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How to bend a cone(two stroke pipe model)

Question asked by Tiago Angelo on Aug 6, 2014
Latest reply on Nov 2, 2014 by Michael Lord

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Good evening folks, I have been trying to make a two stroke exhaust, and would like to use Solidworks to curve all the conic sections, because doing this by hand is a trial and error effort.

The basic model is attached(linked from my dropbox), and I'm not asking for anyone to do it, just on how to do it, I have been searching for the past hours, but all that I can find is single cone projects/examples and that doesn't really fit with my needs.

The basic aspect is something along this lines:

In fact thats the original pipe of my bike a Gas Gas EC 125, the most important thing that I really want to get out of the Solidworks model is the initial 180º turn, that will be made with the first 4 cones(around 422mm in length, the turn radius is about 200mm if I'm not mistaken, and if is important for anyone that can help me the pipe will be realized in 304 stainless with 0.8mm thickness, laser cut.

Exhaust pipe model:

Dropbox - escapeGG.SLDPRT

Best regards, and thanks in advance.

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Michael Lord Aug 7, 2014 2:09 AM

Tiago,

These parts in production would be punched with a tool to a form. Then as you can see the individual parts are welded together.

So to model it I would do exactly as it is made. Model each piece. Sketch the two Conic arches on two perpendicular planes, then sketch the guide lines for the bend. Then loft between then. Mirror to give you the two halves

I have attach a sample doing similar but using a boundary surface.

If you are trying to reproduce to manufacture you will not be able to flatten to obtain a shape to cut.

Attachments

Sample Tube.zip429.5 KB

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Martin Vasilev @ Michael Lord on Oct 27, 2014 9:23 AM

Hello everybody,

I'm also interested in that idea.

Michael Lord would you give us some jokers about bending cone by sectors. Here you pick if what I mean:

Hope you get the idea, all we have is demension of the cone / "R"-bid radius, "r" - small radius, "H" - height / than we have to make it bended like that for example.

Thanks in advance!

Regards

Martin

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Martin Vasilev @ Martin Vasilev on Oct 29, 2014 11:40 AM

The pic:

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Michael Lord @ Martin Vasilev on Oct 29, 2014 7:05 PM

Martin

Sorry for the delayed response. The approach to this would be similar (but with with much more work) as it requires a 3D sketch for the loft! I'll try are put something together over the next couple of days.

As for how they have manufactured in the image, I would suggest they have cut the segments from a series of different size tubes/ pipes.

Michael

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Martin Vasilev @ Michael Lord on Oct 30, 2014 2:45 AM

Hello Michael,

I'll meet no problems to manufacture it as soon as I'll be able to design them. I'm newbe in solidworks world, so need some "tips&trick" for that problem. It'll be completely enough for me just to understand how to make 90 degree elbow cone.

Thanks for replay !

Regards

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Michael Lord @ Martin Vasilev on Nov 2, 2014 4:58 AM

Martin,

I have attached an example file (SOLIDWORKS 2015) and STEP version (which might work with Feature Recognition)

This how I approached it:

3D sketch using lines and fillets (not spline - reason shown soon)> Sketch circle (size - less than you require) > Sweep. I used Surface Sweep but there should be no reason why you can't use solid

I then created new planes on all the intersection The reason why I didn't use a spline

New Plane> select circle

I then Split the part using the Planes, I did this so I could work on one section at a time! Also so I could create a plane (mid-plane) to create the guide curves for the guide lines of the loft

I then could create the the circle (tube size ans /or shape - Green) on the planes.

I then created a new plane for the sketch guide lines (Purple)

Repeat for all the sections

As I used Surface Lofts I then knitted the sections together then Thickened to create the solid!

Hope this helps!

Michael

Attachments

Exhaust Split STEP.zip2.5 MB
Exhaust Split.zip1.5 MB

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6 Replies

Michael Lord Aug 7, 2014 2:09 AM
Mark Correct
Correct Answer
Tiago,

These parts in production would be punched with a tool to a form. Then as you can see the individual parts are welded together.
So to model it I would do exactly as it is made. Model each piece. Sketch the two Conic arches on two perpendicular planes, then sketch the guide lines for the bend. Then loft between then. Mirror to give you the two halves
I have attach a sample doing similar but using a boundary surface.

If you are trying to reproduce to manufacture you will not be able to flatten to obtain a shape to cut.
Attachments
- Sample Tube.zip429.5 KB
Like • Show 2 Likes2
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- Martin Vasilev @ Michael Lord on Oct 27, 2014 9:23 AM
  Mark Correct
  Correct Answer
  Hello everybody,
  
  I'm also interested in that idea.
  Michael Lord would you give us some jokers about bending cone by sectors. Here you pick if what I mean:
  Hope you get the idea, all we have is demension of the cone / "R"-bid radius, "r" - small radius, "H" - height / than we have to make it bended like that for example.
  Thanks in advance!
  
  Regards
  Martin
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  - Martin Vasilev @ Martin Vasilev on Oct 29, 2014 11:40 AM
    Mark Correct
    Correct Answer
    The pic:
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  - Michael Lord @ Martin Vasilev on Oct 29, 2014 7:05 PM
    Mark Correct
    Correct Answer
    Martin
    Sorry for the delayed response. The approach to this would be similar (but with with much more work) as it requires a 3D sketch for the loft! I'll try are put something together over the next couple of days.
    As for how they have manufactured in the image, I would suggest they have cut the segments from a series of different size tubes/ pipes.
    
    Michael
    Like • Show 1 Like1
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    - Martin Vasilev @ Michael Lord on Oct 30, 2014 2:45 AM
      Mark Correct
      Correct Answer
      Hello Michael,
      
      I'll meet no problems to manufacture it as soon as I'll be able to design them. I'm newbe in solidworks world, so need some "tips&trick" for that problem. It'll be completely enough for me just to understand how to make 90 degree elbow cone.
      Thanks for replay !
      
      Regards
      Like • Show 0 Likes0
      Actions
      - Michael Lord @ Martin Vasilev on Nov 2, 2014 4:58 AM
        Mark Correct
        Correct Answer
        Martin,
        
        I have attached an example file (SOLIDWORKS 2015) and STEP version (which might work with Feature Recognition)
        This how I approached it:
        3D sketch using lines and fillets (not spline - reason shown soon)> Sketch circle (size - less than you require) > Sweep. I used Surface Sweep but there should be no reason why you can't use solid
        I then created new planes on all the intersection The reason why I didn't use a spline
        New Plane> select circle
        I then Split the part using the Planes, I did this so I could work on one section at a time! Also so I could create a plane (mid-plane) to create the guide curves for the guide lines of the loft
        I then could create the the circle (tube size ans /or shape - Green) on the planes.
        I then created a new plane for the sketch guide lines (Purple)
        Repeat for all the sections
        As I used Surface Lofts I then knitted the sections together then Thickened to create the solid!
        Hope this helps!
        
        Michael
        Attachments
        Exhaust Split STEP.zip2.5 MB
        Exhaust Split.zip1.5 MB
        Like • Show 4 Likes4
        Actions

How to bend a cone(two stroke pipe model)

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