Cylindrical Jig Lubrication for Head Assembly Flange Deformation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing head assembly attaching methods by ball caulking face challenges in preventing deformation of the flange during caulking, leading to compromised load and resonance characteristics, and are costly due to specialized base plate designs or increased process complexity with ultrasonic vibration techniques.

Innovation Solution

A method using a cylindrical jig with a lubricant path to supply lubricant to a caulking ball, allowing it to smoothly pass through the boss of the head assembly without deforming the flange, while minimizing costs by continuously feeding lubricant during the caulking process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional ball caulking is used without lubrication, then the caulking process is simple, but the flange deforms and load/resonance characteristics deteriorate

Engineering Contradiction:

Improveflange deformation preventionVSAvoidcaulking process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent introduces lubricant as an intermediary substance between the caulking ball and the boss-flange interface. The lubricant reduces friction and prevents direct metal-to-metal contact that causes flange deformation, while adding minimal complexity to the caulking process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the friction parameter at the caulking interface by applying lubricant. This parameter change allows the caulking ball to pass through the boss smoothly without generating excessive force that would deform the flange, thereby improving manufacturing precision

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If ultrasonic vibration is applied during caulking, then flange deformation is prevented, but the number of processes increases and costs increase

Engineering Contradiction:

Improveflange deformation preventionVSAvoidnumber of processes

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Instead of using ultrasonic vibration as an intermediary mechanism, the patent uses lubricant as a simpler intermediary substance that achieves the same goal of preventing flange deformation without requiring additional process steps or equipment

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a disposable or consumable lubricant that can be easily applied and does not require expensive ultrasonic vibration equipment or multiple process steps, thereby maintaining productivity while achieving the desired manufacturing precision

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If a special shaped base plate is used, then flange deformation is prevented, but manufacturing costs increase

Engineering Contradiction:

Improveflange deformation preventionVSAvoidbase plate manufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent uses lubricant as an external intermediary rather than modifying the base plate structure itself. This approach maintains the simplicity and ease of manufacturing the base plate while still preventing flange deformation through the lubrication mechanism

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Instead of changing the geometric parameters of the base plate structure, the patent changes the friction parameter at the caulking interface by applying lubricant. This keeps the base plate design simple and easy to manufacture while achieving the desired deformation prevention

Inventive Principle:

Principle #35Parameter changes

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 prevents flange deformation, maintains high precision and proper load and resonance characteristics, and reduces costs by simplifying the process without the need for specialized base plates or multiple ultrasonic vibration steps.

Implementation Method 1

supplying lubricant along a cylindrical jig to the caulking ball set on the boss

Methodology Applied

Scientific EffectLubrication: Lubrication

Implementation Method 2

pushing the caulking ball with the cylindrical jig to pass the caulking ball through an inside of the boss and diametrally expand and plastically deform the boss

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS8745844B2Head assembly attaching method, cylindrical jig, and caulking ball

Publication Date: 2014.06.10 NHK SPRING CO LTD

AI summary

A method of attaching a head assembly having an annular hollow boss to an arm having a through hole of a carriage is provided. The head assembly includes a load beam of a head suspension and a base plate fixed to a base part of the load beam. The boss is formed on the base plate. The method includes steps of, inserting the boss into the through hole, thereby setting the head assembly to the arm of the carriage, supplying lubricant along the cylindrical jig to the caulking ball and pushing the caulking ball with the cylindrical jig to pass the caulking ball through an inside of the boss and diametrally expand and plastically deform the boss, thereby fixedly fitting the boss of the head assembly to the through hole of the arm of the carriage. The method causes no deformation of a flange formed on the base plate during caulking and is achievable at low cost.