Multi-Functional Fastener Thread Rolling With Chip-Relief Slots
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Solution Overview
Problem
Conventional fastener manufacturing methods result in increased screwing resistance, chip accumulation, and reduced engagement with objects due to cylindrical shanks and limited thread convolution types, requiring additional processing that weakens the fastener and increases production costs.
Innovation Solution
A method involving a preparing operation to shape metal blanks with a shank, head, and drilling portion, and a threading operation using rolling plates with slit grooves and convex units to form thread convolutions, slots, and main ribs, reducing contact area and allowing chip exclusion, thereby reducing screwing resistance and enhancing engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shank is formed to be cylindrical by conventional thread rolling, then the manufacturing process is simple, but the contact area with the object increases resulting in increased screwing resistance
Solution Approach 1:
The rolling surface is segmented into multiple convex units with protrusions, which divide and concentrate the forming pressure during thread rolling. This segmentation allows the shank to be formed with reduced contact area and integrated chip slots without requiring complex multi-step processes, thus maintaining manufacturing simplicity while reducing screwing resistance
Solution Approach 2:
The convex units with protrusions create localized high-pressure zones during rolling, forming thread convolutions and chip slots only where needed on the shank surface. This local quality approach reduces the overall contact area between the shank and the object, thereby reducing screwing resistance while maintaining ease of manufacture
2Productivity
If conventional thread rolling is used, then the processing operation is complete in one step, but the fastener cannot provide enough space for accommodating chips
Solution Approach 1:
The convex units with protrusions perform preliminary action by forming chip slots and thread convolutions simultaneously during the thread rolling process. This preliminary formation of chip accommodation spaces prevents chip accumulation during the screwing operation, maintaining processing efficiency without requiring additional chip removal steps
Solution Approach 2:
The invention merges the thread forming function and chip slot formation function into a single thread rolling operation using convex units with protrusions. This combining of functions allows the fastener to provide chip accommodation space while completing the threading operation in one step, maintaining productivity while preventing chip accumulation
3Object-generated harmful factors
If additional processing operations such as milling or grinding are used to shape slots, then chip exclusion capability is improved, but processing time and labor force increase
Solution Approach 1:
The convex units with protrusions perform preliminary action by forming the chip slots and thread convolutions simultaneously during the thread rolling process. This preliminary formation of chip exclusion pathways eliminates the need for subsequent milling or grinding operations, improving chip exclusion capability while reducing processing time and labor
Solution Approach 2:
The invention merges multiple functions (thread forming, chip slot formation, and chip exclusion pathway creation) into a single thread rolling operation. This consolidation eliminates the need for additional processing steps, thereby improving chip exclusion capability while significantly reducing processing time and labor requirements
4Object-generated harmful factors
If additional processing operations are used to shape slots, then chip exclusion is improved, but the strength of the processing area is weakened
Solution Approach 1:
The convex units with protrusions perform preliminary action by forming chip slots through controlled plastic deformation during thread rolling, rather than through material removal. This preliminary formation maintains the metallurgical integrity of the fastener, improving chip exclusion capability without weakening the processing area strength
Solution Approach 2:
The invention replaces the mechanical cutting system (milling or grinding) with a mechanical forming system (thread rolling with convex units). This substitution forms chip slots through plastic deformation rather than material removal, maintaining the strength of the processing area while achieving chip exclusion capability
5Ease of manufacture
If conventional thread rolling with one kind of thread convolutions is used, then the manufacturing process is simple, but the servable range of the fastener is limited
Solution Approach 1:
The rolling plates with convex units and protrusions are designed to form multiple types of thread convolutions (e.g., triangular, trapezoidal, rectangular) and integrated chip slots in a single operation. This multi-functionality increases the servable range of the fastener while maintaining manufacturing process simplicity
Solution Approach 2:
The rolling surface is segmented into multiple convex units that can be configured to create different thread profiles and patterns. This segmentation allows a single set of rolling plates to produce various thread types, expanding the servable range of the fastener without complicating the manufacturing process
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 achieves reduced screwing resistance, efficient chip removal, and improved engagement with objects, preventing cracking and fatigue while saving labor and processing costs.
Implementation Method 1
A general process for manufacturing a fastener is usually executed to cold forging a plurality of metal blanks to shape each metal blank with a head and a shank
Implementation Method 2
the rolling plates presses the metal blank to move the metal blank, and the rolling of the metal blank forms a plurality of thread convolutions on the shank
Data Source
AI summary
A method for manufacturing a multi-functional fastener includes a preparing operation, a forming operation and a threading operation. The preparing operation prepares a metal blank cut from a length of a metal material. The forming operation is executed so that the metal blank forms a shank, a head, and a drilling portion connected to the shank. The threading operation is executed to roll the metal blank with a thread rolling set having two opposite rolling plates. Each rolling plate has slit grooves and convex units arranged in alternation. Each of the convex units has protrusions each situated between two adjacent slit grooves, which allows the threading operation to equip the shank of the metal blank with thread convolutions, slots formed between the thread convolutions for helping quick removal of chips, and main ribs formed between any two adjacent slots for increasing cutting efficiency.