Metal Pipe Flange Forming with Local Thinning for Easier Welding
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Solution Overview
Problem
Existing forming devices face challenges in welding metal pipes with flange portions, as high pressure required for welding can lead to electrode wear and uneven welding quality due to the high thickness of flange portions.
Innovation Solution
A forming device with first and second dies featuring protrusion portions on the flange forming surfaces that do not abut when closed, allowing for the formation of thin wall portions at the flange, reducing the pressure needed for welding by controlling the drive unit to press the flange portions with these protrusions, thereby facilitating easier welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flange portion is formed with standard thickness, then the structural strength is maintained, but high welding pressure is required causing electrode wear and uneven welding quality
Solution Approach 1:
The invention applies local quality by creating a thin wall portion at a specific location on the flange portion where welding is performed. The flange portion has different thicknesses in different areas: a thin wall portion for welding and a thicker portion for structural strength. This resolves the contradiction by making the welding area thinner to reduce electrode wear while maintaining overall structural integrity.
2Strength
If high pressure is applied during welding of the flange portion, then welding strength is achieved, but electrode wear increases and welding quality becomes uneven
Solution Approach 1:
By creating a localized thin wall portion at the welding area, the invention allows welding to be performed with lower pressure, resulting in more uniform welding quality across the flange portion while still achieving adequate welding strength at the specific welding location.
3Ease of operation
If the flange portion thickness is reduced to enable easier welding, then welding pressure is decreased, but the overall structural strength may be compromised
Solution Approach 1:
The invention maintains structural strength by keeping the majority of the flange portion at standard thickness while only reducing the thickness at the specific welding location. This localized thinning allows easier welding without compromising the overall structural integrity of the flange portion.
Solution Approach 2:
The flange portion is segmented into different thickness zones: a thin wall portion for welding and thicker portions for structural support. This segmentation allows each area to serve its specific function optimally.
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 decreases the welding pressure and improves the welding process by creating thin wall portions at the flange, allowing for efficient welding without excessive pressure, thus preventing electrode wear and ensuring consistent quality.
Implementation Method 1
the protrusion portion pressing the flange portion
Data Source
AI summary
A forming device which expands a metal pipe material to form a metal pipe having a pipe portion and a flange portion includes first and second dies paired with each other and including pipe forming surfaces for forming the pipe portion and flange forming surfaces for forming the flange portion, a drive unit that drives at least one of the first and second dies, and a controller that controls the drive unit, in which, on at least one of the flange forming surfaces of the first and second dies, a protrusion portion protruding by an amount not to abut against the other flange forming surface when the dies are closed is formed and the controller controls the drive unit to form a thin wall portion at which a thickness of the flange portion becomes partially small at the flange portion by the protrusion portion pressing the flange portion.