Inner Cavity Near-Net Shaping for Special-Shaped Pipe Expansion
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Solution Overview
Problem
The production of large-scale special-shaped connecting pipes for nuclear power requires a more efficient method to maintain the position of the workpiece during processing, as conventional methods are limited by the irregular shape of the inner cavity and the complexity of the forging process, leading to high production costs and long cycles.
Innovation Solution
An inner cavity near-net-shaping device for micro cast-rolling additive manufacturing, comprising a main transmission assembly, inner cavity near-net-shaping assembly, and main feed assembly, which includes a servo motor, inner cavity mold, expansion cylinder, and wedge-shaped sliders, allowing for precise control and expansion of the inner cavity to accommodate various pipe shapes, thereby simplifying the process and reducing labor intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional forging process is used to produce large-scale special-shaped connecting pipes, then the pipes can be manufactured with required strength, but the production process becomes long and complex, requiring large-scale forging equipment and flaw detection devices, leading to high production cost
Solution Approach 1:
The patent replaces the conventional mechanical forging process with a micro cast-rolling additive manufacturing process. This substitution eliminates the need for large-scale forging equipment and complex flaw detection devices, while maintaining the required pipe strength through controlled material deposition and layer-by-layer construction.
Solution Approach 2:
The patent changes the manufacturing parameters from traditional forging conditions to additive manufacturing parameters, including controlled material deposition rates, layer thickness, and thermal cycles during printing. These parameter changes enable the production of complex-shaped pipes with required mechanical properties without needing complex post-processing equipment.
2Strength
If conventional forging process is used to produce large-scale special-shaped connecting pipes, then the pipes can be manufactured with required strength, but the production cycle becomes long, leading to high production cost
Solution Approach 1:
The patent performs preliminary action by directly printing the final pipe structure with its complex internal cavities and shapes during the additive manufacturing process itself, rather than creating a blank form first and then performing multiple subsequent machining and shaping operations. This eliminates intermediate manufacturing links and significantly shortens the production cycle.
Solution Approach 2:
The patent achieves continuity of useful action by maintaining uninterrupted material deposition and layer-by-layer construction throughout the manufacturing process. The additive manufacturing process continuously builds the pipe structure without the need to stop for intermediate forging, machining, or heat treatment operations, thereby improving production efficiency.
3Adaptability or versatility
If the inner cavity of special-shaped connecting pipe has irregular shape, then the pipe can meet functional requirements, but it becomes difficult to maintain the position of the processed part fixed during processing
Solution Approach 1:
The patent applies the inversion principle by building the pipe structure from the inside out during additive manufacturing. The irregular inner cavity shape is created directly through material deposition guided by digital models, rather than attempting to machine or form the shape after creating a solid blank. This eliminates positioning difficulties associated with conventional processing of irregular shapes.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical forming to additive deposition, allowing the irregular inner cavity shape to be defined by digital parameters and layer-by-layer material placement. This parameter-based approach enables precise control of complex geometries without requiring physical fixtures or positioning mechanisms during processing.
4Productivity
If additive manufacturing is used to produce large irregular steel pipes, then the manufacturing process can be shortened and production cost reduced, but corresponding manufacturing equipment must be designed
Solution Approach 1:
The patent applies segmentation by dividing the additive manufacturing equipment into modular functional units: a printing system for material deposition, an expansion mechanism for cavity formation, and a feed system for material supply. This modular segmentation allows the complex equipment to be designed and assembled from standardized components, reducing overall system complexity while maintaining high production efficiency.
Solution Approach 2:
The patent designs the additive manufacturing equipment with universal components that can handle various pipe geometries and materials. The expansion mechanism and printing system are configured to accommodate different inner cavity shapes and sizes, making the equipment versatile for producing various large irregular steel pipes without requiring complete redesign for each application.
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 solution enables near-net-shaping of inner cavities for various connecting pipes, reducing production time, controlling internal defects, and lowering production costs, while improving work efficiency and versatility.
Implementation Method 1
the inner cavity surface of the expansion cylinder is evenly distributed along a circumferential direction thereof with the inner wedge-shaped slider, and the expansion push rod comprises a first shaft section, a second shaft section, an outer wedge-shaped slider and a third shaft section
Data Source
AI summary
An inner cavity near-net-shaping device for micro cast-rolling additive manufacturing of large-scale special-shaped pipe, includes a main transmission assembly, an inner cavity near-net-shaping assembly and a main feed assembly. The inner cavity near-net-shaping assembly comprises an inner cavity mold, an expansion cylinder and an expansion push rod, the expansion cylinder is provided with a gap in a direction of a thin wall thickness thereof, an inner cavity surface of the expansion cylinder is evenly distributed along a circumferential direction thereof with the inner wedge-shaped slider, and the expansion push rod comprises a first shaft section, a second shaft section, an outer wedge-shaped slider and a third shaft section, an outer surface of the second shaft section of the expansion push rod is evenly distributed along a circumferential direction thereof with an outer wedge-shaped slider.