Split Bending Die Assembly for Thin-Wall Pipe Buckling Control
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Solution Overview
Problem
Existing pipe/tube bending machines face issues with distortion and buckling due to unequal stresses during the bending process, particularly in thin-walled pipes, and existing solutions like hydraulic cylinders are maintenance-intensive and not suitable for all machines.
Innovation Solution
A die assembly with a split bending die and a clamp die, featuring movable plates and a wedge plate that compresses to reduce the channel width, providing support to the workpiece and minimizing distortion, is used in conjunction with a bending machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic cylinders are used to press downward on the bending die to reduce the width of the groove, then the workpiece walls are supported during bending, but the system becomes maintenance-intensive and messy
Solution Approach 1:
The patent replaces the hydraulic cylinder system with a purely mechanical wedge-based system. The wedge plate is driven by a lead screw mechanism that converts rotational motion into linear motion, pushing the wedge against the movable plates to reduce channel width. This mechanical substitution eliminates hydraulic fluid, hoses, and pumps, thereby reducing maintenance requirements and messiness while maintaining the workpiece support function.
Solution Approach 2:
The patent introduces a wedge plate as an intermediary element between the lead screw mechanism and the movable plates. The wedge plate converts the linear motion from the lead screw into a lateral force that compresses the movable plates inward, reducing the channel width. This intermediary mechanism provides a clean, maintenance-free way to achieve the same effect as hydraulic cylinders.
2Loss of substance
If thin wall pipe is used to reduce steel quantity, then material savings are realized, but the pipe distorts and buckles more easily during bending
Solution Approach 1:
The patent applies preliminary anti-action by reducing the channel width before and during the bending process. The movable plates are positioned to provide support to the thin-walled pipe walls before the bending forces are applied, preventing the pipe from distorting or buckling. The wedge mechanism actively compresses the channel width during bending, providing continuous support to counteract the unequal stresses that cause thin-walled pipe failure.
Solution Approach 2:
The patent makes the channel width dynamic rather than static. The movable plates can adjust the channel width during the bending process, allowing the die to adapt to the changing dimensions of the pipe as it bends. This dynamic adjustment provides optimal support throughout the bending operation, preventing distortion of thin-walled pipes while maintaining material efficiency.
3Reliability
If the channel width is reduced to support thin-walled pipes, then distortion and buckling are minimized, but the die assembly becomes more complex
Solution Approach 1:
The patent segments the bending die into multiple independent components: a fixed die, movable plates, and a wedge plate. Each movable plate can be independently adjusted by the wedge mechanism to reduce the channel width. This segmentation allows the die to provide precise, localized support to the pipe walls without requiring a completely complex overall structure. The modular design makes the system manageable and maintainable.
Solution Approach 2:
The patent introduces dynamic elements through the movable plates and wedge mechanism. Instead of a static die structure, the movable plates can adjust their position during bending to provide optimal support. The lead screw and wedge mechanism provide a simple yet effective way to create this dynamic adjustment, achieving high bending quality without excessive 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
The die assembly effectively reduces channel width to securely grasp and bend workpieces, minimizing distortion and buckling, and is maintenance-friendly, suitable for both hydraulic and electric bending machines.
Implementation Method 1
a wedge plate positioned between the first plate and the second plate. The wedge plate is configured to be movable relative to the movable plates between a retracted position and an engaged position so that movement of the wedge plate from the retracted position to the engaged position is configured to cause the movable plates to move to from the first position to the second position reducing the width of the channel
Data Source
AI summary
A die assembly having a bending die and a clamp die. The bending die comprises one or more movable plates and a wedge plate. The bending die includes a channel formed in one or more of the plates configured to receive a pipe or other workpiece to be formed. The movable plates are movable between a first position wherein each plate is spaced from the adjacent plate a predetermined distance and a second position wherein each plate is compressed so there is less distance between the plates. Movement of the wedge plate from the retracted position to the engaged position causes the movable plates to move from the first position to the second position. Compression of the movable plates correspondingly reduces the width of the channel to help grasp any workpiece inserted therein.