Caulked Assembly Thick Portion Axial Compression
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Solution Overview
Problem
Conventional caulking methods for assembling a hollow or solid columnar body with a plate-like body face challenges such as limited accuracy in perpendicularity, stress concentration, and increased costs due to the need for flanges, special shapes, and circumferential grooves, which are unsuitable for thin plates and low-strength materials, and restrict the assembly of slim shafts and hollow columnar bodies.
Innovation Solution
A method involving the formation of a thick portion or step portion along the inner edge of a mounting hole in the plate-like body, allowing the columnar body to be inserted and compressed axially to deform the thick or step portion, thereby fixing it to the outer surface without requiring circumferential grooves, flanges, or special shapes, enabling secure assembly of thin plates and low-strength materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flange portion is formed on the midway part of the shaft body to sandwich the press component, then the press component can be firmly assembled, but the shaft material must be approximately 50% thicker than required, increasing material and processing costs
Solution Approach 1:
Instead of forming a flange on the shaft body (columnar body) to achieve sandwiching, the invention inverts the approach by forming a thick portion on the plate-like body itself. The thick portion is then compressed to bite into the circumferential groove, achieving the same sandwiching effect without requiring additional shaft thickness or flange formation.
Solution Approach 2:
The invention applies local quality by forming a thick portion only at the specific location where the mounting hole is provided in the plate-like body, rather than requiring the entire shaft body to be thicker. This localized thickening provides the necessary sandwiching capability only where needed, reducing overall material usage.
2Ease of manufacture
If a circumferential groove is formed on the columnar body to enable caulking, then assembly can be achieved without flanges, but stress concentration occurs and the shaft diameter is limited
Solution Approach 1:
The invention inverts the conventional approach by moving the circumferential groove formation from the columnar body to the plate-like body. The thick portion is formed on the plate-like body and compressed to bite into the groove, rather than forming the groove on the columnar body and having the plate bite into it. This inversion eliminates stress concentration on the columnar body while maintaining caulking effectiveness.
3Loss of substance
If the plate-like body is made thinner to reduce material usage, then material cost decreases, but the accuracy in perpendicularity and the like of the caulked columnar body cannot be ensured
Solution Approach 1:
The invention applies preliminary action by pre-forming the thick portion on the plate-like body before the caulking process. This thick portion provides a built-in stop and positioning feature that guides the columnar body into proper alignment during insertion, ensuring perpendicularity accuracy even when the plate-like body is thin. The thick portion acts as a preliminary positioning element that prevents misalignment during assembly.
4Ease of operation
If a circumferential groove is formed on the columnar body, then directivity may be generated in the shaft, but adding another circumferential groove to cancel directivity increases processing cost
Solution Approach 1:
The invention extracts the circumferential groove formation from the columnar body and relocates it to the plate-like body. By doing so, the columnar body remains free of grooves and maintains its symmetry, eliminating directivity issues without requiring additional grooves or complex processing. The groove is taken out from the shaft and placed on the plate, simplifying the overall manufacturing process.
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 method reduces material and processing costs, enhances assembly accuracy, and allows for the secure fixation of slim columnar bodies and hollow structures without stress concentration, enabling efficient assembly of components with high manufacturing efficiency.
Implementation Method 1
compressively pressing the thick portion from an axial direction of the columnar body to plastically deform the thick portion toward a center of the mounting hole
Data Source
AI summary
Provided is a method for manufacturing a caulked assembly that is capable of manufacturing the caulked assembly at a low cost, preventing reduction of the strength of a columnar body caused by a circumferential groove, preventing deformation of the columnar body, and assembling a slimmer columnar body with a plate-like body. A mounting hole 10 for inserting and assembling a columnar body 2 is provided in a metallic plate-like body 1, and a thick portion 11 is formed along an inner circumferential edge of the mounting hole 10. Thereafter, as shown in FIG. 1(a), the columnar body 2 is inserted into the mounting hole 10 of the plate-like body 1 so that the plate-like body 1 is set in an assembly position on an outer circumferential surface of the columnar body 2. Further, the thick portion 11 is compressively pressed from an axial direction of the columnar body so as to be plastically deformed toward the center of the mounting hole 10 to thereby tighten and fix the thick portion 11 to the outer circumferential surface of the columnar body 2.