Filled Projection Forming for Resistance Welding Collapse
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Solution Overview
Problem
The challenge in electric resistance welding of ductile and lightweight metals like aluminum and magnesium is the premature collapse of projections, which adversely affects the weld process due to insufficient strength.
Innovation Solution
A method involving the use of a lower die with a recess and an upper die to form projections by forcing a filler material into the metal panel, creating a filled projection that resists collapse during welding, with the filler material supplementing the strength of the projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projections are formed on ductile and lightweight metal sheets for welding, then the welding process can proceed, but the projections collapse prematurely under electrode force
Solution Approach 1:
The patent applies composite materials by combining the base metal sheet with a filler material to form a composite projection structure. The filler material is forced into the metal sheet through a die, creating a composite structure where the filler reinforces the projection, preventing collapse under electrode force during welding while maintaining the lightweight and ductile properties of the original metal sheet
2Strength
If filler material is forced into metal panel to create filled projection, then projection strength increases and collapse is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the projection formation process with the filler material insertion process into a single integrated operation. The die simultaneously forms the projection and forces the filler material into the metal sheet in one pressing action, eliminating the need for separate steps and reducing overall process complexity despite adding filler material functionality
Solution Approach 2:
The filler material is positioned and prepared in advance before the forming operation. The die is pre-configured with the filler material ready to be forced into the metal sheet, so that when the pressing operation occurs, the filler is already in position to be incorporated into the projection, streamlining the 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
This method enhances the strength of projections, preventing premature collapse and ensuring high-quality electric resistance welds by supporting the projection against deformation during the welding process.
Implementation Method 1
lowering an upper die onto the filler material so that the filler material is forced into the metal panel
Implementation Method 2
the filler material supplementing the strength of the projection
Data Source
AI summary
A method for making a projection on a metal panel includes providing a lower die having a recess in the shape of the desired projection, laying the metal panel atop the lower die, positioning a filler material atop the metal panel, and lowering an upper die onto the filler material so that the filler material is forced into the metal panel and in turn forces the metal panel into the recess of the lower die whereby a projection is formed and the projection is filled with the filler material.