Flange Yoke Elevated Zone for Balanced Machining
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Solution Overview
Problem
Current flange yoke designs lead to unbalanced machining loads and vibrations during cutting tool operation, resulting in reduced tool lifespan, lower surface quality, extended machining times, increased fluid consumption, and higher production costs due to pulsed operations.
Innovation Solution
The introduction of an elevated zone on the connection surface of the flange yoke, which allows for balanced material removal and reduces vibrations, thereby stabilizing the cutting tool operation and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the connection surface is aligned with the assembly base before machining, then the machining setup is simplified, but the cutting tool experiences unbalanced loads and vibrations leading to reduced tool lifespan and lower surface quality
Solution Approach 1:
The patent applies preliminary action by creating an elevated zone on the connection surface before the actual machining operation. This pre-formed elevation ensures that when material is removed during machining, the cutting tool maintains balanced contact with the workpiece throughout the process, preventing unbalanced loads and vibrations that would otherwise occur with conventional alignment methods
2Ease of manufacture
If conventional machining methods are used with the connection surface aligned with the assembly base, then the machining process is straightforward, but vibrations cause pulsed operation and extended machining times
Solution Approach 1:
The elevated zone is formed as a preliminary feature before final machining operations. This pre-formed structure enables the cutting tool to operate continuously at higher speeds without experiencing pulsed operation or vibrations, thereby extending cutting tool life and reducing total machining time while maintaining process simplicity
Solution Approach 2:
The invention changes the geometric parameter of the connection surface by creating an elevated zone with specific height and dimensions. This parameter modification transforms the machining process from a vibration-prone operation to a stable, continuous cutting process that can proceed at optimized speeds
3Reliability
If the cutting tool operates at minimum speed to avoid vibrations, then tool breakage is prevented, but machining time increases and production costs rise
Solution Approach 1:
By pre-forming the elevated zone on the connection surface, the invention eliminates the need to operate at minimum cutting speeds. The elevated structure provides stable support during machining, allowing the tool to run at higher speeds without risk of breakage, thus reducing machining time and associated costs
4Manufacturing precision
If extended machining times are required due to vibration prevention, then surface quality is maintained, but cutting fluid consumption increases and disposal costs rise
Solution Approach 1:
The elevated zone is created as a preliminary feature that enables faster machining speeds while maintaining surface quality. This reduces the total machining time required, thereby decreasing cutting fluid consumption and disposal costs without compromising the quality of the machined connection surface
Data Source
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AI summary
Invention is about the flange yoke (A) attaching the driveshaft (B), which provides the rotational motion and power transmission between differential and transmission in motor vehicles, to the vehicle via connection surfaces (20) formed by machining assembly bases (10) by cutting tools (C). The invention characterized by comprising positive raised zones (21) from mentioned assembly bases (10).