Friction Welding Fixing Element Bead Groove Oxide Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fastening elements with radially running beads for friction welding face contamination issues due to oxide layers, which are not effectively removed, leading to compromised connection durability and material loss during the welding process.
Innovation Solution
The fastening element features radially extending beads with a front groove embedded in the friction surface, allowing for efficient removal of contaminants like oxides, which are pushed into the groove, and a design that minimizes bead elevation to ensure direct contact and optimal material utilization, with optional rear grooves for additional material accommodation and improved manufacturing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If beads are designed as milling cutter-like cutting edges for removing oxide layers, then contamination removal capability is improved, but bead material is lost and mixed with oxide contaminants, compromising connection durability
Solution Approach 1:
The end face is segmented into distinct functional zones: scraping surfaces for oxide removal, front grooves for contaminant collection, and a preserved central friction welding zone. This segmentation prevents bead material from mixing with oxide contaminants while maintaining effective contamination removal.
Solution Approach 2:
The harmful oxide layers and contaminated materials are extracted and isolated into front grooves embedded in the friction surface, separating them from the connection zone. This ensures that bead material is not mixed with contaminants, preserving connection durability.
2Object-affected harmful factors
If beads are elevated significantly above the friction surface for effective scraping, then contamination removal is improved, but bead material is consumed faster and connection zone material is lost
Solution Approach 1:
The beads are designed with localized scraping surfaces that are only slightly elevated above the friction surface. This local quality change provides sufficient scraping capability while minimizing material loss and preserving the connection zone material.
3Object-affected harmful factors
If multiple grooves are added to accommodate bead material and contaminants, then contamination management is improved, but device complexity increases
Solution Approach 1:
The front grooves are embedded within the friction surface plane rather than adding external structures. This dimensional integration manages contaminants effectively while minimizing increases in device complexity.
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 design ensures a secure, quick, and efficient friction-welded connection by effectively removing contaminants and maintaining material availability, enhancing connection reliability and manufacturing efficiency, particularly suitable for automatic fabrication.
Implementation Method 1
dirt is first rubbed off by the scraping surface during the friction welding process
Implementation Method 2
the friction effect and thus plasticization of the material of both the fastening element and the component very quickly results
Data Source
Figure 1a~8
AI summary
The invention relates to a fixing element, comprising a concentric front face forming a friction surface for friction welding joining to a planar component fixed against the rotational and axial forces acting on the component by the fixing element and with several radial beads on the front face. The beads are defined in the rotational direction by a front groove let into the friction surface, the beads only having a marginal axial projection relative to the friction surface and are provided with a scraper surface from which the scraped material is pushed into the front groove during the welding process.