Metal Pipe Flange Forming with Multi-Directional Dies
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Solution Overview
Problem
Existing forming devices for metal pipes with flanges lack sufficient strength and rigidity, particularly in areas where flanges are formed by crushing metal pipe material laterally.
Innovation Solution
A forming device with a forming tool comprising first and second dies facing each other in a cross-sectional view, and a third die on either side, allowing for the formation of flange portions that protrude in a direction perpendicular to the pipe, enhancing strength and rigidity by sandwiching the metal pipe material in multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flange portions are formed by crushing metal pipe material laterally with upper and lower dies, then the metal pipe with flange can be formed, but the strength and rigidity of the metal pipe are insufficient
Solution Approach 1:
The forming process is segmented into two distinct stages: first forming the pipe portion between upper and lower dies, then forming flange portions by sandwiching the pipe material between lateral dies. This segmentation allows each stage to be optimized independently, achieving both structural integrity and manufacturing efficiency
Solution Approach 2:
The invention transitions from traditional lateral crushing to multi-directional forming by introducing lateral dies that sandwich the pipe material from the sides. This dimensional change enables flange portions to protrude in the vertical direction while maintaining lateral confinement, significantly improving strength and rigidity
2Strength
If flange portions are formed by crushing metal pipe material laterally, then the metal pipe can be formed, but the rigidity of the metal pipe is insufficient
Solution Approach 1:
The forming tool merges multiple die components (upper die, lower die, and lateral dies) into an integrated system that performs both pipe formation and flange formation in a coordinated manner. This unified approach achieves enhanced rigidity while managing device complexity through functional integration
3Manufacturing precision
If the first die and second die are divided in the second direction to sandwich metal pipe material, then flange portions protruding in the first direction can be formed, but the forming process becomes more complex
Solution Approach 1:
The first die and second die are segmented into multiple portions along the second direction, creating sandwiching regions that precisely control flange formation. This segmentation enables accurate positioning and shaping of flange portions while maintaining manageable die structures through modular design
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A forming device forms a metal pipe with a flange and includes a forming tool for forming the metal pipe, in which the forming tool includes a first die and a second die facing each other in a first direction in a cross-sectional view, and a third die disposed on at least one side of a metal pipe material in a second direction intersecting the first direction, and at least one of the first die and the second die is divided in the second direction and sandwiches a part of the metal pipe material in the second direction to form a flange portion.