Composite Screw With Tungsten Carbide Insert
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Solution Overview
Problem
Existing screws made entirely of high-strength steel for tapping are costly and wasteful, as only the tapping portion requires high strength, while the rest of the screw does not.
Innovation Solution
A composite screw design featuring a screw body with reception recesses filled with weld material and a rigid body of high strength and stiffness material, such as tungsten carbide, which is secured using a welding process, allowing the screw body to be made from a lower-cost material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the screw is made entirely from high strength steel material, then the screw can endure tapping stresses, but the material cost increases and high strength steel material is wasted
Solution Approach 1:
The screw is divided into two distinct parts: a screw body made from lower-cost material and a tapping portion made from high-strength material. The reception recess creates a clear segmentation boundary, allowing each part to be optimized independently for its specific function.
Solution Approach 2:
The high-strength material is applied locally only to the tapping portion where it is actually needed to endure tapping stresses, while the screw body uses a more economical material. This localized application of material properties eliminates unnecessary material usage.
2Strength
If the screw is made entirely from high strength steel material, then the screw can endure tapping stresses, but the material cost increases
Solution Approach 1:
The screw is divided into two distinct parts: a screw body made from lower-cost material and a tapping portion made from high-strength material. The reception recess creates a clear segmentation boundary, allowing each part to be optimized independently for its specific function.
Solution Approach 2:
The high-strength material is applied locally only to the tapping portion where it is actually needed to endure tapping stresses, while the screw body uses a more economical material. This localized application of material properties eliminates unnecessary material usage.
3Loss of substance
If the reception recess is filled with composite unit including weld material and rigid body, then the high strength material is used only where necessary, but the device complexity increases
Solution Approach 1:
The weld material and rigid body are combined into a single composite unit that is inserted as one assembly. This merging simplifies the manufacturing process by treating the composite structure as a single replaceable component rather than separate parts requiring multiple assembly steps.
Solution Approach 2:
The weld material acts as an intermediary substance that bonds the rigid body to the screw body. This intermediary layer facilitates the connection between dissimilar materials (the rigid body and the screw body) and enables stress transfer between them.
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
The composite screw effectively endures tapping stresses with high strength and stiffness while reducing material costs by using high-strength materials only where necessary.
Implementation Method 1
The weld material is filled in the at least one reception recess and secured to the screw body
Data Source
AI summary
A composite screw includes a tapping end portion that includes a circular bottom surface, a peripheral surface and a main thread. The peripheral surface extends from the circular bottom surface. The main thread is formed around the peripheral surface. A reception recess is recessed from the circular bottom surface and the peripheral surface. The main thread has a discontinuation where the reception recess opens at the peripheral surface. A rigid body and a weld material fill the reception recess. The rigid body has an outer surface and an auxiliary thread. The outer surface is exposed from the reception recess. The auxiliary thread is formed on the outer surface and connected to the main thread to fill the discontinuation.