Amorphous Alloy Warp Knitting Needle for Fatigue and Wear Resistance
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Solution Overview
Problem
The current manufacturing process of needles for warp knitting machines is costly, inefficient, and results in low strength and short service life due to high bending and molding impacts, necessitating a more cost-effective and efficient production method that enhances strength and durability.
Innovation Solution
A needle for warp knitting machines is manufactured using an amorphous alloy injection molding process comprising specific proportions of zirconium, copper, nickel, titanium, beryllium, and yttrium, followed by mixing, injection molding, sprue removal, thickness processing, slotting, polishing, and electroplating steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stamping and bending process is used to manufacture needle, then manufacturing process is established, but manufacturing cost is high and production efficiency is low
Solution Approach 1:
The patent replaces traditional mechanical stamping and bending processes with injection molding technology. The needle components are directly formed through injection molding, eliminating the need for sequential mechanical operations such as stamping, bending, and assembly. This substitution of manufacturing methodology dramatically improves production efficiency while reducing manufacturing costs.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single injection molding process. The needle body, hook, and other components are formed simultaneously in one molding cycle, consolidating what were previously separate stamping, bending, and assembly operations into an integrated manufacturing process.
2Shape
If traditional bending and molding process is used for needle head, then needle shape is formed, but strength of needle head is reduced and service life is shortened
Solution Approach 1:
The patent applies preliminary action by pre-heating the injection mold to control cooling rates during the molding process. This temperature control ensures that the needle head forms with optimized crystalline structure and internal stress distribution, achieving both the required shape and maximum strength without subsequent heat treatment or mechanical processing.
Solution Approach 2:
The patent utilizes parameter changes in the injection molding process, specifically controlling injection pressure, temperature, and cooling rate, to optimize the needle head properties. By adjusting these parameters, the process achieves both accurate shape formation and enhanced mechanical strength, eliminating the strength reduction caused by traditional cold bending operations.
3Productivity
If amorphous alloy injection molding process is used, then production cost is reduced and efficiency is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies local quality by using different materials for different parts of the needle. The needle body is made from amorphous alloy for high strength and elasticity, while the hook portion uses a different material composition optimized for wear resistance. This localized material differentiation allows each component to perform optimally while maintaining overall manufacturing efficiency.
Solution Approach 2:
The patent employs composite materials by combining amorphous alloy with traditional metals in a multi-material injection molding process. The amorphous alloy provides superior mechanical properties for the needle body, while traditional materials are used for specific functional areas, creating a composite structure that balances performance requirements with manufacturing feasibility.
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
The amorphous alloy process results in a needle with improved fatigue resistance, toughness, and strength, doubling its service life while reducing production costs and simplifying the manufacturing process for large-scale automation.
Implementation Method 1
The die is provided with cooling circulation water for the rapid cooling of the feed as a melted liquid state into a solid block
Implementation Method 2
heating the raw materials to above 700° C. by high-frequency heating in this vacuum or argon protection state
Implementation Method 3
injecting the melt into a die at a high speed greater than 0.5 m/s and a high pressure
Implementation Method 4
a layer of coating is formed on the surface of the product, with a greatly improved wear resistance of the product
Data Source
AI summary
A needle for a warp knitting machine, manufactured by means of an amorphous alloy injection molding process and comprising the following components: in parts by weight, 57.5-65.5 parts of zirconium, 11-16 parts of copper, 7-13 parts of nickel, 5-10 parts of titanium, 1-7 parts of aluminum, 1-7 parts of beryllium and 0.3-2 parts of yttrium. A method for manufacturing a needle for a warp knitting machine by means of an amorphous alloy injection molding process, comprising the following steps: (1) material mixing and smelting for manufacture into small blocks; (2) injection molding; (3) alloy opening removal; (4) thickness machining; (5) slotting; (6) polishing; and (7) electroplating. Beryllium and yttrium are added into amorphous alloy zirconium-based metal; beryllium can improve the toughness of a latch needle product, and has high fatigue limit and high wear resistance; yttrium powder can improve the strength, toughness and wear resistance of a latch needle blank.