Tube-End Flanging Roller Alignment for Cleaner Flange Contours
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Solution Overview
Problem
Existing devices for flanging tube ends often result in particle formation and increased wear of flanging rollers, leading to reduced service life and suboptimal flange contours.
Innovation Solution
The device features flanging rollers with axes of rotation inclined at an angle relative to the receiving unit's longitudinal axis, allowing for reduced particle formation and improved contact with the workpiece, combined with adjustable spindles and beading rollers for precise contouring and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the flanging roller axis of rotation is oriented parallel to the receiving unit longitudinal axis, then the device structure is simple, but particle formation increases and wear increases
Solution Approach 1:
The patent changes the orientation parameter of the flanging roller axis from parallel to inclined at an angle (2-45 degrees) relative to the receiving unit longitudinal axis. This parameter change reduces particle formation during the flanging process while maintaining acceptable device complexity.
2Device complexity
If the flanging roller axis of rotation is oriented parallel to the receiving unit longitudinal axis, then the device structure is simple, but wear of flanging rollers increases
Solution Approach 1:
The patent modifies the angular parameter of the flanging roller axis orientation to reduce wear and extend service life. The inclined orientation (2-45 degrees) creates more favorable contact conditions that reduce wear while keeping the device structure relatively simple.
3Productivity
If the flanging roller contacts the workpiece along the entire contour, then the shaping process is efficient, but the flange contour quality deteriorates
Solution Approach 1:
The patent changes the contact parameter by inclining the flanging roller axis, which transforms the contact from a broad surface contact to a more focused line or point contact along the shaping contour. This improves flange contour quality while maintaining shaping efficiency.
Solution Approach 2:
The inclined axis orientation introduces a new dimensional aspect to the contact geometry, creating a specific contact line along the contour rather than a simple parallel contact. This dimensional change enables both efficient shaping and high contour quality.
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 configuration reduces wear on flanging rollers, extends their service life, and enables the production of clean, high-quality flange contours with reduced maintenance, while allowing for adjustable flange and bead formation.
Implementation Method 1
The orientation of the axis of rotation of the flanging roller at an angle relative to the longitudinal axis of the receiving unit can reduce particle formation during flanging. This results in reduced wear of the flanging rollers
Data Source
AI summary
A device (10) for flanging a tube end has a receiving unit for the workpiece (12) to be flanged and at least one tool holder (30). Provision is furthermore made for at least one flanging roller (34), which is fastened to the tool holder (30) by way of a spindle (32). The flanging roller (34) can rotate about an axis of rotation (36) along the longitudinal axis of the spindle (32). The longitudinal axis (22) of the receiving unit (20) and the axis of rotation (36) of the flanging roller (34) are oriented at an angle relative to one another.