Dual-Ring Joining Structure for Bending-Resistant Metal Joints
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Solution Overview
Problem
The existing joining apparatuses, such as those described in Japanese Patent Application Publication No. 2004-017048, are prone to damage from bending stress due to having only one ring-shaped joining site, which concentrates stress and can lead to structural weaknesses, especially in longer welded objects.
Innovation Solution
A method and device for manufacturing a joining apparatus that involves joining two metal members at two distinct sites using the Ring Mash joining method, with specific configurations of lap allowances and joint widths to distribute stress and control the timing of joining, thereby enhancing strength and reducing the generation of burrs and spatter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only one ring-shaped joining site is used, then the device complexity is reduced, but the strength against bending stress deteriorates
Solution Approach 1:
The patent divides the joining apparatus into multiple joining sites (first joining site and second joining site) along the axial direction. This segmentation allows bending stress to be distributed across multiple locations rather than concentrated at a single point, thereby improving the overall strength against bending stress while maintaining reasonable device complexity.
2Strength
If multiple joining sites are used, then the strength against bending stress is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent implements segmentation by creating multiple joining sites with different configurations (different lap allowance lengths or joint widths). This allows the apparatus to achieve enhanced strength while managing manufacturing complexity through systematic variation of geometric parameters rather than complete redesign.
Solution Approach 2:
Each joining site is given different local characteristics through varying lap allowance lengths or joint widths. This local quality differentiation allows each joining site to contribute differently to the overall strength, optimizing the structure for bending stress resistance while controlling manufacturing complexity.
3Productivity
If simultaneous joining at multiple sites is performed, then the productivity is improved, but the manufacturing precision deteriorates due to burr and spatter generation
Solution Approach 1:
The patent applies preliminary action by designing the joining sites with different geometric parameters (different lap allowance lengths or joint widths) before the joining process. This pre-configured differentiation causes the joining reactions to occur at different times during the pressing operation, sequentially controlling burr and spatter generation while maintaining high productivity.
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 approach results in a joining apparatus with increased strength against bending stress and reduced energy requirements, while minimizing the generation of burrs and spatter, by strategically varying the timing and configuration of the joining sites.
Implementation Method 1
a current is applied while a member is press-inserted into an opening provided in another member, so as to soften both of the members by generated Joule heat
Implementation Method 2
soften both of the members by generated Joule heat and cause a plastic flow thereof. As a result, both of the members are joined in a solid state
Data Source
AI summary
A method of manufacturing a joining apparatus includes: providing a first metal member including an opening and a joint structure; providing a second metal member including an outer circumferential wall capable of contacting an inner circumferential wall that surrounds the opening and a joined structure, to which the joint structure is joined; causing the first metal member and the second metal member to move relative to each other, bringing one of a first joining section, which is configured by the inner circumferential wall and the outer circumferential wall, and a second joining section, which is configured by the joint structure and the joined structure, into contact, and separating the other joining section; starting energization between the first and the second metal members; bringing components of the other joining section into contact with each other; and joining the first and second joining sections by the relative movement and the energization.