Multi-Nozzle Cooling of Hollow Bends for Uniform Hardness
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Solution Overview
Problem
Manufacturing hollow bent parts with extremely small bending radii is challenging due to issues like wrinkles, folds, reduced plate thickness, and non-uniform cooling, which leads to hardness and strength inconsistencies in the circumferential direction.
Innovation Solution
A cooling device with multiple nozzle configurations and control mechanisms that inject refrigerant at specific angles to ensure uniform cooling, preventing backflow and enhancing collision pressure, thereby maintaining hardness uniformity in hollow bent parts with small bending radii.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If bending processing is performed with a small bending radius (1 to 2 times or less than diameter), then the hollow bent part can achieve compact shape and high strength-to-weight ratio, but wrinkles or folds occur on the inner circumferential side and plate thickness is significantly reduced on the outer circumferential side
Solution Approach 1:
The patent applies temperature parameter changes to resolve the contradiction. By heating the hollow material to a specific temperature range before bending, the material becomes more formable, allowing small bending radii to be achieved without causing wrinkles, folds, or excessive plate thickness reduction. The temperature parameter transformation enables the material to accommodate sharp bends while maintaining surface quality.
2Strength
If rapid cooling is applied after heating to achieve high strength through quenching, then the hollow material gains high strength properties, but non-uniform cooling occurs in the circumferential direction leading to hardness inconsistencies
Solution Approach 1:
The patent applies local quality by providing different cooling conditions to different regions of the hollow material. The cooling device is configured to supply cooling fluid to both the inner and outer circumferential surfaces, ensuring uniform heat extraction throughout the cross-section. This local differentiation of cooling approach prevents hardness inconsistencies while achieving the desired strength through quenching.
Solution Approach 2:
The patent introduces a cooling fluid as an intermediary medium to achieve uniform cooling. The cooling fluid circulates through channels that contact both the inner and outer circumferential surfaces of the hollow material, acting as a mediator to evenly extract heat and prevent localized hardness variations while maintaining overall strength.
3Device complexity
If conventional cooling devices are used with nozzles facing the outer circumferential surface only, then the device structure is simple, but the refrigerant flows along the outer surface without effectively cooling the inner circumferential side
Solution Approach 1:
The patent applies segmentation by dividing the cooling function into multiple independent nozzle systems. One set of nozzles is positioned to cool the outer circumferential surface, while another set is positioned to cool the inner circumferential surface. This segmentation of the cooling device ensures that both surfaces receive adequate cooling while maintaining relatively simple device structure.
Solution Approach 2:
The patent applies dimensionality change by positioning cooling nozzles in different spatial locations - both outside and inside the hollow material. This multi-dimensional arrangement of cooling nozzles allows the refrigerant to effectively reach and cool both the outer and inner circumferential surfaces, transforming a single-direction cooling approach into a multi-directional cooling system.
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
The solution achieves uniform cooling and sufficient hardness in the circumferential direction of hollow bent parts with small bending radii, improving the manufacturing process and product quality.
Implementation Method 1
cooling the hollow material by injection of a refrigerant
Implementation Method 2
cooling the hollow material by injection of a refrigerant
Implementation Method 3
injection direction of the refrigerant is a third injection direction forming an angle of 20 degrees or more and 70 degrees or less with respect to a bent inner circumferential surface of the bent portion
Data Source
AI summary
This cooling device includes a first cooling mechanism and a second cooling mechanism. The first cooling mechanism includes a first nozzle disposed to be aligned with a heating coil on a downstream side and whose injection direction of a refrigerant is a first injection direction, a second nozzle disposed to be aligned with the first nozzle on a downstream side and whose injection direction of the refrigerant is a second injection direction intersecting the first injection direction, a first valve selectively switching a supply destination of the refrigerant between one and the other of the first nozzle and the second nozzle, and a first control unit controlling the first valve. The second cooling mechanism includes a third nozzle disposed on a side opposite to the first nozzle and the second nozzle with the extension line sandwiched therebetween and whose injection direction of the refrigerant is a third injection direction forming an angle of 20 degrees or more and 70 degrees or less with respect to a bent inner circumferential surface of a bent portion.