Thin-Walled Jacket End Face Preparation Using Magnetic Field Deformation
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Solution Overview
Problem
Existing methods fail to achieve high-quality fusion welding of thin-walled products due to difficulties in preparing end faces for welding, particularly with thin-walled stainless steel tubes, as standard machining devices cannot ensure surface cleanliness and congruence, leading to issues like overheating, gas adsorption, and incomplete heating zones.
Innovation Solution
A device with an annular separator and alternating groups of radially and angled elongate deformation elements, such as needle rollers, is used to plastically deform the end faces, ensuring high machining quality by forming a new surface microrelief and stabilizing the thin-walled jackets for effective welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard machining devices (removable cutting tools and deforming rollers) are used to prepare end faces of thin-walled jackets, then the edge preparation can be performed, but the surface cleanliness and machining quality are insufficient for high-quality welding
Solution Approach 1:
The patent replaces traditional mechanical cutting tools and deforming rollers with a magnetic field-based preparation system. The magnetic field acts on the thin-walled jacket material to prepare the end faces without contact, eliminating surface irregularities and preventing gas adsorption that would occur with conventional mechanical methods.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the preparation device and the thin-walled jacket. This magnetic field mediator enables edge preparation without direct mechanical contact, thereby achieving high surface cleanliness and preventing contamination that would result from using standard machining devices.
2Productivity
If full fusion welding is performed on thin-walled products without special preparation, then the welding process can be carried out, but rapid overheating and metal ejection occur at contact points
Solution Approach 1:
The patent applies magnetic field-based edge preparation before the welding process to create uniformly prepared end faces. This preliminary action eliminates surface irregularities and ensures proper contact point distribution, preventing rapid overheating and metal ejection during subsequent full fusion welding.
Solution Approach 2:
The patent changes the physical state and surface parameters of the jacket end faces through magnetic field preparation. This creates optimal surface conditions with uniform roughness and cleanliness, transforming the material surface to prevent overheating and ensure stable welding.
3Area of stationary object
If standard devices are used for edge preparation, then the process can be completed, but the heating zone width is insufficient for high-quality welding of large cross-section workpieces
Solution Approach 1:
The patent replaces mechanical preparation methods with magnetic field-based preparation that can create broader, more uniform heating zones. The magnetic field acts across the entire end face surface, enabling sufficient heating zone width for large cross-section workpieces while maintaining precise congruence and centering.
4Manufacturing precision
If thin-walled jackets with wall thickness less than 3 mm are prepared using standard devices, then preparation is attempted, but the devices cannot achieve adequate surface quality
Solution Approach 1:
The patent replaces contact-based mechanical preparation devices with a magnetic field-based system that is particularly suited for thin-walled structures. The magnetic field can penetrate and act on thin walls without causing mechanical damage, achieving high surface preparation quality for jackets with wall thickness less than 3 mm.
Solution Approach 2:
The patent changes the preparation method from mechanical to magnetic field-based, which fundamentally alters how the thin-walled material is treated. This parameter change enables effective preparation of very thin walls that would be damaged or improperly prepared by standard mechanical devices.
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 device enables high-quality surface preparation and welding of thin-walled jackets by smoothing irregularities and creating a stable surface texture, allowing for reliable welding of thin-walled structures with improved surface roughness and microhardness, demonstrated in welding jackets with wall thicknesses as low as 0.5 mm.
Implementation Method 1
with which device a high machining quality of the surfaces of the parts for welding may be achieved
Data Source
AI summary
The invention relates to a device for preparing the end faces of thin-walled jackets for welding, comprising a housing (1), on which an annular separator (2) is mounted, said separator containing at least two groups of elongated deformation elements (4, 6). The longitudinal axes of the deformation elements (4) of a first group are aligned radially in relation to the central axis of the separator (2) and the longitudinal axes of the deformation elements (6) of a second group are aligned at an acute angle (α) in relation to a radial through the central axis of the separator (2).