Description:TECHNICAL FIELD

The present disclosure relates to the field of manufacturing technology. Particularly, but not exclusively, the present disclosure relates to an apparatus for forming or thickening a tube. Further embodiments of the present disclosure disclose apparatus and process for thickening the tube at an inner surface of its brim.

BACKGROUND OF THE DISCLOSURE

A tube is a long hollow cylinder made of materials such as metal, plastic or composites. The tubes may be used in various applications in the field of domestic, medical, fuel gas distributions, automotive and other applications including air conditioning and refrigeration. For example, in the automotive applications such as two-wheelers, tubes may be used in frames, seating systems, fuel delivery components and automotive link arms require tubes to be welded in series to create an integrated frame. The tubes may be welded using a various known welding methods such as MIG welding, flux-cored arc welding, TIG welding, stick welding etc. depending upon the material of the tube and the size of the tube. Welding is a process of joining parts together by heating the surfaces to the point of melting. In the process of welding different zones may be formed such as fusion zone, weld interface, heat affected zone etc. The fusion zone is a section of the material that is present after an object has been welded. The fusion zone begins and ends at the portion of the material that have been coalesced. This zone will have a chemical composition that is a mixture of the substrate being welded together and any additional filler material that may have been used.

The weld interface is a region composed of an unmixed zone of weld. The heat affected zone (HAZ) is the area of the base material which is not melted but its microstructure and properties are altered by the welding. The fusion zone and the HAZ acts as a stress raiser zone in the material. The stress raiser zones increase stress concentration factor, further reducing the fatigue behavior of the welded connection. To avoid these stress raiser zones the tubes of uniform higher thickness can be used, or tubes thickened only at its free ends can be used in the automotive applications. The tubes of higher uniform thickness can be used in the application, but it adds unnecessary weight to the overall assembly. The latter approach i.e., the use of tubes thickened at the ends ensures overall weight reduction of the entire assembly as only the end parts which are to be welded are thickened.

The conventional process known in art for producing variable thickness tubes are flexible rolling, swage auto-frettage process, tube drawing using position controlled mandrel methods, extrusion with special die setup and also internally and externally upsetting ends of the tube. The ends of the tubes can be thickened using the above-mentioned process. The above said processes have several restraints such as higher investment in tooling and/or low productivity due to increased cycle time. Also, in conventional systems it is difficult to thicken the tube from the inner circumference simultaneously in both the sides.

The present disclosure is directed to overcome one or more limitations stated above.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional process are overcome by process as claimed and additional advantages are provided through the provision of processes as claimed in the present disclosure.

Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the disclosure, an apparatus for thickening brim portions in an inner surface of a tube is disclosed. The apparatus includes a first support member, that is configured to rigidly support an outer surface along its length. The apparatus further includes a second support member configured to rigidly support the inner surface of the tube along its length excluding the brim portions on the inner surface of the tube. The second member is a multi-piece mandrel. The apparatus also includes a punch driven by an external power source, wherein the punch is configured to exert force simultaneously on the brim portions of the tube. Application of force by the punch on the brim portions of the tube plastically deforms the brim portions of the tube to conform to a shape of the second support member at either ends to thicken the brim portions in the inner surface of the tube.

In an embodiment of the disclosure, the first support member is driven by a first external power source to exert a longitudinal force on the first support member to impart lateral inward movement on the first support movement on the first support, to rigidly support the outer surface of the tube.

In an embodiment of the disclosure, portion of the second support member is defined with a chamfer at either end.

In an embodiment of the disclosure, the first and second external power source is at least one of a hydraulic drive or pneumatic drive.

In another non-limiting embodiment of the disclosure, a tube is formed using the apparatus. The tube including a body portion and a brim portion at both ends of the of the body portion. The brim portion at both ends of the body portion is such that, thickness of the brim portion in the inner surface of the tube is greater than thickness of the body portion of the tube.

In an embodiment of the disclosure, the body portion of the tube is of uniform thickness.

In another non-limiting embodiment of the disclosure, a process of thickening a brim portion on an inner surface of a tube is disclosed. The process includes supporting by a first support member along an outer surface of the tube along its length. The process also includes supporting by a second support member along the inner surface of the tube along its length excluding the brim portion on the inner surface of the tube, wherein the second support member is a multipiece mandrel. An application of force by the punch on the brim portion of the tube plastically deforms the brim portion of the tube to conform to a shape of the second support member at either ends to thicken the brim portion on the inner surface of the tube.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

FIG.1 illustrates a pictorial view of an apparatus used for thickening brim portion in an inner surface of a tube, in accordance with an embodiment of the present disclosure.

FIG.2 illustrates a pictorial view of the apparatus of FIG.1 after the tube has deformed, in accordance with an embodiment of the present disclosure.

FIG.3 illustrates a pictorial view of a second support member, in accordance with an embodiment of present disclosure.

FIG.4 illustrates cross-sectional view of the tube that is plastically deformed in the inner surface of the tube using the apparatus of FIG.1, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent processes do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for illustration purpose and description only and is not intended as a definition of the limits of the present disclosure. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

Embodiments of the present disclosure discloses an apparatus for thickening brim portion in an inner surface of a tube, particularly, but not limited to, tubes that may be used in components of automobile. The apparatus includes a first support member, which is configured to rigidly support an outer surface of the tube along its length. The first support member may be driven by a first external power source. The apparatus further includes a second support member, which is configured to rigidly support an inner surface of the tube along its length excluding the inner surface of the brim portion of the tube.

In an embodiment, the apparatus includes a punch, driven by a second external power source. The punch may be configured to exert force on the brim portions on either ends of the tube. The application of the force by the punch plastically deforms the brim portion of the tube thereby thickening the tube at its brim on either end. In an embodiment, the tube may get thickened on an inner surface of the brim portion at both ends of the tube. The second support member used in the present disclosure is a multi-piece mandrel having plurality of pieces assembled into the inner surface of the tube. The ends of the second surface are tapered, such that they define a portion of die for plastic deformation at the brim portions of the tube.

The tube formed using the apparatus comprises a body portion and the brim portions in both ends of the body portion. The brim portion at the both ends of the body portion is such that, the thickness of the brim portion of the tube is greater than the thickness of the body portion of the tube. The body portion of the tube may be of uniform thickness and the portion of the brim on either ends of the body may have an increased thickness than that of the body portion.

The process of thickening the brim portions on the inner surface of the tube may include supporting by the first support member at over the entire length of the outer surface. Further, the tube is supported by the second support member at the central portion along the inner surface excluding the brim portions on the inner surface on either ends of the tube. The free ends on either sides of the tube are not supported, and this portion forms the material to be deformed to conform to the shape of the ends of the second support member. The second support member may be configured to support the central portion of the inner surface of the tube rigidly. The first support member, the punch and the block may be driven by an external any power source to perform the required process.

The terms “comprises”, “comprising”, or any other variations thereof used in the specification, are intended to cover a non-exclusive inclusion, such that an assembly that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or method. In other words, one or more elements in an assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly.

Henceforth, the present disclosure is explained with the help of one or more figures of exemplary embodiments. However, such exemplary embodiments should not be construed as limitation of the present disclosure.

The following paragraphs describe the present disclosure with reference to FIGS.1 to 4. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.

FIG.1 is an exemplary embodiment of the present disclosure, illustrating a pictorial view of an apparatus (100) used for thickening brim portions (201) in an inner surface (111) of a tube (101). As shown in FIG.1, the apparatus (100) includes a first support member (102), a second support member (103) and a punch (104). The tube (101) is held firmly between the first support member (102) and the second support member (103), on an outer and inner surface of the tube (110 and 111) respectively. The first support member (102) is configured to rigidly support the tube (101) on the outer surface (110). Further, the second support member (103) is configured to rigidly support the tube (101) from inside i.e. the inner surface (111). The block (105) as shown in the FIG.1 is configured to impart a lateral outward movement on the second support member (103). In an embodiment, the first support member (102) is driven by a first external power source which provides necessary force to firmly hold the tube (101) between the first and the second support member (102 and 103). The punch (104) may be positioned at either ends of the tube (101) and is driven by a second external power source [not shown]. The first external power source drives the first support member (102) in the radially inward direction. In an embodiment, the radially inward force on the first support member (102) as said above imparts inward force on the first support member (102) which may rigidly support the tube (101). The longitudinal force of the punch (104) driven by the second external power source may be imparted over the brim portion (201) of the tube (101). The force imparted by the punch (104) acts as compressive force on the brim portion (201) of the tube (101). The compressive force plastically deforms the brim portion (201) on either ends of the tube (101) into a portion of a die formed by the portion of second support member (103) along with the first support member (102) at the either ends. Further, the compressive force acting on the brim portion (201) of the tube (101) deforms the tube (101) into the shape of the die formed by the support members (102 and 103). The die as said above is created by the taper provided on the extreme ends of the second support member (103). The result of plastic deformation of the tube (101) in the die is as shown in FIG.2.

In an embodiment, the second support member (103) may be a multi-piece mandrel as shown in FIG.3. The second support member (103) may include a plurality of pieces which is depicted in FIG.3 as 103a, 103b, 103c, 103d, 103e, 103f, 103g, 103h, 103i, 103j and 103k. In an embodiment, each of the plurality of pieces 103a-103k may be assembled within the tube (101). The piece 103i of the plurality of pieces 103a-103k may be positioned at a substantially central portion in a space defined by the inner surface (111) of the tube (101). Further, the plurality of pieces 103a-103h and 103j-103k may be assembled circumferentially on the piece 103i. In an embodiment, assembling of the plurality of pieces 103a-103k ensures that an outward lateral force is imparted on the inner surface (111) of the tube (101). The outward lateral force on the inner surface (111) of the tube (101) ensures that the tube is forced against the first support member (102), thereby ensuring that the tube (101) may be secured in position so as to allow the thickening of the brim portions (201) of the tube (101). In an embodiment, the second support member (103) may be tapered on either ends to define the die portion for plastic deformation of the brim portion (201) of the tube (101).

Further, the tube (101) is held firmly over the entire portion of the outer surface (110) and over the central portion on the inner surface (111). The inner surface (111) of brim portion (201) of the tube (101) other than the central portion of the inner surface (111) may not be supported. The inner surface (111) of brim portion (201) of the tube (101) on both ends may be subjected to compressive force by a punch (104). The force imparted over the brim portions (201) of the tube (101) plastically deforms the tube (101) into the shape of the die created by the chamfered portion of the second support members (103) along with the entire length of the first support member (102). Once the tube (101) is held firmly by the first and second support members (102 and 103), the tube (101) is subjected to compressive force. The compressive force is imparted by the punch (104) which may be driven by the second external power source. As shown in FIG.1, the tube (101) is subjected compressive force on one or both ends. The compressive force that is imparted on the ends of the tube (101) plastically deforms the brim portion (201) of the tube (101). The plastically deformed tube (101) takes the shape of the die that is formed by the tapered portion of the second support member (103) along with the entire length of the first support member (102) as said above. The thickness of the brim portion (201) of the tube (101) increases after the plastic deformation, as it takes the shape of the die. The first and second external power sources may be any one of but not limiting to a hydraulic drive, pneumatic drive, and the like. The tube (101) formed using the said apparatus (100) and the said process may have the body portion (200) and the brim portion (201) as shown in FIG.4.

As shown in FIG.4, the tube (101) includes the body portion (200) and the brim portion (201). The body portion (200) of the tube (101) may be of uniform cross section. The brim portion (201) may be on both ends of the body portion (200) of the tube (101). The brim portion (201) is formed by the plastic deformation into the die. The brim portion (201) has a thickness greater than thickness of the body portion (200) of tube (101). The thickness of the brim portion (201) of the tube may range from 20% to 30% greater than the thickness of the body portion (200) according to present disclosure but not limiting to this range. As shown in FIG.4, it picturizes a completely manufactured tube (101) with the inner brim portions of the tube having an increased thickness. In an embodiment, the process of thickening may be carried out on variety of materials such as but not limiting to a mild steel with certain alloy elements.

The apparatus (100) can simultaneously thicken the inner surface (111) of the brim portion on both the ends of the tube (101), this ensures lower cycle time which improves the productivity of the apparatus (100). The process has low operation cost over the conventional device due use of less tonnage equipment. Also, the tubes (101) undergo strain hardening during the process, facilitating in increase in strength of the tube (101).

Equivalents

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding the description may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the description.

Referral Numerals:

Description Reference Number
Apparatus 100
Tube 101
Brim portion 101a
First support member 102
Second support member 103
Punch 104
Support block 105
Outer surface 110
Inner surface 111
Body portion 200
Deformed brim portion 201

Claims:We claim:

1. An apparatus (100) for thickening brim portions (101a) in an inner surface (111) of a tube (101), the apparatus (100) comprising:
a first support member (102), configured to rigidly support an outer surface (110) of the tube (101) along its length;
a second support member (103), configured to rigidly support the inner surface (111) of the tube (101) along its length excluding the brim portions (101a) on the inner surface (111) of the tube (101), wherein the second support member (103) is a multi-piece mandrel; and
a punch (104) driven by a second external power source, wherein the punch (104) is configured to exert force on the brim portions (101a) of the tube (101),
wherein, application of force by the punch (104) on the brim portions (101a) of the tube (101) plastically deforms the brim portions (101a) of the tube (101) to conform to a shape of the second support member (103) at either ends to thicken the brim portions (101a) on the inner surface (111) of the tube.

2. The Apparatus (100) as claimed in claim 1, wherein the punch is configured to exert force simultaneously on the brim portions (101a) of the tube (201).

3. The apparatus (100) as claimed in claim 1, wherein the first support member (102) is driven by a first external power source to exert a radially inward force on the first support member (102) to impart an inward movement on the first support member (102), to rigidly support the outer surface (110) of the tube (101).

4. The apparatus (100) as claimed in claim 3, wherein the second support member (103) is defined with a taper at either ends.

5. The apparatus (100) as claimed in claim 1, wherein the first and the second external power source is at least one of a hydraulic drive or pneumatic drive or servo electric motor drive.

6. A tube (101) formed using an apparatus (100) as claimed in claim 1.

7. A tube (101) comprising:
a body portion (200); and
a brim portion (101a) at both ends of the body portion (200),
wherein, the brim portion (101a) at either or both ends of the body portion (200) is such that, thickness of the brim portion (101a) in the inner surface (111) of the tube (101) is greater than thickness of the body portion (200) of the tube (101).

8. The tube (101) as claimed in claim 7, wherein the body portion (200) of the tube (101) is of uniform thickness.

9. A process of thickening brim portions (101a) on an inner surface (111) of a tube (101), the process comprising:
supporting, by a first support member (102), an outer surface (110) of the tube (101) along its length;
supporting, by a second support member (103), the inner surface (111) of the tube along its length excluding the brim portion (201) on the inner surface (111) of the tube (101), wherein the second support member (103) is a multi-piece mandrel; and
applying force, by a punch (104), at the brim portion (201) of the tube (101),
wherein, application of force by the punch (104) on the brim portion (201) of the tube (101) plastically deforms the brim portion (201) of the tube (101) to conform to a shape of the second support member (103) at either ends to thicken the brim portion (201) on the inner surface (111) of the tube.

10. The process as claimed in claim 9, wherein the force is applied simultaneously on the brim portions (101a) of the tube (101).

11. The process as claimed in claim 9, wherein first support member (102) and the punch (104) is driven by at least servo electric motor drive one of an external hydraulic and pneumatic power source.

12. The process as claimed in claim 9, wherein the first support member (102) is driven by a first external power source to exert a radially inward force on the first support member (102) to impart an inward movement on the first support member (102), to rigidly support the outer surface (110) of the tube (101).