Rolling-Bulging Tube Forming for Uniform Wall Thickness
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Solution Overview
Problem
Current hydraulic bulging technologies for forming tubular products often result in non-uniform wall thickness, leading to reduced performance and efficiency due to excessive thinning of the bulging area.
Innovation Solution
A rolling-bulging forming hydraulic machine that simultaneously applies internal pressure hydraulic bulging and external rolling forming, using a frame with upper and lower rolling mechanisms and fixed and movable liquid bulging hydraulic cylinders to coordinate diameter reduction and expansion, ensuring uniform wall thickness and enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hydraulic bulging technology is used to form tubular products, then the tube blank can be formed in a radial expansion manner under internal pressure, but the wall thickness of the bulging area is excessively thinned, resulting in non-uniform wall thickness and reduced forming performance
Solution Approach 1:
The patent combines hydraulic bulging technology with external rolling technology into a integrated rolling-bulging forming system. The hydraulic cylinder applies internal pressure for radial expansion while external rolling rollers simultaneously compress the outer surface, merging two forming mechanisms to achieve both shape transformation and wall thickness control in a single process
Solution Approach 2:
The external rolling rollers apply localized compressive force to specific regions of the tubular workpiece during bulging. This local quality approach allows differential control of wall thickness in different areas, preventing excessive thinning in the bulging zone while maintaining the desired radial expansion shape
2Shape
If only internal pressure hydraulic bulging is applied, then the tubular product can be expanded radially, but the forming process takes longer and production efficiency is reduced
Solution Approach 1:
The patent merges hydraulic bulging and external rolling into a single coordinated forming process. Both mechanisms operate simultaneously on the tubular workpiece, combining the radial expansion capability of hydraulic bulging with the shape control and speed advantages of external rolling, thereby improving forming speed and production efficiency
Solution Approach 2:
The external rolling rollers continuously compress the outer surface of the tubular workpiece throughout the bulging process. This continuous useful action maintains plastic deformation throughout the material, accelerating the forming process and reducing the time required to achieve the desired tubular expansion compared to hydraulic bulging alone
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 machine achieves uniform wall thickness and improved performance of tubular products by synchronizing internal pressure and external rolling, increasing production efficiency and quality.
Implementation Method 1
the fixed liquid bulging hydraulic cylinder and the movable liquid bulging hydraulic cylinder are used to perform hydraulic bulging on the to-be-machined tubular product
Implementation Method 2
a tube blank can be formed in a radial expansion manner under the internal pressure
Implementation Method 3
the upper rolling mechanism and the lower rolling mechanism are used to roll surfaces of a to-be-machined tubular product
Implementation Method 4
the diameter reduction and expansion of the to-be-machined tubular product are carried out simultaneously and coordinated with each other
Data Source
AI summary
The present invention discloses a rolling-bulging forming hydraulic machine for tubular products, which includes a frame. The frame is provided with an upper rolling mechanism, a lower rolling mechanism, a fixed liquid bulging hydraulic cylinder and a movable liquid bulging hydraulic cylinder. The upper rolling mechanism and the lower rolling mechanism are arranged oppositely, and the upper rolling mechanism and the lower rolling mechanism are used to roll surfaces of a to-be-machined tubular product. The fixed liquid bulging hydraulic cylinder and the movable liquid bulging hydraulic cylinder are arranged oppositely, and the fixed liquid bulging hydraulic cylinder and the movable liquid bulging hydraulic cylinder are used to perform hydraulic bulging on the to-be-machined tubular product.