Thin-Walled Tube Manufacturing
Thin-Walled Tube Manufacturing
(OP)
I'm wondering if anyone out there might have suggestions for manufacturing techniques for an extremely thin-walled tube requiring very tight tolerances on the ID.
The application is an inconel cylinder encasing a piston which requires very tight tolerances on the (~2") ID; the wall thickness is on the order of .010".
The part is currently machined, but is very expensive. I was thinking that a more consistant method of manufacture might be to expand a thicker-walled tube to the proper size by running a solid cylinder through it and then stress relieving it.
Suggestions?
The application is an inconel cylinder encasing a piston which requires very tight tolerances on the (~2") ID; the wall thickness is on the order of .010".
The part is currently machined, but is very expensive. I was thinking that a more consistant method of manufacture might be to expand a thicker-walled tube to the proper size by running a solid cylinder through it and then stress relieving it.
Suggestions?





RE: Thin-Walled Tube Manufacturing
Your description is essentially the Drawn Over Mandrel process that is the foundation for precision tube manufacturing around the world. Welded or seamless tubes are drawn to reduce the diameter and/or the thickness, while also increasing strength, reducing surface roughness, etc. Not sure what your tolerances are, but you may be able to get a precision drawn tube to meet your requirements. Here is a link with some additional information:
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RE: Thin-Walled Tube Manufacturing
RE: Thin-Walled Tube Manufacturing
The first is the Magneform machine. There are several incarnations of this process. The second is the flow forming process. Flowform is the one I used.
Depending on your exact requirements there are several other process that maybe able to accomodate your part.
http://www.magneform.com/apps.html
Flow forming
http://www.flowform.com/flowforming/index.php
http://www.pmfind.com/
RE: Thin-Walled Tube Manufacturing
RE: Thin-Walled Tube Manufacturing
RE: Thin-Walled Tube Manufacturing
RE: Thin-Walled Tube Manufacturing
If you are looking for a final tolerance of + 0.0002 inches, then no, flow forming will not be capable of that. Take a look at the following link, which shows a typical tolerance of + 0.002 inches for the ID of a 2 inch tube:
http://www
It sounds like flow forming may be a good option for you to pursue, with the caveat that a secondary operationmay be needed if insane tolerances are required. I thnk honing of the ID would be more appropriate than grinding. Another possibility to consider would be abrasive flow machining (extrude hone) of the ID.