Pilger die and pilger mandrel for manufacturing dashpot tube for nuclear fuel assembly and method of manufacturing the pilger die and the pilger mandrel

A pilger mandrel of a pilgering apparatus for producing a dashpot tube for a nuclear fuel assembly through two pilgering processes including a first-step pilgering process and a second-step pilgering process within an allowable error range of 3% or less, the pilger mandrel being configured to conduct the second-step pilgering process and comprising:

• a mandrel working section having a length corresponding to a length of a working section of a pilger die of the pilgering apparatus, the mandrel working section being formed by grinding in such a way that an outer diameter Mx(x) of the pilger mandrel is reduced from a position of x=1.0 to a position of x=0.0 such that the outer diameter of the pilger mandrel at the position of x=1.0 is less than an initial inner diameter of a zirconium alloy tube by 0.7 mm to 3.56 mm and the outer diameter of the pilger mandrel at the position of x=0.0 is greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• and
• a mandrel sizing section extending from a tail end of the mandrel working section along a longitudinal direction of the pilger mandrel, the mandrel sizing section being formed by grinding such that the outer diameter Mx(x) of the pilger mandrel has at a leading end thereof a value greater than the final inner diameter of the zirconium alloy tube by 1.5% to 3.5% and is reduced from the leading end to a tail end thereof along a longitudinal direction of the pilger mandrel,
• wherein:
• a pilger die equation for defining the outer diameter of the zirconium alloy tube is Dx(x)=ODf+X(x)Cx·(ODs−ODf−MTd(x)·WL−MC(x))+X(x)·MTd(x)·WL;
• and
• a pilger mandrel equation for defining an outer diameter of the pilger mandrel is Mx(x)=IDf+X(x)Cx·(IDs−IDf−MTm(x)·WL−MC(x))+X(x)·MTm(x)·WL;
• where:
• WL=a length of the working section;
• x=relative position coordinates (1.0, 0.9, . . . , 0.0, −0.1, −0.2 . . . ), wherein the length WL of the working section is sectioned into equal parts, and a relative position coordinate of the tail end of the working section is designated as 0.0, and relative position coordinates of the sectioned parts are increased in increments of 0.1 from the position of 0.0 towards a left side to a leading end of the working section which has a relative position coordinate of 1.0, and the relative position coordinates are reduced in decrements of −0.1 from the position x=0.0 towards a right side;
• X(x)=a distance rate (x·WL/40) from 0.0 of the working section to a position coordinate x;
• Mx(0.0)=an outer diameter of the pilger mandrel when x is 0.0, Mx(0.0) being set to a value greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• Mx(1.0)=an outer diameter of the pilger mandrel when x is 1.0, Mx(1.0) being set to a value greater than an initial outer diameter of the zirconium alloy tube by 0.2% to 0.5%;
• ODs=an initial outer diameter of the zirconium alloy tube;
• ODf=a final outer diameter of the zirconium alloy tube;
• Cx=a curve value (1.9-2.3) of a groove of the pilger die;
• Mx(x)=an outer diameter of the pilger mandrel at a position coordinate x;
• MTd(x)=MTm(x)=a decrement of the outer diameter of the pilger mandrel from the position coordinate 0.0 towards the right side to a position coordinate x=(the outer diameter of the pilger mandrel when x is 0.0−Mx(f))·(−x)/the number of sectioned parts), (x= . . . 0.1, 0.0, −0.1, . . . );
• Mx(f)=an outer diameter of a tail end of the pilger mandrel, Mx(f) being set to a value less than the final inner diameter of the zirconium alloy tube by 5% to 8%;
• Mx(1.0) which is an outer diameter of the pilger mandrel when x is 1.0 is set to a value less than an initial inner diameter of the zirconium alloy tube by 0.7 mm to 3.56 mm;
• Mx(0.0) which is an outer diameter of the pilger mandrel when x is 0.0 is set to a value greater than a thickness of W(0.0) by 1.5% to 3.5%;
• MC(x)=a mandrel clearance=0.381 mm·|x|;
• IDs=the initial inner diameter of the zirconium alloy tube;
• and
• IDf=the final inner diameter of the zirconium alloy tube.

A method of pilgering a dashpot tube for a nuclear fuel assembly, the method comprising the steps of

• providing a pilgering apparatus having a pilger die and a pilger mandrel, and
• pilgering a zirconium alloy tube such that an outer diameter of the zirconium alloy tube is changed from 31.75 mm to 22.6 mm and an inner diameter of the zirconium alloy is changed from 25.65 mm to 21.23 mm within an allowable error range of 3% or less, so that a factor Q, a natural logarithm ratio of a reduction of a tube wall thickness to a reduction of the outer diameter, is 4 or more,
• wherein the pilger die comprises:
• a pilger groove;
• a working section formed along a circumferential outer surface of the pilger die by grinding such that a radius Rx(x) of the pilger groove is reduced from, at a pilgering start point, a half of an initial outer diameter of the zirconium alloy tube to, at a pilgering end point, a half of a final outer diameter of the zirconium alloy tube formed;
• a sizing section extending a predetermined length from a tail end of the working section, the sizing section being formed by grinding so that the radius Rx(x) of the pilger groove has a constant value in the half of the final outer diameter of the zirconium alloy tube;
• a roll off section extending a predetermined length from a tail end of the sizing section, the roll off section being formed by grinding such that the radius Rx(x) of the pilger groove is increased from the half of the final outer diameter of the zirconium alloy tube;
• and
• a pocket section connecting the roll off section to the working section,
• wherein the working section is formed by grinding such that the radius Rx(x) of the pilger groove is a radius (Dx(x)/2) of a circle having a center at a position spaced apart from the circumferential outer surface of the pilger die by a die gap (Ws) in the radial direction,
• and the pilger mandrel comprises:
• a mandrel working section having a length corresponding to a length of a working section of the pilger die of the pilgering apparatus, the mandrel working section being formed by grinding in having an outer diameter Mx(x) of the pilger mandrel being reduced from a position of x=1.0 to a position of x=0.0 such that the outer diameter of the pilger mandrel at the position of x=1.0 is less than an initial inner diameter of the zirconium alloy tube by 0.7 mm to 3.56 mm and the outer diameter of the pilger mandrel at the position of x=0.0 is greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• and
• a mandrel sizing section extending from a tail end of the mandrel working section along a longitudinal direction of the pilger mandrel, the mandrel sizing section being formed by grinding such that the outer diameter Mx(x) of the pilger mandrel has at a leading end thereof a value greater than the final inner diameter of the zirconium alloy tube by 1.5% to 3.5% and is reduced from the leading end to a tail end thereof along a longitudinal direction of the pilger mandrel,
• wherein:
• a pilger die equation for defining the outer diameter of the zirconium alloy tube is Dx(x)=ODf+X(x)Cx·(ODs−ODf−MTd(x)·WL−MC(x))+X(x)·MTd(x)·WL;
• and
• a pilger mandrel equation for defining an outer diameter of the pilger mandrel is Mx(x)=IDf+X(x)Cx·(IDs−IDf−MTm(x)·WL−MC(x))+X(x)·MTm(x)·WL;
• where:
• WL=a length of the working section;
• x=relative position coordinates (1.0, 0.9, . . . , 0.0, −0.1, −0.2 . . . ), wherein the length WL of the working section is sectioned into equal parts, and a relative position coordinate of the tail end of the working section is designated as 0.0, and relative position coordinates of the sectioned parts are increased in increments of 0.1 from the position of 0.0 towards a left side to a leading end of the working section which has a relative position coordinate of 1.0, and the relative position coordinates are reduced in decrements of −0.1 from the position x=0.0 towards a right side;
• X(x)=a distance rate (x·WL/40) from 0.0 of the working section to a position coordinate x;
• Mx(0.0)=an outer diameter of the pilger mandrel when x is 0.0, Mx(0.0) being set to a value greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• Mx(1.0)=an outer diameter of the pilger mandrel when x is 1.0, Mx(1.0) being set to a value greater than an initial outer diameter of the zirconium alloy tube by 0.2% to 0.5%;
• ODs=an initial outer diameter of the zirconium alloy tube;
• ODf=a final outer diameter of the zirconium alloy tube;
• Cx=a curve value (1.9-2.3) of a groove of the pilger die;
• Mx(x)=an outer diameter of the pilger mandrel at a position coordinate x;
• MTd(x)=MTm(x)=a decrement of the outer diameter of the pilger mandrel from the position coordinate 0.0 towards the right side to a position coordinate x=(the outer diameter of the pilger mandrel when x is 0.0−Mx(f))·(−x)/the number of sectioned parts), (x= . . . 0.1, 0.0, −0.1, . . . );
• Mx(f)=an outer diameter of a tail end of the pilger mandrel, Mx(f) being set to a value less than the final inner diameter of the zirconium alloy tube by 5% to 8%;
• Mx(1.0), which is an outer diameter of the pilger mandrel when x is 1.0, is set to a value less than an initial inner diameter of the zirconium alloy tube by 0.7 mm to 3.56 mm;
• Mx(0.0), which is an outer diameter of the pilger mandrel when x is 0.0, is set to a value greater than a thickness of W(0.0) by 1.5% to 3.5%;
• MC(x)=a mandrel clearance=0.381 mm·|x|;
• IDs=the initial inner diameter of the zirconium alloy tube;
• and
• IDf=the final inner diameter of the zirconium alloy tube.

A method of manufacturing a pilger die of a pilgering apparatus for producing a dashpot tube for a nuclear fuel assembly through two pilgering processes including a first-step pilgering process and a second-step pilgering process within an allowable error range of 3% or less, the method comprising:

• forming a groove on the pilger die from a pilgering start point such that a radius Rx(x) of the groove is a radius (Dx(x)/2) of a circle having a center at a position spaced apart from a circumferential outer surface of the pilger die by a die gap (Ws) in the radial direction,
• the forming of the groove including:
• forming a working section along the circumferential outer surface of the pilger die by grinding such that the radius Rx(x) of the groove is reduced from a half of an initial outer diameter of a first-pilgered zirconium alloy tube to, at a pilgering end point, a half of a final outer diameter of a second-pilgered zirconium alloy tube;
• forming a sizing section extending a predetermined length from a tail end of the working section, the sizing section being formed by grinding such that the radius Rx(x) of the groove is constant in the half of the final outer diameter of the second-pilgered zirconium alloy tube;
• forming a roll off section extending a predetermined length from a tail end of the sizing section, the roll off section being formed by grinding such that the radius Rx(x) of the groove is increased from the half of the final outer diameter of the second-pilgered zirconium alloy tube;
• and
• forming a pocket section connecting the roll off section to the working section;
• and
• forming a top side relief by grinding the pilger die in a circumferential direction such that a circle defined by the top side relief has a center C3 at a position spaced apart from a center C1 of the circle, defined by the radius Rx(x) of the groove, by a Bt(x) in the radial direction of the pilger die and has a radius Rt(x),
• wherein:
• WL=a length of the working section;
• x=relative position coordinates (1.0, 0.9, . . . , 0.0, −0.1, −0.2 . . . ), wherein the length WL of the working section is sectioned into equal parts, and a relative position coordinate of the tail end of the working section is designated as 0.0, and relative position coordinates of the sectioned parts, are increased in an increment of 0.1 from the position of 0.0 towards a left side to a leading end of the working section which has a relative position coordinate of 1.0, and the relative position coordinates are reduced in decrements of −0.1 from the position x=0.0 towards a right side;
• X(x)=a distance rate (x·WL/40) from 0.0 of the working section to a position coordinate x;
• Mx(0.0)=an outer diameter of a pilger mandrel of the pilgering apparatus when x is 0.0, Mx(0.0) being set to a value greater than a final inner diameter of the second-pilgered zirconium alloy tube by 1.5% to 3.5%;
• Mx(1.0)=an outer diameter of the pilger mandrel when x is 1.0, Mx(1.0) being set to a value greater than the initial outer diameter of the first-pilgered zirconium alloy tube by 0.2% to 0.5%;
• ODs=the initial outer diameter of the first-pilgered zirconium alloy tube;
• ODf=the final outer diameter of the second-pilgered zirconium alloy tube;
• Cx=a curve value (1.9-2.3) of the groove;
• Mx(x)=an outer diameter of the pilger mandrel at a position coordinate x,
• MTd(x)=MTm(x)=a decrement of the outer diameter of the pilger mandrel from the position coordinate 0.0 towards the right side to a position coordinate x=(the outer diameter of the pilger mandrel when x is 0.0−Mx(f))·(−x)/the number of sectioned parts), (x= . . . 0.1, 0.0, −0.1, . . . );
• Mx(f)=an outer diameter of a tail end of the pilger mandrel, Mx(f) being set to a value less than the final inner diameter of the second-pilgered zirconium alloy tube by 5% to 8%;
• Mx(1.0), which is an outer diameter of the pilger mandrel when x is 1.0, is set to a value less than an initial inner diameter of the first-pilgered zirconium alloy tube by 0.7 mm to 3.56 mm;
• Mx(0.0), which is an outer diameter of the pilger mandrel when x is 0.0, is set to a value greater than a thickness of W(0.0) by 1.5% to 3.5%;
• MC(x)=a mandrel clearance=0.381 mm·|x|;
• IDs=the initial inner diameter of the first-pilgered zirconium alloy tube;
• IDf=the final inner diameter of the second-pilgered zirconium alloy tube;
• Bt(x)=((Wd(x)/2)2−Rx(x)2−(Ws/2)2)/(2(Rx(x)·sin(α(x))−Ws/2));
• α(x)=55°−20°·(1−x);
• Rt(x)=((Wd(x)/2)2+(Bt(x)+Ws/2)2)1/2;
• Wd(x)/2=((Dx(x)/2)2−(Ws/2)2)1/2+Ft(x;
• Ft(x) (a maximum distance between the groove and the top side relief)=(Dx(y(x))−Dx(x))/2;
• y(x) (a new coordinate x varied depending on a tube feed rate (TubeInFeed), the new coordinate x at which the zirconium alloy tube comes into contact with the pilger die)=x+(AD(1.0)·W(1.0)·TubeInFeed)/(AD(x)·W(x)·WL);
• W(x) (a thickness of the zirconium alloy tube at a position of x)=(Dx(x)−Mx(x))/2;
• AD(x)=(Dx(x)+Mx(x))/2;
• Dx(y(x))=an outer diameter of the zirconium alloy tube at a position of y(x);
• AD(1.0)=a medial outer diameter between the inner diameter of the zirconium alloy tube and the outer diameter of the pilger mandrel at a position of x=1.0;
• TubeInFeed=a tube feed rate, a length of the zirconium alloy tube that is fed during one stroke in which a saddle reciprocates between an inlet position ET and an outlet position AT, and
• α(x)=an angle between a line connecting the center of the circle (groove circle) defined by the groove to a start point of the top side relief and a horizontal line passing through the center of the groove circle.

A method of manufacturing a pilger mandrel of a pilgering apparatus for producing a dashpot tube for a nuclear fuel assembly through two pilgering processes including a first-step pilgering process and a second-step pilgering process within an allowable error range of 3% or less, the method comprising:

• forming a mandrel working section by grinding the pilger mandrel such that a length thereof corresponds to a length of a working section of a pilger die of the pilgering apparatus, and an outer diameter Mx(x) of the pilger mandrel is reduced from a position of x=1.0 to a position of x=0.0 such that the outer diameter of the pilger mandrel at the position of x=1.0 is less than an initial inner diameter of a zirconium alloy tube by 0.7 mm to 3.56 mm and the outer diameter of the pilger mandrel at the position of x=0.0 is greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• and
• forming a mandrel sizing section by grinding the pilger mandrel from a tail end of the mandrel working section along a longitudinal direction of the pilger mandrel, such that the outer diameter Mx(x) of the pilger mandrel has at a leading end thereof a value greater than the final inner diameter of the zirconium alloy tube by 1.5% to 3.5% and is reduced from the leading end to a tail end thereof along the longitudinal direction of the pilger mandrel,
• wherein:
• a pilger die equation for defining the outer diameter of the zirconium alloy tube is Dx(x)=ODf+X(x)Cx·(ODs−ODf−MTd(x)·WL−MC(x))+X(x)·MTd(x)·WL;
• and
• a pilger mandrel equation for defining an outer diameter of the pilger mandrel is Mx(x)=IDf+X(x)Cx·(IDs−IDf−MTm(x)·WL−MC(x))+X(x)·MTm(x)·WL,
• where:
• WL=a length of the working section;
• x=relative position coordinates (1.0, 0.9, . . . , 0.0, −0.1, −0.2 . . . ), wherein the length WL of the working section is sectioned into equal parts, and a relative position coordinate of the tail end of the working section is designated as 0.0, and relative position coordinates of the sectioned parts are increased in an increment of 0.1 from the position of 0.0 towards a left side to a leading end of the working section which has a relative position coordinate of 1.0, and the relative position coordinates are reduced in decrements of −0.1 from the position x=0.0 towards a right side;
• X(x)=a distance rate (x·WL/40) from 0.0 of the working section to a position coordinate x;
• Mx(0.0)=an outer diameter of the pilger mandrel when x is 0.0, Mx(0.0) being set to a value greater than a final inner diameter of the zirconium alloy tube by 1.5% to 3.5%;
• Mx(1.0)=an outer diameter of the pilger mandrel when x is 1.0, Mx(1.0) being set to a value greater than an initial outer diameter of the zirconium alloy tube by 0.2% to 0.5%;
• ODs=an initial outer diameter of the zirconium alloy tube,
• ODf=a final outer diameter of the zirconium alloy tube,
• Cx=a curve value (1.9-2.3) of the groove;
• Mx(x)=an outer diameter of the pilger mandrel at a position coordinate x;
• MTd(x)=MTm(x)=a decrement of the outer diameter of the pilger mandrel from the position coordinate 0.0 towards the right side to a position coordinate x=(the outer diameter of the pilger mandrel when x is 0.0−Mx(f))·(−x)/the number of sectioned parts), (x= . . . 0.1, 0.0, −0.1, . . . );
• Mx(f)=an outer diameter of a tail end of the pilger mandrel, Mx(f) being set to a value less than the final inner diameter of the zirconium alloy tube by 5% to 8%;
• Mx(1.0), which is an outer diameter of the pilger mandrel when x is 1.0, is set to a value less than an initial inner diameter of the zirconium alloy tube by 0.7 mm to 3.56 mm;
• Mx(0.0), which is an outer diameter of the pilger mandrel when x is 0.0, is set to a value greater than a thickness of W(0.0) by 1.5% to 3.5%;
• MC(x)=a mandrel clearance=0.381 mm·|x|;
• IDs=the initial inner diameter of the zirconium alloy tube;
• and
• IDf=the final inner diameter of the zirconium alloy tube.