Drive Shaft Weld Knurling to Eliminate Sharp Weld Curls
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Solution Overview
Problem
Welding operations in drive shaft assemblies result in undesirable features like jagged weld curls and contaminants, which are difficult and costly to remove using existing methods such as wire brushing and shearing.
Innovation Solution
A system comprising a knurling apparatus with textured plates that deform the outer surface of the weld curl to form a knurled surface, minimizing and removing objectionable features during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If wire brushing or shearing is used to remove weld curls, then the sharp edges and contaminants can be removed, but the process becomes impractical, ineffective, and costly
Solution Approach 1:
The invention changes the physical state and surface parameters of the weld curl by applying controlled plastic deformation through knurling. The knurling process transforms the sharp, jagged weld curl surface into a textured, rounded surface with improved geometry, eliminating the need for secondary removal operations while maintaining cost-effectiveness and practicality in manufacturing
Solution Approach 2:
The invention converts the harmful sharp edges and contaminants of the weld curl into a beneficial textured surface finish. By applying knurling pressure, the previously objectionable weld curl is transformed into a functional surface feature that eliminates sharp edges while creating a desirable textured appearance, effectively turning a defect into an asset
2Object-affected harmful factors
If traditional removal methods are used, then weld curls can be addressed, but the process is time-consuming and reduces manufacturing efficiency
Solution Approach 1:
The invention merges the weld curl management process into a single integrated operation. By combining the knurling process that simultaneously addresses weld curl defects and creates the desired surface finish, the invention eliminates multiple separate operations (wire brushing, shearing, inspection), thereby significantly improving manufacturing efficiency and productivity
Solution Approach 2:
The knurling process is applied immediately after welding while the weld curl is still in its formed state. This preliminary action prevents the need for subsequent removal operations by addressing the weld curl defects at the optimal time in the manufacturing sequence, thereby maintaining high productivity while effectively eliminating defects
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 knurling process effectively removes or reforms weld curls, improving the appearance and safety of drive shaft assemblies by eliminating sharp edges and contaminants, enhancing the manufacturing efficiency and reducing costs.
Implementation Method 1
a knurling apparatus with textured plates that deform the outer surface of the weld curl to form a knurled surface
Data Source
AI summary
A system for manufacturing a drive shaft assembly comprises a welding apparatus configured to weld a tube to an end fitting to form the drive shaft assembly having an annular weld. A transport apparatus is configured to transport the drive shaft assembly away from the welding apparatus. A knurling apparatus receives the drive shaft assembly from the transport apparatus. The knurling apparatus is configured to knurl the weld of the drive shaft assembly. The knurling apparatus includes a pair of knurling plates having textured surfaces in facing relationship. One of the knurling plates is configured to move relative to the other of the knurling plates to roll the drive shaft assembly between the textured surfaces, thereby knurling the weld to improve an appearance and texture of the outer surface of the drive shaft assembly.