Burnishing Roller Set for Pipe End Flare Control
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Solution Overview
Problem
Roll grooving methods often result in an unwanted 'bell' shape flare at the open end of pipe elements, which can exceed critical tolerance limits, and fail to provide an optimal surface finish for effective sealing with mechanical couplings.
Innovation Solution
A roller set comprising an inner roller with a flange and an outer roller with three raised features, including a conical and curved surface, that align with corresponding depressions on the inner roller to control and prevent pipe end flare, while improving surface finish through controlled contact widths and surface geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll grooving is used to form circumferential grooves in pipe elements, then groove formation is achieved, but pipe end flare occurs causing bell shape deformation
Solution Approach 1:
The outer roller is divided into multiple functional zones with three distinct raised features: a first raised feature for groove formation, a second raised feature for burnishing, and a third raised feature for flare prevention. This segmentation allows each zone to perform its specific function independently, achieving groove formation without pipe end flare.
Solution Approach 2:
Different regions of the outer roller are given different surface properties and geometries. The first raised feature has a specific geometry for groove formation, the second raised feature has a burnishing surface for surface finish improvement, and the third raised feature is positioned to prevent flare. This local differentiation resolves the contradiction by addressing both groove formation and shape control in specific locations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The roller set effectively mitigates pipe end flare, maintains critical diameter tolerances, and enhances surface finish for improved sealing and mechanical coupling performance, achieving a factor of three improvement in pressure capability and significant improvements in bending stiffness and strength.
Implementation Method 1
The first summit comprises a curved surface adapted to burnish a portion of the pipe element
Data Source
AI summary
A roller set for roll forming pipe elements has an outer roller that engages the pipe element at three points to prevent teetering of the pipe element. The outer roller has a summit positioned on a raised feature, the summit comprising a curved surface adapted to burnish the pipe elements.