Threaded Tube Stamping Method for Material Waste Reduction
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Solution Overview
Problem
The high cost of raw materials and material waste in producing threaded components from solid metal stock, particularly in high-volume production environments, where specialized tools are required to cut threads, leading to inefficiencies and increased expenses.
Innovation Solution
A method and apparatus that transform flat sheet stock into externally or internally threaded tubular members through a series of stamping operations, including shearing, embossing, curling, and forming, which reduces material usage and eliminates the need for large volume runs, allowing for flexible production of tubular items without the need for expensive solid stock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid metal stock is used to make threaded components, then strength and structural integrity are improved, but raw material cost and material waste increase significantly
Solution Approach 1:
The solid metal stock is segmented into a tubular structure with hollow interior, removing unnecessary material from the center while maintaining external thread strength. The flat stock is formed into a tube where only the wall material is needed for structural integrity, eliminating waste of core material.
Solution Approach 2:
The tubular structure provides localized strength where needed - the wall thickness and external dimensions are optimized for thread strength, while the hollow interior eliminates unnecessary material. This local optimization maintains strength at critical areas while reducing overall material usage.
2Strength
If solid metal stock is used for threaded components, then structural strength is improved, but manufacturing cost increases due to specialized tools and processing requirements
Solution Approach 1:
The thread pattern is embossed onto the flat stock before the tube is formed. This preliminary action allows threads to be created during the forming process itself, eliminating the need for separate thread cutting operations on solid stock and reducing tooling requirements.
Solution Approach 2:
The material is transformed from flat stock to tubular form through progressive stamping operations, changing the geometric parameters during forming. This allows threads to be embossed on flat material and then formed into tubes, avoiding the need for complex thread cutting tools required for solid stock.
3Manufacturing precision
If traditional thread cutting methods are used on solid stock, then thread precision is achieved, but production time and equipment complexity increase
Solution Approach 1:
The thread embossing operation is merged with the tube forming operations in a progressive die sequence. Multiple operations including embossing, curling, stamping, and closing are combined into one continuous process, eliminating separate thread cutting steps and improving production efficiency.
Solution Approach 2:
The progressive die assembly performs multiple functions - embossing thread patterns, forming tubular shapes, and closing seams - all in one tooling system. This multi-functional approach replaces multiple specialized tools (lathe, thread cutter, forming tools) with a single integrated system.
4Loss of substance
If flat stock is formed into tubular shape after embossing threads, then material usage is reduced, but thread alignment across the seam becomes challenging
Solution Approach 1:
The thread pattern is embossed on the flat stock before forming operations. This preliminary embossing ensures threads are created on the material itself, and the progressive forming process maintains thread alignment by controlling the deformation sequence and using registration features in the tooling.
Solution Approach 2:
The flat stock with embossed threads is progressively curved and formed into a tubular shape. The helical nature of the thread pattern and the controlled curvature of the forming process work together to maintain thread alignment across the seam, with the thread helix angle compensating for the seam closure.
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 significantly reduces material costs, allows for more flexible production of threaded components, and results in lighter yet stronger tubular members compared to solid stock, without sacrificing strength, while minimizing the need for specialized tools and reducing waste.
Implementation Method 1
The substantially flat work piece is then subjected to a plurality of stamping operations wherein the flat stock is formed from a substantially flat form into a tubular shape
Implementation Method 2
a thread pattern embossed on at least one side
Data Source
AI summary
The invention includes a method, and a component made according to the method having at least one thread pattern formed thereon from a stamping method. The invention includes a tubular member comprising a body having a wall formed from a wrapped sheet of stock to define an interior wall and an exterior wall, a seam in the wall defining a first and second end of the wrapped sheet of stock, and a thread pattern stamped on the exterior wall. The method comprises the steps of forming a blank from sheet of stock having a first surface. A thread pattern is formed onto the first surface while in a substantially sheet-like form. A bending operation then forms the sheet stock into a tubular member such that the thread pattern, located on the tube's external surface, is substantially aligned about its circumference.