Burnishing Roller Set for Pipe Grooving Without End Flare
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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 diameter tolerances and compromise fluid tight seals, especially when forming circumferential grooves.
Innovation Solution
A roller set with an inner and outer roller, featuring raised features and corresponding depressions, that align to control and prevent pipe end flare by maintaining precise contact and surface finish during roll forming, including a rotatable ring on the outer roller to reduce friction and prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roll grooving is used to form circumferential grooves in pipe elements, then groove formation is achieved, but pipe end flare occurs causing diameter tolerance exceedance
Solution Approach 1:
The roller is divided into multiple functional zones along its length: a burnishing zone with a smooth curved surface for surface finishing, a grooving zone with raised features for groove formation, and a support zone for structural stability. This segmentation allows each zone to perform its specific function without interfering with others, preventing pipe end flare while maintaining groove formation capability
Solution Approach 2:
Different regions of the roller are given different surface properties and geometries: the burnishing zone has a smooth curved surface for surface finishing, while the grooving zone has raised features for material displacement. This local differentiation enables the roller to simultaneously achieve surface burnishing and groove formation without causing pipe end flare
2Ease of manufacture
If roll grooving deforms pipe material to form grooves, then groove features are created, but pipe end flares outward forming a bell shape
Solution Approach 1:
The burnishing zone is positioned to contact and pre-compress the pipe end surface before the grooving zone applies material displacement forces. This preliminary action stabilizes the pipe end material, preventing it from flaring outward during the subsequent grooving operation
Solution Approach 2:
The burnishing zone applies a counteracting compressive force to the pipe end surface that opposes the outward flare tendency caused by the grooving zone. This preliminary anti-action prevents the bell-shaped deformation by balancing the material forces during the rolling process
3Ease of manufacture
If standard rollers are used for grooving, then groove formation is achieved, but surface finish is insufficient for effective sealing
Solution Approach 1:
The roller combines multiple functions into a single component: burnishing (surface finishing) and grooving (feature formation) are integrated into one roller body. This merging eliminates the need for separate operations and ensures that surface finishing and groove formation occur simultaneously with consistent quality
Solution Approach 2:
The roller features a localized burnishing zone with a smooth curved surface specifically designed for surface finishing, distinct from the grooving zone. This local quality differentiation enables the roller to provide both groove formation and high-quality surface finish in a single pass
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 solution effectively mitigates pipe end flare, maintains critical diameter tolerances, and enhances surface finish for improved sealing, 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.