Endless Metal Ring Resin Removal for Nitriding
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Solution Overview
Problem
Existing methods for manufacturing endless metal rings for CVT belts face issues with nitriding failure due to resin residue from barrel polishing, leading to reduced life expectancy and endurance of the CVT belt.
Innovation Solution
An ultrasonic washing process is employed to remove resin residue from the metal surface before the rolling step, preventing its fixation and facilitating its removal, thereby reducing nitriding failure by ensuring nitrogen molecules can penetrate and form a uniform diffusion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If barrel polishing is conducted using media made by mixing abrasive grains and resin binder, then polishing effectiveness is improved, but resin residue remains on the metal surface causing nitriding failure
Solution Approach 1:
The patent applies preliminary action by performing ultrasonic washing to remove resin residue immediately after barrel polishing and before the rolling and nitriding processes. This preliminary cleaning prevents the resin from interfering with subsequent nitriding, resolving the contradiction between using resin-based polishing media and achieving successful nitriding.
Solution Approach 2:
The patent converts the harmful effect of resin residue into a beneficial process by using ultrasonic washing. The resin binder that causes nitriding failure is systematically removed through ultrasonic cavitation, transforming the problematic residue into a controlled removal process that enables successful nitriding while maintaining the advantages of resin-based polishing media.
2Device complexity
If resin residue is not removed before rolling, then the rolling process becomes simpler, but the resin becomes fixed to the surface making removal extremely difficult
Solution Approach 1:
The patent performs ultrasonic washing as a preliminary action before the rolling process to remove resin residue while it is still easily removable. By acting before the rolling process fixes the resin to the surface, the patent maintains process simplicity while ensuring easy resin removal, avoiding the need for complex post-rolling removal methods.
3Device complexity
If ultrasonic washing is performed without rotating the endless metal ring, then the washing process is simpler, but resin removal effectiveness is reduced
Solution Approach 1:
The patent applies dynamics by rotating the endless metal ring during ultrasonic washing. This rotation dynamically exposes all surfaces of the ring to ultrasonic cavitation, significantly improving resin removal effectiveness. The rotational motion works synergistically with ultrasonic vibration to achieve complete resin removal while maintaining relatively simple washing equipment.
4Productivity
If nitriding is performed with resin residue on the surface, then the manufacturing process is faster, but the surface strength and hardness are reduced
Solution Approach 1:
The patent performs ultrasonic washing as a preliminary action before nitriding to remove resin residue. This quick washing step maintains high manufacturing productivity by avoiding lengthy post-nitriding cleaning, while ensuring complete resin removal that enables uniform nitrogen diffusion and achieves the required surface strength and hardness.
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 reduces nitriding failure rates to nearly zero, enhancing the surface strength and hardness of the endless metal ring, leading to improved product yield and extended life expectancy of the CVT belt while also reducing manufacturing costs.
Implementation Method 1
an ultrasonic wave generator (30) to wash and hold the endless metal ring (110)
Implementation Method 2
the rotation mechanism rotates the endless metal ring in the circumferential direction to remove resin having adhered to a surface of the endless metal ring
Implementation Method 3
ensuring nitrogen molecules can penetrate and form a uniform diffusion layer
Data Source
Figure 1~2
Figure 3(a)~3(k)
Figure 4(a)~4(e)
AI summary
Provided is an endless metal ring manufacturing method for manufacturing an endless metal ring (110) by carrying out a barrel polishing step (pr5) for polishing the endless metal ring (110) by using a barrel of a resin material, a rolling step (pr7) for rolling the endless metal ring (110) which was cleaned, and a nitriding step for nitriding the endless metal ring (110) which was rolled, wherein after the barrel polishing step (pr5) and before the rolling step (pr7), provided is a resin removing step (pr6) for removing resin that has adhered to the endless metal ring (110).