Rotor of a screw hydraulic downhole motor, method for its production and a device for its production

A method for producing a rotor for a screw downhole motor, comprising the steps of:

• arranging a tubular blank within a housing;
• placing, inside said tubular blank, a unitary forming member which is a solid member in the form of a screw having more than one helical surface thread and a cross-sectional profile equidistant with respect to a desired profile of said rotor;
• centering and sealing said tubular blank relative to the housing and the forming member;
• supplying a working fluid to produce a pressure between said tubular blank and said housing, under which the tubular blank is subjected to three-dimensional deformation along helical surfaces of the forming member so that the length of a circle of a neutral cross-section of the rotor changes, and the ratio of the length of the cross-section of the rotor to the length of a circumscribed circle thereof lies within 0.9 to 1.05;
• relieving the pressures and removing the formed rotor together with the forming member from the housing;
• and
• removing the forming member from the formed rotor of the screw downhole motor.

A method of forming a hollow rotor of substantially constant wall thickness as a multiple-thread screw with the number of helical surfaces exceeding one, for use with a screw hydraulic downhole motor, said method comprising the steps of:

• imparting a shape of a helical polyhedron with rounded-off vertices, to a tubular blank, in a first stage, such that the diameter of a circle circumscribed therearound exceeds the diameter of a circle circumscribed around said hollow rotor, and such that the number of faces of said helical polyhedron is equal to the number of threads of the helical surfaces of said rotor, said step of imparting including the steps of:
• placing a unitary preliminary forming element having an outside surface serving as a formative surface, inside a tubular blank;
• and
• applying fluid pressure to the outside surface of the tubular blank to force the tubular blank against the formative surface;
• and
• forming said helical surfaces on said helical polyhedron blank to form said rotor, in a second stage, said step of forming said helical surfaces including:
• placing a unitary final forming element having an outside surface serving as a formative surface, inside a tubular blank, and
• applying fluid pressure to the outside surface of the tubular blank to force the tubular blank against the formative surface of the final forming element, so as to form the rotor with the ratio of the length of the rotor cross-sectioned contour to the length of a circle circumscribed around the contour being substantially between 0.9 and 1.05.

A method of forming a hollow rotor of substantially constant wall thickness as a multiple-thread screw with the number of helical surfaces exceeding one, for use with a screw hydraulic downhole motor, said method comprising the steps of:

• imparting a shape of a helical polyhedron with rounded-off vertices, to a tubular blank, in a first stage, such that the diameter of a circle circumscribed therearound exceeds the diameter of a circle circumscribed around said hollow rotor, and such that the number of faces of said helical polyhedron is equal to the number of threads of the helical surfaces of said rotor, said step of imparting including the steps of:
• placing a unitary preliminary forming element having an outside surface serving as a formative surface, inside a tubular blank;
• and
• applying fluid pressure to the outside surface of the tubular blank to force the tubular blank against the formative surface;
• forming said helical surfaces on said helical polyhedron blank to form said rotor, in a second stage, said step of forming said helical surfaces including:
• placing a unitary final forming element having an outside surface serving as a formative surface, inside a tubular blank;
• and
• applying fluid pressure to the outside surface of the tubular blank to force the tubular blank against the formative surface of the final forming element, so as to form the rotor with the ratio of the length of the rotor cross-sectioned contour to the length of a circle circumscribed around the contour being substantially between 0.9 and 1.05.
• securing at least one end of said blank to a union coupling simultaneously with said step of forming said helical surfaces, said step of securing including the steps of:
• inserting a union coupling having a shaped outside surface into a tubular blank;
• and
• subsequently exerting pressure on the tubular blank to force said tubular blank against the shaped outside surface of the union coupling.

A device for making a hollow rotor of substantially constant wall thickness as a multiple-thread screw with the number of helical surfaces exceeding one, so as to form the rotor with the ratio of the length of the rotor cross-sectioned contour to the length of a circle circumscribed around the contour being substantially between 0.9 and 1.05, for use with a screw hydraulic downhole motor, said device comprising:

• a housing;
• a unitary forming element having an outside surface which defines a formative surface for said rotor, said forming element removably accommodated in said housing;
• a plurality of centering bushings for installing the forming element in the housing, said centering bushings including fitting areas for tightly receiving a tubular blank used for forming said rotor so that the bushings are positioned between the housing and the forming member;
• a plurality of sealing means for sealing said housing;
• a chamber defined by;
• said forming element and said sealing means defining a chamber for pressure-feeding of fluid therein.

A device for making a hollow rotor of substantially constant wall thickness as a multiple-thread screw with the number of helical surfaces exceeding one, so as to form the rotor with the ratio of the length of the rotor cross-sectioned contour to the length of a circle circumscribed around the contour being substantially between 0.9 and 1.05, for use with a screw hydraulic downhole motor, said device comprising:

• a housing;
• a unitary preliminary forming element having an outside surface which defines a formative surface for said rotor, said preliminary forming element being removably accommodated in said housing and said preliminary forming element being a helical polyhedron with rounded-off vertices, with the number of faces of the polyhedron being equal to the number of threads on the helical surfaces of the rotor;
• a plurality of centering bushings for installing the forming element in the housing, said centering bushings including fitting areas for tightly receiving a tubular blank used for forming said rotor;
• a plurality of sealing means for sealing said housing;
• a chamber defined by said housing, said forming element, said bushings and said sealing means for pressure-feeding of fluid therein;
• and
• a unitary finishing forming element for finishing formation of the rotor after removal of the preliminary forming element, the finishing forming element being removably accommodated in the housing after removal of the preliminary forming element and the diameter of a circle circumscribed around the finishing forming element being less than the diameter of a circle circumscribed around said preliminary forming element.