Tube Bending Mandrel Lubrication Through Articulated Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mandrel assemblies in tube bending machines fail to provide sufficient lubrication, leading to overheating, malfunctioning, and potential tube rupture, necessitating manual pre-lubrication in demanding applications.
Innovation Solution
A mandrel assembly with articulation elements featuring through-holes and a deflector element to distribute lubricant effectively across the tube interior, eliminating the need for manual pre-lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If lubricant is supplied through the mandrel rod and distributed by outlet ports on the mandrel body, then the lubrication system is simple, but the lubrication distribution is insufficient in demanding applications
Solution Approach 1:
The lubrication system is segmented into multiple distribution paths: the mandrel body outlets and the articulation element through-holes. This segmentation allows lubricant to reach multiple locations simultaneously, improving distribution coverage without requiring a complex multi-pump system. The articulation elements act as independent distribution segments that deliver lubricant to specific high-friction zones.
Solution Approach 2:
The articulation elements serve as intermediary components that receive lubricant from the mandrel body and redistribute it to the spaces between successive articulation elements. This intermediary function ensures that lubricant reaches areas that would otherwise be difficult to access, improving overall lubrication effectiveness without directly modifying the main supply system.
2Reliability
If manual pre-lubrication is performed by the operator, then lubrication is sufficient, but the process requires additional manual intervention and time
Solution Approach 1:
The mandrel assembly performs self-lubrication through its articulated structure. The articulation elements with through-holes automatically distribute lubricant to the spaces between them during the bending operation, eliminating the need for manual pre-lubrication. The system uses its own motion and structure to deliver lubricant where needed, making the process self-sufficient.
Solution Approach 2:
The lubricant distribution channels in the articulation elements are pre-configured to deliver lubricant to critical areas before the bending operation begins. The through-holes are positioned to ensure lubricant reaches the spaces between articulation elements in advance, preparing the interface for optimal lubrication during the bending process.
3Productivity
If poor lubrication occurs, then the process may be more economical without additional systems, but overheating and tube rupture risks increase
Solution Approach 1:
The system uses multiple lubricant distribution points (mandrel body outlets plus articulation element through-holes) to provide excessive lubrication coverage in critical areas. This partial over-lubrication ensures that even under high-friction conditions, sufficient lubricant is present to prevent overheating and rupture, while the articulated structure directs this excess lubricant precisely where needed.
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
Enhances lubrication distribution, ensuring consistent lubrication, preventing overheating, and reducing the risk of tube rupture, while making the process more reliable, repeatable, and economical.
Implementation Method 1
a network of lubricant transport channels formed through the mandrel body and communicating with a lubricant feed passage formed along the mandrel rod
Implementation Method 2
said deflector element being configured to radially deflect outwardly the lubricant exiting the through-holes
Implementation Method 3
A fundamental aspect is the formation of a substantial lubricant film in the gap between the mandrel assembly and the inner surface of the tube
Data Source
Figure 1~2
Figure 3~4
AI summary
A mandrel assembly for a tube bending machine, comprising a mandrel body (21), a mandrel rod (23), a series of articulation elements (24-26) connected to one another and to the mandrel body (21) through respective cylindrical or spherical hinges (27-28), and a network of lubricant transport channels (31-36) formed through the mandrel body (21) and communicating with a lubricant feed passage (23a) formed along the mandrel rod (23). The network of lubricant transport channels (31-36) comprises a plurality of lubricant outlet ports (34, 36) arranged on the distal end (21b) or on a peripheral surface (21c) of the mandrel body (21). A plurality of through-holes (37) extending along the longitudinal direction of the respective articulation element (24-26) is formed through each of the articulation elements (24-26). The through-holes (37) are configured to convey a lubricant to the front side of an extreme distal articulation element (26) of the series of articulation elements (24-26). The extreme distal articulation element (26) comprises a deflector element (38).