Metal Pipe Forming Pressure Control for Uniform Hardenability
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Solution Overview
Problem
Existing forming devices experience variations in hardenability of metal pipes due to pressure drops caused by contact between dies and cooling, leading to decreased adhesion and inconsistent pipe formation.
Innovation Solution
A forming device with a controller that maintains a consistent pressure in the metal pipe material by controlling the gas supply, using a first pressure for pipe formation and a second pressure for flange formation, and includes a gas storage system to intermittently supply gas, ensuring stable expansion and shaping of both pipe and flange portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas is supplied into heated metal pipe material to expand and form pipe portion and flange portion simultaneously, then productivity is improved, but pressure drops occur causing variations in hardenability
Solution Approach 1:
The cavity is divided into two separate portions: a first cavity for forming the pipe portion and a second cavity for forming the flange portion. This segmentation allows independent pressure control and forming timing for each portion, preventing pressure drops that would otherwise occur during simultaneous formation while maintaining high productivity.
Solution Approach 2:
The pipe portion is formed first in the first cavity while maintaining stable gas pressure, before the flange portion is formed in the second cavity. This preliminary action ensures that the pipe portion achieves consistent hardenability before the pressure is redirected to form the flange portion.
2Manufacturing precision
If dies are joined to form cavity for pipe portion, then manufacturing precision is improved, but adhesion between pipe and dies decreases due to pressure drop
Solution Approach 1:
Gas pressure is maintained continuously during the entire forming process. The gas supply is controlled to ensure pressure stability in the first cavity during pipe portion formation, preventing adhesion loss while maintaining precise die contact for accurate shaping.
Solution Approach 2:
The pipe portion is formed first while maintaining stable gas pressure and die adhesion, before the dies are repositioned to form the flange portion. This preliminary formation ensures precise shaping with consistent adhesion.
3Strength
If gas pressure is increased to maintain adhesion, then strength is improved, but variations in hardenability increase due to pressure instability
Solution Approach 1:
By segmenting the cavity into separate first and second portions, the system can maintain appropriate gas pressure levels for each forming stage independently. This prevents the need to over-pressurize the system, which would cause hardenability variations, while still maintaining sufficient adhesion for precise forming.
Solution Approach 2:
The pipe portion is formed first under controlled gas pressure that maintains adhesion without causing pressure instability. This preliminary formation at optimal pressure ensures uniform hardenability before the pressure is adjusted for flange portion formation.
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 prevents pressure drops, maintains adhesion between the pipe and dies, and reduces variations in hardenability, allowing for consistent formation of pipe and flange portions with desired shapes and sizes.
Implementation Method 1
a gas supply unit which supplies a gas into a metal pipe material held between the upper die and the lower die so as to expand the metal pipe material
Implementation Method 2
the controller controls the gas supply of the gas supply unit so as to maintain a pressure in the metal pipe material at a first pressure when the gas is supplied from the gas supply unit into the metal pipe material
Implementation Method 3
a heated metal pipe material which is held between the first die and the second die
Implementation Method 4
variations in hardenability of metal pipes due to pressure drops caused by contact between dies and cooling
Data Source
AI summary
The controller controls the gas supply of the gas supply unit so as to maintain a pressure in a metal pipe material at a first pressure when a gas is supplied into the metal pipe material which is formed into a pipe portion in a main cavity portion in a state where an upper die and a lower die are joined to each other. It is possible to prevent pressure drop in the pipe portion caused by cooling of the pipe portion due to a contact between the dies, and the pipe portion. Thus, it is possible to suppress a decrease in a force for pressing the pipe portion against the dies. It is possible to suppress a decrease in adhesion between the pipe portion and the dies when the metal pipe is formed, and it is possible to suppress occurrence of variations in hardenability in the pipe portion.