Centrifugally-cast tube and related method and apparatus for making same
An improved centrifugally-cast tube is provided, along with a related method and apparatus of making the tube. The tube includes a plurality of grooves and bosses that are mechanically machined into an interior surface of the tube, such as by a broaching process. The profile of grooves and bosses may be defined by a plurality of intersecting concave and convex radii. The tube is resistant to creep, carburization and metal dusting. The tube also has an enhanced heat transfer rate, and a desirable surface roughness. A method of making the tube is also provided. The method essentially consists of mechanically deforming the interior surface of the tube by passing a series of cutting inserts on support rings having incrementally-differing dimensions over the interior surface. An apparatus is also provided which includes a telescoping shaft upon which is mounted at least one cutting tool that has a plurality of cutting inserts and is adapted to form a plurality of grooves and bosses in the interior surface of the tube. The grooves and bosses may be straight or spiraled.
1. A method of improving a centrifugally-cast tube comprising a plurality of grooves and bosses each having a predetermined profile in an internal face of the tube and produced by cutting tools mounted on a shaft passing through a bore of the tube, the method comprising:
passing one or more convex assemblies of cutting tools having only a plurality of cutting inserts with a convex profile for forming the grooves, the one or more convex assemblies comprising successive convex cutting tools of increasing dimensions that are passed through the bore of the tube until the predetermined profile of grooves is achieved; and
passing one or more concave assemblies of cutting tools having only a plurality of cutting inserts with a concave profile for forming the bosses, the one or more concave assemblies comprising successive concave cutting tools of increasing dimensions that are passed through the bore of the tube until the predetermined profile of bosses is achieved.
2. The method of claim 1 , wherein the dimensions of each subsequent set of cutting tools are larger than the corresponding dimensions of the cutting tools employed in the immediately preceding pass.
3. The method of claim 2 , wherein the dimensions incrementally increase at a rate of between 0.05 mm and 0.1 mm per pass.
4. A method of improving a centrifugally-cast tube with a length greater than 3 meters comprising:
sizing, in view of the length of the centrifugally-cast tube, a length of a spacer collar disposed between two consecutive cutting tools attached to a shaft and each comprising a plurality of cutting inserts adapted to mechanically form a plurality of grooves or bosses each having a predetermined profile within a bore of the tube, providing an annular space defined by an interior surface of the tube, the collar, and the adjacent cutting tools sufficient to house metal shavings cut from the interior surface of the tube during a complete length of a machining pass through the tube without filling the annular space so as to avoid damaging a surface roughness of the profile cut into the interior surface of the tube,
passing, through the bore of the tube, the shaft comprising a first assembly of successive cutting tools each comprising only convex cutting inserts for forming the grooves and being of increasing dimensions to form the grooves of the predetermined profile with a surface roughness of less than 125 RMS (CLA); and
passing, through the bore of the tube comprising the grooves, a second assembly of successive cutting tools each comprising only concave cutting inserts for forming the bosses and being of increasing dimensions to form the bosses of the predetermined profile with a surface roughness of less than 125 RMS (CLA).
5. The method according to claim 4 , wherein the cutting tools each comprise a supporting ring mounted on the shaft and cutting inserts attached to the respective supporting ring, wherein the supporting rings each support a same type of cutting insert and are of different sizes, thereby providing cutting tools of different sizes.
6. The method according to claim 5 , wherein the cutting inserts are releasably connectable to the supporting rings, and each of the inserts comprises a disk with a peripheral cutting edge, and the method comprises rotating the respective cutting insert when a section of the peripheral cutting edge is worn, so that an unused section of the peripheral cutting edge is positioned for cutting.
7. A method of improving a centrifugally cast tube with cutting tools mounted on a shaft passing through a bore of the tube, the method comprising:
passing, through the bore of the tube, the shaft comprising a first assembly of successive cutting tools each comprising only convex cutting inserts and being of increasing dimensions to form grooves of a predetermined profile with a surface roughness of less than 125 RMS (CLA); and
passing, through the bore of the tube comprising the grooves, a second assembly of successive cutting tools each comprising only concave cutting inserts and being of increasing dimensions to form bosses of a predetermined profile with a surface roughness of less than 125 RMS (CLA).