks in hazardous workplaces. Ergonomic design elements like hydraulic elevators reduce operator fatigue during heavy pipe handling.

8. Industry 4.0 Compatibility

Leading models integrate with Industry 4.0 systems via TCP/IP communication and barcode readers, enabling real-time production monitoring. Operators can track cycle times, material usage, and machine performance, while simulation and collision control features prevent errors. Data analytics support continuous process optimization, aligning with modern smart factory initiatives and enabling seamless integration with CAD systems and measuring machines.