Flash Ring Separator for Friction Welding

Solution Overview

Problem

Friction welding often results in flash rings that break loose during turning, causing damage to the finished product and potentially leading to scrap, especially when the parts are finely finished or chromed.

Innovation Solution

A flash ring separator is used to intercept and separate the extruded metal flash, forming indentations in the flash ring to make it frangible, preventing it from breaking loose as a single annular unit during lathe turning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If friction welding is used to join metal parts, then joining time is reduced and material strength is improved, but flash rings form that can break loose during turning and damage the finished product

Engineering Contradiction:

Improvejoining timeVSAvoidflash ring damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The flash ring is segmented into multiple smaller fragments by positioning the flash ring separator to create radial gaps or notches in the flash ring, preventing it from breaking loose as a single annular unit that could damage the workpiece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flash ring separator is introduced as an intermediary component between the flash ring and the workpiece. The separator intercepts the flash as it forms and positions it away from the workpiece surface, preventing direct contact and potential damage

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the flash ring is removed by turning in a lathe, then the flash is eliminated, but the flash ring may break loose and scour the surface of the spinning part

Engineering Contradiction:

Improvesurface finishVSAvoidflash ring stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The flash ring is segmented into multiple smaller fragments by positioning the flash ring separator to create radial gaps or notches in the flash ring, preventing it from breaking loose as a single annular unit that could damage the workpiece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flash ring separator performs preliminary action by intercepting and positioning the flash ring during formation, preventing the harmful effect of the flash ring breaking loose and damaging the workpiece surface during subsequent turning operations

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of manufacture

If the flash ring remains intact during welding, then it can be removed as a single unit, but it may break loose and cause scrap of the entire welded assembly

Engineering Contradiction:

Improveflash removalVSAvoidscrap rate

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The flash ring is segmented into multiple smaller fragments by positioning the flash ring separator to create radial gaps or notches in the flash ring, preventing it from breaking loose as a single annular unit that could damage the workpiece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flash ring separator converts the potentially harmful intact flash ring into beneficial small fragments that cannot damage the workpiece. The separator uses the natural formation of the flash ring to create a controlled fragmentation pattern that eliminates the scraping hazard

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 flash ring separator reduces scrap and damage by ensuring the flash ring fragments during machining, improving efficiency and cost savings by eliminating the need for careful handling and extending tooling life.

Implementation Method 1

The metal in the joint region is heated to a temperature such that the metal becomes plastic

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

friction welding fulfills a unique role. Friction welding is solid-state welding process that induces plasticity in the metals being joined via heat generated by mechanical friction between the pieces

Methodology Applied

Scientific EffectFriction welding: Friction Welding

Implementation Method 3

metal flash is extruded from the joint region to impinge on the flash ring separator, forming a flash ring having at least one indentation therein formed by the flash ring separator

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS8393521B1Flash ring separator

Publication Date: 2013.03.12 CATERPILLAR INC

AI summary

A method of producing a welded assembly from a first metal part and a second metal part includes bringing the first metal part and the second metal part into contact with one another at a joint region while providing a flash ring separator adjacent the joint region configured to intercept and separate flash. After heating the joint region, the first and second metal parts are forced together to join the first metal part to the second metal part, extruding metal flash from the joint region. The extruded flash impinges on the flash ring separator, forming a flash ring having at least one indentation. During subsequent machining of the welded assembly to remove the flash ring, the flash ring may fragment at the indentation, so that it does not cause damage by becoming hung around the assembly.