Pipe Forming Die Shielding for Flange Accuracy and Fragment Containment
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Solution Overview
Problem
In forming devices, the concern is that foreign matter such as fragments generated during the formation of metal pipes under high-pressure gas conditions may scatter and deform the flange part, and existing solutions to prevent deformation by opening the sub-cavity part risk allowing these fragments to escape and cause contamination.
Innovation Solution
A forming device with an upper and lower die, a shielding member to prevent foreign matter from scattering, and a heating mechanism to expand the metal pipe material, where the sub-cavity part is extended outward and the shielding member is positioned to block foreign matter from exiting, using the die's own components to function as the shielding mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sub-cavity part is made open to the outside to prevent flange part deformation, then the flange part can be formed without deformation, but foreign matter such as fragments may fly to the outside and scatter
Solution Approach 1:
The die is segmented into multiple functional regions: the main cavity part for forming the pipe body, the sub-cavity part for forming the flange, and the shielding member that creates a protected discharge region. This segmentation allows the sub-cavity to remain open while directing foreign matter into a controlled area, resolving the contradiction between preventing deformation and containing foreign matter.
Solution Approach 2:
The shielding member acts as an intermediary element between the sub-cavity part and the external environment. It redirects the flow of foreign matter away from the surrounding area while maintaining the open configuration of the sub-cavity, thus preventing both flange deformation and foreign matter scattering simultaneously.
2Object-affected harmful factors
If the sub-cavity part is closed to contain foreign matter, then foreign matter scattering is prevented, but the flange part may deform under high-pressure gas
Solution Approach 1:
The die structure is divided into functional zones where the sub-cavity part remains open for proper flange formation, while the shielding member creates a separate protected zone to contain and redirect foreign matter. This segmentation eliminates the need to close the sub-cavity while still achieving foreign matter containment.
Solution Approach 2:
The shielding member serves as an intermediary that intercepts foreign matter before it can scatter externally, while allowing the sub-cavity to remain open for accurate flange formation. This mediator element resolves the contradiction by providing a third space that captures harmful factors without compromising the forming quality.
3Object-affected harmful factors
If a shielding member is added to prevent foreign matter scattering, then foreign matter containment is improved, but the device complexity increases
Solution Approach 1:
The shielding member is designed to perform multiple functions: it shields against foreign matter scattering, guides the flow of expanded metal pipe material, and structurally integrates with the die body. By making the shielding member multi-functional, the additional component justifies its presence through multiple benefits rather than just one, reducing the perceived complexity increase.
Solution Approach 2:
The shielding member is merged with the die structure itself rather than being a completely separate component. It is provided as an integral part of the die, combining the forming function and the shielding function into a unified structure, thereby minimizing the increase in device complexity while achieving foreign matter containment.
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 effectively prevents foreign matter from scattering to the surroundings, ensuring the formation of a desired flange shape without contamination, and allows for easy insertion and removal of the metal pipe material without hindrance.
Implementation Method 1
a heating mechanism that energizes the metal pipe material to heat the metal pipe material
Implementation Method 2
a gas supply part for supplying a gas for expanding the metal pipe material into the metal pipe material held between the lower die and the upper die and heated by the heating mechanism
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
In a case where foreign matter such as fragments is generated in a main cavity part (MC) or sub-cavity parts (SC1, SC2) in the expanding and forming of a metal pipe material between an upper die (12) and a lower die (11), the movement of foreign matter in an outward direction in an extending direction of the sub-cavity parts (SC1, SC2), crossing an extending direction of the metal pipe material is blocked by protrusions (96b, 96b) of an upper die holder (96) that is a shielding member provided on the extending line of the sub-cavity parts (SC1, SC2) in the expanding of the metal pipe material.