Connecting Element Cold Rolling for Integral Ball Sections
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Solution Overview
Problem
Existing methods for producing connecting elements with spherical sections require multiple processing steps, including welding and additional processing of slugs, which are inefficient and costly.
Innovation Solution
A method involving the cold forming of a cylindrical blank between rolling tools to create spherical sections and connecting sections in a single operation, eliminating the need for welding and slug processing, using flat rolling jaws with trough-shaped recesses to achieve deformation and separation of excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connecting elements are produced by welding spherical sections to a connecting element, then the spherical sections can be manufactured separately and connected, but the production process becomes complex and costly with multiple processing steps
Solution Approach 1:
The patent combines multiple manufacturing operations (forming spherical sections, creating connecting sections, and separating slugs) into a single rolling process. The rolling tools simultaneously shape the spherical sections and connecting sections while excess material is separated as slugs during the same operation, eliminating the need for separate welding and processing steps.
Solution Approach 2:
The rolling process performs preliminary shaping of the spherical sections and connecting sections during the forming operation itself, rather than requiring subsequent welding or assembly operations. The separating edges are positioned to automatically separate slugs during the rolling process, preparing the final product in one continuous operation.
2Productivity
If welding is used to connect spherical sections, then the connecting element can be assembled from individual components, but production time and costs increase
Solution Approach 1:
The patent merges the forming and connecting operations into a single rolling process. The connecting sections are formed integrally with the spherical sections during rolling, and slugs are separated simultaneously, eliminating the time required for welding and multiple processing steps.
Solution Approach 2:
The rolling process operates continuously to form both spherical sections and connecting sections in one uninterrupted operation. The separating edges continuously separate slugs as the material is being formed, maintaining continuous productive action without interruption for welding or additional processing.
3Ease of manufacture
If spherical sections are formed by rolling with high deformation, then a single operation can produce the connecting element, but the rolling tools must achieve very large degree of deformation
Solution Approach 1:
The rolling process is divided into multiple revolutions (10-15 revolutions) to achieve the required deformation gradually. The rolling tools apply incremental deformation in each revolution, accumulating the total deformation needed to form spherical sections from cylindrical blanks without requiring excessive force in a single step.
Solution Approach 2:
The rolling process uses dynamic, progressive deformation through multiple revolutions rather than static, single-step forming. The rolling tools continuously reshape the material through repeated cycles, allowing the material to adapt and deform progressively into the spherical shape with connecting sections.
4Loss of substance
If slugs are separated during rolling, then excess material can be removed, but additional separating edges and processing are required
Solution Approach 1:
The slug separation function is merged into the rolling tools themselves. The separating edges are integrated features of the rolling tools, allowing slug removal to occur during the same operation that forms the spherical sections and connecting sections, rather than requiring separate slug removal equipment.
Solution Approach 2:
The rolling tools automatically separate slugs through their own geometry (separating edges extending beyond the central longitudinal axis) during the rolling operation. The process is self-service in that the same tools that form the product also perform the slug separation without requiring additional dedicated separation mechanisms.
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
Enables the rapid and cost-effective production of connecting elements with high deformation capability, allowing for secure locking with clip elements and minimizing waste, with the entire process completed in a single rolling operation.
Implementation Method 1
the rolling of an at least partially cylindrical, one-piece blank between at least two rolling tools and the shaping of the at least two spherical sections and optionally the connecting section are provided during rolling
Implementation Method 2
By rolling a cylindrical blank, it is possible to achieve a very large degree of deformation, so that the two spherical sections can be formed
Data Source
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AI summary
The invention relates to a method for producing a connecting element (40) comprising at least two ball-type sections (54, 56), wherein two ball-type sections are directly adjacent to one another or wherein two ball-type sections are connected to one another by a connection section, which method provides the step of rolling an integral blank that is cylindrical, at least in part, between at least two rolling tools, and the step of shaping the at least two ball-type sections and optionally the connection section during the rolling. The invention also relates to a connecting element and a rolling tool for producing a connecting element.