DESC:METHOD OF MANUFACTURING OF HEMI SPHERICAL DISHED END BY FULLY MACHINING PROCESS”

FIELD OF THE INVENTION

[001] This invention relates to manufacturing of hemi spherical dished end by fully machining from hollow forging raw material.
BACK GROUND OF THE INVENTION

[002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[003] Manufacturing of hemispherical dished end by conventional method needs bullet and outer circumference ring. The outer ring controls the outer diameter of the hemispherical dished end and bullet controls the inner diameter of the hemispherical dished end. Bullet and ring are chosen by the required size of the hemispherical dished end. Plate preparation requires machining operation in order to maintain the annular gap between ring and bullet during pressing. This annular gap requires for removal of the dished end after pressing operation completion. After material preparation plate is loaded to furnace for heating up to 1050 degree Celsius, soaking time depends upon the thickness of the plate. After heating of the plate by the flow car of 5ton capacity, heated plate has placed on the bullet with the help of centering pin for self-centering of plate. Plate pressing is done by 2000-ton press, which leads to formation of Dished end formed. After that stress relieving process is carried out followed by shot blasting for removal of scaling on the surface of the dished end. These operations take huge amount of money to spend to form the dished end at various sizes.
[004] Hence, the present invention has been proposed so as to address the shortcomings of prior art(s). This method is entirely different from the conventional forming method.
OBJECTS OF THE INVENTION
[005] It is therefore an object of present invention to propose manufacturing of hemi spherical dished end by fully machining from hollow forging raw material.
[006] Another object of the invention is to overcome drawbacks associated with the prior art(s).
[007] A still further object of present invention is to avoid bullet and ring requirement, heating of the plate for 1050 degree, heat treatment process, shot blasting work for cleaning.
[008] At the outset of the description that follows, it is to be understood that the ensuing description only illustrates a particular form of this invention. However, such a particular form is only an exemplary embodiment and is not intended to be taken restrictively to imply any limitation on the scope of the present invention.

[009] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF THE INVENTION
[0010] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.

[0011] Accordingly, here hollow forging for manufacturing of hemispherical dished end has been adopted.

[0012] Drawing is prepared through AUTO CAD, wherein first rough machining work of inner profile of the hemi spherical dished end is done. Material removal is carried out step by step by using vertical lathe by boring operation. During rough machining, stock is maintained for final machining. Diametrically inner bore maintains around 10 mm material stock. Since forgings are costly and more heavy, once inner diameter boring rough machining is over, final machining is conducted. Both inner profile and outer profile final machining is carried out using cnc vertical lathe with automatic turret indexing machine. Final machining is done as per program in the machine with proper tooling. After that job is turned with the help of crane for final machining of outer profile. Outer profile is also done as per cnc program with proper tooling. On the top of the job face requires edge preparation for welding. That is achieved by profile machining on the pipe that pipe is used as a holding and guide the outer profile of the hemispherical dished end. Now, edge preparation with the required style is machined on the dished end.

[0013] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

[0014] 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 to form a further embodiment of the disclosure.

[0015] 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 ACCOMPAYING DRAWINGS
[0016] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein: -
Figure 1 shows: raw material hollow forging.
Figure 2 shows: stock removed from hollow forging maintain for final machining up to 10 mm vertical lathe conventional.
Figure 3 shows:10 mm stock removal in id final matching vertical CNC lathe.
Figure 4 shows: od profile machining on vertical CNC lathe.
Figure 5 shows: fixture for edge preparation machining from pipe with id same od of hemispherical dished end.
Figure 6 shows: Flow chart of the invention.
[0017] 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.
DETAIL DESCRIPTION OF THE INVENTION WITH REFERENCE OF THE ACCOMPAYING DRAWINGS OF PREFERRED EMBODIMENT
[0018] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0019] The proposed invention makes a disclosure regarding Method of manufacturing of hemi spherical dished end by fully machining process. The method involves the following steps:
-Pre –drilling and rough boring operation in hollow forging raw material (Figure 1);
-Maintenance of stock during both pre-drilling and rough boring operation by using vertical lathe machine;
[0020] As shown in figure 2, the inner diameter rough machining is done using vertical lathe machine with 10mm stock maintaining outer diameter of 1190mm and inner diameter of 1050mm with straight portion as 194mm.

-Finishing inner diameter profile of hemispherical dished end by using cnc vertical lathe machine by programming;
Referring to figure 3, the inner diameter final machining is carried out with cnc vertical lathe machine with cnc programming. Here, the 10mm stock is removed and the diameter of 1060mm required profile is obtained after machining.

-Finishing outer profile machining of hemispherical dished end by using cnc vertical lathe machine by programming;
Referring to figure 4, the outer diameter profile machining is conducted at the same cnc vertical lathe, Hemi spherical dished end with inverted position clamped with bed.
-Since for edge preparation clamping will be difficult, a pipe with outer profile is machined .so that the Hemi spherical dished end is loaded on the pipe. Due to the self-weight, the dished end needs not to be clamped. Edge preparation with the required style is formed on the top surface of the dished end;
[0021] Thus, edge preparation from cylindrical pipe is done at cnc vertical lathe as illustrated in figure 5. After preparation of fixture, hemi spherical dished end is placed on the profile pipe (Figure 6) and machining takes place at cnc vertical lathe.
Further, reference may be made to figure 7 illustrating method steps.

[0022] Non –standard size of hemi spherical dished end is manufactured through this method of the present invention.

ADVANTAGES OF INVENTION

-Manufacturing of hemi spherical dished end by fully machining from hollow forging raw material obviating drawbacks of the prior art(s);
-Avoids bullet and ring requirement, heating of the plate for 1050 degree, heat treatment process, shot blasting work for cleaning;
- Simple method of Manufacturing.
TEST RESULT

CYCLE TIME FOR HOT FORMING METHOD
STEPS FOR HOT FORMING HOURS
RAW MATERIAL PREPARATION (GAS CUTTING ,MACHINING ) 16
BULLET PREPARATION 56
RING PREPARATION 56
HEATING CYCLE AT 50TON LPG FURNACE 8
BULLET AND RING SETTING AT 2000TON PRESS 8
PRESSING AT 2000 TON PRESS 8
HEAT TREATMENT NORMALIZING AT 150 TON FURNACE 16
SHOT BLASTING OPERATION ID AND OD 8
RAW MATERIAL INSPECTION 8
ID PROFILE MACHINING (LUG PLATE WELDING ,JOB SETTING ,PROGRAMMING AND MACHINING ) 48
OD PROFILE MACHINING (JOB SETTING ,PROGRAMMING,MACHINING) 16
SUPPORT PIPE MACHINING FOR EDGE PREPARATION 8
EDGE PREPARATION MACHINING 8
TOTAL CYCLE TIME 264
CYCLE TIME FOR FULLY MACHINING
STEPS INVOLVED IN FULLY MACHINING METHOD HOURS
PRE-DRILLING AT RADIAL DRILLING MACHINE (HSS-DRILL BIT )DIA 63MM 16
PRE-BORING AT RADIAL DRILLING MACHINE (DIA 101MM) 16
ID PROFILE MACHINING AT VERTICAL CONVENTIONAL LATHE WITH CARBIDE TIP 56
ID PROFILE MACHINING AT CNC VERTICAL CONVENTIONAL LATHE 32
OD PROFILE MACHINING AT CNC VERTICAL LATHE 16
SUPPORT PIPE MACHINING 8
EDGE PREPARATION AT CNC VERTICAL LATHE 8
TOTAL CYCLE TIME 152

COMPARISON OF HOT FORMING VS MACHINING OF DISHED ENDS
CATEGORY HOT FORMING FULLY MACHINING
RAW MATERIAL STAGE NORMALIZED FULLY KILLED NORMALIZED FULLY KILLED
ULTIMATE TENSILE STRENGTH 540N/MM SQUARE 504N/MMSQUARE
%OF ELONGATION 32 30
MANUFACTURING METHOD ROLLED FORGING OPEN DIE
ULTIMATE TENSILE STRENGTH 485N/MM SQUARE 504N/MM SQUARE
HEAT TREATMENT NORMALIZING REQUIRED NORMALIZING NOT REQUIRED

[0023] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0024] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

[0025] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) 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 following appended claims 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 particulars 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 analogues 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, claims, 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”.

[0026] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

[0027] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.

[0028] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.

[0029] 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 by the following claims.
,CLAIMS:We Claim
1. Method of manufacturing of hemi spherical dished end by fully machining process comprising steps of:
-Pre –drilling and rough boring operation in hollow forging raw material;
-Maintenance of Stock during both pre-drilling and rough boring operation by using vertical lathe machine;
-Finishing inner diameter profile of hemispherical dished end by cnc vertical lathe machine;
-Finishing outer profile machining of hemispherical dished end by using cnc vertical lathe machine.
- Machining of a pipe with outer profile.

2. The Method of manufacturing of hemi spherical dished end as claimed in claim 1, wherein the inner diameter rough machining is done using vertical lathe machine with 10mm stock maintaining outer diameter of 1190mm and inner diameter of 1050mm with straight portion as 194mm.
3. The Method of manufacturing of hemi spherical dished end as claimed in claim 1 or 2, wherein the inner diameter final machining is carried out with cnc vertical lathe machine, in which the 10mm stock is removed and the diameter of 1060mm required profile is obtained after machining.
4. The Method of manufacturing of hemi spherical dished end as claimed in claims 1-3, wherein the outer diameter profile machining is conducted at the same cnc vertical lathe and Hemi spherical dished end with inverted position clamped with bed.
5. The Method of manufacturing of hemi spherical dished end as claimed in claims 1-4, wherein Edge preparation with the required style is formed on the top surface of the dished end.

6. The Method of manufacturing of hemi spherical dished end as claimed in claims 1-5, wherein the edge preparation from cylindrical pipe is done at cnc vertical lathe.

7. The Method of manufacturing of hemi spherical dished end as claimed in claims 1-6, wherein after preparation of fixture, hemi spherical dished end is placed on the profile pipe and machining takes place at cnc vertical lathe.