Sub-muffler Cylinder Roll Bending for Polygonal Shapes
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Solution Overview
Problem
The existing manufacturing methods for sub-muffler outer cylinders with polygonal cross-sectional shapes require multiple dedicated press dies, increasing equipment costs and limiting the use of low-cost equipment.
Innovation Solution
A roll bending method using a push roll and receive rolls with adjustable push-in amounts to form cylindrical-shaped bodies with polygonal cross-sectional shapes, allowing for the production of sub-muffler outer cylinders with polygonal cross-sectional shapes using low-cost equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press-forming method using dedicated press dies is used to manufacture sub-muffler outer cylinders with polygonal cross-sectional shapes, then manufacturing precision and shape accuracy are improved, but device complexity and equipment cost increase due to requiring multiple dedicated press dies
Solution Approach 1:
The roll bending device is designed to universally form various polygonal cross-sectional shapes (trapezoidal, rectangular, pentagonal, hexagonal, etc.) using a single equipment configuration. By adjusting the number of receive rolls and their arrangement, the same device can produce different polygonal shapes without requiring dedicated press dies for each shape, thus achieving multi-functionality and reducing equipment complexity
Solution Approach 2:
The device employs adjustable and movable receive rolls that can be positioned at different locations and angles according to the desired cross-sectional shape. This dynamic adjustability allows the same equipment to adapt to different manufacturing requirements, transforming a static dedicated-tooling approach into a flexible, reconfigurable system that maintains precision while reducing device complexity
2Manufacturing precision
If multiple dedicated press dies are used for different cross-sectional shapes, then manufacturing precision for each shape is improved, but manufacturing time and productivity are reduced due to requiring die changes
Solution Approach 1:
A single roll bending device with adjustable receive rolls can form multiple polygonal cross-sectional shapes (trapezoidal, rectangular, pentagonal, hexagonal, etc.) without requiring die changes. The equipment is designed to accommodate different shape requirements through repositioning and reconfiguring the receive rolls, enabling continuous production across different product variants and significantly improving manufacturing efficiency
Solution Approach 2:
The manufacturing process employs periodic adjustment of receive roll positions and configurations corresponding to different production batches or product variants. Instead of stopping for die changes, the system periodically reconfigures the receive rolls according to the required cross-sectional shape, maintaining continuous production flow and high productivity while ensuring precision for each shape type
3Device complexity
If conventional roll bending with uniform push-in amount is used, then device simplicity is maintained, but manufacturing precision for polygonal cross-sectional shapes deteriorates due to inability to form accurate corner parts
Solution Approach 1:
The bending process applies different push-in amounts to different regions of the workpiece: larger push-in amounts are applied specifically at corner parts to achieve accurate angular formation, while smaller push-in amounts are applied to side parts to maintain proper dimensions. This localized differentiation of bending parameters enables high precision in corner formation without over-complicating the overall device structure
Solution Approach 2:
The bending process is segmented into distinct zones: corner regions receive greater push-in force through specifically positioned receive rolls, while side regions receive lesser push-in force. This segmentation of the bending action allows independent optimization of corner accuracy and side dimensional control, achieving high manufacturing precision while maintaining relatively simple device architecture through targeted local adjustments
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
Enables the cost-effective manufacturing of sub-muffler outer cylinders with polygonal cross-sectional shapes without the need for multiple press dies, utilizing a general roll bending device configuration.
Implementation Method 1
pushing one push roll toward two receive rolls and then bending a plate-shape workpiece to form the sub-muffler outer cylinder made of a cylindrical-shaped body
Data Source
AI summary
A manufacturing method of a sub-muffler outer cylinder is provided. The manufacturing method includes pushing one push roll toward two receive rolls, and then bending a plate-shape workpiece to form the sub-muffler outer cylinder made of a cylindrical-shaped body. A push-in amount in a part of the workpiece corresponding to a corner part of the cylindrical-shaped body is made larger than a push-in amount in a part of the workpiece corresponding to a side part of the cylindrical-shaped body to form the cylindrical-shaped body having a polygonal cross-sectional shape.