Integral Pipe Flange Forming via Diameter Expansion
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Solution Overview
Problem
Existing methods for forming flanges on vehicle exhaust pipes through welding lead to stress concentration and potential breakage due to vibrations, and are labor-intensive and costly.
Innovation Solution
A method involving increasing the diameter of the pipe end, removing radially-symmetric portions to form projecting parts which are then bent orthogonally to create an integral flange, eliminating the need for separate flange welding and allowing for a reduced part count and lighter pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate flanges are welded to the outer periphery of pipe ends, then flange connection is achieved, but stress concentration occurs at the weld leading to cracks and breakage
Solution Approach 1:
The flange is merged with the pipe body by forming it as an integral part through diameter expansion and bending of the pipe wall itself, eliminating the separate flange component and weld joint. This combining of the flange and pipe body into a single monolithic structure removes the stress concentration point at the weld interface while maintaining structural strength.
2Ease of manufacture
If separate flanges are welded to pipe ends, then connection is achieved, but additional labor and manufacturing costs are incurred
Solution Approach 1:
The flange formation process is merged into the pipe manufacturing process itself. By expanding the pipe diameter at the end portion and bending the pipe wall to form the flange, the separate flange manufacturing and welding operations are eliminated, reducing both labor costs and manufacturing time.
Solution Approach 2:
The flange is formed preliminarily during the pipe manufacturing process rather than as a separate post-processing step. The diameter expansion and bending operations are performed on the pipe body itself before final assembly, integrating multiple operations into a streamlined sequence that improves productivity.
3Weight of moving object
If separate flanges are welded to pipe ends, then connection structure is achieved, but pipe weight increases
Solution Approach 1:
The flange and pipe body are merged into a single integral structure, eliminating the need for separate flange components. This reduction in part count directly reduces the total weight of the assembly while simplifying the overall device structure.
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 method reduces stress concentration, prevents breakage from vibrations, lowers manufacturing costs, and simplifies the manufacturing process by eliminating the welding step while achieving a lighter and more efficient pipe coupling system.
Implementation Method 1
the two projecting portions are bent outward so that the projecting portions are approximately orthogonal to the pipe body and form the flange at the end of the pipe
Data Source
AI summary
A method for forming a flange at an open end of a pipe comprises increasing the diameter of the open end of the pipe to form a radially-enlarged pipe wall. Radially-symmetric portions of the radially-enlarged pipe wall are then removed so as to form at least two opposing projecting portions, which are then bent outwardly so as to be at least substantially orthogonal to the pipe, thereby forming the flange on the pipe.