Rectangular-Ribbed Metal Core for Small-Diameter Tube Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Small diameter metal tubes are difficult to form due to the need for greater forming force and increased tendency to buckle, and they lack consistent diameter control and recyclability, which limits their use as cores for sheet materials.
Innovation Solution
A thin wall bellows tube with a rectangular ribbed profile is formed from a metal strip using a multi-pass roll-forming process, creating a corrugated profile that is then helically wound into a cylindrical core with a mechanical lockseam, allowing for adjustable diameter and improved strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal strip is formed into small diameter tubes, then recyclable cores can be produced, but greater forming force is required and buckling tendency increases
Solution Approach 1:
The tube forming process is divided into multiple sequential rolling passes, each creating a segment of the final corrugated profile. This segmentation allows the metal strip to be progressively deformed into the desired shape without requiring excessive force in a single operation, while maintaining recyclability of the final product
Solution Approach 2:
The metal strip undergoes preliminary corrugation and profile formation through multiple rolling passes before being formed into the final tubular shape. This preliminary action pre-strengthens the strip structure and reduces the forming force needed for the final tube formation, while ensuring the product maintains its recyclable metal composition
2Weight of moving object
If tube wall thickness is decreased, then lighter cores can be produced, but buckling tendency increases
Solution Approach 1:
The tube structure incorporates a corrugated profile with alternating ridges and valleys, creating a composite geometric structure that provides enhanced buckling resistance. This geometric reinforcement allows the use of thinner metal walls while maintaining the structural integrity needed to prevent buckling during handling and use
Solution Approach 2:
The corrugated profile introduces controlled curvatures and rounded transitions in the tube wall structure. These curved geometric features distribute stress more effectively and increase buckling resistance, enabling the use of lighter, thinner-walled tubes that would otherwise be prone to deformation
3Manufacturing precision
If forming force is increased, then small diameter tubes can be formed, but diameter control consistency deteriorates
Solution Approach 1:
The diameter control process is segmented into multiple rolling passes, each contributing a controlled amount of deformation. This incremental approach allows for precise control of the final tube diameter while avoiding the need for excessive forming force that would compromise dimensional consistency
Solution Approach 2:
The multi-pass rolling process provides inherent feedback control, where each pass builds upon the previous deformation state. This sequential process allows for real-time adjustment and maintains consistent diameter control throughout the forming operation, preventing the diameter variation that would result from high-force single-pass forming
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 enables the formation of recyclable metal cores with consistent dimensions and increased strength, facilitating efficient sheet winding and handling while reducing environmental impact by providing a recyclable alternative to traditional cores.
Implementation Method 1
a corrugated profile that is then helically wound into a cylindrical core
Implementation Method 2
the profiled strip is fed into a tube forming machine at which the strip is curled or wrapped between three sets of rollers (lead, mandrel and buttress rollers) into helical tubes
Data Source
AI summary
Disclosed is a tubular core on which sheets of metal or other material can be wound and supported, for shipment, handling and dispersal, and a method for forming the core. The core comprises a metal sheet or strip which has a rectangular-ribbed cross-sectional profile comprising rectangular, flat ribs, and which is wound spirally into a tubular configuration. The core is formed by passing the strip through a plurality of roll-forming stands, to progressively form sections of the ribs and progressively define the sections into the rectangular ribbed profile in which the flat ribs collectively form a support surface for the sheets which are to be wound on the core.