Ball Screw Nut Laminate Body for Precision Hydraulic Forming
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Solution Overview
Problem
The hydraulic forming method for manufacturing machine components, such as nuts for ball screw devices, is costly due to the high expense of forming dies with complex shapes required for precise machining of tubular members with intricate designs.
Innovation Solution
A ball screw device is designed with a nut comprising a laminate body of multiple plates laminated axially, where the inner surface of the laminate body matches the outer surface of a tubular member, allowing for cost-effective hydraulic forming using a forming die with a laminate structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a forming die with a complex shape is used to manufacture precise machine components, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The forming die is divided into multiple plate members that can be laminated together. Each plate member has a relatively simple structure, but when combined, they form the complex three-dimensional shape required for precise forming. This segmentation allows each component to be manufactured separately at lower cost while achieving the overall precision requirement through their combined configuration.
Solution Approach 2:
The forming die uses a composite structure made of multiple plate members laminated together. This composite approach allows the die to achieve complex geometries and high precision surfaces that would be expensive to manufacture as a single piece, while the individual plates can be produced more economically and assembled into the final complex configuration.
2Manufacturing precision
If a forming die with a complex shape is used to manufacture precise machine components, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The forming die is segmented into multiple plate members with relatively simple individual structures. Each plate member can be designed and manufactured independently, reducing the complexity of individual components. The complex overall shape is achieved through the lamination and arrangement of these simpler segments, making the system easier to manufacture and maintain.
3Productivity
If hydraulic pressure is applied to deform tubular material, then productivity is improved, but manufacturing cost increases
Solution Approach 1:
The hydraulic forming process uses a segmented forming die composed of multiple plates. This segmentation allows for efficient hydraulic pressure application while reducing the overall manufacturing cost of the forming system. The modular plate structure enables standardized production of die components, lowering costs while maintaining the high productivity benefits of hydraulic forming.
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 approach reduces manufacturing costs by using a laminate forming die that is less expensive to produce and maintain, while ensuring the precision and accuracy required for complex machine components.
Implementation Method 1
a hydraulic pressure is applied to the inner peripheral surface of the tubular material so that the tubular material is plastically deformed radially outward
Implementation Method 2
the tubular material is plastically deformed radially outward until the tubular material has a shape along the forming peripheral surface
Data Source
AI summary
A ball screw device includes a nut (3), a screw shaft, and a plurality of balls arranged between the nut (3) and the screw shaft. The nut (3) includes a first member (11) disposed to surround the screw shaft, a second member (10) disposed between the screw shaft and the first member (11), and a third member (12) disposed between the first member (11) and the second member (10). The third member (12) includes a laminate body (12A) having a plurality of plates (22a, 22b) laminated in an axial direction. The laminate body (12A) includes an inner surface facing an outer surface of the second member (10). The inner surface of the laminate body (12A) has a shape corresponding to a shape of the outer surface of the second member (10).