Spinning Roller Adjusting Diameter and Angle for Tubular Workpiece Shaping
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Solution Overview
Problem
Existing methods for forming a reduced diameter portion on a metallic tubular member, such as a cylinder, face challenges in achieving accurate and efficient shaping, especially when the inclined angle or diameter reduction is significant, leading to increased processing time and difficulty in mass production due to the need for multiple paths and complex adjustments.
Innovation Solution
A method and apparatus that utilize a spinning process with multiple intermediate cross sections and center points, adjusting the relative position, revolution diameter, and angle of a roller to form a changed diameter portion by maintaining continuous contact with the workpiece, allowing for precise shaping and reducing the number of paths required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of paths is increased to achieve accurate shaping of complex reduced diameter portions, then manufacturing precision is improved, but processing time is prolonged
Solution Approach 1:
The invention applies dynamics by making the roller's revolution diameter and revolution plane angle adjustable during the spinning process. Instead of using fixed parameters requiring multiple paths, the system dynamically changes the roller configuration to match the target shape at each cross-section, enabling complex shapes to be formed in a single continuous operation while maintaining high precision and reducing processing time
Solution Approach 2:
The invention changes physical parameters of the roller (revolution diameter and plane angle) to adapt to different forming requirements. By calculating and adjusting these parameters based on the target outer shape at each intermediate cross-section, the system can accurately form complex reduced diameter portions without increasing the number of paths, thus resolving the contradiction between precision and processing time
2Manufacturing precision
If the roller revolution diameter and plane angle are adjusted for each intermediate cross section, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The invention uses feedback by calculating the required roller parameters (revolution diameter and plane angle) based on the target outer shape and providing this information to the control system. The control system then adjusts the roller configuration accordingly, creating a closed-loop system that ensures high precision while managing complexity through automated calculation and control
Solution Approach 2:
The invention makes the roller serve multiple functions by enabling it to adjust both its revolution diameter and plane angle. This multi-functional roller can adapt to various forming requirements for different cross-sections, eliminating the need for multiple specialized rollers or complex tooling changes, thus improving precision without proportionally increasing device complexity
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 approach enables the rapid and accurate formation of a changed diameter portion with a target outer shape, significantly reducing processing time and maintaining high accuracy, while also allowing for smooth surface formation and increased wall thickness, thus enhancing the efficiency and quality of the process.
Implementation Method 1
perform a spinning process, between neighboring intermediate cross sections out of said plurality of intermediate cross sections, adjusting a revolution diameter of said roller at the center point of each intermediate cross section
Data Source
AI summary
A plurality of intermediate cross sections and center points thereof are provided for a plurality of target processed portions from an unprocessed portion of a workpiece up to a final target processed portion. By adjusting a relative position between each intermediate cross section of the workpiece W and rollers 11, 12 revolving around the workpiece between neighboring intermediate cross sections, adjusting a revolution diameter of the roller and an angle of its revolution plane, mating the center point, diameter and inclined angle of the revolution plane inside of a revolving locus of the roller, with the center point, diameter and inclined angle of each intermediate cross section of the workpiece, and driving the roller and workpiece relatively to each other, with a part of outer peripheral surface of the roller being always in contact with an outer peripheral surface of the workpiece, a spinning process is performed to change the diameter of the portion to be processed of the workpiece.