Profiled Hose Nipple Forming With Cavity-Assisted Burr Prevention
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Solution Overview
Problem
Existing methods for producing profiled hose nipples often result in the formation of chips, burrs, and reduced inner diameters, leading to inefficiencies and potential damage to fluid lines during connection.
Innovation Solution
A divisible forming tool with radially inwardly projecting ring-shaped webs and outwardly pointing ring-shaped grooves is used to increase the pipe diameter, allowing material to be displaced into the grooves without contact with the tool wall, preventing burr formation on critical surfaces and maintaining the inner diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining methods (turning, grinding) are used to produce the nipple profile, then manufacturing precision is improved, but chips are produced that must be carefully removed or parts disposed of
Solution Approach 1:
The patent replaces traditional mechanical machining operations (turning, grinding) with a forming process using a forming punch and divisible forming tool. This substitution eliminates chip production while achieving the required profile geometry through plastic deformation and material displacement into the tool's cavities and grooves.
2Loss of substance
If roller burnishing or hammering is used to produce the profile, then chip production is reduced, but the processes are relatively time-intensive and machines require complex adjustment
Solution Approach 1:
The forming tool is divided into multiple parts (first and second forming tool parts) that can be assembled and disassembled. This segmentation allows for simplified adjustment and maintenance while enabling rapid production. The divisible tool design eliminates the complexity of traditional roller burnishing or hammering machines while maintaining high productivity through a single-forming operation.
3Loss of substance
If hammering or roller burnishing is used to produce the profile, then chip production is reduced, but burrs are formed that may damage the fluid line
Solution Approach 1:
The patent converts the potential harm of burr formation into a benefit by designing the forming tool with specific cavity and groove geometries. The material is directed into controlled cavities and grooves during forming, and any excess material forms burrs only in non-critical regions (profile troughs), while critical surfaces (profile webs) remain burr-free. This approach eliminates the harmful effect of burrs on fluid line damage.
4Shape
If cold working reduction in diameter is used to deform the pipe end into profiled shape, then the profile shape is achieved, but the diameter of the pipe in the region of the nipple is reduced
Solution Approach 1:
Instead of reducing the pipe diameter through cold working to create the profile, the patent inverts the approach by using a forming punch that increases the diameter while simultaneously creating the profile shape. The forming punch is designed with a diameter larger than the original pipe, and material is displaced radially outward into the tool's cavities and grooves, achieving both profile formation and diameter increase.
5Shape
If the diameter of the pipe is reduced in the region of the nipple, then the profile shape is achieved, but the flow in the region of the nipple is reduced
Solution Approach 1:
The patent inverts the traditional approach by increasing rather than reducing the pipe diameter during profile formation. The forming punch diameter is larger than the original pipe diameter, and the forming process simultaneously creates the profile shape and increases the diameter, thereby maintaining or improving volume flow in the nipple region.
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 enables the production of hose nipples with a simple, rapid, and cost-effective process that avoids diameter reduction and burr-related damage, ensuring a secure and non-throttling connection for fluid lines.
Implementation Method 1
pressing or drawing a forming punch into the pipe portion, wherein the forming punch is designed in such a way that when it is being pressed or drawn into the pipe portion, the diameter of the pipe portion increases and the material of the pipe portion is radially outwardly displaced into the profile of the elongate cavity
Data Source
AI summary
The invention relates to the production of profiled hose nipples. The invention was based on the object of providing a method and an apparatus which allow hose nipples of the type outlined in the introduction to be produced in a simple manner such that the formation of burrs is avoided and there is no reduction in diameter. This object is achieved in that during the forming of pipe portions (1) in the apparatus (2, 7, 9) according to the invention in the region of the subsequent ring-shaped webs (4) of the nipple profile (3), the material of the pipe portion (1), at its outwardly pointing end (4), does not come into contact with the tool in the region of the parting joints (6) of the apparatus (2, 7). This can be realized by additional cavities (14) in the tool (2, 7).