Liquid Cooling Jacket Friction Stir Joining With Reduced Burrs
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Solution Overview
Problem
Conventional methods for manufacturing liquid cooling jackets result in larger recessed grooves and coarser joined surfaces due to the flow of plastically fluidized material into tapered surfaces, leading to reduced joining quality and increased burr formation.
Innovation Solution
A method involving a primary joining rotary tool with a base end pin and distal end pin, where the base end pin has a larger taper angle and a pin stepped portion, and the distal end pin has a flat surface with a protrusion, is used to perform friction stirring with specific contact points to minimize the recessed groove size and prevent material adherence, ensuring a smoother joined surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction stir joining is performed with a conventional rotary tool having a shoulder portion and stirring pin, then joining can be performed, but plastically fluidized material flows into the groove formed in the tapered surface, causing the groove to malfunction and deteriorating joining quality
Solution Approach 1:
The invention extracts and removes the groove structure from the rotary tool design. Instead of having a groove in the tapered surface that collects plastically fluidized material, the patent uses a smooth tapered surface without any grooves, channels, or recesses that could trap material. This eliminates the harmful effect of material adherence while maintaining the joining function.
Solution Approach 2:
The invention inverts the conventional design approach by eliminating the groove structure entirely. Rather than designing a groove to control material flow and then dealing with material accumulation, the patent uses the opposite approach: a grooveless tapered surface that prevents material accumulation from the outset, allowing material to flow smoothly without adherence.
2Stability of the object's composition
If friction stir joining is performed with a rotary tool having a tapered surface, then metal members can be stably joined, but the joined surfaces become coarse and burrs are generated
Solution Approach 1:
The invention changes the geometric parameters of the rotary tool surface by eliminating grooves and recesses. The tapered surface is designed with smooth transitions and optimized angles that control material flow while preventing surface degradation. This parameter optimization maintains joining stability while improving surface finish quality and reducing burr formation.
3Adaptability or versatility
If the height position of joining is changed, then different joining configurations can be achieved, but defects are liable to be formed and burrs are generated
Solution Approach 1:
The grooveless tapered surface design provides universal applicability across different joining positions and configurations. The smooth tapered geometry maintains consistent material flow control regardless of the height position or orientation of the joining operation, enabling versatile application while maintaining high joining quality without defects or burrs.
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 method effectively reduces the size of recessed grooves, stabilizes the joining quality, and enhances the strength of the joined surfaces by controlling the flow of plastically fluidized material and reducing burr formation.
Implementation Method 1
performing friction stirring
Implementation Method 2
friction stir joining in a state where the stirring pin being rotated is inserted into an abutted portion
Implementation Method 3
the plastically fluidized material flows into the groove
Data Source
AI summary
Provided is a method for manufacturing a liquid cooling jacket including a jacket body and a sealing body joined to the jacket body. The method includes steps of: preparing; placing; first primary joining with a rotary tool; and second primary joining with the rotary tool. The rotary tool includes a base end pin and a distal end pin. The distal end pin includes a flat surface and a protrusion protruding from the flat surface. In the first primary joining and the second primary joining, friction stirring is performed in a state where the jacket body and the sealing body are brought in contact with the flat surface of the distal end pin and the base end pin and only the jacket body is brought in contact with a distal end surface of the protrusion.