KEVOS® MAKEOS · Fabrication
Segmented Flange Ring Plan (Segment Size, Plate Fit, Yield, Welds)
If I make this large flange ring from segments cut out of plate, how big is each segment’s rectangle, will it fit my plate, and how much plate is wasted?
Plan for a large flat ring (flange, stiffener or base ring) welded from equal segments cut from plate: the area of each ring-sector segment (as the plane area tool for a ring sector), the bounding rectangle each segment needs (chord of the outside edge by the width from the outside edge to the inside chord), whether it fits the plate size, material yield, ring mass and the length of butt welds, checked against the plate size and your least yield.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Ring outside diameter | mm | Outside diameter of the finished ring. |
| Ring inside diameter | mm | Inside diameter of the finished ring. |
| Number of segments | Number of equal segments welded together. | |
| Plate thickness | mm | Thickness of the plate. |
| Density | kg/m³ | Density of the plate. |
| Cutting allowance around each segment | mm | Extra added around each segment for cutting. |
| Plate and limits | ||
| Plate width | mm | Width of the plate available. |
| Plate length | mm | Length of the plate available. |
| Least yield of a segment rectangle | % | Least share of each rectangle used by its segment. |
Method and formulas
- Segment area = (R² − r²) θ ÷ 2 with θ = 360° ÷ n (as the plane area tool for a ring sector).
- Rectangle length = 2R sin(θ ÷ 2) + allowance; width = R − r cos(θ ÷ 2) + allowance.
- Yield = segment area ÷ rectangle area; ring mass = n × area × thickness × density; welds = n × (R − r).
- Example: each of 6 segments needs 1,510 × 384.17 mm (50.546% yield); the ring weighs 276.21 kg with 1.2 m of butt weld.
Limitations
- Rectangles nested one per space; staggering segments head-to-tail on the plate improves yield.
- Weld shrinkage and machining allowance on the faces are not included.
- Example values are illustrations. Replace them with values for your actual task.
Typical uses
- Plan a large flange or base ring from plate
- Choose the number of segments for a plate size
- Estimate plate and welding for a ring
Who it is for
- Boilermakers
- Fabrication supervisors
- Estimators
What you get
- Segment area and bounding rectangle
- Plate fit and yield
- Ring mass and butt weld length
Interpreting the result
- More segments improve yield and fit smaller plate, but add welds: balance plate cost against welding.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 66–81. Topic reference; no source tables or recommended settings are reproduced.
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Open the Segmented Flange Ring Plan (Segment Size, Plate Fit, Yield, Welds) calculator
