Expansion Chucking Device High-Temperature Soldering
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Solution Overview
Problem
The existing expansion clamping devices for machine tools, particularly those using hot-work steels, are difficult to manufacture due to their high cost and challenging machining properties, leading to long machining times and high production costs.
Innovation Solution
The use of low-alloy heat-treated steel for the base body and a soldering material with a melting point above the hardening temperature of the steel, combined with high-temperature soldering, gas quenching, nitriding, and surface treatment to achieve a strong and corrosion-resistant structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hot-work steels are used for the base body, then high temperature resistance is achieved, but machining difficulty increases and manufacturing cost rises
Solution Approach 1:
The patent changes the material parameter from hot-work steel to low-alloy heat-treated steel, and changes the temperature parameter by using a soldering material with melting point above the hardening temperature of the base body. This allows the base body to be heated to austenite transformation temperature during soldering, then rapidly cooled to achieve quenching hardening, thereby achieving high temperature resistance while maintaining machining ease.
2Temperature
If hot-work steels are used for the base body, then high temperature resistance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from expensive hot-work steel to cost-effective low-alloy heat-treated steel. By controlling the heating temperature during soldering to exceed the hardening temperature of the low-alloy steel, and then applying rapid cooling, the base body achieves quenching hardening and high temperature resistance, thereby reducing manufacturing cost while maintaining temperature resistance.
3Strength
If high-temperature soldering is performed, then strong connection is achieved, but the base body material must withstand high temperatures
Solution Approach 1:
The patent changes the temperature parameter by using a soldering material whose melting point is above the hardening temperature of the base body. During high-temperature soldering, the base body is heated to austenite transformation temperature, then rapidly cooled to achieve quenching hardening. This creates a strong connection while transforming the base body material into a hardened state with enhanced strength.
Solution Approach 2:
The patent converts the potential harm of overheating the base body during high-temperature soldering into a benefit. By intentionally heating the low-alloy steel base body above its hardening temperature and then rapidly cooling it, the overheating process creates free carbon that enables quenching hardening, thereby achieving both strong connection and enhanced base body strength simultaneously.
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
This approach results in a cost-effective and efficient expansion clamping device with high strength and surface hardness, reducing manufacturing complexity and costs while maintaining performance.
Implementation Method 1
the expansion sleeve is connected to the base body by high-temperature soldering with a soldering material whose melting point is above the hardening temperature of the low-alloy heat-treated steel
Implementation Method 2
the base body made of low-alloy heat-treatable steel is heated, for example when using palladium or copper as the brazing material, to temperatures that are about 150 to 350° C. and in particular 200 to 300° C. higher than the hardening temperature
Implementation Method 3
The quenching is preferably carried out by means of a gas, in particular by means of a nitrogen gas or helium gas. A gas pressure of more than 6 bar and in particular 10 to 12 bar is expediently used here
Implementation Method 4
the base body and the expansion sleeve connected thereto to be nitrided and in particular gas-nitrated, with the nitriding process being carried out after the high-temperature soldering and quenching
Data Source
Figure 1~2
AI summary
The expanding clamping device has a base body (2) and an expanding bush (5), which is inserted into the base body under formation of closed pressure chamber (7) or which surrounds the base body. The base body has light alloyed tempered steel. The expanding bush is connected with the base body by high temperature soldering with soldering material, where the melting temperature of the expanding bush lies above the hardening temperature of the tempered steel. The soldering material has palladium alloy or copper or nickel alloy, where the base body and expanding bush are gas-nitrated. An independent claim is also included for a method for manufacturing an expanding clamping device.