Flow Formed Joint Outer Part with Grease Pockets
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Solution Overview
Problem
Existing methods for producing joint outer parts, such as those for constant velocity joints, result in stiffer components with uneven load distribution and reduced service life due to lack of effective lubrication and material optimization.
Innovation Solution
A flow forming method that includes forming concave regions in joint outer parts to create additional grease pockets, optimizing lubrication and hardening processes, allowing for improved load distribution and extended service life by using a contour mandrel and flow forming rollers to shape the parts with concave tracks and structure edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If flow forming is used to produce joint outer parts, then weight is reduced and material usage is optimized, but service life is reduced due to uneven load distribution and insufficient lubrication
Solution Approach 1:
The flow forming process creates local variations in wall thickness and material density within the joint outer part. The elastic regions are strategically positioned to provide localized compliance where needed, while maintaining overall structural integrity. This local quality differentiation allows the part to distribute loads more evenly across multiple balls, improving service life without sacrificing weight benefits
Solution Approach 2:
The flow forming process pre-shapes the joint outer part with optimized elastic regions before final assembly. This preliminary forming creates the desired compliance characteristics and load distribution patterns in advance, ensuring that the part is pre-conditioned for optimal performance and extended service life
2Strength
If forged joint outer parts are used, then stiffness is increased, but load distribution becomes uneven and service life is reduced
Solution Approach 1:
The flow forming process creates local variations in wall thickness and material density within the joint outer part. The elastic regions are strategically positioned to provide localized compliance where needed, while maintaining overall structural integrity. This local quality differentiation allows the part to distribute loads more evenly across multiple balls, improving service life without sacrificing weight benefits
Solution Approach 2:
The flow forming process changes the physical parameters of the material during forming, creating regions with different elastic properties. By controlling the forming pressure and temperature parameters, the process generates a gradient of material properties within the part, with softer elastic regions for compliance and harder regions for structural support, achieving both stiffness and extended service life
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 enhances lubrication between joint components, reduces friction, and optimizes the hardening process, leading to increased service life of both the joint outer and inner parts by distributing load uniformly and providing additional lubricant reservoirs.
Implementation Method 1
a flow forming method is known, for example, from DE 10 2013 101 555 B3. In the flow forming, a workpiece is formed by way of the use of rollers at high pressures and low temperatures in comparison with other reshaping methods
Implementation Method 2
By virtue of the fact that the flow forming method is carried out at temperatures below the material-specific recrystallization temperature, high work hardening occurs in the workpiece in comparison with other reshaping methods
Implementation Method 3
joint outer parts which are produced by means of flow forming have the advantage, in particular, in comparison with forged and therefore stiffer joint outer parts that all balls of the constant velocity joint are uniformly loadbearing as a result of the elasticity of the joint outer part
Data Source
AI summary
A method for producing a joint outer part by means of flow forming is provided. A blank is arranged on a contour mandrel such that it cannot rotate with respect to the contour mandrel. The contour mandrel is driven in such a way that the blank and the contour mandrel rotate about a common axis. The blank is shaped at least partially with the aid of a flow forming roller which acts on the blank in order to form the joint outer part. At least one track is formed with a concave region in the joint outer part.