US20140116668A1 - Cooler pipe and method of forming - Google Patents

Cooler pipe and method of forming Download PDF

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Publication number
US20140116668A1
US20140116668A1 US13/664,485 US201213664485A US2014116668A1 US 20140116668 A1 US20140116668 A1 US 20140116668A1 US 201213664485 A US201213664485 A US 201213664485A US 2014116668 A1 US2014116668 A1 US 2014116668A1
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United States
Prior art keywords
pipe
backing material
helical
cooler pipe
workpiece
Prior art date
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Abandoned
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US13/664,485
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English (en)
Inventor
Malay Maniar
Sarang Saurabh
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Priority to US13/664,485 priority Critical patent/US20140116668A1/en
Assigned to GM Global Technology Operations LLC reassignment GM Global Technology Operations LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MANIAR, MALAY, SAURABH, SARANG
Assigned to WILMINGTON TRUST COMPANY reassignment WILMINGTON TRUST COMPANY SECURITY AGREEMENT Assignors: GM Global Technology Operations LLC
Priority to DE102013221632.7A priority patent/DE102013221632A1/de
Priority to CN201310530005.0A priority patent/CN103785707B/zh
Publication of US20140116668A1 publication Critical patent/US20140116668A1/en
Assigned to GM Global Technology Operations LLC reassignment GM Global Technology Operations LLC RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: WILMINGTON TRUST COMPANY
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/06—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of metal tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
    • B21D17/04—Forming single grooves in sheet metal or tubular or hollow articles by rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D9/00—Bending tubes using mandrels or the like
    • B21D9/15—Bending tubes using mandrels or the like using filling material of indefinite shape, e.g. sand, plastic material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/42—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being both outside and inside the tubular element
    • F28F1/424—Means comprising outside portions integral with inside portions
    • F28F1/426—Means comprising outside portions integral with inside portions the outside portions and the inside portions forming parts of complementary shape, e.g. concave and convex
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F1/00—Tubular elements; Assemblies of tubular elements
    • F28F1/10—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses
    • F28F1/42—Tubular elements and assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with projections, with recesses the means being both outside and inside the tubular element
    • F28F2001/428—Particular methods for manufacturing outside or inside fins
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2210/00—Heat exchange conduits
    • F28F2210/06—Heat exchange conduits having walls comprising obliquely extending corrugations, e.g. in the form of threads

Definitions

  • the present invention relates to a cooler pipe and a method of forming a cooler pipe using roll-forming.
  • Cooler pipes may be included in applications where fluid at a higher temperature is conveyed or flowed through the cooler pipe to reduce the temperature of the fluid to a lower temperature, by conducting heat away from the fluid through the wall of the cooler pipe.
  • a cooler pipe may be used, for example, in heat exchanger and/or engine systems, which may include vehicle powertrain systems, to circulate a fluid which may be a gas or a liquid and to lower the temperature of the circulated fluid.
  • a cooler pipe may be used to recirculate and reduce the temperature of exhaust gases in a combustion engine and in this configuration may be referred to as an exhaust gas recirculating (EGR) pipe.
  • EGR exhaust gas recirculating
  • the capability of the cooler pipe to transfer heat away from a fluid flowing through the cooler pipe is a function of a number of factors, including the capability of the pipe to convect the fluid and to conduct heat away from the fluid as the fluid flows through the cooler pipe.
  • the capability of the cooler pipe to convect the fluid may be a function of the flow capacity or flow rate of the cooler pipe, which may be defined by and proportional to the cross-sectional area of the pipe cavity.
  • the capability of the cooler pipe to conduct heat away from the fluid may be a function of the inner surface area of the pipe conducting heat away from fluid flowing through the pipe, the thickness and heat conductivity of the pipe wall, and the outer surface area of the cooler pipe radiating heat away from the pipe.
  • Another consideration in fabricating a cooler pipe is configuring the overall size and shape of the cooler pipe to fit within a packaging envelope defined by the system into which the cooler pipe is incorporated to, for example, provide clearance and/or air circulation around the exterior surface of the cooler pipe.
  • the packaging envelope may be constrained by the size of the engine compartment, by the configuration of the engine and location of inlet/outlet ports to which the cooler pipe may be attached, and by clearances required between the cooler pipe and components adjacent the cooler pipe.
  • the cooler pipe in operation may be subject to significant temperature fluctuations, vibration, high temperature, and high pressure conditions.
  • the cooler pipe must be configured with sufficient thermal stress resistance, fatigue strength, cracking resistance, and pipe burst strength to maintain the integrity of the cooler pipe over time in operation and resist cracking, bursting, or other sealing failures.
  • Weight of the cooler pipe may also be a design consideration, for example, in vehicle applications where overall weight of the vehicle system, including weight contributed by the cooler pipe, may impact fuel efficiency.
  • FIGS. 5A and 5B a conventional means for milling a cooler pipe 50 C from a stock pipe 50 A is illustrated.
  • stock pipe refers to a length of pipe which may be of a standard size or may be a commercially available, e.g., stocked, pipe.
  • the stock pipe may be substantially straight along its length.
  • FIG. 5A shows a cross-sectional view of the stock pipe 50 A having a generally cylindrical wall 52 defining a hollow portion 58 and a longitudinal axis 60 .
  • the wall 52 includes an outer surface 54 having an outer radius B 4 , and an inner surface 56 having an inner radius B 5 .
  • the wall 52 has a uniform thickness B 1 prior to milling a helical slot 64 along an axial length of the stock pipe 50 A to form the cooler pipe shown in cross-sectional view in FIG. 5B .
  • the milled helical slot 64 includes a milled surface 62 and is characterized by a milled depth B 3 .
  • Cooling of a fluid (not shown) conveyed through the milled cooling pipe 50 C occurs by flowing the heated fluid through the hollow portion 58 such that heat is transferred by convection of the fluid and conducted via the inner surface 56 through the thickness of the wall 52 to the outer surface 54 , where the transferred heat is radiated from the outer surface 54 to the environment surrounding the cooler pipe 50 C.
  • the area of the outer surface 54 of the cooler pipe 50 C is increased incrementally by the milled surface 62 , thereby increasing the surface area available to radiate heat from the cooler pipe 50 C, as compared with the outer surface area 54 of the stock pipe 50 A, and increasing the thermal conductivity of the milled cooler pipe 50 C relative to the stock pipe 50 A.
  • milling the helical slot 64 reduces the total wall thickness B 1 by the milled depth B 3 to a wall thickness B 2 in the milled portion, thereby reducing the strength of the wall 52 of the cooler pipe 50 C relative to the unmilled stock pipe 50 A.
  • the effective wall thickness B 2 defines the integrity and effective wall strength of the cooler pipe 50 C, including, for example, resistance of the cooler pipe 50 C to cracking, bursting or thermal fatigue.
  • the surface characteristics of the milled surface 62 may further impact the effective strength of the cooler pipe 50 C.
  • the stock pipe 50 A must have an initial wall thickness B 1 which is thick enough to provide machining stock to mill the slot 64 to a depth B 2 sufficient to provide the cooling efficiency required by the cooler pipe 50 C, while retaining a minimum effective wall thickness B 2 after machining, where the minimum effective wall thickness B 2 must be sufficiently thick to compensate for any stress risers residual on the milled surface 62 .
  • the fluid transfer capacity e.g., the flow rate of fluid conveyed through the cooler pipe 50 C
  • the fluid transfer capacity is defined by the cross-sectional area of the hollow portion 58 , which is proportional to the inner radius B 5 .
  • system packaging constraints may limit the overall size of the cooler pipe 50 C and the size of the outer radius B 4 , such that the fluid transfer capacity of the cooler pipe 50 C and the inner radius B 5 may be constrained by the wall thickness B 1 required to provide the effective wall thickness B 2 after milling the slot 64 .
  • the thicker portions of the wall 52 e.g., those having a thickness B 1 , are less efficient at conducting heat than the thinner portion of the wall 52 , e.g, the slotted portion having a thickness B 2 .
  • the milled cooler pipe 50 C is disadvantaged by requiring a thicker wall portion B 1 having an incremental wall thickness B 3 to provide machining stock to mill the slot 64 .
  • the incremental wall thickness B 3 decreases heat transfer efficiency through the wall 52 , introduces a weight penalty, and restricts the flow transfer capacity of the cooler pipe 50 C by limiting the size of the hollow portion 58 .
  • the milled cooler pipe 50 C is further disadvantaged by generating waste or scrap material from milling the slot 64 , and introducing the potential for stress risers resulting from the milled surface finish of the slot surface 62 .
  • Another method for producing a helically corrugated metal pipe involves first forming lengthwise corrugations in an elongated strip of sheet metal, with the corrugations extending along the length of the strip. The corrugated strip is then spiraled into a helical form so that opposite edges of the corrugated strip come together and can be joined by crimping, lock seaming, or welding to form a seam along the corrugated length of the pipe.
  • This method is disadvantaged by the multiple forming steps involved corrugating, spiraling and joining the metal strip.
  • the wall strength including the burst strength, thermal fatigue strength and stress cracking resistance of the pipe may be defined by the integrity of the seam or crimp joining the opposite edges of the corrugated strip, which may be susceptible to crimping or welding discontinuities due to process variation and dimensional variability in the corrugated edges being joined and which may impact pipe integrity and sealing.
  • a cooler pipe and a method of roll-forming a cooler pipe from a workpiece including a generally cylindrical wall defining a hollow portion is provided.
  • the workpiece may be configured to include a wall having cylindrical outer and inner surfaces concentrically disposed about a longitudinal axis of the workpiece.
  • the cooler pipe may be configured as an exhaust gas recirculating (EGR) pipe for use with an engine.
  • the method includes filling a hollow portion defined by the inner surface of the workpiece with a backing material, and roll-forming a helical groove extending axially along the wall to form the cooler pipe using a rolling tool configured to exert a rolling force on the outer surface of the wall.
  • the backing material is configured to exert a supportive force against the inner surface and in opposition to the rolling force.
  • the helical groove thus formed includes a helical recess formed in the outer surface of the wall and a helical protrusion extending radially from the inner surface of the wall and into the backing material.
  • the helical recess is characterized by a continuous extruded grain flow extending the axial length of the helical groove resulting from deformation of the workpiece material during roll-forming of the groove.
  • the wall of the workpiece is characterized by a first radial thickness and the helical groove is characterized by a second radial thickness, and the first thickness and the second thickness are substantially the same.
  • a plurality of helical grooves may be formed at axial intervals on the workpiece to configure the cooler pipe.
  • the method further includes removing the backing material from the cooler pipe after roll-forming the workpiece to form the cooler pipe.
  • the backing material may be removed from the cooler pipe in portions, by one of shaking, vibrating, and gravitating each of the portions of the backing material from the cooler pipe after roll-forming, and/or by rinsing the backing material from the hollow portion using one of a fluid and a gas.
  • the method may include recycling the backing material after removing the backing material from the cooler pipe and reusing at least a portion of the backing material as backing material during forming of a subsequent cooler pipe.
  • the supportive force provided by the backing material is sufficient to prevent collapse of the wall during roll-forming.
  • the backing material may include an aggregate and/or granular material, such as sand, and may be configured as a suspension including the granular material.
  • the method may include compacting the backing material in the hollow portion of the workpiece prior to roll-forming the helical groove.
  • the backing material may be configured such that the helical protrusion extending from the inner surface of the wall and into the backing material displaces and/or compresses the backing material adjacent the helical protrusion within the hollow portion.
  • the roll-formed cooler pipe provided herein may be fabricated with a thinner wall thickness relative to a milled cooler pipe, by eliminating the machining stock required to produce a milled slot, resulting in a roll-formed cooler pipe which is lower in weight, higher in heat transfer efficiency, and substantially the same or better in wall strength, thermal fatigue strength and cracking resistance than a conventional milled cooler pipe, and which may be roll-formed without producing scrap or waste material during forming of the helical slot.
  • FIG. 1A is a schematic partial plan view of a workpiece defining a hollow portion
  • FIG. 1B is a schematic cross-sectional view of section 1 B- 1 B of the workpiece of FIG. 1A ;
  • FIG. 2A is a schematic partial plan view of the workpiece of FIG. 1A showing the hollow portion filled with a backing material and the workpiece being roll-formed to form a cooler pipe;
  • FIG. 2B is a schematic cross-sectional view of section 2 B- 2 B of the workpiece of FIG. 2A ;
  • FIG. 3A is a schematic partial plan view of a cooler pipe formed from the workpiece of FIG. 1A by roll-forming as shown in FIG. 2A , with the backing material removed;
  • FIG. 3B is a schematic cross-sectional view of section 3 B- 3 B of the cooler pipe of FIG. 3A ;
  • FIG. 4A is a schematic cross-sectional view of section 1 B- 1 B of the workpiece of FIG. 1A without the backing material;
  • FIG. 4B is a schematic cross-sectional view of section 3 B- 3 B of the workpiece of FIG. 3A without the backing material;
  • FIG. 5A is a schematic cross-sectional view of a stock pipe
  • FIG. 5B is a schematic cross-sectional view of a conventional cooler pipe formed by milling the stock pipe of FIG. 5A .
  • FIGS. 1A-3B illustrate a method of forming a cooler pipe from a workpiece, generally indicated at 10 , and shown as an unformed workpiece 10 A in FIGS. 1A-1B , as a partially formed cooler pipe 10 B in FIGS. 2A-2B , and as a formed cooler pipe 10 C in FIGS. 3A-3B .
  • the cooler pipe 10 C may be configured as an exhaust gas recirculating (EGR) pipe for use with an engine (not shown).
  • EGR exhaust gas recirculating
  • the cooler pipe 10 C is formed by roll-forming a helical groove 30 along a cooling length L using a rolling tool 40 , which in the example shown may include at least one roller 40 configured to exert a rolling force 38 on an outer surface 14 of the workpiece 10 A.
  • the workpiece 10 A may be generally tubular having a longitudinal axis 20 , and may be configured as a pipe.
  • the workpiece 10 A may be a stock pipe, or a length or portion of a stock pipe.
  • stock pipe refers to a length of pipe which may be of a standard size or shape and may be a commercially available, e.g., stocked, pipe.
  • the workpiece 10 A may be configured as a substantially straight length of stock pipe.
  • the workpiece 10 A may be made of metal or metal alloy material deformable by roll-forming, such as a steel-based material, stainless steel, aluminum-based material, or other.
  • the workpiece 10 A is made of a stainless steel, preferably having a high chromium content, to provide high temperature strength and fatigue resistance, as would be desirable, for example, for a cooler pipe 10 C operating in an environment with temperature fluctuations including high temperatures, vibration, etc., which subject the cooler pipe 10 C to thermal and/or mechanical fatigue stresses.
  • the cooler pipe 10 C when configured as an EGR pipe or similar for use on an engine such as a vehicle engine, would be subjected to such an environment.
  • the workpiece 10 A includes a wall 12 which is defined by an outer surface 14 and an inner surface 16 .
  • the wall 12 is characterized by a wall thickness A 1 .
  • the inner surface 16 of the workpiece 10 A defines a hollow portion 18 .
  • the workpiece 10 A is generally cylindrical, defining a longitudinal axis 20 and opposing workpiece or pipe ends 24 , and the wall thickness A 1 is uniform about the circumference of the wall 12 .
  • At least one of, or both, of the ends 24 define an opening 22 through which the hollow portion 18 is accessible.
  • the ends 24 and/or openings 22 may be configured for attachment to an interfacing component.
  • a portion 26 of the workpiece 10 A may be defined by the cooling length L.
  • the portion 26 is deformed by the rolling tool 40 to define the helical groove 30 , thereby forming the cooler pipe 10 C, where the portion 26 defines a cooling portion of the cooler pipe 10 C, and the cooling length L may correspond generally to the axial length of the helical groove 30 .
  • the method of forming the cooler pipe 10 C includes, as shown in FIGS. 1A-1B , providing a backing material 28 to the hollow portion 18 of the workpiece 10 C.
  • the backing material 28 may be provided to the hollow portion 18 via one or both of the openings 22 , in a quantity and configuration to substantially fill the hollow portion 18 with the backing material 28 for at least the length L, and such that the backing material 28 provides support to the portion 26 during deformation of the wall 12 to form the helical groove 30 .
  • the rolling tool 40 exerts a sufficient rolling force 38 against the workpiece 10 A to deform the workpiece wall 12 to form the helical groove 30 .
  • the backing material 28 exerts a supportive force 36 against the inner surface 16 of the workpiece 10 A, and in opposition to the rolling force 38 .
  • the backing material 28 prevents collapse, buckling, cracking and/or wrinkling of the workpiece 10 A or other undesirable forming defects, such as folds, discontinuities, tool marks, etc., in the helical groove 30 and cooler pipe 10 C from occurring during the roll-forming process.
  • the uniform supportive force 36 provided by the backing material 28 to the workpiece wall 12 allows roll-forming of a workpiece 10 A having a relatively thin wall 12 .
  • a relatively thin wall 12 may be characterized by a wall thickness A 1 of 0.75 mm or less.
  • the wall thickness A 1 may be 0.6-0.7 mm.
  • the backing material 28 is characterized by sufficient compressibility such that the workpiece 10 A may be deformed to form a helical protrusion 34 extending from the interior surface 16 and projecting into the backing material 28 filling the hollow portion 18 during roll-forming, as shown in FIGS. 2A-2B for the partially formed cooler pipe 10 B.
  • the backing material 28 may include a solid material, a suspension, or an aggregate.
  • the backing material 28 may include a granular material, which may be a sand-based or sand-containing material.
  • the backing material 28 may be provided to the hollow portion 18 of the workpiece 10 A using a filling or compaction method which compacts or densifies the backing material 28 to a predetermined or minimum compacted density to exert supportive pressure 36 against the inner surface 16 of the workpiece 10 A sufficient to prevent collapse, buckling and/or wrinkling of the workpiece 10 A during forming of the helical groove 30 .
  • the compacted backing material 28 may be incrementally compressible and/or displaceable within the hollow portion 18 such that, during roll-forming of the helical groove 30 , the backing material 28 in contact with and/or immediately proximate to the helical protrusion 34 is compressed or displaced by the helical protrusion 34 to extend or radially protrude into the backing material 28 as shown in the cross-sectional view of FIG. 2B when formed.
  • the helical protrusion 34 increases the effective surface area of the inner surface 16 of the cooler pipe 10 C, thereby increasing the heat transfer efficiency of the cooler pipe 10 C relative to a cooler pipe having a cylindrical inner surface, such as the inner surface 56 of the milled cooler pipe 50 C shown in FIG. 5B .
  • the helical protrusion 34 by extending radially into the hollow portion 18 of the cooler pipe 10 C, may cause increased convection of fluid (not shown) flowing through the cooler pipe 10 C, by directing or controlling the flow pattern of the fluid through the hollow portion 18 and thereby increasing heat transfer efficiency through the fluid.
  • the directed or controlled fluid flow may include a helical, angular, or corkscrew pattern of fluid motion through the hollow portion 18 , which may increase the amount of time the fluid is in contact with the inner surface 16 of the cooler pipe 10 C, and/or increase the area of inner surface 16 the fluid is in contact with as the fluid flows through the cooler pipe 10 C, thereby increasing heat transfer efficiency.
  • the helical protrusion 34 by extending radially into the hollow portion 18 , acts to disrupt or break a boundary layer of fluid flowing through the hollow portion 18 of the cooler pipe 10 C in use, where the boundary layers may form at the periphery of the hollow portion 18 , e.g., at the inner surface 16 of the rolled cooler pipe 10 C. Disrupting the boundary layer of fluid flowing through the hollow portion 18 changes the characteristics of at least a portion of the fluid flow through the hollow portion 18 from laminar flow to non-laminar flow, thereby increasing heat transfer efficiency.
  • the backing material 28 may be a granular material, such as sand.
  • the granular material may be combined with at least one other material in one of a suspension or aggregate to form the backing material 28 .
  • the backing material 28 may be configured as a suspension including a granular material and a fluid, such as a water-based or organic fluid, where the relative proportions of the granular material and the fluid may be controlled to provide a backing material 28 having a density sufficient to exert the supportive force 36 , where the density may be specified for the suspension in an uncompacted and/or compacted state.
  • the backing material 28 may include a granular material which may be combined with another material to provide an aggregate.
  • the aggregate may be a compressible aggregate, e.g., one capable of compaction to a higher density, such as a combination of sand and a clay filler or other organic material, a foundry sand, or a green sand.
  • the aggregate may be a combination of a first granular material of a first size and/or shape, and at least one other granular material having a different size and/or shape than the first granular material.
  • the grain size and/or grain shape of the granular material may be controlled or specified to provide a backing material 28 having a packing density corresponding to the grain size and/or grain shape, where the packing density, grain size and/or grain shape may correspond to the magnitude of the supportive force 36 which can be exerted by the backing material 28 when compacted in the hollow portion 18 .
  • the backing material 28 may include fine sand having a grain size of 0.25 mm or less.
  • the fine sand may have a grain size of 0.2 mm or less.
  • the shape of the sand for example, may be angular or rounded.
  • the helical groove 30 is formed along the cooling length L using a rolling tool 40 configured to contact the outer surface 14 of the workpiece 10 A and to exert a deforming force 38 , which may also be referred to herein as a rolling force 38 , on the wall 12 to form the helical groove 30 .
  • the rolling tool 40 may be configured, as shown in the non-limiting example of FIG.
  • rollers 40 which may be arranged and/or manipulated relative to the workpiece 10 A such that the workpiece 10 A is advanced axially and radially relative to and in interfering contact with the rolling tool 40 , where the interfering contact is sufficient for the rolling tool 40 to exert a rolling force 38 on the outer surface 14 and the wall 12 of the workpiece 10 A.
  • the roller 40 may be configured to define the profile or shape of the recess 32 and may be radiused, profiled, polished or otherwise finished to smoothly interface with the outer surface 14 .
  • FIG. 2A is non-limiting. Other configurations are possible, including, for example, rotating and axially advancing the workpiece 10 A relative to a fixtured rolling tool 40 , rotating and advancing the rolling tool 40 relative to a fixtured workpiece 10 A, axially advancing the workpiece 10 A while rotating the rolling tool 40 , etc., to form the helical groove 30 .
  • the rolling tool 40 may be configured as an annular rolling tool (not shown), where the workpiece 10 A is presented to and axially advanced with the longitudinal axis 20 skewed to the axis of the annular rolling tool 40 to define the helical angle of the helical groove 30 .
  • the rolling tool 40 and the method of roll-forming the helical groove 30 may be configured to control the rolling force 38 and/or the depth A 3 of penetration of the rolling tool 40 relative to the outer surface 14 , where the depth A 3 of penetration may correspond to the depth of the helical recess 32 formed by the rolling tool 40 .
  • the rolling force 38 required to form the helical groove 30 and/or the helical recess having a depth A 3 may vary relative to the material chemistry and/or mechanical properties of the material forming the workpiece 10 A, the supportive force 36 exerted by the backing material 28 in opposition to the rolling force 38 , the configuration of the backing material 28 in the hollow portion 18 , etc.
  • the helical groove 30 formed by the rolling tool 40 includes a helical recess 32 defined on the outer surface 14 and a helical protrusion 34 extending radially inward from the inner surface 16 .
  • the continuous, e.g., uninterrupted, helical groove 30 extends axially along the cooling length L of the portion 26 to define the cooler pipe 10 C.
  • Deformation and/or extrusion of the wall 12 by the rolling tool 40 causes grain flow in material of the workpiece 10 A at the surface of the recess 32 and proximate to, e.g., immediately adjacent the surface of the recess 32 , where the grain flow characterizing the deformed material defining the recess 32 is consistent with the contact profile of the rolling tool 40 and the direction and magnitude of the rolling force 38 .
  • the grain flow resulting from extrusion of the recess 32 and the helical groove 30 may be referred to herein as extruded grain flow.
  • continuous extruded grain flow and “uninterrupted extruded grain flow” refer to a grain flow which is not interrupted by discontinuities in the grain flow which may be resultant from, for example, secondary operations such as machining, milling, broaching, welding, brazing, crimping, seaming, etc.
  • the continuous contact of the rolling tool 40 with, and uninterrupted rolling force 38 exerted on, the workpiece 10 A during forming of the helical groove 30 generates a smooth surface having a uniform extruded surface finish extending continuously along the full length of the helical recess 32 , which may also be described as a rolled surface finish.
  • the smooth surface defined by the helical recess 32 having been formed by contact with the rolling tool 40 , would be absent of scratches, gouges, machining marks or other discontinuities or stress risers which may be characteristic of a machined surface formed by a machining or milling process.
  • the smooth surface and extruded or rolled surface finish increase the thermal stress and fatigue resistance of the cooler pipe 10 C by providing a work hardened surface absence forming discontinuities or other stress risers.
  • the portion 26 of the cooler pipe 10 C includes a wall portion 48 adjacent the helical groove 30 which remains undeformed, e.g., is not contacted by the rolling tool 40 during forming of the helical groove 30 .
  • the wall portion 48 extends between adjacent axial segments of the helical groove 30 , such that the wall portion 48 is configured as a helical wall portion, which is generally cylindrical and characterized by the wall thickness A 1 .
  • the helical groove 30 may be characterized by a thickness A 2 , which in the example shown may be substantially the same thickness as the wall thickness A 1 , e.g., A 2 ⁇ A 1 , such that the thickness of the cooler pipe 10 C remains substantially the same as the thickness of the workpiece 10 A.
  • the thicknesses A 2 and A 1 are substantially the same when the helical groove thickness A 2 is nominally or minimally reduced as the result of extruding the wall 12 to roll-form the helical groove 30 , e.g., when the helical groove thickness A 2 is at least 90% of the wall thickness A 1 .
  • the uniform thickness A 1 , A 2 of the cooler pipe 10 C increases the heat transfer efficiency of the cooler pipe 10 C in use relative to, for example, the machined cooler pipe 50 C shown in FIG. 5B .
  • the uniform thickness A 1 , A 2 of the cooler pipe 10 C provides uniformity of pipe strength, e.g., burst strength and/or resistance to cracking, fatigue, etc., as determined by or relative to the thickness of the cooler pipe 10 C in use.
  • the method of forming the cooler pipe 10 C from the workpiece 10 A includes removing the backing material 28 from the cooler pipe 10 C and from the hollow portion 18 after forming. Because the helical protrusion 34 extends radially into the backing material 28 after forming the helical groove 30 , it would be understood removal of the backing material may require removing the backing material 28 in portions. The backing material 28 may be decompacted or otherwise reduced in density to facilitate its removal from the cooler pipe 10 C.
  • the backing material 28 may be decompacted and/or removed by shaking, vibrating, and/or gravitating, the backing material 28 , which may be granular material, from the cooler pipe 10 C, such that the backing material 28 is removed from the hollow portion 18 via the opening 22 .
  • the backing material 28 may be removed from the cooler pipe 10 C by rinsing the backing material 28 from the hollow portion 18 using a fluid, which may be a liquid or gas, or by suspending the backing material 28 in a fluid to reduce the density of the backing material 28 prior to removal by rinsing, shaking, etc., or by using a combination of these.
  • the granular characteristics of the backing material 28 facilitate full removal of the backing material 28 from the cooler pipe 10 C to provide an inner surface 16 which is clean, e.g., uncontaminated by the backing material 28 , and/or the cooler pipe 10 C may be cleaned after removal of the backing material 28 .
  • the backing material 28 may be recycled and may be reused in a subsequent roll-forming operation as backing material in another workpiece to be roll-formed.
  • FIGS. 1A-3B is not intended to be limiting.
  • Other configurations of a cooler pipe 10 C may be formed using the method described herein.
  • rolling tool 40 and method may be configured to form a cooler pipe 10 C including a plurality of helical grooves 30 , where each of the helical grooves 30 is spaced at an interval from another of the helical grooves along the axial length of the workpiece.
  • the plurality of helical grooves may be formed such that each helical groove 30 does not intersect another helical groove.
  • Each of the plurality of helical grooves may have a different configuration, for example, a different helical angle, recess depth A 3 , etc., as may be required to provide the heat transfer capability required of the cooler pipe 10 C.
  • FIGS. 4A-5B a roll-formed (rolled) cooler pipe 10 C formed by the roll-forming process described herein is illustrated in FIGS. 4A-4B for comparison with the milled cooler pipe 50 C formed by a known milling operation and shown in FIGS. 5A-5B .
  • the outer and inner surfaces 14 , 16 of the rolled cooler pipe 10 C are respectively defined by an outer and inner radius A 4 , A 5 .
  • the outer and inner surfaces 54 , 56 of the milled cooler pipe 50 C are respectively defined by an outer and inner radius B 4 , B 5 .
  • the rolled cooler pipe 10 C and the milled cooler pipe 50 C are subjected to the same system operating conditions, including packaging considerations and operating temperatures, pressures, loading and vibrations, and are made of the same or substantially the same material having the same material strength and/or thermal conductivity characteristics.
  • a 1 B 2 .
  • a 3 B 3 .
  • the resulting cooler pipe 10 C has a uniform wall thickness A 1 , A 2 throughout, where the wall thickness A 1 may be the minimum required to provide the effective wall strength for the system, thus minimizing the weight of the cooler pipe 10 C.
  • the minimum wall thickness A 1 and uniformity of wall thickness and helical groove thickness A 2 , where A 1 ⁇ A 2 provides for efficient and uniform heat transfer from the inner surface 16 to the outer surface 14 .
  • the milled cooler pipe 50 C is disadvantaged by the weight and non-uniformity of the thicker wall 52 , where the thickness B 1 of wall 52 exceeds that of wall 12 by the thickness B 3 of the machining stock required to maintain the effective minimum wall thickness B 2 , and the non-uniform and thicker cross-section corresponding to B 1 decreases heat transfer efficiency relative to the rolled cooler pipe 10 C.
  • the helical protrusion 34 extending from the inner surface 16 of the rolled cooler pipe wall 12 increases the effective surface area of the hollow portion 18 of the rolled cooler pipe 10 C relative to the cylindrical surface area of the hollow portion 58 of the milled cooler pipe 50 C, which is smaller due to the absence of any protrusions and due to a relatively smaller inner radius B 5 , where as described previously, B 5 ⁇ A 5 .
  • the relatively larger surface area of the hollow portion 18 and the increased convection of the fluid flowing through the cooler pipe 10 C caused by the helical protrusion 34 thereby increases heat transfer through the inner surface 16 from fluid flowing through the rolled cooler pipe 10 C relative to heat transfer through the inner surface 54 of the conventional milled cooler pipe 50 C.
  • the rolled cooler pipe 10 C may have an increased resistance to mechanical and thermal stress fatigue cracking relative to the milled cooler pipe 50 C. Further, the continuous extruded grain flow defined by the extruded recess 32 may also contribute to an absence of stress risers and/or to increased fatigue resistance due to localized work hardening of the recess surface during the roll-forming process, thus increasing the resistance of the cooler pipe 10 C to thermal and or mechanical stresses.
  • a cooler pipe 10 C configured as an EGR pipe may include a first end 24 and/or opening 22 configured for attachment to an engine gas outlet port and a second end 24 and/or opening 22 configured for attachment to an inlet port.
  • the cooler pipe 10 C may be configured as a cooler pipe for use within other heat exchanging systems, including by way of non-limiting example, radiators, intercoolers, and other forms of heat exchangers used in engine-related and non-engine related systems.
US13/664,485 2012-10-31 2012-10-31 Cooler pipe and method of forming Abandoned US20140116668A1 (en)

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DE102013221632.7A DE102013221632A1 (de) 2012-10-31 2013-10-24 Kühlerrohr und Verfahren zum Formen
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CN116550758B (zh) * 2023-07-06 2023-09-12 太原理工大学 一种无缝金属波纹复合管高效定径调整斜轧设备及方法

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