RU2744077C1 - Method for manufacturing multiwire elastic shell - Google Patents

Abstract

FIELD: technological processes.

SUBSTANCE: invention relates to machining of materials and can be used in production of twisted shell with contacting coils operating in aggressive media. Proposed method comprises winding of wires on displacing mandrel to retain shell from self-twisting on mandrel. After coiling of wire on mandrel, the specified length of the resulting shell blank is cut off, the ends of the shell workpiece are fixed in end supports, the mandrel is shifted inside the shell workpiece towards one of its ends, freed end of shell is welded to end of end support, mandrel is shifted inside shell blank to opposite end and shell end is welded to butt end of second end support. Winding of wires is performed at longitudinal translational movement of mandrel with provision of specified tension of wires by means of tensioning device. Containment of self-impregnation shell is performed by means of forming disc with hole, through which wires and mandrel are passed to form coiled structure of shell.

EFFECT: improving winding process stability, providing tight laying of turns.

8 cl, 4 dwg

Description

Technology area

This technical solution relates to the field of mechanical processing of metals without significant material removal and can be used in the manufacture of a twisted shell with contacting turns, operating in corrosive environments, at elevated temperatures.

Prior art

The known method is described in the patent of the USSR No. 443505 "Method of making wire spirals with a" dash ""; IPC: В21F 3/02, priority 09/12/1970, published 09/15/1974, author: Yan Balbatun (Poland).

A method of manufacturing wire spirals with a "dash" by periodically winding a wire on a mandrel and forming a "dash" by pulling the wire along the generating mandrel, characterized in that, in order to improve the quality of products, before the formation of each section of the spiral, the wire is turned by a predetermined angle in the direction, opposite to the winding direction.

Features that coincide with the essential features of the invention, periodic winding of a wire on a mandrel.

The disadvantages of this method include the looseness of the laying of the turns of the spiral, high labor intensity of the process and low productivity.

As a prototype for the method, the author's certificate of the USSR No. 649493 “Method of winding an endless multiwire spiral” IPC was chosen: B21F 3/04, B21F 45/06; priority 02.02.1976, published 28.02.1979, authors: A.I. Mokhnatiuk, I.V. Yatsyna (SU).

A method of winding an endless multi-wire spiral by winding several wires on a non-rotating cantilever mandrel mounted with the possibility of axial reciprocating movement, while keeping the spiral on the mandrel from self-twisting, characterized in that, in order to increase the productivity and quality of the spirals, the axial reciprocating movement the mandrels relative to the winding head are produced with an amplitude less than the winding pitch and with a frequency greater than the angular speed of spiral winding.

Features that coincide with the essential features of the invention are the winding of a multi-wire spiral by winding several wires onto a non-rotating cantilever mandrel mounted with the possibility of axial translational movement, while keeping the spiral on the mandrel from self-twisting.

The disadvantages of this method include the high complexity of the process. Due to the reciprocating movement of the mandrel, a constant change in the process occurs, which leads to a violation of its stability due to the inertia of the moving mechanical elements in the movement cycles. The absence of a tensioning device leads to sagging of the wires, the formation of local gaps between the turns and, as a result, to an uneven and loose fit (laying) of the turns in the spiral and deviation from the required dimensions. Difficulty in synchronizing the rollers and mandrel can affect the accuracy of the spiral geometry.

Disclosure of invention

The task to be solved by the claimed invention is the development of a method for manufacturing a multi-wire elastic twisted casing, with an increase in the stability of the winding process, ensuring a tight packing of turns, the accuracy of obtaining the dimensions of the casing while reducing the labor intensity of the process, ensuring the rigidity of fastening the casing in the operating device, including elevated temperatures.

The technical result consists in eliminating the inertia of the process of the reciprocating movement of the mandrel, applying the tension of the wires and optimizing the winding parameters, replacing the reciprocating movement of the mandrel with a translational movement, using supports for the subsequent fastening of the shell in the device.

The technical result is achieved by the fact that in the method of manufacturing a multi-wire elastic twisted casing, including winding wires onto a moving mandrel, keeping the casing from self-unscrewing on a mandrel, according to the invention, after winding the wire onto the mandrel, a predetermined length of the resulting sheath blank is cut, the ends of the sheath blank are fixed into the end supports. Then the mandrel is shifted inside the shell towards one of its ends, the free end of the shell is welded to the end of the end support. Next, the mandrel is shifted inside the shell towards the opposite end, the released end of the shell is welded to the end of the second end support. In this case, the winding of the wires is carried out with the longitudinal translational movement of the mandrel with the provision of a given tension of the wires by means of the tensioning device. The casing is kept from self-unrolling by means of a forming disk with a hole through which wires and a mandrel are passed to form a twisted structure of the casing.

The combination of essential features provides a technical result: elimination of the inertia of the process of reciprocating movement of the mandrel, application of wire tension and optimization of winding parameters, replacement of the reciprocating movement of the mandrel with a translational movement, the use of adapters for subsequent fastening of the shell in the device. This makes it possible to solve the problem of developing a method for manufacturing a multiwire elastic twisted casing with an increase in the stability of the winding process, ensuring a tight packing of turns, the accuracy of obtaining the dimensions of the casing while reducing the labor intensity of the process, ensuring the rigidity of fastening the casing in the operating device.

The achieved result is provided not only by the presence of known distinctive features, but also depends on their interaction with other essential features of the claimed device. This allows the device to expand its functionality and provide a solution to the problem of reducing the overall dimensions and simplifying the design.

The extended function provided by the known distinctive features, and the receipt of an unexpected positive result from the use of these features in combination with other features, indicates the compliance of the proposed technical solution with the criterion of "inventive step".

Brief Description of Drawing Figures

FIG. 1 shows the structure of the shell.

FIG. 2 shows a diagram of the winding of the shell.

FIG. 3 shows the external view of the shell with the mandrel.

FIG. 4 shows the external view of the manufactured shell with supports and welded joints.

Embodiments of the invention

The proposed invention is the manufacture of a multi-wire elastic shell 1 (Fig. 1) in the form of a spiral spring. The sheath is made of a heat-resistant material, for example, a nickel-chromium wire made of alloy Kh20N80 with intermediate 2 and end supports 3 of the same material. When working at high temperatures, elastic shells are prone to sagging and the appearance of gaps between the turns, which can damage the internal communication elements. The use of heat-resistant materials and supports makes it possible to increase the rigidity and ensure a snug fit of the shell turns at high temperatures.

As shown in FIG. 2, the winding of the shell on a mandrel 4 of six wires 5 is carried out on a universal lathe in the "threading" mode.

When the wires 5 are wound onto the mandrel 4, a shell blank 8 is obtained. The rotor 6 of the device with coils 7 is installed in the chuck of the lathe (not shown in Fig. 2). A self-centering chuck 9 is used as a device for moving (S) the shell blank 8, which secures the mandrel 4. The same function can be performed by the clamping device 10 ...

To form the inner cavity of the shell blank 8, an elastic wire of any material, for example, steel, with a diameter of 1 mm is used.

The tension of the wires 5 is set and provided by the tensioning device 11 in the process of winding them onto the mandrel 4. This provides an inter-turn pressure sufficient for the tight packing of the turns and the accuracy of obtaining the dimensions of the shell blank 8.

The forming disk 12 with a hole is held to prevent the shell blank 8 from self-unrolling and the wire 5 is twisted into the shell 1 onto the mandrel 4. This allows solving the problem of increasing the stability of the winding process, ensuring the density of the coils packing and the accuracy of obtaining the dimensions of the shell 1.

In this case, each wire 5 previously wound on the coil 7 is passed through the pressure plates of the adjusting tensioner 11. After that, all wires 5 and the mandrel 4 are passed into the disk with the hole 12 and fixed in the self-centering chuck 9 or in the clamping device 10. Then, the wire tension is adjusted 5 due to the adjusting tensioning device 11. By adjusting the pressure plates, a constant maximum required tension of the coiled wires 5 is provided. This allows solving the problem of increasing the stability of the coiling process. The disk with the hole 12, which serves as the former of the twisted structure of the shell blank 8, is rigidly fixed at the required distance from the rotor 6. This distance provides a predetermined angle and pitch of winding wires 5.

The winding of wires 5 onto the mandrel 4 is performed with the simultaneous start of the main movement of the spindle rotation with the rotor 6 and the feed movement. The movement of the mandrel 4 occurs due to the longitudinal translational movement of the self-centering chuck 9, or the clamping device 10. In comparison with the prototype, the replacement of the reciprocating movement of the mandrel with a translational movement increases the stability of the winding process.

Uniform pulling of wires 5 from spools 7, absence of breaks and sagging testifies to optimal process parameters and device settings. In this case, each wire 5 coming from the coils 7, at the boundary of the hole in the disk 12, begins to twist around the mandrel 4, forming a shell blank 8. The wires 5 are wound onto the mandrel 4 with a step equal to the sum of all the diameters of the wires 5. This makes it possible to ensure tight packing of the turns and obtain the accuracy of the dimensions of the sheath 1.

After winding the shell blank 8 (Fig. 3) on the cut-off wheel, its required length is cut off together with the mandrel 4, preparing for subsequent assembly and welding. This makes it possible to solve the problem of the accuracy of obtaining the dimensions of the shell 1. Then, the blank 8 of the shell is assembled with the mandrel 4 inside with the supports 2 and 3 (Fig. 1), and to facilitate the installation of the blank 8 of the shell, it is "screwed" into the supports 2 and 3. End supports 3 are installed flush with the ends of the shell blank 8. After fixing the ends of the shell blank 8 into the end supports 3, the mandrel 4 is shifted inside the shell blank 8 towards one of its ends, the released shell end face 1 is welded with the end support end 3 using laser spot welding LS with a continuous seam 13 (Fig. 4). Then the mandrel 4 is shifted inside the shell blank 8 towards the opposite end and the released end of the shell 1 is welded with the end of the second end support 3 with a continuous seam 13.

Laser welding (LS) of the supports 2 and 3 with the shell workpiece 8 (Fig. 4) is performed “into the corner” by separate points in manual mode. Welding to the end supports 3 is carried out at an angle of 45 ° relative to the end of the shell 1, provided that the mandrel 4 is removed from the welded joint. This improves the quality of the welded joint. Welding of the intermediate support 2 with the shell 1 is carried out with a filler wire made of alloy Kh20N80 according to the mode ensuring the minimum energy input, at an angle of 45 ° relative to the axis of the shell 1. The ends of the intermediate support 2 with the outer forming surface of the shell 1 are laser-welded with an intermittent seam 14. This simplifies the process manufacture of multi-wire sheath 1 and reduces labor intensity.

Reliable connection of the shell 1 with the supports 2 and 3 made of heat-resistant material makes it possible to solve the problem of the rigidity of fastening the shell 1 in a device operated at elevated temperatures.

The developed technology was used to weld assembly units consisting of shell 1, wire 5 wound from heat-resistant alloy Х20Н80, intermediate 2 and two end supports 3 made of alloy Х20Н80. The external view of the shell 1 and the welds of the intermediate support 2 and end supports 3 is shown in Fig. four.

The proposed invention provides the necessary technical and operational characteristics for a specific unit and for the entire structure as a whole.

INDUSTRIAL APPLICABILITY The proposed invention can be used for the manufacture of electrical connectors in aviation and space technology, in nuclear power engineering, in metallurgy, mechanical engineering, etc. Where there are increased requirements for the safety of internal communication elements when working at high temperatures. The proposed version of the elastic shell was tested on existing equipment using available materials. This proves its performance and confirms its industrial applicability.

Claims (8)

1. A method of manufacturing a multi-wire elastic twisted sheath, including winding wires onto a moving mandrel with the sheath holding from self-unscrewing on a mandrel, characterized in that after winding the wire onto a mandrel, a predetermined length of the resulting sheath blank is cut off, the ends of the sheath blank are fixed into the end supports, the mandrel is shifted inside shell blanks towards one of its ends, weld the vacated shell end with the end support end, shift the mandrel inside the shell blank towards the opposite end, weld the free shell end with the second end support end, while winding the wires is carried out with longitudinal translational movement of the mandrel ensuring a predetermined tension of the wires by means of a tensioning device, and the retention of the sheath from self-unscrewing is carried out by means of a forming disk with a hole through which wires and a mandrel are passed to form a twisted structure of the sheath. 2. The method according to claim 1, characterized in that the ends of the shell blank are fixed by screwing them into the end supports. 3. The method according to claim 1, characterized in that the wires are wound onto the mandrel with a step equal to the sum of all wire diameters. 4. The method according to claim 1, characterized in that a heat-resistant wire is used as the winding wires. 5. The method according to claim 1, characterized in that after cutting the required length of the shell blank, at least one intermediate support is installed on it. 6. The method according to claim 5, characterized in that the ends of at least one intermediate support are welded to the outer surface of the shell blank. 7. The method according to claim 1, characterized in that the welding of said ends is carried out by laser welding with a circular continuous seam. 8. The method according to claim 6, characterized in that the welding of said ends and surfaces is carried out by laser welding with an intermittent seam.

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