Shaped Wire Element from Wound Mesh
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Solution Overview
Problem
The production of cylindrical or hollow-cylindrical shaped wire bodies from knitted wire tubes results in irregular cutting, leading to chaff formation and material waste, and the use of lubricants can leave residues that are undesirable in final products, especially in applications requiring 100% chaff-free materials and contamination-free cooling elements.
Innovation Solution
A method involving winding a wire mesh section onto itself with predetermined length and windings to ensure uniform deformation, followed by radial compression and axial forming, allowing for precise cutting and elimination of lubricant residues, enabling the production of chaff-free, uniformly shaped wire bodies with consistent density and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If knitted wire tubes are cut into sections for production, then cylindrical shaped wire bodies can be produced, but irregular cutting occurs leading to chaff formation and material waste
Solution Approach 1:
The wire mesh is pre-formed into a tubular shape with predetermined dimensions and structure before the final shaping process. This preliminary formation allows for precise cutting without chaff generation, as the mesh structure is already optimized for the intended application. The pre-formed tube includes precisely defined end edges that prevent fraying during subsequent processing.
Solution Approach 2:
The invention changes the structural parameters of the starting material from conventional knitted wire to wire mesh with specific mesh sizes, wire diameters, and weave patterns. These parameter changes enable the material to be cut and formed without generating chaff, while maintaining the desired cylindrical shape and physical properties in the final product.
2Ease of manufacture
If lubricants are applied to wire before knitting, then the knitting process can be carried out properly, but lubricant residues remain on the surface of the finished product
Solution Approach 1:
The invention extracts and eliminates the lubricant application step from the manufacturing process. By using wire mesh as the starting material instead of knitted wire, the need for lubricants during the forming process is removed entirely. This extraction of the harmful element (lubricants) prevents residue contamination while maintaining manufacturing feasibility through alternative forming methods suitable for wire mesh.
Solution Approach 2:
The invention replaces the reusable knitted wire material (which requires lubricants) with wire mesh that can be processed without lubricants. This substitution uses a different material system (wire mesh vs. knitted wire) that inherently does not require lubricant application, thereby eliminating the harmful residue problem while maintaining the ability to produce cylindrical shaped bodies.
3Reliability
If manual inspection and chaff removal is performed on each hose section, then 100% chaff-free starting material can be achieved, but manufacturing effort and time increase dramatically
Solution Approach 1:
The invention converts the potential harm of cutting wire mesh (which could generate chaff) into a beneficial process by using precise cutting methods that actually prevent chaff formation. The controlled cutting of wire mesh, when performed on pre-formed tubes with optimized structure, results in clean cuts without fraying or chaff generation, thereby achieving both efficiency and reliability simultaneously.
Solution Approach 2:
The wire mesh is pre-formed into tubular sections with precisely defined dimensions and structurally optimized end edges before final assembly. This preliminary formation ensures that the material is ready for direct use without requiring subsequent manual inspection or chaff removal, as the pre-forming process already guarantees the absence of defects.
4Object-generated harmful factors
If wire mesh is used instead of knitted wire, then lubricant residues are eliminated, but the wire mesh tends to fray at edges and create surface irregularities during plastic deformation
Solution Approach 1:
The invention optimizes the structural parameters of the wire mesh, including mesh size, wire diameter, weave pattern, and end edge configuration. These parameter changes are specifically designed to prevent fraying during plastic deformation while maintaining the ability to form cylindrical shapes. The optimized parameters ensure that the wire mesh behaves predictably during forming without requiring lubricants.
Solution Approach 2:
The wire mesh is pre-formed into tubular shapes with structurally reinforced end edges and uniform wall thickness before final assembly. This preliminary formation process, when performed on optimized wire mesh, prevents edge fraying and surface irregularities by establishing the correct geometry and structural integrity in advance, eliminating the need for lubricants while maintaining manufacturing precision.
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 cylindrical or hollow-cylindrical shaped wire bodies with uniform density and surface quality, eliminating material waste and lubricant residues, and enabling precise cutting without chaff formation, suitable for applications requiring high precision and cleanliness.
Implementation Method 1
The invention relates to a method for producing a wire shaped body from a wire mesh by plastic deformation
Data Source
Figure 1~6
Figure 2~4
Figure 5
AI summary
A section of mesh (26) of defined length is wound (28) onto itself transversely to its longitudinal direction and the section of mesh wound onto itself is then compressed (32) transversely to its longitudinal direction into an intermediate product (34), wherein the wound section of mesh, immediately prior to being formed into the intermediate product (34), runs with the leading edge thereof arranged in the inside to the trailing edge thereof lying externally on the peripheral surface of the wound section of mesh in such a way that the same number of mesh layers is always stacked when viewed over the full circumference of the wound section of mesh. The intermediate product (34) is then shaped by axial compression (36) into the shaped wire element in such a way that the peripheral surface of the shaped wire element demonstrates an at least approximately constant uniform pattern.