Pipe With Rib Free Casting Non-Linear Internal Geometry
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Solution Overview
Problem
Conventional methods such as extrusion molding, press forming, welding, and metal mold casting find it extremely difficult to manufacture pipes with internal ribs that are non-linearly shaped, as they require complex geometries that are hard to achieve.
Innovation Solution
A pipe with a rib is manufactured using a free casting method where molten metal is drawn up through a shape defining member, allowing for the formation of bent or twisted portions by moving the starter or shape defining member, enabling the creation of pipes with internal ribs and non-linear shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (extrusion molding, press forming, welding, metal mold casting) are used to manufacture pipes with internal ribs, then manufacturing process is relatively simple, but it is extremely difficult to achieve non-linear shapes with internal ribs
Solution Approach 1:
The patent changes the fundamental parameter of the manufacturing method from conventional solid-state or mold-based processes to a molten metal free-casting process. This allows the metal to be drawn up through a shape-defining member in a molten state, enabling complex non-linear shapes with internal ribs that cannot be achieved by conventional methods. The metal is then cooled and solidified to form the final structure.
Solution Approach 2:
The patent introduces dynamic movement of the shape-defining member relative to the molten metal surface. By moving the shape-defining member horizontally or vertically, or by tilting it, the patent can create non-linear shapes including bent portions, twisted portions, and varying cross-sections along the longitudinal direction, while maintaining internal rib structures.
2Manufacturing precision
If a mold is used in continuous casting to define both longitudinal and sectional shapes, then shape definition is precise, but the casting must pass through the mold which limits shape flexibility
Solution Approach 1:
The patent separates the shape definition function into two independent parts: the shape-defining member defines only the sectional shape (cross-sectional geometry including internal ribs), while the longitudinal shape is determined by the movement trajectory of the shape-defining member. This segmentation allows independent optimization of sectional precision and longitudinal flexibility.
Solution Approach 2:
The patent makes the shape-defining member movable in multiple directions (horizontal movement parallel to molten metal surface, vertical movement, and tilting). This dynamic capability allows the same shape-defining member to create various longitudinal shapes (linear, bent, twisted, helical) while maintaining consistent sectional geometry, achieving both precision and versatility.
3Adaptability or versatility
If free casting method is used to create non-linear shapes, then shape flexibility is improved, but manufacturing pipes with internal ribs becomes extremely difficult
Solution Approach 1:
The patent designs the shape-defining member with a nested structure where a core rod contains internal channels or cavities that form the rib portions. The rib-forming structure is nested within the pipe-forming structure, allowing both the pipe wall and internal ribs to be formed simultaneously in a single casting process without requiring separate manufacturing steps.
Solution Approach 2:
The patent uses a carefully designed shape-defining member as an intermediary tool that transfers the desired geometry from the molten metal to the final casting. This shape-defining member acts as a mediator that enables the formation of complex internal rib structures by controlling the flow and solidification of molten metal around its internal features.
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 allows for the production of pipes with internal ribs and non-linear shapes that were previously difficult to manufacture, offering flexibility in design and potential applications such as heat exchangers.
Implementation Method 1
the starter is drawn up, and then, the molten metal is also drawn out following the starter by a surface film and surface tension of the molten metal
Implementation Method 2
cooling and solidifying the molten metal that has passed through the shape defining member and been drawn up
Data Source
AI summary
A method for manufacturing a pipe with a rib, in which a rib portion formed inside a pipe portion includes bent portions in accordance with bending of the pipe portion or a twisted portion in accordance with twisting of the pipe portion, includes drawing out molten metal held in a furnace by using a starter, from a surface of the molten metal, and drawing up the molten metal through a shape defining member defining a sectional shape of the pipe with the rib to be cast, and cooling and solidifying the molten metal passed through the shape defining member and drawn up. The bent portions are formed by moving at least one of the starter and the shape defining member in a horizontal direction. The twisted portion is formed by rotating at least one of the starter and the shape defining member about an axis extending along a vertical direction.