Embossed Stainless Pipe Forming for Precise Diameter and Pattern Control
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Solution Overview
Problem
The existing embossed stainless steel pipe manufacturing processes face challenges in accurately setting the width of flat stainless steel sheets for precise outer diameters, managing increased hardness and tensile strength in thick sheets, adjusting gaps for smooth curving and rounding, and preventing pattern deformation during the manufacturing of embossed stainless steel pipes.
Innovation Solution
The implementation of a slitting machine to accurately cut flat stainless steel sheets with vertical planes, a tempering device to reduce hardness, and an optimized gap adjustment mechanism between rollers to ensure smooth curving and rounding, while maintaining the integrity of embossed patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large-width flat stainless steel sheet is used to manufacture embossed stainless steel pipes, then the productivity is improved, but the manufacturing precision of outer diameter deteriorates due to difficulty in setting the width corresponding to the outer diameter
Solution Approach 1:
The patent applies segmentation by dividing the large-width flat stainless steel sheet into multiple smaller-width sheets using a slitting machine. This allows the production process to handle sheets of optimal width for precise embossed pipe manufacturing while maintaining high productivity through efficient utilization of the original large sheet material.
2Ease of manufacture
If the gap between curving rollers is adjusted for smooth curving of thick stainless steel sheets, then the ease of manufacture is improved, but the manufacturing precision deteriorates due to pattern deformation
Solution Approach 1:
The patent applies parameter changes by systematically adjusting the gap between curving rollers to optimal values that balance smooth curving of thick stainless steel sheets with preservation of embossed pattern precision. Through experimental optimization, specific gap parameters are determined that enable both ease of manufacture and manufacturing precision.
3Manufacturing precision
If the embossed degree is increased to enhance product quality, then the product quality is improved, but the device complexity increases due to need for precise gap adjustment and elasticity management
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical gap adjustment mechanisms with a hydraulic pressing system. The hydraulic press provides precise, controllable force application that achieves high embossed degrees without requiring complex mechanical adjustment mechanisms, thereby reducing device complexity while maintaining product quality.
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
This approach allows for the precise manufacturing of embossed stainless steel pipes with accurate outer diameters, improved quality, and reduced defects by ensuring the correct sheet width, tempering for reduced hardness, and optimal roller gap adjustments, enhancing productivity and quality.
Implementation Method 1
a tempering device installed between the embossing machine and the pipe mill to temper the flat stainless steel sheet having a thickness of 2.5 mm or more
Implementation Method 2
a slitting machine configured to slit a large-width flat stainless steel sheet into a plurality of flat sheets such that side surfaces of each of the slit flat stainless steel sheets are formed vertically
Implementation Method 3
an embossing press roller including an upper roller having a relief embossing pattern formed thereon and a lower roller having an intaglio embossing pattern formed thereon
Implementation Method 4
a pipe mill configured to curve and round the embossed stainless steel sheet supplied through the embossing machine in order to manufacture an embossed pipe
Implementation Method 5
the pipe mill being configured to weld the weld seam portion of the embossed stainless steel pipe in order to complete the embossed stainless steel pipe
Data Source
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AI summary
Disclosed are an embossed stainless steel pipe manufacturing apparatus capable of changing the construction of an embossed stainless steel sheet such that the embossed stainless steel sheet is efficiently welded, selecting a welding means suitable for the construction of the embossed stainless steel sheet, and smoothly manufacturing an embossed stainless steel pipe from a thick stainless steel sheet using a tempering electric furnace and an embossed stainless steel pipe manufacturing method improved through the addition of a molten fusion process using the same material suitable for an embossed stainless steel pipe requiring narrow, precise, and accurate welding.