Composite Gear Hub Torque Transmission via Resin Interlocking
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Solution Overview
Problem
Existing composite bodies for torque transmission, such as gear wheels, face high production costs due to extensive machining operations and have limited torque transmission capabilities, with a risk of shear failure under sudden torque applications.
Innovation Solution
The composite body features a radially inner hub body and an outer body with sinusoidal profiles produced by massive forming, eliminating the need for expensive machining, and an intermediate layer for connection, enhancing adhesion and torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machining operations (flanging, knurling, punching, drilling) are performed on metal parts to ensure good contact and torque transmission, then the reliability of torque transmission is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The metal parts are pre-formed with integrated profiles and geometric features during the forming process itself, before assembly. The hub body receives the intermediate layer through a pre-formed recess, and the outer body has pre-formed profiles that interlock with the intermediate layer, eliminating the need for subsequent machining operations like flanging, knurling, punching, or drilling.
Solution Approach 2:
The patent combines multiple functions into the intermediate layer: it provides adhesive bonding, mechanical interlocking through geometric profiles, and torque transmission. This merging of functions into a single component eliminates the need for separate machining operations on the metal parts to create these features.
2Manufacturing precision
If sharp-edged profiles are produced by machining operations like broaching, then the precision of profile geometry is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces mechanical machining operations (like broaching) with a forming process. The profiles are created through plastic deformation and shaping of the metal parts during forming, which achieves the required geometric precision without the high costs associated with subsequent machining operations.
3Ease of manufacture
If plastic plugs extending through flange openings are used for torque transmission, then the assembly process is simplified, but the torque transmission capacity is limited and shear failure risk increases under sudden torque
Solution Approach 1:
The patent transitions from one-dimensional axial insertion (plugs through flange openings) to two-dimensional surface contact and three-dimensional interlocking. The intermediate layer covers the entire surface area between the hub body and outer body, with geometric profiles creating multi-point contact and interlocking engagement, dramatically increasing the torque transmission capacity while maintaining assembly simplicity.
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 production costs, increases torque transmission capacity, and minimizes shear risk, making the composite body suitable for high-torque applications like motor vehicle gears.
Implementation Method 1
The synthetic material inserted between the two parts connects the two parts, whereby an interlocking engagement is produced by way of the holes provided in the flange of the inner part in addition to the existing adhesive force
Data Source
AI summary
A method of producing a composite body, such as a gear wheel or torsional vibration damper, including a radially inner hub body provided with outer profiles, a surrounding outer body provided with inner profiles, and an intermediate layer of synthetic resin material which connects the outer profiles of the hub body with the inner profiles of the outer body; the hub body being with an inner contour adapted to mount the composite body on a shaft.