Metal Strip Pre-Forming with Edge Chamfering for Welded Tubes
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Solution Overview
Problem
The manufacturing of small-diameter roll-formed and welded tubes faces challenges in achieving optimal heat transfer and weld quality due to inconsistencies in embossed patterns and inner surface irregularities, particularly when using aluminum tubing, which affects the efficiency and cost-effectiveness in HVAC&R applications.
Innovation Solution
An apparatus and method for pre-forming metal strips involving a separate embossing tool and strip edge chamfering tool, where the chamfering tool is positioned downstream to minimize the impact on embossed patterns, and the rolls are designed to create a clearance that allows for chamfering of longitudinal side edges without affecting the embossed pattern, resulting in a reduced weld bead height and improved welding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If an embossed metal plate is manufactured using a pipe making machine with interlocking rollers, then the tube structure is formed, but the embossed patterns become deformed and inconsistent, making welding impossible
Solution Approach 1:
The patent divides the forming process into two separate stages: first forming the tube structure using conventional interlocking rollers, then separately applying the embossed pattern. This segmentation prevents the embossed patterns from being deformed during the tube forming process, as the patterns are applied after the structural formation is complete.
Solution Approach 2:
The patent applies the embossed pattern to the metal plate before the welding process, ensuring that the patterns are already in place and protected before any welding operations occur. This preliminary action ensures pattern consistency is maintained throughout subsequent manufacturing steps.
2Manufacturing precision
If the central section of the strip edge chamfering tool is dimensioned to avoid affecting embossed patterns, then the embossed pattern integrity is maintained, but the tool design becomes more complex
Solution Approach 1:
The chamfering tool is designed with different dimensional characteristics in different sections: the central section has a larger dimension that matches the embossed pattern area to avoid affecting it, while the side sections have smaller dimensions optimized for chamfering. This local differentiation allows the tool to perform chamfering operations without compromising the embossed pattern integrity.
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 approach enables the production of small-diameter tubes with enhanced heat transfer properties and improved weld quality by maintaining the integrity of the embossed pattern while minimizing the inner weld bead, thus addressing the challenges of cost reduction and performance in HVAC&R applications.
Implementation Method 1
The first and second rolls are shaped such that the clearance comprises side sections arranged on each side of the central section, in which the clearance has a reduced height. The side sections are located in a position where the longitudinal side edges of the metal strip will pass, so that the longitudinal side edges on each side of the metal strip become chamfered when being passed between the pair of rolls.
Data Source
Figure 1~2
Figure 3a~3c
Figure 4~6
AI summary
An apparatus and method for pre-forming a metal strip (40) for the manufacture of roll formed and welded tubes, comprising an embossing tool (20) and a strip edge chamfering tool (30) wherein the embossing tool comprises an embossing roll (1) having a cylindrical surface (2) with a central embossing portion (3, 3'), and the strip edge chamfering tool comprises an edge chamfering roll (31) comprising a recessed central section (34) and side sections (35) on each side of the central section, and an anvil roll (32), wherein the edge chamfering roll (31) and the anvil roll (32) are configured to receive and pass the metal strip in a clearance (33) formed between the rolls, wherein the clearance (33) has a reduced height in the side sections, which are located in a position where the longitudinal side edges of the metal strip will pass, so that the longitudinal side edges on each side of the metal strip, and on the embossed side of the metal strip become chamfered when being passed between the pair of rolls (31, 32).