HK1237304B - Roller with compound angle flange - Google Patents

Description

Roller with compound angle flange

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/043,956, filed August 29, 2014, the entire contents of which are incorporated herein by reference.

Technical Field

The present invention relates to rollers for roll forming tubular elements.

Background Art

Circumferential grooves and other features, such as shoulders and beads, can be formed in tubular elements by various methods, with one method of particular interest being roll grooving. The roll grooving method involves engaging an inner roller with the inner surface of the tubular element and, in an opposite manner, engaging an outer roller with the outer surface of the tubular element, and incrementally compressing the sidewall of the tubular element between the rollers while rotating at least one roller. Rotation of one roller (typically the inner roller) causes relative rotation between the roller set and the tubular element, and features on the inner and outer rollers form corresponding features on the inner and outer surfaces of the tubular element. In one exemplary roll grooving method, the rollers remain in a fixed position and the tubular element rotates relative to the rollers about its longitudinal axis. In another exemplary embodiment, the tubular element remains stationary and the roller set traverses the circumference of the tubular element.

For example, during the roll-forming of circumferential grooves in a tubular element, it is important to maintain engagement of the tubular element with the rollers. As disclosed in U.S. Patent No. 5,279,143 (incorporated herein by reference) and illustrated herein in FIG. 1 , it can be observed that, with clockwise rotation of the inner roller (when viewed along the line-of-sight axis defined by arrow 9 ), if an orientation angle 10 in the vertical plane between the longitudinal axis 12 of the tubular element 14 and the rotational axis 16 of the inner roller 18 is maintained, the tubular element 14 will be forced inwardly toward the roller (to the left in FIG. 1 ), causing the tubular element 14 to abut and maintain contact with a flange 20 extending outwardly from the inner roller 18. An orientation angle 10 of approximately 1° to 2° provides the appropriate tracking force to maintain engagement of the tubular element 14 with the rollers. If the orientation angle 10 is reversed, the force on the tubular element 14 is reversed, and the tubular element will tend to rotate away from the rollers and disengage therefrom.

Figure 1 shows a side view of a pipe element and rollers, depicting an orientation angle 10 in the vertical plane; however, similar tracking issues exist due to the orientation angle in the horizontal plane (shown in Figure 2). Figure 2 shows a pipe element 14 (shown in dashed lines) and inner roller 18 from above (outer rollers are not shown for clarity). Also shown is an orientation angle 22 between the longitudinal axis 12 of the pipe element 14 and the rotational axis 16 of the inner roller 18, which is tilted to the left in the horizontal plane. With respect to clockwise rotation of the inner roller 18 (when viewed along the line of sight defined by arrow 9), an excessively left-leaning orientation angle (typically exceeding approximately 2°) is disadvantageous because the pipe may overtrack aggressively toward the flange 20. Aggressive overtracking can cause friction between the pipe end and the flange, leading to shearing of pipe material from the pipe end face when the pipe is loaded upward against the flange. Conversely, a right-leaning orientation angle 22 (shown in Figure 3) results in opposing forces acting on the pipe element 14, which cause the pipe element 14 to rotate out of engagement with the rollers. While an orientation angle of exactly zero (with axes 12 and 16 aligned in a horizontal plane, not shown) provides proper tracking and minimizes contact between the tube end and the flange (and thereby minimizes the adverse effects of friction), it is not always possible to ensure and/or maintain an orientation angle of exactly zero in the horizontal plane. Furthermore, it is advantageous to avoid a right-hand orientation angle (shown in FIG. 3 ) to prevent disengagement of the tube element. Thus, while a left-hand orientation angle can be disadvantageous if excessive, it is preferred over a right-hand orientation angle and provides an acceptable margin against disengagement of the tube element compared to a zero-degree orientation angle. Clearly, there is a need for an improved inner roller that mitigates the adverse effects of aggressive tracking, thereby enabling the use of a wider range of left-hand orientation angles in the horizontal plane to ensure that the tube element tracks toward the flange and maintains proper engagement with the roller during roll-forming. (Note that for counterclockwise rotation of the inner roller 18 , the opposite occurs when viewed along line of sight 9 , and the right-hand orientation angle shown in FIG. 3 provides the desired tracking of the tube element toward the flange 20 ).

Summary of the Invention

The present invention relates to a roller for roll-forming tubular elements. In one exemplary embodiment, the roller includes a body rotatable about an axis. A flange extends circumferentially around the body and projects radially outward from the body relative to the axis. The flange includes a surface having at least a first surface portion angularly oriented at a first orientation angle relative to the axis and a second surface portion angularly oriented at a second orientation angle relative to the axis.

In a specific embodiment, the shape of the body is substantially cylindrical, and the axis is coaxial with the longitudinal axis of the body. By way of example, the flange may have a circular periphery. In one example, the first surface portion and the second surface portion are continuous with each other. In a specific example, the first surface portion and the second surface portion have an annular shape. By way of example, the first surface portion may be positioned closer to the body than the second surface portion. In a specific example, the first orientation angle is from about 91° to about 93°, and may be about 92°. By way of further example, the second orientation angle is from about 93° to about 96°, and may be about 95°.

In another exemplary embodiment, the flange includes a third surface portion that is positioned closer to the body than the first surface portion.The third surface portion may have an orientation angle of approximately 90° relative to the axis.

In certain exemplary embodiments, the body includes an outer surface having a plurality of raised features extending outwardly therefrom. The raised features may comprise a cylindrical surface or a conical surface. By way of example, at least two of the raised features may extend circumferentially around the body and be positioned in spaced relationship with one another along the axis. The raised features may comprise a knurled surface facing radially outward relative to the axis. The present invention also includes an apparatus for roll-forming a tubular element utilizing the rollers described above.

In another exemplary embodiment of a roller for roll-forming a tubular element, the roller includes a body rotatable about an axis. A flange extends circumferentially around the body and projects radially outward from the body relative to the axis. The flange includes an arcuate surface having a center of curvature such that the arcuate surface recedes from a line perpendicular to the axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a partial cross-sectional side view of a roller for roll-forming a tubular element according to the prior art;

2 and 3 are partial top views of rollers for roll-forming tubular elements according to the prior art;

FIG4 is an isometric view of an exemplary apparatus for roll-forming a tubular element utilizing rollers according to the present invention;

5 and 6 are partial cross-sectional side views of exemplary rollers for roll-forming tubular elements according to the present invention;

7 , 8 , 9 and 10 are partial longitudinal cross-sectional views of exemplary rollers according to the present invention; and

7A and 9A are partial transverse cross-sectional views of exemplary rollers according to the present invention.

DETAILED DESCRIPTION

FIG4 shows an apparatus 24 for roll-forming tubular elements. Apparatus 24 includes a housing 26 on which are rotatably mounted an inner roller 28 and an outer roller 30 according to the present invention. Inner roller 28 rotates about an axis of rotation 32, driven in this example by an electric motor 34. Outer roller 30 is an idler roller and is mounted on a frame 36 for rotation about an axis 38, which is preferably oriented generally parallel (in both horizontal and vertical planes) to axis 32 of inner roller 28. Frame 36 is movable toward and away from inner roller 28 (as indicated by arrow 40), in this example by hydraulic actuator 42.

In operation, as shown in FIG5 , the inner surface 14 a of the tubular element 14 engages the inner roller 28, with the end of the tubular element preferably engaging the flange 44 of the inner roller. As shown in FIG4 and 6 , the hydraulic actuator 42 moves the outer roller 30 into engagement with the outer surface 14 b of the tubular element 14. The motor 34 rotates the inner roller 28 about the axis 32, and the actuator 42 urges the outer roller 30 against the outer surface 14 b of the tubular element 14, thereby roll-forming a circumferential groove 45 in the tubular element. The outer roller 30 rotates about its axis 38 as an idler roller, and the tubular element 14 rotates about its longitudinal axis 12.

Figures 7 and 8 illustrate partial cross-sectional views of an exemplary embodiment of an inner roller 28 according to the present invention. Inner roller 28 includes a body 46 rotatable about axis 32. Body 46 is generally cylindrical in cross-section, with axis 32 being generally coaxial with the body's longitudinal axis. As shown in Figure 7, body 46 has an outer surface 48 from which two raised features 50 and 52 extend outward. Raised features 50 and 52 are positioned in spaced relation to one another along axis 32. Raised features 50 and 52 may have a knurled surface 54 that faces radially outward relative to axis 32. Knurled surface 54 provides purchase and reduces slippage between inner surface 14a of tubular element 14 and inner drive roller 28. In the embodiment shown in Figure 7, raised features 50 and 52 depict cylindrical surfaces. In contrast, in the embodiment shown in Figure 8, raised features 50a and 52a are conical and lie within a common conical surface.

The flange 44 shown in Figures 7 and 8 has a circular perimeter 56 and extends circumferentially around the body 46. The flange 44 protrudes radially outward from the body 46 relative to the axis 32. The flange 44 includes a surface 58 having a first surface portion 60 and a second surface portion 62. In this example, the first surface portion 60 and the second surface portion 62 are continuous with each other, with the first surface portion 60 being positioned closer to the body 46 than the second surface portion 62. As shown in Figure 7A, the first surface portion 60 and the second surface portion 62 have an annular shape. Referring again to Figures 7 and 8, the first surface portion 60 is angularly oriented relative to the axis 32, with an orientation angle 64 that can range from approximately 91° to approximately 93°. An orientation angle 64 of approximately 92° is desirably advantageous. The second surface portion 62 is also angularly oriented relative to the axis 32 and has an orientation angle 66 that is greater than angle 64. The orientation angle 66 can range from approximately 93° to approximately 96°, with an orientation angle 64 of approximately 95° desirably advantageous. When the first and second surface portions are annular, they may have a width of about 0.18 to about 0.5 inches, with 0.375 inches being considered advantageous. It has been found worthwhile to establish the width of the surface portions in relation to the thickness of the pipe element to be machined.

FIG9 illustrates another exemplary embodiment of an inner roller 68 according to the present invention. Inner roller 68 includes a body 70 rotatable about an axis 72 that is generally cylindrical in shape and generally coaxial with the longitudinal axis of the cylinder. Body 70 has an outer surface 74 from which two raised features 76 and 78 extend outward. Raised features 76 and 78 are positioned in spaced relationship to one another along axis 72. Raised features 76 and 78 may have a knurled surface 80 that faces radially outward relative to axis 72. Knurled surface 80 provides retention and reduces slippage between the inner surface of tubular element 14 and inner drive roller 68.

The flange 82 shown in FIG9 has a circular perimeter 84 and extends circumferentially around the body 70. The flange 82 protrudes radially outward from the body 70 relative to the axis 72. The flange 82 includes a surface 86 comprising a first surface portion 88, a second surface portion 90, and a third surface portion 92. The first surface portion 88 is positioned closer to the body 70 than the second surface portion 90. The third surface portion 92 is positioned closer to the body 70 than the first surface portion 88. In this example, the first surface portion 88 and the second surface portion 90 are continuous with each other, and the first surface portion 88 and the third surface portion 92 are continuous with each other. As shown in FIG9A, the first surface portion 88, the second surface portion 90, and the third surface portion 92 have an annular shape. Referring again to FIG9, the first surface portion 88 is angularly oriented relative to the axis 72, having an orientation angle 94 that can range from approximately 91° to approximately 93°. An orientation angle of approximately 92° is desirably advantageous. The second surface portion 90 is also angularly oriented relative to the axis 72, having an orientation angle 96 that is greater than angle 94. Orientation angle 96 may range from about 93° to about 96°, with an orientation angle of about 95° desirably being advantageous.Third surface portion 92 has an orientation angle 98 of about 90° and may extend radially outward from outer surface 74 of body 70 to form an annulus.

10 shows an embodiment of an inner roller 100 in which the flange 102 has an arcuate surface 104. The arcuate surface 104 is positioned with a radius of curvature 106 such that the surface 104 recedes from the end of a pipe element engaged with the inner roller 100 as the surface 104 moves away from an axis of rotation 108 of a body 110 comprising the inner roller 100.

It has been discovered that the inner roller according to the present invention allows for a wider range of left-leaning orientation angles between the longitudinal axis of the tubular element and the axis of rotation of the inner roller, with respect to clockwise rotation of the inner roller. This orientation angle of the flange surface portion reduces the contact area between the tube end and the flange and allows for more aggressive tracking to maintain engagement of the tubular element with the roller, while also mitigating the adverse frictional effects between the tube end and the flange of the inner roller that are otherwise associated with excessive left-leaning orientation angles in the horizontal plane.

Claims (33)

1. A roll for roll forming tube elements, the roll comprising: A body capable of rotating around an axis; A flange extending circumferentially around the body and projecting radially outward from the body relative to the axis, the flange including a surface facing the tube element during roll forming of the tube element, wherein the surface has at least a first surface portion oriented at a first orientation angle relative to the axis, and a second surface portion oriented at a second orientation angle relative to the axis; wherein The body includes an outer surface having at least two protruding features extending radially outward from the outer surface, the boundary between the first surface portion and the second surface portion being positioned in the radial direction beyond the at least two protruding features. 2. The roller of claim 1, wherein the body is substantially cylindrical in shape and the axis is coaxial with the longitudinal axis of the body. 3. The roller of claim 1, wherein the flange has a circular periphery. 4. The roller of claim 1, wherein the first surface portion and the second surface portion are continuous with each other. 5. The roller of claim 4, wherein each of the first surface portion and the second surface portion has an annular shape. 6. The roller of claim 1, wherein the first surface portion has an annular shape. 7. The roller of claim 1, wherein the second surface portion has an annular shape. 8. The roller of claim 1, wherein the first surface portion is positioned closer to the body than the second surface portion. 9. The roller of claim 8, wherein the first orientation angle is from 91° to 93°. 10. The roller of claim 8, wherein the first orientation angle is 92°. 11. The roller of claim 8, wherein the second orientation angle is from 93° to 96°. 12. The roller of claim 8, wherein the second orientation angle is 95°. 13. The roller of claim 8, wherein the flange includes a third surface portion positioned closer to the body than the first surface portion, the third surface portion having an orientation angle of 90° relative to the axis. 14. The roller of claim 1, wherein the body includes an outer surface having a plurality of raised features extending outward from the outer surface. 15. The roller of claim 14, wherein the raised feature comprises a cylindrical surface. 16. The roller of claim 14, wherein the raised feature includes a conical surface. 17. The roller of claim 14, comprising at least two of the raised features that extend circumferentially around the body and are positioned to be spaced apart from each other along the axis. 18. The roller of claim 17, wherein the at least two of the raised features include knurled surfaces that are radially outward relative to the axis. 19. An apparatus for roll forming tube elements, the apparatus utilizing the roll of claim 1. 20. A roll for roll forming tube elements, the roll comprising: A basic cylindrical body, which is capable of rotating about an axis coaxial with the longitudinal axis of the body; A generally circular flange extends circumferentially around the body and projects radially outward from the body relative to the axis; the flange includes a surface facing the tube element during roll forming, wherein the surface has at least a first surface portion oriented at a first orientation angle relative to the axis and a second surface portion oriented at a second orientation angle relative to the axis, the first surface portion being closer to the body than the second surface portion, the first orientation angle being smaller than the second orientation angle, and the first surface portion and the second surface portion being continuous with each other; wherein The basic cylindrical body includes an outer surface having at least two protruding features extending radially outward from the outer surface, and the boundary between the first surface portion and the second surface portion is positioned in the radial direction beyond the at least two protruding features. 21. The roller of claim 20, wherein the first orientation angle is from 91° to 93°. 22. The roller of claim 20, wherein the second orientation angle is from 93° to 96°. 23. The roller of claim 20, wherein the first orientation angle is 92°. 24. The roller of claim 20, wherein the second orientation angle is 95°. 25. The roller of claim 20, wherein the flange includes a third surface portion positioned closer to the body than the first surface portion, the third surface portion having an orientation angle of 90° relative to the axis, and the third surface portion being continuous with the first surface portion. 26. The roller of claim 25, wherein each of the first surface portion, the second surface portion, and the third surface portion has an annular shape. 27. The roller of claim 20, wherein the first surface portion has an annular shape. 28. The roller of claim 20, wherein the second surface portion has an annular shape. 29. The roller of claim 20, wherein the body includes an outer surface having a plurality of raised features extending outward from the outer surface. 30. The roller of claim 20, comprising at least two of the raised features that extend circumferentially around the body and are positioned to be spaced apart from each other along the axis. 31. The roller of claim 30, wherein the at least two of the raised features include knurled surfaces that are radially outward relative to the axis. 32. An apparatus for roll forming tube elements, the apparatus utilizing the roll of claim 20. 33. A roll for roll forming tube elements, the roll comprising: A body capable of rotating around an axis; A flange extends circumferentially around the body and projects radially outward from the body relative to the axis; the flange includes an arcuate surface facing the tube element during roll forming, and the arcuate surface has a center of curvature that recedes from a line perpendicular to the axis.