Micro-Casting Roll Forming for Dense Large Special-Shaped Pipes
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Solution Overview
Problem
The production of large special-shaped connection pipes for nuclear power requires a more efficient manufacturing method due to their complex shapes and high-temperature, high-pressure requirements, as current forging processes are lengthy and costly, and existing additive manufacturing methods lack suitable equipment for irregular steel pipes.
Innovation Solution
A roll forming device for micro-casting and rolling additive manufacture, comprising a supporting assembly, sliding assembly, and roller system assembly, which allows for immediate roll forming after laser cladding, with adjustable components and flexible movement facilitated by guide rails and hydraulic cylinders, enabling precise processing of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser cladding is used for manufacturing large special-shaped connection pipes, then the manufacturing process can be simplified and production cost reduced, but the metal layer lacks density and requires additional pressing device auxiliary work
Solution Approach 1:
The patent combines laser cladding with roll forming into an integrated micro-casting and rolling additive manufacture process. The roll forming device with multiple rollers is directly applied to the workpiece during or immediately after laser cladding, merging the deposition and densification operations into a unified manufacturing system that eliminates the need for separate pressing device auxiliary work
Solution Approach 2:
The roll forming operation is performed immediately after laser cladding while the metal layer is still in a favorable state for densification. This preliminary action approach ensures the metal layer achieves proper density during the additive manufacturing process itself, preventing defects before they can propagate
2Manufacturing precision
If traditional forging process is used for large special-shaped connection pipes, then the microstructures and internal defects can be controlled, but the production process becomes lengthy and production cost increases
Solution Approach 1:
The micro-casting and rolling additive manufacture process enables continuous deposition and forming operations without the need for intermediate cooling, machining, or heat treatment steps required in traditional forging. The laser cladding and roll forming operations proceed continuously, building the connection pipe layer by layer in a single uninterrupted manufacturing sequence
Solution Approach 2:
The invention extracts and eliminates the lengthy intermediate steps inherent in traditional forging processes, such as extensive machining, multiple heat treatments, and assembly operations. By using additive manufacturing with roll forming, only the essential deposition and densification steps remain, dramatically reducing total process time
3Reliability
If large-scale forging equipment is used for producing large special-shaped connection pipes, then the required microstructures and internal defect control can be achieved, but the equipment scale and production cost increase
Solution Approach 1:
The roll forming device is divided into multiple independent rollers that can be individually controlled and positioned. This segmentation allows the system to handle large special-shaped connection pipes through a series of smaller, more manageable forming actions, eliminating the need for a single large-scale forging press while maintaining equivalent or superior defect control
Solution Approach 2:
The invention replaces the traditional mechanical forging system with a combination of laser energy field and controlled roll forming. The laser provides the energy for material deposition and heating, while the rollers provide localized mechanical pressure for densification, substituting the need for massive mechanical forging equipment
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 device reduces processing procedures, minimizes defective products, and enhances processing quality by allowing for automatic adjustment of working angles and various processing types, making it suitable for complex nuclear power pipe manufacturing.
Implementation Method 1
a first hydraulic cylinder and a second hydraulic cylinder, a first hydraulic pushing rod and a second hydraulic pushing rod
Implementation Method 2
a first roller and a second roller, both the outer shape of the first roller and the outer shape of the second roller are stepped shafts
Implementation Method 3
roller system assembly includes a roller cover, a first roller, a second roller
Data Source
AI summary
The present invention discloses a roll forming device for micro-casting and rolling additive manufacture for large special-shaped pipes, comprises a supporting assembly, a sliding assembly, and a roller system assembly. The sliding assembly includes a guide rail, hydraulic cylinders, hydraulic push rods and a guide rail sliding frame. Two ends of the guide rail are respectively fixedly connected with the centers of two ends of the frame plate in a width direction, the lower surface of the sliding plate of the guide raid sliding frame is slidably connected with the guide rail, housings of the hydraulic cylinders are respectively fixedly connected to the centers at both ends of the frame plate in the width direction. The invention adopts the structures of the guide rail, the hydraulic cylinder and the steering hinge rod to expand the working range of the device and the working types of workable parts.