Measuring Tube Forming With Mandrels for Precise SAW Waveguides
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Solution Overview
Problem
Existing methods for manufacturing measuring tubes for fluid measuring devices are not cost-effective and lack precision, particularly in forming waveguide areas for surface acoustic waves.
Innovation Solution
A method involving a tubular semi-finished product with waveguide areas, where the product is inserted into a forming tool with mandrels to apply a pressing force, plastically deforming the center section and forming the fluid channel with precise geometry, including waveguides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for measuring tubes, then the production process is simple, but the manufacturing precision and cost-effectiveness are insufficient
Solution Approach 1:
The waveguide areas are prepared in advance on the tubular semi-finished product before the forming process. This preliminary preparation ensures that the waveguide areas are precisely positioned and shaped before plastic deformation occurs, resolving the contradiction by achieving high precision without requiring complex post-processing steps
Solution Approach 2:
A mandrel is introduced as an intermediary tool during the forming process. The mandrel serves as a precision template that transfers its geometry to the waveguide areas through the plastic deformation process, enabling high manufacturing precision while keeping the forming process itself relatively simple
2Measurement precision
If high precision is achieved in waveguide area formation, then the measurement accuracy improves, but the manufacturing cost increases
Solution Approach 1:
The waveguide areas are formed with precise geometry during the preliminary preparation stage on the semi-finished product. This approach achieves high measurement precision for surface acoustic waves while avoiding costly post-processing operations, as the precision is built-in during the forming process itself
Solution Approach 2:
The mandrel acts as a physical copy or template of the desired waveguide geometry. By pressing the material against the mandrel during forming, the precise geometry is replicated without requiring complex CNC machining or other expensive high-precision manufacturing methods
3Reliability
If the waveguide areas are formed with complex geometry, then the functional performance improves, but the manufacturing time increases
Solution Approach 1:
The mandrel serves as a mediator that enables complex waveguide geometries to be formed rapidly through a single plastic deformation process. The complex shape is achieved in one forming operation rather than through multiple sequential machining steps, thus maintaining high functional performance while improving manufacturing speed
Solution Approach 2:
The forming process utilizes plastic deformation parameters to transform the tubular semi-finished product into the final waveguide geometry. By controlling the pressing force and mandrel geometry, complex waveguide shapes are achieved efficiently in a single process step, avoiding time-consuming incremental manufacturing
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 precise and cost-effective manufacturing of measuring tubes with accurately formed waveguide areas, enabling efficient excitation, measurement, and coupling of surface acoustic waves.
Implementation Method 1
performing a forming step in which a pressing force is applied to at least one axial center section of the tubular semi-finished product and at least the center section is plastically deformed
Data Source
AI summary
In a method of manufacturing a measuring tube of a fluid measuring device, a tubular semi-finished product having a through-opening extending in a longitudinal direction (L) of the tubular semi-finished product is provided, a circumferential wall of the tubular semi-finished product having at least one waveguide area which, after completion of the measuring tube, forms a waveguide for surface acoustic waves of an acoustic measuring device, and the waveguide area extending along a longitudinal direction (L) of the tubular semi-finished product and from an outer surface to an inner surface of the tubular semi-finished product. The tubular semi-finished product is inserted into a forming tool, and at least one mandrel is inserted into the through-opening, an outer geometry of the mandrel corresponding to an inner geometry of a fluid channel of the measuring tube to be formed from the through-opening. In a forming step in which a pressing force (F) is applied to at least one axial center section of the semi-finished product, at least the center section is plastically deformed, the through-opening being formed into the fluid channel. Finally, the mandrel is removed.