Drawn Axle Housing Tube Forming for Thin Walls Without Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tubes used for housing axle shafts in vehicles have varying wall thicknesses, require welding of separate components, and lack efficiency in weight reduction while maintaining yield strength, which hinders fuel efficiency and manufacturing efficiency.
Innovation Solution
A method of manufacturing a drawn tube with a hollow interior using a multi-step die assembly process that involves forming a billet into a pre-formed billet, then an extruded tube, and finally a drawn tube with a reduced wall thickness of 3 to 18 millimeters, achieving a yield strength of at least 750 MPa without the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional tubes are made by welding separate components (tube portion and spindle end), then the tube can be assembled, but the manufacturing time and expense increase
Solution Approach 1:
The patent merges the tube portion and spindle end into a single integrated tube structure formed by one continuous extrusion process. The extrusion die is designed with multiple cavities that form different sections of the tube in one operation, eliminating the need to manufacture and weld separate components together.
Solution Approach 2:
The extrusion die is segmented into multiple cavities (first cavity for tube portion, second cavity for spindle end) that form different sections of the tube simultaneously. This segmentation allows complex multi-section tubes to be produced in a single extrusion operation without requiring multiple welding steps.
2Weight of moving object
If conventional tubes use separate components that are welded together, then the tube can be constructed, but the weight increases and fuel efficiency decreases
Solution Approach 1:
The patent combines multiple tube sections into a single monolithic structure produced by continuous extrusion. This eliminates the need for welding separate components, reducing overall weight while simplifying the manufacturing process to a single operation.
Solution Approach 2:
The patent uses different alloy compositions in different sections of the tube (as defined by the multi-cavity extrusion die) to optimize weight and strength characteristics for each specific section, allowing weight reduction without compromising overall structural integrity.
3Strength
If conventional tubes are made with sufficient wall thickness to ensure yield strength, then the tube can avoid failure, but the weight increases
Solution Approach 1:
The patent applies different material properties (alloy compositions) to different sections of the tube based on their specific functional requirements. High-strength alloys are used in sections requiring maximum strength, while lighter alloys are used in sections where lower strength is acceptable, optimizing the overall strength-to-weight ratio.
Solution Approach 2:
The patent creates a composite tube structure with multiple alloy compositions within a single extruded component. Each alloy section is strategically placed to provide the necessary strength characteristics for its specific location, reducing overall weight while maintaining required yield strength throughout the tube.
4Ease of manufacture
If conventional tubes require welding of separate components, then the tube can be assembled, but manufacturing expense increases
Solution Approach 1:
The patent consolidates the manufacturing of multiple tube sections into a single extrusion process using a multi-cavity die. This eliminates the need for separate manufacturing operations and welding processes, reducing both manufacturing cost and process complexity.
Solution Approach 2:
The extrusion die is segmented into multiple cavities that form different tube sections in one operation. This segmentation enables complex multi-section tubes to be produced through a single, simplified process rather than requiring multiple manufacturing steps and assembly operations.
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 results in a lighter tube with increased yield strength, reducing manufacturing time and costs by eliminating the need for welding and allowing for a single-piece construction, thereby enhancing fuel efficiency and manufacturing efficiency.
Implementation Method 1
pressing the billet into the cavity of the first die to form a bore at one end of the billet thereby producing a pre-formed billet
Implementation Method 2
pressing the pre-formed billet into the cavity of the second die assembly to elongate the pre-formed billet and form a hollow interior therein thereby producing an extruded tube
Implementation Method 3
pressing the extruded tube into the cavity of the third die assembly to further elongate the extruded tube and decrease the thickness of the wall of the extruded tube
Data Source
Figure 1~3D
Figure 4A~5B
Figure 6
AI summary
A method is used to manufacture a drawn tube having a hollow interior for housing an axle shaft. The method includes the steps of placing a billet into a first die assembly and pressing the billet into the first die to producing a pre-formed billet. The method also includes the steps of moving the pre-formed billet from the first die assembly to a second die assembly and pressing the pre-formed billet into the second die assembly to produce an extruded tube. The method further includes the steps of moving the extruded tube from the second die assembly to a third die assembly and pressing the extruded tube into the third die assembly to further elongate the extruded tube and decrease the thickness of the wall of the extruded tube to of from about 3 to about 18 millimeters to produce the drawn tube having the yield strength of at least 750 MPa.