Cold-Formed Driveshaft Flange for Lightweight Low-Machining Production
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Solution Overview
Problem
Existing three-arm and four-arm driveshaft flanges produced by hot forming methods are heavy, require extensive machining, and incur high energy costs due to the need for heating, which also harms the environment.
Innovation Solution
The driveshaft flanges are manufactured from sheet metal using the cold forming method, allowing them to be produced in two parts that can be fitted together, resulting in a lightweight, thin-walled design with reduced material usage and no need for heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot forming method using forging technology is used, then the driveshaft flange can be produced with traditional manufacturing processes, but the flange becomes heavy and requires extensive machining
Solution Approach 1:
The patent changes the manufacturing process parameters from hot forming to cold forming, and from forging to deep drawing. This parameter change enables production of thin-walled structures that are lightweight while maintaining structural integrity through the cold forming process
Solution Approach 2:
The patent employs thin-walled structure design in the deep drawn flange, utilizing the properties of thin shells to achieve lightweight construction while maintaining sufficient strength and stiffness for the application
2Ease of manufacture
If hot forming method is used, then the flange can be produced with traditional processes, but high energy costs are incurred due to heating parts at high temperatures
Solution Approach 1:
The patent changes the temperature parameter from high temperature hot forming to ambient temperature cold forming. This eliminates the need for heating equipment and high energy consumption while enabling the use of thin-walled sheet metal structures
3Ease of manufacture
If hot forming method is used, then the flange can be produced with traditional processes, but the heat energy harms the environment
Solution Approach 1:
The patent changes the thermal parameter from high temperature processing to cold forming at ambient temperature. This eliminates heat energy consumption and associated environmental harm while maintaining manufacturing feasibility through deep drawing technology
4Ease of manufacture
If forging technology is used, then the flange can be produced with traditional methods, but a lot of machining is applied due to geometry coming out of the mould
Solution Approach 1:
The patent changes the forming method from forging to deep drawing, which allows direct formation of the final flange geometry with minimal post-machining. The deep drawing process can directly create the required flange shape, hole positions, and mounting features in a single operation
Solution Approach 2:
The patent incorporates all necessary features including mounting holes, bolt fitting areas, and final geometry directly in the deep drawing process. This preliminary formation of all features eliminates or minimizes subsequent machining operations
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 results in a driveshaft flange that is lighter, more cost-effective to produce, and environmentally friendly, while maintaining the required strength and reducing waste and machining needs.
Implementation Method 1
The invention relates to three-arm and four-arm driveshaft flanges, which are produced from sheet metal by cold forming method
Implementation Method 2
three-arm driveshaft flange consisting of a triangular three-arm flange produced from sheet metal by cold forming method and a triangular or circular three-arm centring part produced from sheet metal by cold forming method and joined to the three-arm flange by fitting
Data Source
AI summary
The invention relates to a driveshaft flange used in the driveshaft (M), which provides rotational movement and power transmission between the differential and the gearbox in motor vehicles, and to a production method.