Cogwheel Sintered Part Machining With Exit-Surface Support
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Solution Overview
Problem
Current methods for producing sintered parts face challenges in mass production due to issues with chip formation and machining efficiency, particularly during the machining process where tension stress leads to chip generation and reduced productivity.
Innovation Solution
The method involves using a plate member with a tooth pattern matching the cogwheel shape to support the compacted part during machining, applying compressive stress to counteract tension stress and enhance machining speed and efficiency, thereby reducing chip formation and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a machining process is applied to a compacted part without support, then the tool can access the exit surface, but tension stress causes chip formation and reduces productivity
Solution Approach 1:
A plate member is introduced as an intermediary support element during the machining process. The plate member has a tooth pattern that matches the cogwheel shape, providing support to the exit surface while allowing the tool to machine the compacted part. This mediator prevents chip formation by supporting the exit surface without interfering with the machining operation.
Solution Approach 2:
The plate member applies compressive stress to counterbalance the tension stress generated by the machining process. By supporting the exit surface, the plate member creates an opposing force that prevents the tensile stresses from causing chip formation, thereby maintaining both reliability and productivity.
2Reliability
If the exit surface is supported during machining, then chip formation is reduced, but the tool path and machining efficiency may be affected
Solution Approach 1:
The plate member is created as a copy of the desired cogwheel tooth pattern. By machining a first compacted part along with a raw material plate, the tooth pattern is copied onto the plate member. This copied pattern then serves as the support structure for subsequent machining operations, simplifying the overall process.
Solution Approach 2:
The plate member with the tooth pattern is prepared in advance through a preliminary machining operation. This preliminary action creates the support structure before the actual production machining begins, allowing for efficient and consistent support during all subsequent machining operations without adding complexity to the main production process.
3Ease of manufacture
If a raw material plate is machined together with the compacted part to form the tooth pattern, then the plate member is created, but additional machining time is required
Solution Approach 1:
The machining of the compacted part and the raw material plate are merged into a single simultaneous operation. The tool machines both the compacted part and the raw material plate together, creating the tooth pattern on the plate member while also machining the compacted part. This combining of operations reduces the total number of separate machining steps.
Solution Approach 2:
The raw material plate serves itself by being machined together with the compacted part to automatically create the necessary tooth pattern. The plate member creates its own support structure through the combined machining operation, eliminating the need for separate plate fabrication and pattern creation steps.
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 effectively reduces chip formation and enhances machining speed, leading to increased productivity in producing sintered parts with a cogwheel shape by canceling tension stress and ensuring proper support of the exit surface during machining.
Implementation Method 1
uses a plate member to support the exit surface of a compacted part, thereby providing compressive stress in the compacted part which cancels the tension stress generated by the machining process
Implementation Method 2
a step of sintering the machined compacted part to make a sintered part
Data Source
AI summary
A method of making a sintered part includes a step of applying a machining process to a compacted part with a tool to make a machined compacted part having a cogwheel shape, and a step of sintering the machined compacted part to make a sintered part, wherein the machining process is such that a surface of the compacted part on a side where the tool exits is supported by a plate member having a tooth pattern with same specifications as a tooth pattern of the cogwheel shape, and the tool is used to machine portions of the compacted part corresponding to tooth spaces of the plate member.