Curved Surface Mechanical Joining Without Heat-Affected Weakening
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Solution Overview
Problem
Existing methods for joining surfaces with simple curvatures, such as those found in aluminum alloy tubes and brackets, suffer from reduced strength, brittleness, welding cracks, and reduced corrosion resistance due to heating during processes like brazing or welding, leading to high discard rates.
Innovation Solution
A method involving material deformation using a stamp and template to create a form-fit and force-fit connection without heating, utilizing a mandrel and template to deform the surfaces into a deep drawing opening, forming a snap-like joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or brazing is used to join aluminum alloy parts, then the parts are permanently connected, but the material strength is reduced due to heat-affected areas
Solution Approach 1:
The patent replaces thermal joining processes (welding/brazing) with a mechanical joining process. A stamp is pressed against the curved surface of a tube to create a localized plastic deformation that forms a connection with a bracket. This mechanical approach eliminates heat-affected zones while maintaining joint strength and material properties.
Solution Approach 2:
The patent changes the joining mechanism from thermal energy input to mechanical force application. By applying localized compressive force through a stamp with a specific geometry, the material is plastically deformed to create a form-fit connection, avoiding the thermal parameters that cause material degradation.
2Ease of manufacture
If brazing is used to join parts, then the parts are connected, but the material strength is reduced due to furnace heating
Solution Approach 1:
The patent replaces thermal joining processes (welding/brazing) with a mechanical joining process. A stamp is pressed against the curved surface of a tube to create a localized plastic deformation that forms a connection with a bracket. This mechanical approach eliminates heat-affected zones while maintaining joint strength and material properties.
3Reliability
If welding is used to join aluminum alloy parts, then the parts are permanently connected, but welding cracks and brittleness occur
Solution Approach 1:
The patent replaces thermal joining processes (welding/brazing) with a mechanical joining process. A stamp is pressed against the curved surface of a tube to create a localized plastic deformation that forms a connection with a bracket. This mechanical approach eliminates heat-affected zones while maintaining joint strength and material properties.
Solution Approach 2:
The patent changes the joining mechanism from thermal energy input to mechanical force application. By applying localized compressive force through a stamp with a specific geometry, the material is plastically deformed to create a form-fit connection, avoiding the thermal parameters that cause material degradation.
4Ease of operation
If a stamp is placed inside a mandrel, then access is obtained from both sides for joining curved surfaces, but the device complexity increases
Solution Approach 1:
The patent places the stamp inside the mandrel, with the stamp positioned within the hollow interior of the mandrel structure. This nesting arrangement allows the stamp to apply force from the inside of the tube while the mandrel provides structural support and positioning, enabling access to curved surfaces that would otherwise be difficult to reach.
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 maintains or enhances the strength of the joined parts, eliminating areas affected by heat and reducing the risk of damage, resulting in a statically and dynamically strong joint.
Implementation Method 1
A joining method used to connect at least two parts... This type of joining belongs to a group of methods for joining through material deformation
Implementation Method 2
The stamp is then moved toward the two curved surfaces from a starting point, forcing the material forming the two surfaces into this deep drawing opening
Implementation Method 3
Below the elasticity limit of a material, the part returns to its original shape after the force is no longer applied
Data Source
AI summary
A method and a device for obtaining a joint between two surfaces of two parts that have a simple curvature are proposed in which a mandrel is placed below the first surface, which contains a moving stamp in its interior. A template is placed above the second surface, which has a deep drawing opening. The stamp is moved along the surface normals of the two surfaces, such that material forming the two surfaces is forced into the deep drawing opening, wherein the deep drawn and compressed portion of the first surface engages behind the remaining part of the second surface to obtain a form-fit connection between the two surfaces. The stamp blocks a channel inside the mandrel until pressure from a medium therein causes the stamp to move.