Hydro-formed T-fitting Shovel-nose Punch Design
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Solution Overview
Problem
Existing T-fitting manufacturing processes using hydro-forming result in a significant amount of unnecessary copper material at the opposite end of the orthogonal T-section, which does not contribute to the fitting's functionality and increases production costs.
Innovation Solution
Employing shovel-nose punches in the hydro-forming process to reduce the spacing between forming ends, allowing for a tapered or shovel-nose shape that minimizes excess copper buildup, thereby optimizing the T-fitting design and manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If cylindrical end punches are used in hydro-forming, then the T-fitting can be formed, but a large amount of unnecessary copper material remains at the position opposite the orthogonal T-opening
Solution Approach 1:
The patent changes the geometric parameters of the punch nose from cylindrical to tapered/shovel-nose shape. This parameter change allows the punch to gradually compress and redirect copper flow during hydro-forming, reducing excess material accumulation at the opposite end of the T-fitting while maintaining process simplicity
Solution Approach 2:
The patent applies local quality by creating a non-uniform punch nose geometry with a tapered or shovel-nose shape at the compression point. This localized geometric variation optimizes copper material distribution specifically at the critical region where excess material accumulates, without affecting other parts of the forming process
2Quantity of substance
If the spacing between punch ends is reduced to minimize excess copper, then material waste decreases, but the forming process becomes more complex
Solution Approach 1:
The patent modifies the punch nose geometry parameters (taper angle, nose radius, length) to achieve optimal material distribution. These parameter changes allow for reduced spacing between punch ends while controlling excess copper formation, balancing material efficiency with manageable device complexity
Solution Approach 2:
The shovel-nose shape introduces curved surfaces instead of sharp edges, creating a smoother transition zone that facilitates controlled copper flow. This curvature reduces stress concentrations and improves material distribution, achieving better material efficiency without significantly increasing manufacturing 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 solution achieves a copper savings of 10% to 12% in T-fittings by reducing excess material, lowering production costs without compromising the quality or functionality of the T-fittings.
Implementation Method 1
hydro-forming process utilizing generally cylindrical end punches
Implementation Method 2
compress the copper tube to form the orthogonal T-extension
Data Source
AI summary
A punch for forming opposite ends of a copper tube into a T includes a tapered or shovel-nose such that the spacing between the ends of the opposed punches is reduced, thereby reducing the excess copper remaining in the T once formed. A method of forming the fitting employs the shovel-nose punches in a hydro-forming process to accommodate such results.