Tube Flanging Method Uniform Thickness

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Solution Overview

Problem

Existing methods for forming flanges, such as cutting or welding, result in material waste and potential strength weaknesses, particularly in maintaining uniform thickness and efficient process efficiency for mass production.

Innovation Solution

A tube flanging method involving a forming mold where the tube edge is expanded and bent using a spinning process, followed by friction stir processing to form a flange with a linearly integrated cross section and uniform thickness, allowing for high reproducibility and design freedom.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the flange is formed by cutting the pipe body, then precise dimensions can be achieved, but material waste is severe

Engineering Contradiction:

Improvedimensional precisionVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The invention changes the processing method from cutting (removal) to bending (deformation), transforming the pipe edge into a flange shape through plastic deformation while maintaining material continuity and uniform thickness throughout the process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the cutting mechanical system with a bending mechanical system, using forming molds and pressing forces to reshape the pipe edge into a flange rather than removing material through cutting

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of substance

If the flange is formed by welding separate parts, then material waste is reduced, but the fusion zone strength is weak

Engineering Contradiction:

Improvematerial wasteVSAvoidfusion zone strength

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The invention merges the pipe body and flange into a single integrated structure formed by bending the pipe edge in place, eliminating the need for separate flange parts and welding operations, thereby achieving both material efficiency and structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts the flange forming process from the welding process, creating the flange directly on the pipe body through bending rather than joining separate components, thus avoiding the creation of weak fusion zones

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If the pipe edge is bent to form a flange, then process efficiency is improved, but the thickness becomes non-uniform

Engineering Contradiction:

Improveprocess efficiencyVSAvoidthickness uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention applies preliminary constraints through forming molds before the bending process, positioning the pipe edge and controlling the deformation path to ensure uniform thickness is maintained throughout the flange formation process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention introduces forming molds as intermediaries between the pressing force and the pipe edge, using the molds to distribute and control the applied force uniformly, thereby maintaining constant thickness during the bending process

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If plastic injection molding is used for the flange, then exact dimensions including thickness are achieved, but coupling strength with metal pipes is reduced

Engineering Contradiction:

Improvedimensional precisionVSAvoidcoupling strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The invention changes the material parameter from plastic to metal, forming the flange directly from the metal pipe body through bending, thereby maintaining both the dimensional precision needed and the high coupling strength of metal-to-metal connections

Inventive Principle:

Principle #35Parameter changes

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 formation of flanges with uniform thickness, enhancing process efficiency and allowing for high-quality mass production while maintaining the original tube thickness, thus addressing the limitations of existing methods.

Implementation Method 1

applying an external force to the exposed edge of the tube to expand the exposed edge of the tube; applying an external force to the expanded edge to bend the expanded edge toward an outer surface of the forming mold

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

The bent edge may be formed into the flange having the linearly integrated cross section by a friction stir process

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10252310B2Tube flanging method

Publication Date: 2019.04.09 IND ACADEMIC COOPERATION FOUND JEJU NAT UNIVERSTIY

AI summary

A tube flanging method includes the steps of: disposing a tube such that an edge thereof is exposed to the outside of a forming mold while the tube is inserted into the forming mold; applying an external force to the exposed edge of the tube to expand the exposed edge of the tube; applying an external force to the expanded edge to bend the expanded edge toward an outer surface of the forming mold; and applying an external force to the bent edge to form a flange, the flange having a linearly integrated cross section and being perpendicular to the longitudinal direction of the tube. With this configuration, it is possible to bend the tube to form the flange at a uniform thickness.