PORTION EXTERNALLY”

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 the apparatus and process for thickening the tube at its intermediate.

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 including 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. Automotive assembly lines need tubes with extra thickness at its intermediate portion for various applications. This can be achieved with using tube with extra thickness for thorough length or through intermediate thickening of tube. The latter approach ensures overall weight reduction of the entire assembly.

Conventionally, there are known prior arts that disclose various process of producing variable thickness tubes. For instance, flexible rolling is disclosed in the prior art US7107682B2 which iterates about a rolling technique to produce flat sheets of varying thickness and using them for tube production which at end will lead to variable wall thickness tubes. Other processes include swage auto-frettage, wherein the thick-walled tubes are provided with desired internal profile by inserting a mandrel with slightly higher diameter into the tube. Other processes include tube drawing using position-controlled mandrel method, a specially designed mandrel is used in this case for producing tubes with variable thickness along longitudinal direction. Yet another patent US6807837B1 discloses about use of reducing die along with no internal mandrel. An axial force of tensile nature on one side and that of compressive nature on the other side of the die is applied. Variation of relative magnitude of these forces lead to production of variable wall thickness. In brief, 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. Deployment of the processes mentioned above are limited either due to economic constraints such as higher investment in tooling and/or low productivity due to increased cycle time. Also, tube may buckle due to compressive forces involved.

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 a tube at its intermediate portion is disclosed. The apparatus includes a first support member, that is configured to support an outer surface of the tube. At least a portion of the first support member is defined with a profile to be featured on the intermediate portion of the tube. The apparatus further includes a mandrel configured to support the inner surface of the tube and a second support member is configured to support an end of the mandrel. The apparatus includes a punch structured to abut an end of the tube between a free end of the mandrel and the first support member. The punch is configured to exert axial force onto the tube. Application of axial force by the punch plastically deforms the tube resulting in thickening of the tube at the intermediate portion externally keeping internal diameter constant.

In an embodiment of the disclosure, the first support member is configured to exert radial force onto the outer surface of the tube from clamping the tube. The profile is defined at a substantially intermediate portion of the first support member.

In an embodiment of the disclosure, the mandrel is configured to radially support the inner surface of the tube. In an embodiment of the disclosure, plastically deforming the tube results in accumulation of material in the profile defined by the first support member, thereby thickening the intermediate portion of the tube along the outer surface.

In an embodiment of the disclosure, the apparatus includes a retractor structured to abut another end of the tube between the fixed end of the mandrel and the first support member the retractor is configured to exert axial force in a direction opposite to the direction of axial force exerted by the punch.

In an embodiment of the disclosure, the punch is coupled to an actuator to exert axial force onto the tube. The retractor is coupled to the actuator to exert axial force onto the tube. The actuator is at least one of an electric actuator and a hydraulic actuator.

In another non-limiting embodiment, a tube including a body portion defined with an inner surface and an outer surface is disclosed. The body portion is configured such that, thickness at an intermediate portion of the tube along the outer surface is greater than thickness of other portions of the outer surface of the tube.

In an embodiment of the disclosure, the inner surface of the tube is of uniform thickness.

In another non-limiting embodiment of the disclosure, a process of thickening a tube at its intermediate portion through an apparatus is disclosed. The process includes positioning a first support member on an outer surface of the tube. Further, a mandrel is positioned with an inner surface of the tube such that an end of the mandrel is supported by a second support member. Further, an axial force is exerted by the punch onto the tube to plastically deform the tube resulting in thickening of the tube at the intermediate portion.

In an embodiment of the disclosure, the process includes exerting the axial force by a retractor in a direction opposite to the axial force exerted by the punch which plastically deform the intermediate portion of the outer 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 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.l illustrates a schematic view of an apparatus used for thickening a tube at its intermediate portion, in accordance with an embodiment of the present disclosure.

FIG.2 illustrates a schematic view of a section of apparatus including first support member, tube and a second support member, in accordance with an embodiment of the present disclosure.

FIG.3 illustrates the apparatus of FIG.1 depicting the tube being thickened at the intermediate portion, in accordance with an embodiment of present disclosure.

FIG.4 illustrates a cross-sectional view of a thickened tube, in accordance with an embodiment of the present disclosure.

FIG.5 illustrates a schematic view of a tube to be thickened by the apparatus of FIG.l.

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 spirit and 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 the purpose of illustration 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 a tube at its intermediate portion, particularly tubes used in components of automobile. The apparatus includes a first support member, which is configured to rigidly support an outer surface of the tube. The first support member may be defined with a profile corresponding to a profile of the intermediate portion of the tube to be thickened. In an embodiment, the first support member may be configured to exert radial force onto the outer surface of the tube for clamping the tube. The profile in the first support member may be defined at a substantially intermediate portion of the tube. Further, a mandrel may be configured to support an inner surface of the tube, the mandrel may be configured to radially support the inner surface of the tube.

The apparatus may further include a punch structured to abut an end of the tube between a free end of the mandrel and the first support member. The punch may be configured to exert axial force onto the tube. A retractor may be positioned on an opposite end of the punch. The retractor may be designed to abut another end of the tube between a fixed end of the mandrel and the first support member. The retractor may be configured to exert axial force in a direction opposite to the direction of axial force exerted by the punch. In an embodiment, the punch and the retractor may be coupled to an actuator to exert axial force on the tube. The actuator may be a linear actuator including at least one of an electric actuator and a hydraulic actuator. The punch and the retractor in combination may be configured to apply compressive force on the tube and plastically deform the tube. Plastically deforming the tube may result in thickening of the tube at the intermediate portion. The tube formed by the apparatus of the present disclosure may include a body portion defined with the inner surface and the outer surface. The body portion may be configured such that thickness at the intermediate portion of the tube along the outer surface is greater than thickness of other portion of the tube.

The terms “comprises...a”, “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 FIG(s) 1 to 5. In the figures, the same element or elements which have similar functions are indicated by the same reference signs. For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated methods, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention pertains.

The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description. It is to be understood that the disclosure may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices or components illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions or other physical characteristics relating to the embodiments that may be disclosed are not to be considered as limiting, unless the claims expressly state otherwise. Hereinafter, preferred embodiments of the present disclosure will be described referring to the accompanying drawings. While some specific terms of “adjacent,” “juxtaposed,” “substantially”, “between”, “along”, “free end”, “fixed end” or “left” and other terms containing these specific terms and directed to a specific direction will be used, the purpose of usage of these terms or words is merely to facilitate understanding of the present invention referring to the drawings. Accordingly, it should be noted that the meanings of these terms or words should not improperly limit the technical scope of the present invention.

FIG.l is an exemplary embodiment of the present disclosure, illustrating a pictorial view of an apparatus (10) used for thickening intermediate portions (I) of an outer surface (TO) of a tube (T). In an embodiment, the tube (T) to be thickened is depicted in FIG.5 As shown in FIG.l, the apparatus (10) may include a first support member (1), a mandrel (2) and a punch (5). The tube (T) may be held firmly between the first support member (1) and the mandrel (2), on the outer surface (TO) and inner surface (TI) of the tube (T) respectively. The first support member (1) may be configured to rigidly support and clamp the tube (T) on the outer surface (TO). The first support member (1) may include an outer surface that may be configured to receive clamping force from an actuator. The outer surface of the first support member (1) may be connected to the actuator. In an embodiment, at least a portion of the first support member (1) may be defined with a profile corresponding to a profile of an intermediate portion (I) of the tube (T). That is the intermediate portion (I) of the first support member (1) may feature a profile that may be defined on an outer surface (TO) of the tube (T). The profile may be defined on the inner surface of the first support member (1). Further, the mandrel (2) may be configured to rigidly support the tube (T) from inside i.e., the inner surface (TI). A second support member (4) as shown in the FIG.l may be configured to support the mandrel (2). The second support member (4) may be configured to firmly accommodate the mandrel (2). In an embodiment, the first support member (1) may be driven by a first external power source which provides necessary force to firmly hold the tube (T) between the first support member (1) and the mandrel (2). The punch (5) may be designed to abut an end of the tube (T) between free end of the mandrel (2) and the first support member (1) and may be driven by an external power source [not shown]. In some embodiments, the dimension of the punch (5) may be similar to that of the tube (T) being thickened in the apparatus. The first external power source drives the first support member (1) in the radially inward direction. In an embodiment, the radially inward force on the first support member (1) as said above imparts inward force on the first support member (1) which may rigidly support the tube (T).

Similarly, the mandrel (2) may be configured to radially support the inner surface (TI) of the tube (T) and may exert radially outward force on the tube (T). In an embodiment, the punch (5) may exert axial force over an end portion of the tube (T) when driven by an actuator. In some embodiments, the punch (5) may be displaced axially by an actuator to apply compressive load on the ends of the tube (T) to deform the tube (T). In an embodiment, the apparatus (10) may include a retractor (3) that may be designed to abut another end of the tube between a fixed end of the mandrel (2) and the first support member (1). The retractor (3) may be fixed to the second support member (4) either rigidly or removably. The retractor (3) may be coupled to an actuator (not shown). The retractor (3) may be configured to support the tube (T) during compression. In some embodiments, the retractor (3) may be designed to push the tube (T) out of the mandrel (2). In an embodiment, the retractor (3) may be positioned adjacent to the second support member (4) [as shown in FIG.l]. The retractor (3) may be configured to exert axial force in a direction opposite to the direction of the axial force exerted by the punch (5) [as depicted by arrows within the feature depicted by ref. numeral 5]. The force imparted by the punch (5) acts as compressive force on the tube (T) and the retractor (3) imparts equal force opposite to the force of the punch (5) to hold the tube (T) in position. The compressive force plastically deforms the intermediate portion (I) into the profile defining the die formed in the first support member (1). Further, the compressive force acting on the tube (T) deforms the tube (T) into the shape of the die formed by the profile in the first support member (1). The tube (T) may be plastically deformed due to the compressive forces due to which the material accumulates in the profile defined by the first support member (1). The result of plastic deformation of the tube (T) in the profile defined by the first support member (1) is as shown in FIG.3, the substantially intermediate portion (I) of the tube (T) may be thickened.

Further, the tube (T) is held firmly over the entire portion of the inner surface (TI) by the mandrel (2) and over the entire portion excluding substantially intermediate portion (I) on the outer surface by the first support member (1). The tube (T) on both ends may be subjected to compressive force by the punch (5) and the retractor (3) [as shown in FIG.3]. The force imparted over the ends of the tube (T) plastically deforms the tube (T) into the shape of the die created by the profile of the first support members (1). The compressive force may be imparted by the punch (5) which may be driven by the actuator. As shown in FIG.l to 3, the tube (T) may be subjected to compressive force on one or both ends. The compressive force that is imparted on the ends of the tube (T) plastically deforms the substantially intermediate portion (I) of the tube (T). The thickness of the intermediate portion (I) of the tube (T) increases after the plastic deformation, as it takes the shape of the profile in of the first support member (1). The actuator may be any one of but not limiting to a hydraulic drive, pneumatic drive, and the like. The tube (T) formed using the said apparatus (10) and the said process may have the body portion (B) and the intermediate portion (I) as shown in FIG.4.

As shown in FIG.4 the tube (T) includes of the body portion (B) and the intermediate portion (I). The inner surface (TI) of the body portion (B) of the tube (T) may be of uniform cross section. The intermediate portion (I) may be formed by the plastic deformation into the die formed in the first support member (1). The intermediate portion (I) may have a thickness greater than thickness of the body portion (B) of tube (T). The thickness of the intermediate portion (I) of the tube (T) may be about maximum of 30% greater than the thickness of the body portion (B). As shown in FIG.3, it picturizes a completely manufactured tube (T) held between first support member (1) and the mandrel (2) of the apparatus (10). 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 (10) can thicken the tube (T) at the substantially intermediate portion (I) ensuring lower cycle time and improving the productivity of the apparatus (10). The process has low operation cost over the conventional device due use of less tonnage equipment. Also, the tubes (T) undergo strain hardening during the process, facilitating in increase in strength of the tube (T).

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: