DE102013018515A1 - Process for producing a shaped wire body and shaped wire bodies - Google Patents

Abstract

The invention relates to a method for producing a shaped wire from at least one wire, wherein the elongated wire is injected through an opening in a forming space of a forming device such that the wire transforms into a helical spiral structure and forms a precursor in the forming space, which with Help the forming device is transformed into the wire molding.

Description

The invention relates to a method for producing a shaped wire body from at least one wire. Furthermore, the invention relates to a manufactured by forming, to be flowed through by a mass flow wire molding of at least one wire.

Wire shaped articles of the type mentioned in the introduction have long been known and are used in particular as filters, cooling elements and the like. For this purpose, a mass flow to be cleaned or cooled, for example a liquid or a gas, is passed through the shaped wire body.

Wire-formed articles are mass-produced products, in the manufacture of which even slight simplifications in the production process lead to a significant reduction in both the technical and the financial outlay.

To date, shaped wire bodies are manufactured from precursors, which are plastically deformed to form the shaped wire body by using appropriate shaping devices in the desired, final shape.

The precursors are usually wire mesh, wire mesh or Drahtgewirke, ie precursors that have already undergone highly complex and expensive manufacturing processes. Since wire knits, wire mesh and Drahtgewirke are usually manufactured in continuous processes, for example, knitted endless hoses or continuous mats, woven or knitted endless mats, they must be pretreated before forming, for example, cut to the desired length. Not only large amounts of metal waste, such as chaff, wire filaments, etc. fall to this. Also, the manufactured hose and mat sections usually have to be freed manually of residues, such as chaff and wire filaments, which have become entangled in the separation of endless material in the hose and mat sections. Furthermore, there is also the problem that a defined specification of the weight of the finished wire shaped body is hardly possible. Thus, for example, knitted wire hoses can never be cut off so precisely from the endless hose during separation that the resulting hose section has a tightly tolerated weight, since it can not be controlled at which point stitches of the endless hose are severed or not.

In addition, the wire material usually has to be oiled before knitting, weaving or knitting so that the knitting, weaving or knitting process can proceed without friction.

The preproducts thus prepared are then inserted into the forming device and formed into the desired shaped wire bodies.

The explanations given above already show the complexity in the production of shaped wire bodies.

Based on this prior art, it was an object of the invention to provide a method for producing a wire shaped body, through the use of which a shaped wire body can be produced which on the one hand has the same physical properties as conventionally produced shaped wire bodies, but whose production is marked compared with the prior art is simplified.

According to the invention, this object is achieved by a method having the features of claim 1 and in particular that for producing the wire shaped body of the elongated wire is injected into a forming space of a forming device such that the wire transforms into a helical helical structure and in the forming space a precursor forms, which is transformed by means of the forming device to the wire shaped body.

Unlike usual in the prior art, eliminating the production of an intermediate product, which must be prefabricated in a separate manufacturing process prior to the actual forming process of the wire molding. According to the invention, a conventional wire is rather injected with force into the forming space of the forming device. When a shoot of the wire, the wire is directed into the forming space and collides with the inner walls of the forming space so that the wire receives a helical helical structure. This process is set by adjusting the speed at which the wire is shot into the forming space and the deformability of the wire. It should be noted that in the present application, the term "helical helical structure" is understood to mean a single or multiple cylindrical spiral or helix. This spiral-preformed wire in the forming space through the insertion then forms a precursor from which the shaped wire body is manufactured in a further step. After separation of the wire, the wire section taken up as a precursor in the shaping device is finally shaped into the shaped wire body with the aid of the shaping device. It should be noted that the wire is separated when reaching the desired length when shooting in the forming space.

During forming, adjacently arranged helical portions of the Wire engaged with each other and plastically deformed so that after forming a defined but permeable to liquids and gases wire structure is maintained.

The process of the present invention eliminates a variety of upstream manufacturing steps that have heretofore been common in conventional manufacturing processes, such as preparing the wires prior to knitting, weaving or knitting, knitting, weaving or knitting the wires into continuous intermediates, and separating individual sections from the continuous intermediates or the unpacking and cleaning of the previously separated from the continuous intermediate hose and mat sections.

Further advantages of the invention will become apparent from the following description, the dependent claims and the drawings.

According to a particularly preferred variant of the method according to the invention, the wire is first received in a high pressure chamber. At closing a pressure in the range of 100 to 1000 bar is generated in the high pressure chamber depending on the thickness and the length of the wire to be eingeschießenden. The high-pressure chamber communicates with the forming space via a closable channel. The channel is closed when pressure is generated and the wire is inserted into the channel. Once sufficient pressure has been built up in the high pressure chamber, the channel is opened. Since there is atmospheric pressure in the forming space, the wire is injected into the forming space by the gas under high pressure. Forming forces that lead to a deformation of the wire, through which the wire receives the desired helical spiral structure arise in particular at the outlet opening of the channel in the forming space on the wire. At the same time, the wire end exits the inner wall of the forming space, whereby the wire is deflected. Once the desired length of wire has been injected into the forming space, the channel is closed while the wire is cut. In order to facilitate the forming of the wire as it enters the forming chamber, it is further proposed to heat the wire to a working temperature with suitable means, such as an induction heater, before the wire is injected into the forming space.

As an alternative to this high-pressure process variant, it is proposed to heat the wire over a predetermined length, for example with burners, an induction heating device or similar heating devices, to forming temperature and then to inject it into the forming chamber with the aid of a conveying device. By heating the wire is achieved that when the wire shoots through the exit opening of the channel in the forming space, forming forces on the wire, which lead to a deformation of the wire, through which the wire receives the desired helical spiral structure. The formability of the wire is supported by heating to the forming temperature.

In order to achieve an even distribution of the wire during shooting, the wire is deflected when shooting into the forming space such that the helically deforming wire undergoes a constant change in its spatial orientation over its length considered. For this purpose, for example, a deflecting device provided in the opening is used, the direction in which the wire shoots into the forming space is changed continuously.

By changing the orientation of the wire in the forming space is achieved in the formation of the precursor that individual sections of the spirally preformed wire engage each other and so formed during subsequent forming of the preform in the wire molding a particularly uniform wire structure throughout the wire molding.

In order that the shaped wire body obtains a predetermined total weight, it is further proposed to separate the wire to be inserted into the forming device when a predetermined length has been reached. Since both the density of the wire material and its cross-sectional dimensions are known, the length of the wire to be processed and the final total weight of the finished wire shaped body can be very precisely predetermined and determined by simple calculation.

Preferably, the wire is inserted in a circle around an imaginary center in the negative mold of the forming device, wherein when inserting the wire and the distance to the imaginary center can be varied.

In order to ensure that the wire structures of the wire shaped body on the outer surface of the wire shaped body after the molding of the shaped wire body to solve, it is also proposed to firmly connect portions of the outer surface of the formed wire shaped body by joining.

Particularly advantageous in the inventive method is the use of a wire with polygonal, preferably rectangular or square cross-section. Precisely because the wire does not have to be knitted, woven or knitted in the present process, makes it possible to use wires with an angular cross-section in a very simple way.

The use of a wire for the wire molding having a polygonal cross-sectional shape uniform over its length instead of using a wire whose cross-sectional shape is round has various advantages.

Thus, it has been shown that by using a cross-section polygonal wire constantly changes its spatial orientation over the length seen in the wire shaped body due to its previously made spiral pre-deformation, laminar and turbulent flows can be generated in the wire shaped body targeted, which influence the flow behavior targeted. The turbulent flows in turn lead to a significant increase in the flow resistance of the wire molding as compared with wire moldings, which are made of wires with round cross-sectional shapes.

In order to realize the same flow behavior, in particular a virtually identical flow resistance in the wire shaped body according to the invention, the length of necessary wire can be reduced compared to conventional wire shaped bodies of wires with a round cross-section, while still a due to the intrinsically unfavorable flow behavior of the wires with angular cross-section can be maintained approximately constant flow resistance.

The fact that a shorter wire length can be used in the wire molding according to the invention, in turn, leads to a reduction of the weight of the wire molding according to the invention compared to the weight of a conventional wire molding of wires with round cross section.

If, for example, a wire shaped body is used as a reference, which is made of a round wire with a wire diameter of one millimeter and a length of 1000 mm, one needs for a wire shaped body according to the invention when using for example a cross-sectionally square wire with an edge length of 0 in each case. 89 mm only a length of 678 mm, resulting in a weight saving of approximately 32%. With a cross-sectionally square wire with an edge length of 0.6 mm and a length of 1000 mm results in a weight saving of approximately 55% with approximately the same flow resistance.

When using a cross-section polygonal wire for the production of the shaped wire body, it is possible to save material significantly with constant flow behavior. It is also possible to selectively influence and adjust the flow behavior and the heat transfer behavior by selective selection of the cross-sectional shapes and wire lengths.

Particularly preferred for the inventive method, a wire is used, which has a rectangular or square cross-sectional shape, since these cross-sectional shapes can be easily made by pulling the wire.

For carrying out the method according to the invention, an arrangement is suitable which has a device for injecting the wire into the forming space of a forming device for forming the wire.

According to a further aspect, the invention relates to a preferably produced by using the inventive method by forming, to be flowed through by a mass flow wire molding of at least one wire, which is characterized in that by injection into the forming space has been transformed into a helical helical structure and his As seen in length, there is an ongoing change in its spatial orientation, with mutually adjacent helical portions of the wire engaging one another.

The invention will be explained in more detail with reference to an embodiment with reference to the drawing. Hereby shows:

1 a schematic side view of a first arrangement for carrying out the method according to the invention;

2a to c is a schematic side view of the in both arrangements according to 1 respectively. 2 used forming device in different operating positions;

3 a schematic side view of a wire shaped body according to the invention; and

4 a schematic side view of a second arrangement for carrying out the method according to the invention.

In 1 is a schematic side view of a first arrangement 10 shown for performing the method according to the invention.

The order 10 has a facility 12 for shooting one of a wire feeder 14 supplied wire 16 as well as one reshaping 18 on. The device 12 stands over a canal 20 in the forming device 18 flows in connection with this. As will be explained later, the wire becomes 16 when shooting into the forming device 18 reshaped so that the wire 16 gets the desired spiral helical structure.

The device 12 has a high pressure chamber 22 , In the high pressure chamber 22 can be generated by a high-pressure pump not shown, a high pressure in a range of 100 to 1000 bar. In the high pressure chamber 22 is also the wire feed 14 arranged on which the wire 16 is wound up.

The high pressure chamber 22 stands over the canal 20 with one in the case 24 the forming device 18 trained forming space 26 the forming device 18 in connection. As in 1 is further shown, is in the mouth region of the channel 20 in the forming space 26 an insert 28 made of hardened steel. The use 28 is also with a slider 30 equipped with the channel 20 gastight against the high pressure chamber 22 can be sealed.

The lower end of the cylindrical forming space 28 is by a lower punch 32 locked. In the case 24 is an upper stamp 34 lowered.

To carry out the method, first the slider 30 closed and the wire 16 from the wire feeder 14 in the channel 20 threaded and pushed so far forward, until he on the slide 30 is at its end. Subsequently, in the high-pressure chamber 22 a high pressure P ₁ of for example 850 bar generated. Once the pressure has reached the set value, the arrangement is 10 operational.

As soon as the pressure has reached the set value, the slider will turn 30 open. Because in the forming space 26 Ambient pressure P _U prevails, the high pressure gas flows from the high pressure chamber 22 in the forming space 28 one. It will be in the channel 20 guided wire 16 carried away and through the use 28 at high speed into the forming space 26 injected. Due to the friction of the wire 16 at the edges of the insert 28 This leads to deformations on the wire surface, the spiral helical structure in which in the forming space 26 einschießenden wire 16 cause. At the same time the wire hits 16 on the inner wall of the forming space 26 on, with the wire 16 is deflected in the forming space. This creates a wire accumulation of the spiral wire 16 which is subject to constant change of direction.

Once, a given length wire 16 from the wire feeder 14 has been deducted, the slider is 30 closed again. On the one hand, the high pressure chamber 22 closed again and on the other hand the wire 16 is cut.

The in the forming space 26 shot wire 16 now forms an intermediate product 36 out of the wire 16 with a helical spiral structure, with individual wire sections looping around each other. The further processing of the precursor 36 is described below with reference to the 2a to c is described.

After closing the slide 30 that is the shooting of the wire 14 in the forming space 26 finished, the upper stamp 34 lowered, as in 2a shown and the precursor 36 compacted and plastically transformed. After the upper punch 34 is lowered to a predetermined compression position, the upper punch 34 stopped (cf. 2c ). In this position was the precursor 36 so far compressed and plastically deformed that further deformation of the material is no longer necessary. From the precursor 36 is now the final wire molding 38 manufactured.

Once the finished wire molding 38 is formed, the upper punch 34 moved back to its original position, as in 1 is shown, and the finished wire molding 38 from the forming space 26 taken. The order 10 is now available again for the implementation of the procedure.

In 3 is a side view of a method according to the invention produced wire molding 38 shown. At the in 3 shown wire shaped body 38 points the wire 16 which has been preformed into a helical helical structure prior to forming only has a continuous change in its spatial orientation along its length, with helical sections of wire adjacent to each other 16 engage each other. The thus shaped wire shaped body 38 can now additionally additionally secured by welding points or welds on the outer surface in addition to its shape.

Particularly preferred for the method according to the invention described above is a wire 16 used with polygonal cross section. As will be explained below, by using, for example, a wire 16 with square cross-section shape very targeted save weight. Furthermore, leaves a wire 16 with polygonal cross-section very well and trouble-free to process well with the arrangement described above.

The weight savings can be made in a wire molding produced according to the invention 38 Compared with a wire formed body made of a wire having a round cross section, they are in a range of 25 to 60%.

In 4 is a second embodiment of an arrangement 40 shown for performing the method. It should be noted that even with the second arrangement 40 a forming device 18 is provided, whose structure to that in the first arrangement 10 described forming device 18 corresponds, so that for simplicity the components and components, which correspond to those of the first arrangement 10 correspond denoted by the same reference numerals.

The second arrangement 40 also has a wire feeder 42 for feeding the wire 16 , To the wire feeder 42 closes a conveyor 44 in which the wire 16 is guided. The conveyor 44 is through a channel 46 with the forming device 18 connected. At the mouth of the canal 46 is also the use of the forming device 28 and the slider 30 provided, like 4 can be seen.

To the channel 46 around is a heater 48 arranged. The heater 48 is capable of the section of the wire 16 who is in the channel 46 is added to heat to a forming temperature of several hundred degrees Celsius. For steel as a material for the wire 16 For example, the forming temperature is in a range of 750 to 950 ° C.

Shall now the wire 16 in the forming space 26 be injected, the section of the wire 16 who is in the channel 46 is recorded, with the help of the heater 48 heated to the desired forming temperature. Due to the small wire diameter, this can be done within a few seconds, depending on the power of the heater.

Once the wire 16 has been heated to the forming temperature, the slider 30 opened and the wire 16 with the help of the conveyor 44 in the forming space 26 injected.

Due to the friction of the wire 16 at the edges of the insert 28 it also happens here, as in the first arrangement 10 , to deformations on the wire surface, which has a helical spiral structure in which in the forming space 26 einschießenden wire 16 cause. At the same time the wire hits 16 on the inner wall of the forming space 26 on, with the wire 16 in the forming space 26 is diverted. By doing that, the wire 16 heated to forming temperature, the wire can be 16 easily reshape, with at the same time a wire accumulation as a precursor 36 from the spiral wire 16 in the forming space 26 is formed, which is subject to a constant change of direction.

Once the desired length wire 16 in forming space 26 has been injected, the slider is 30 closed again, which also causes the wire 16 is cut.

Then this is in the forming space 26 recorded precursor 36 as previously with reference to the 2a to c described in the wire shaped body 38 reshaped. Once the forming process is complete and the wire molding 38 has been removed from the forming device, the inventive method is completed and can be restarted.

LIST OF REFERENCE NUMBERS

10

first arrangement

12

Device for shooting a wire

14

wire feed

16

wire

18

reshaping

20

channel

22

High-pressure chamber

24

casing

26

shaping space

28

commitment

30

pusher

32

lower stamp

34

upper stamp

36

precursor

38

Wire moldings

40

second arrangement

42

wire feed

44

Conveyor

46

channel

48

heater

Claims (10)

Method for producing a shaped wire body of at least one wire, in which the elongated wire is injected through an opening in a forming space of a forming device such that the wire transforms into a helical spiral structure and forms a precursor in the forming space, which with the aid of the forming device the shaped wire is transformed. The method of claim 1, wherein the wire is received in a high-pressure chamber and injected by means of high pressure through a connecting the high-pressure chamber with the forming space channel which opens into the opening into the forming space. The method of claim 1 or 2, wherein the wire is heated to forming temperature before the wire, preferably by means of a conveyor, is injected through the opening in the forming chamber. The method of claim 1, 2 or 3, wherein the wire is deflected when shooting into the forming space, preferably by means provided at the opening deflection such that the helically deforming wire viewed over its length a continuous change in its spatial orientation experiences. Method according to one of claims 1 to 4, wherein the einschießende in the forming space wire is separated when reaching a predetermined length. A method according to any one of claims 1 to 5, wherein the helically preformed wire is circularly shot into the forming space of the forming means about an imaginary center, the radial distance of the wire feed to the imaginary center preferably being changed. Method according to one of the preceding claims, in which portions of the outer surface of the formed wire shaped body are joined together by joining. Method according to one of the preceding claims, in which the wire has a polygonal cross-sectional shape which remains constant over its length, preferably a rectangular or square cross-sectional shape. From a mass flow to be flowed through shaped wire body, which has been manufactured according to a method according to one of the preceding claims from at least one wire, characterized in that the formed by shooting into the forming space to a helical helical structure wire ( 16 ) seen along its length has a continuous change in its spatial orientation, wherein adjacent to each other arranged helical sections of the wire ( 16 ) are engaged with each other. Wire shaped article according to claim 9, characterized in that the wire ( 16 ) has a polygonal cross-sectional shape which is constant over its length and preferably has a rectangular or square cross-sectional shape.

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