Caulking-Fastened Component Stepped Notch Design
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Solution Overview
Problem
The existing methods for fastening components like a ring gear to a differential case using press-fitting and caulking result in protrusions around notches, requiring additional processes to remove them, increasing manufacturing costs and complexity.
Innovation Solution
The implementation of an annular caulking-fastened component with inner-peripheral and end-face stepped portions, which are formed to be larger than the protrusions, allowing these protrusions to be separated from the press-fitting and end faces, thus eliminating the need for their removal and enhancing fastening strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If notches are formed by press working to enable caulking fastening, then fastening strength is improved, but protrusions are formed around the notches requiring additional cutting processes
Solution Approach 1:
The invention performs preliminary action by forming the notches with predetermined shapes (including tapered shapes or shapes with rounded corners) during the press working process itself. This preliminary design of the notch geometry prevents protrusion formation at the notch roots, eliminating the need for subsequent cutting processes to remove protrusions. The fastening strength is maintained through the optimized notch geometry that facilitates material flow during caulking.
Solution Approach 2:
The invention applies parameter changes by modifying the geometric parameters of the notches during press working. Specifically, the notch shape parameters (such as taper angle, corner radius, or depth-to-width ratio) are optimized to control material flow and prevent protrusion formation. By changing these geometric parameters, the process achieves both strong fastening and elimination of additional cutting operations.
2Strength
If notches are formed at intervals in the circumferential direction, then caulking fastening is enabled, but intermittent cutting is required causing burrs and increasing process complexity
Solution Approach 1:
The invention performs preliminary action by designing the notch geometry (tapered shapes or rounded corners) to prevent burr formation during the caulking process. By anticipating and preventing burr formation through proper notch design, the need for subsequent burr removal operations is eliminated, making the manufacturing process easier and more efficient.
Solution Approach 2:
The invention converts the potential harm of intermittent cutting (which causes burrs) into a benefit by designing notches that eliminate burr formation altogether. The tapered or rounded notch geometries guide material flow in a way that prevents burr creation, transforming what would be a problematic intermittent cutting process into a clean, burr-free caulking operation.
3Manufacturing precision
If cutting is performed to remove protrusions from press-fitting surfaces, then fastening precision is improved, but manufacturing cost increases due to additional processes
Solution Approach 1:
The invention performs preliminary action by forming notches with optimized geometries (tapered shapes or rounded corners) during press working that prevent protrusion formation. This preliminary design ensures that the press-fitting surfaces remain clean and precise without requiring subsequent cutting operations, thereby maintaining manufacturing precision while reducing manufacturing cost.
Solution Approach 2:
The invention applies parameter changes by optimizing the notch geometric parameters (taper angle, corner radius, depth) to prevent protrusion formation. By changing these parameters during the press working process, the invention achieves both high press-fitting surface precision and reduced manufacturing cost by eliminating the need for additional cutting processes.
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 reduces manufacturing costs by minimizing the number of processes required and enhances the fastening strength by ensuring the protrusions do not interfere with the counterpart component, leading to consistent load distribution and extended cutting tool life.
Implementation Method 1
the flange is pressed to be widened from inside to outside in a radial direction of the ring gear by plastic deformation processing
Data Source
AI summary
An annular caulking-fastened component to be fastened to a counterpart component by caulking includes a notch formed in an inner peripheral edge portion at one end side in a center axis direction, the notch being to be fixed to the counterpart component by caulking; and at least one of an inner-peripheral stepped portion formed between an inner peripheral surface and the inner peripheral edge portion and outward from the inner peripheral surface in a radial direction and an end-face stepped portion formed between an end face at one end side in the center axis direction and the inner peripheral edge portion and from the end face toward the other end side in the center axis direction.