Flow Forming Separation Discs With Welded Extra Metal
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Solution Overview
Problem
Existing methods for producing separation discs from thin sheet metal with integrally formed elevations are inefficient and costly, as they require expensive and time-consuming welding of separate spacing means, and struggle to achieve desired elevation heights without stressing the material.
Innovation Solution
A method involving the application of extra metal material on a metal sheet blank, which is then flow-formed over a truncated conical mandrel with recesses, allowing the material to fill these recesses and form elevations simultaneously, enabling the creation of separation discs with substantial height spacing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flow forming is used to create integrally formed elevations on thin sheet metal separation discs, then manufacturing cost and time are reduced, but the elevation height is limited by material stress and insufficient material availability
Solution Approach 1:
The invention applies preliminary action by welding extra metal material to the sheet blank before the flow forming process. This pre-positioned material ensures sufficient material availability during forming, allowing the creation of higher elevations without material stress or insufficiency. The extra material is strategically placed at locations where elevations will be formed, enabling the process to achieve greater elevation heights while maintaining manufacturing efficiency.
2Manufacturing precision
If separate spacing means are welded to separation discs, then elevation height can be increased, but manufacturing cost and time increase significantly
Solution Approach 1:
The invention merges two previously separate operations into one integrated process: the application of extra metal material and the flow forming operation. By welding extra material to the blank and then performing flow forming in sequence, the invention creates integrally formed elevations without requiring separate attachment operations. This combination maintains the benefits of integral forming (lower cost, higher productivity) while achieving the elevation heights previously only possible with separate spacing means.
3Reliability
If the ratio of disc thickness to elevation height exceeds 1, then separation performance is optimized, but material stress during forming becomes excessive
Solution Approach 1:
By pre-applying extra metal material to the sheet blank before forming, the invention ensures that sufficient material is available during the flow forming process to create high elevations without excessive thinning or stress. This preliminary material addition allows the formation of elevations that maintain a thickness-to-height ratio of 1:1 or less, optimizing separation performance while avoiding material stress failures.
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 method allows for the production of separation discs with elevated spacing members of substantial height, optimizing the ratio of disc thickness to elevation height, facilitating increased separation efficiency and reducing material stress, while enabling thinner discs to be used in stacks without compromising separation performance.
Implementation Method 1
flow forming said metal sheet blank by means of a roller and said mandrel
Implementation Method 2
applying on said metal sheet blank extra metal material in positions on its top side, by means of welding
Data Source
AI summary
A method for manufacturing a separation disc, starting from a metal sheet blank with a top side and a bottom side, applying on said metal sheet blank extra metal material in positions on its top side, by means of welding, placing the metal sheet blank on a mandrel including a truncated conical support surface with recesses corresponding to spacing members on the completed separation disc, with the bottom side facing said truncated conical support surface, aligning the metal sheet blank so that the positions of the extra metal material after the pressing will correspond to the recesses, flow forming the metal sheet blank by means of a roller and the mandrel, the roller forming the separation disc over the mandrel completing a separation disc with spacing members on said bottom side. A separation disc for a centrifugal separator is made of a metal material and adapted to be compressed in a stack of separation discs inside a centrifugal rotor for separating a liquid or liquid/solid mixture. The separation disc has a truncated conical shape with an outer surface and an inner surface and a plurality of spacing members extending a certain height above the inner surface for providing interspaces between mutually adjacent separation discs in said stack. The thickness of the separation disc and the height of the spacing members have a ratio of at least 1 to 1.