Conical Bolt Collar Removal Through Thread Rolling
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Solution Overview
Problem
Existing cone bolt manufacturing processes require a separate step to remove a collar, which is time-consuming and inefficient, especially when inserting bolts into prefabricated drill holes with sufficient holding values.
Innovation Solution
A cone bolt design featuring a depression and raised material on the transition area between the neck and shank, allowing the collar to be removed through a material flow caused by a rolling tool, enabling the bolt to be driven into the fastening base in a simple and energy-saving manner, and allowing the thread to be rolled onto the shank in the same process step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a collar is added to the conical bolt blank for transfer and centering, then the ease of manufacture is improved, but the device complexity increases and an additional removal step is required
Solution Approach 1:
The collar is designed with a preliminary geometry that enables it to be automatically deformed and removed during the thread rolling process itself, rather than requiring a separate removal operation. The collar's initial shape includes features that facilitate its transformation into the final bolt geometry with integrated collar removal.
Solution Approach 2:
The collar removal operation is merged with the thread rolling process. The same rolling tool that forms the thread also deforms and removes the collar through material flow, combining two operations into one continuous process step, thereby eliminating the need for separate collar removal equipment or steps.
2Reliability
If a separate collar removal step is implemented, then the holding values are improved, but the productivity decreases
Solution Approach 1:
The collar removal and thread rolling operations are merged into a single integrated process step. The rolling tool performs both functions simultaneously, eliminating the need for separate operations and thereby maintaining high productivity while achieving the required holding values through proper material flow control.
Solution Approach 2:
The collar removal is performed continuously during the thread rolling process without interrupting the manufacturing flow. The material flow induced by the rolling tool continuously deforms and removes the collar while simultaneously forming the thread, maintaining continuous useful action throughout the process.
3Ease of operation
If the collar is removed through material flow induced by deformation, then the ease of operation is improved and energy consumption is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The collar geometry parameters are specifically designed to enable controlled material flow during deformation. The collar's initial dimensions, shape, and positioning are optimized so that when subjected to the rolling tool's deformation, the material flows in a predictable manner that achieves both easy operation and acceptable precision without requiring excessive manufacturing control.
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 method eliminates the need for a separate collar removal step, increasing manufacturing cost-effectiveness and allowing for easier insertion of cone bolts into fastening bases with improved holding values.
Implementation Method 1
the collar of the conical bolt blank is removed by the rolling tool through a material flow induced by deformation
Implementation Method 2
Such conical bolts are manufactured by cold extrusion and rolling
Data Source
Figure 1~3
AI summary
The invention relates to a conical bolt (1) and to a method for producing a conical bolt (1) from a conical bolt blank (18). The conical bolt (1) comprises a recess (13) and a material elevation (14) in a transition area (11) between a neck region (7) and a shaft region (9). The method according to the invention is characterized in that a collar (27) of the conical bolt blank (18) is removed between a neck region (24) and a shaft region (29) by shaping.