FIELD OF THE INVENTION:
The invention relates to a development of new elliptical shaped
formed tool for radius forming applicable to a deep blind hole of
circular ring headers.
BACK GROUND OF THE INVENTION:
Many components are assembled in making a compact heat exchanger
for a critical application. During machining inside of these
components, the header burrs were formed which can't be left as such
because when the burrs are carried through the flow they cause
serious damage in the flow path and block the passages in the circuit
leading to catastrophic failure. The burr chips carry radiation to all
the places of loop in service, which may spread radiation to all the
areas. De burring chips may plug the hole in service, which may
damage tubes due to no flow of fluid. Hole size is very small Ge) 3.3
+ 0.1 mm and hence reaming is not possible. No approach from 3.3
mm hole side is available within the existing facilities. In a circular
ring and header segments, each heater assembly was made out of
circular headed segments. Tee and caps and 23 stubs are welded in a
circular path of

maximum 270° orientation. Both ends of the headers are welded with
end caps. The only port opening at the center is of dia 40 mm. Hence
the inevitable need to remove the burrs at any cost and to form 1mm
of radius in the bottom inside entry. All possible conventional
methods were tried unsuccessfully, before striking on this creative,
innovative and novel idea. The removal of burrs ensures personnel
and environment Safety. Otherwise this may carry Nuclear radiation
or plug the Nuclear Loop, which is highly dangerous for both
personnel and environment.
PRIOR ART SEARCH:
A prior Art - US 7, 140, 811 discloses a form tool for metal cutting
head for cutting a portion integrally formed with a mounting portion,
an axially directed bore extending from adjacent, a front end of the
cutting head to a rear end of the cutting head, the front end being
associated with the cutting portion and rear end being associated with
the mounting portion. The resulting cutting head has apertures
communicating between a coolant channel and recesses.

In one aspect of toe invention, fray provided a cutting head
comprising a cutting portion integrally formed with a mounting portion,
an axially directed bore extending from adjacent a front end of the
cutting head to a rear end of the cutting head, the front end being
associated with the cutting portion, a plurality of wedge like head
recess opening out in to the front end of the cutting head, an aperture
at a radially inner most part of each cutting recess, and a central
circular region formed at the front end of the cutting head.
A device in accordance with the present invention may include a
number of additional features and properties either alone or in
combination such as
The invention is directed to a further development that "new elliptical
shaped formed tool design of recess/radius forming in a deep blind
hole of stainless steel circular ring header. The results savings in
cycle time reduction and high productivity.
OBJECTS OF THE INVENTION:
It is therefore, an object of the present invention to propose the

development of an elliptical shaped formed tool for melding of
recess/radius forming in a deep blind hole of stainless steel circular
ring header which eliminates the disadvantage of prior Art.
Another object of the present invention is to propose the development
of an elliptical shaped formed tool for making of recess/radius forming
in a deep blind hole of stainless steel circular ring header which
provides an improved method and inevitable need to remove the burrs
at any cost and to form 1 mm of radius in the bottom inside entry
resulting in reduced cycle time.
A further object of the present invention is to propose the
development of an elliptical shaped formed tool for making of
recessAwdlus forming in a deep bHnd hole of stainless steel circular
ring header which aims at providing personnel and environment
Safety, which la highly dangerous both parsonnel and environment.
A still further object of the present invention is to propose the
development of an elliptical shaped formed tool for making of

recess/radius forming in a deep blind hole of stainless steel circular
ring header which prevents to carry unclear radiation or plug to
Nuclear loop causing dangerous both personal and environment.
An yet further object of the present invention is to propose the
development of an elliptical shaped formed tool for making of
recess/radius forming in a deep blind hole of stainless steel circular
ring header which increases productivity.
BRIEF DESCRIPTION OF THE DRAWING:
Pig. 1 shows a prospective view of an elliptical shaped formed tool for
making of recess/radius forming in a deep blind hole of stainless steel
circular ring header while in operation,
Fig. 1a shows a schematic view of a an elliptical shaped formed tool
for recess/radius forming in a deep blind hole of stainless steel
circular ring header.
DETAILED DESCRIPTION OF THE INVENTION:
Pig. la shows the an elliptical shaped formed tool for metal cutting of

forming/radius making, typically the formed cutting tool comprises
tool shank (not shown) to which the cutting head is secured The
cutting has front and rear ends in longitudinal axis. The cutting head
comprises a cutting portion formed integrally with a high stiff and
flexible string twisted wire is fitted with collect chuck of pneumatic
grinder. This special elliptical shaped of recess/radius forming tool
can be fitted to conventional pneumatic grinder or an electrical
grinder. By this technique, in a deep blind hole, to remove the burrs
at any cost and to form i mm of radius in the bottom inside entry of
stainless steel circular ring header for heat exchanger. Hole size in
stub (1) is very small (ie) 3.3 +0.1 mm and hence roaming is not
possible. No approach from 3.3 mm hole side.In a circular ring

header (6) assembly, each header assembly was made out of circular
header segments, Tee and caps and 23 stubs (1) are welded in a
circular path of maximum 270° orientation. Both ends of the headers
are welded with end caps. The only port opening at the center is dia
40 mm. Hence the inevitable need in a deep blind hole, to remove the
burrs (3) at any cost and to form 1 mm of radius in the bottom inside

entry. High stiff and flexible string twisted wire (2) of dia 1.6 mm was
coupled with a circular multi axis form cutting tool. The removing
burr and radius forming is shown in Fig.1.
The new elliptical shaped formed tool enables removal of burrs and
forming radius in the inside of blind hole of stainless steel circular ring
header. This technique can be used for both manual as well as
mechanized mode. This results in savings in consumables cost cycle
time reduction and higher productivity.

WE CLAIM
1. A new elliptical shaped formed tool for making of recess/radius forming in a deep
blind hole of stainless steel circular ring header (5) of a heat exchanger
comprising:
a tool shank (not shown) for securing the cutting head;
the cutting head having a cutting portion formed integrally with a high stiff and
flexible string wire (2); characterized in that
the said high stiff and flexible string twisted wire (2) fits with a cullet chick of
Pneumatic grinder when the said elliptical shaped formed tool fits to a pneumatic
grinder or an electric grinder for removing the burrs (3) and forming radius in a
deep blind hole.
2. The elliptical shaped formed tool as claimed in claim 1, wherein the said formed
tool is deployed for both manual and mechanized mode.
3. The elliptical shaped formed tool as claimed in claim 1, wherein the tool is
characterized to be employed for forming radius in rear end of the stub, and
axially directed bore forms radius at the rear end.

ABSTRACT

A NEW ELLIPTICAL SHAPED FORMED TOOL FOR MAKING OF
RECESS/RADIUS FORMING IN A DEEP BLIND HOLE OF STAINLESS
STEEL CIRCULAR RING HEADER OF A HEAT EXCHANGER
The present invention relates to a new elliptical shaped formed tool which
is deployed for making recess/radius in a deep blind hole of a circular ring
header (5) a heat exchanger. It consists of a tool shank for securing the

cutting head. The cutting head has a cutting portion formed integrally with

a high stiff and flexible string twisted wire(2) fits with a cullet chuck of a
Pneumatic grinder when the said elliptical shaped formed tools fits to a
pneumatic grinder or an electric grinder for removing the burrs(3) and
forming radius in a deep blind hole.