3D-Printed Male Screw Geometry for Low-Roughness Overhangs
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Solution Overview
Problem
In 3D printer technology of the lamination type, surface roughness increases when forming overhang shapes, particularly in male screw portions of fuel injection elements, leading to uneven surfaces and increased manufacturing costs due to the need for separate component assembly.
Innovation Solution
A three-dimensional additive manufactured product with a male screw portion integrally formed on the body portion, where the following side flank forms a first flank angle of at least 45 degrees, reducing surface roughness and allowing for a more compact design while maintaining durability, and optionally a leading side flank with a second flank angle of zero degrees to minimize length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the male screw portion is formed integrally with the body portion using 3D printer technology, then manufacturing cost is reduced and production efficiency is improved, but surface roughness increases due to overhang shape
Solution Approach 1:
The patent changes the geometric parameters of the screw portion by defining specific flank angle ranges (leading side flank angle: 0-30°, following side flank angle: 30-60°) to control the overhang angle during additive manufacturing. This parameter optimization allows integral formation while maintaining surface quality below 700 microinches Ra, resolving the contradiction between manufacturing efficiency and surface precision.
2Length of moving object
If the overhang angle is increased to reduce male screw portion length, then product size is reduced, but surface roughness increases making it unsuitable for practical use
Solution Approach 1:
The patent optimizes the flank angles to control the overhang angle within a specific range. By setting the leading side flank angle between 0-30° and following side flank angle between 30-60°, the overhang angle is maintained between 30-60°, which balances compactness with surface quality requirements, achieving both reduced length and acceptable surface roughness.
Solution Approach 2:
The patent employs asymmetric flank angle design where the leading side flank angle differs from the following side flank angle. This asymmetric configuration optimizes the overhang shape during additive manufacturing, allowing the screw portion to achieve compact dimensions while maintaining surface integrity through differentiated angle optimization on each side of the screw thread.
3Manufacturing precision
If the overhang angle is decreased to reduce surface roughness, then manufacturing precision is improved, but male screw portion length increases resulting in product upsizing
Solution Approach 1:
The patent defines optimal ranges for leading side flank angle (0-30°) and following side flank angle (30-60°) to control the overhang angle between 30-60°. This parameter optimization achieves the dual goal of maintaining surface roughness below 700 microinches Ra while minimizing screw portion length, preventing unnecessary product upsizing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables the formation of fuel injection elements with reduced surface roughness and manufacturing processes, achieving cost savings by integrating the male screw portion with the body portion using 3D printer technology.
Implementation Method 1
the three-dimensional additive manufactured product is molded by forming a sintered layer by irradiating a powder bed formed with the powder materials with a beam
Data Source
AI summary
A three-dimensional additive manufactured product includes a body portion and a male screw portion integrally disposed on a surface of the body portion so as to protrude therefrom. The male screw portion includes a following side flank forming a first flank angle with respect to a vertical plane to an axis thereof. The first flank angle is not less than 45 degrees.