Steel Pipe Out-of-Roundness Prediction for Faster Forming Control
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Solution Overview
Problem
Current steel pipe manufacturing processes face challenges in accurately predicting and controlling the out-of-roundness of steel pipes after the pipe expanding step, particularly due to the influence of multiple operational steps and variations in sheet thickness and material, leading to increased lead times and manufacturing costs.
Innovation Solution
A method using a machine learning-based out-of-roundness prediction model that incorporates operational parameters from the end bending, press bending, and pipe expanding steps, including attributes of the steel sheet, to accurately predict and control the out-of-roundness of steel pipes, allowing for optimized operational conditions across these steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of 3-point bending press operations is increased to improve out-of-roundness, then the out-of-roundness of the steel pipe is improved, but the manufacturing time is extended
Solution Approach 1:
The patent applies preliminary action by performing end bending on the steel sheet ends before the main press bending process. This pre-shaping of the sheet ends creates a more favorable initial geometry that reduces the number of subsequent press bending operations needed to achieve the desired circular cross-section, thereby decreasing total manufacturing time while maintaining out-of-roundness quality
Solution Approach 2:
The patent changes geometric parameters by optimizing the curvature radius of the end bending and the pressing force parameters in the press bending process. By carefully controlling these parameters, the steel sheet transforms more efficiently toward a circular cross-section, reducing the number of required press operations while achieving the target out-of-roundness specification
2Loss of time
If the number of 3-point bending press operations is reduced to decrease manufacturing time, then the manufacturing time is reduced, but the cross-sectional shape becomes polygonal and out-of-roundness deteriorates
Solution Approach 1:
End bending is performed as a preliminary action to pre-form the steel sheet ends into a curved shape that approximates a circular cross-section. This initial shaping reduces the deformation required in subsequent press bending operations, enabling achievement of the target circular shape with fewer presses while maintaining out-of-roundness quality
Solution Approach 2:
The patent optimizes pressing parameters including the curvature radius of the press tool, the pressing force magnitude, and the positioning of press operations. These parameter adjustments ensure that each press operation contributes maximally to achieving a circular cross-section, allowing reduction in the number of operations while preventing polygonal shape formation and maintaining satisfactory out-of-roundness
3Manufacturing precision
If empirical determination of press bending operations is used to achieve desired out-of-roundness, then the out-of-roundness is improved, but the device complexity and operational complexity increase
Solution Approach 1:
The patent establishes specific parameter ranges and relationships for end bending curvature radius, press bending force, and pressing sequence. These quantified parameter specifications replace vague empirical rules with concrete, repeatable settings that can be directly implemented on equipment, reducing operational complexity while maintaining out-of-roundness quality
Solution Approach 2:
By defining a standardized end bending preliminary step with specific parameter settings, the patent creates a consistent starting condition for the press bending process. This standardization reduces the need for complex real-time adjustments and empirical trial-and-error, simplifying the overall operational procedure while ensuring consistent out-of-roundness results
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 accurate prediction and control of steel pipe out-of-roundness, reducing manufacturing time and costs by optimizing operational conditions, thereby improving yield and achieving desired out-of-roundness in steel pipes.
Implementation Method 1
A method using a machine learning-based out-of-roundness prediction model that incorporates operational parameters from the end bending, press bending, and pipe expanding steps
Implementation Method 2
an end bending step of applying end bending processing on an end of a steel sheet in a width direction
Implementation Method 3
a press bending step of performing forming processing on a steel sheet that has undergone the end bending processing into an open pipe by a plurality of times of pressing
Implementation Method 4
a pipe expanding step of performing forming processing by pipe expansion on the steel pipe obtained by joining ends of the open pipe
Data Source
AI summary
A steel pipe out-of-roundness prediction method of predicting out-of-roundness of a steel pipe after a pipe expanding step in a steel pipe manufacturing process including: an end bending step; a press bending step; and the pipe expanding step, the steel pipe out-of-roundness prediction method includes a step of predicting the out-of-roundness of the steel pipe after the pipe expanding step by using an out-of-roundness prediction model having been trained by machine learning, the out-of-roundness prediction model for which an input data is data including one operational parameter or two or more operational parameters selected from the operational parameters of the end bending step and one operational parameter or two or more operational parameters selected from the operational parameters of the press bending step, and an output data is steel pipe out-of-roundness information after the pipe expanding step.