Forged Corrugated Boss Surface for High Slip Torque
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Solution Overview
Problem
Existing methods for forming anti-slip surfaces on rotating members, such as sprockets, using shot peening or laser processing are limited in increasing friction coefficient and slip torque, and are costly and complex due to precision requirements and difficulty in simultaneous processing on both sides.
Innovation Solution
A rotating member with a boss part and anti-slip surface featuring corrugated rib parts formed by forging, including a main groove and auxiliary grooves, which allows for higher protrusion height and width, enabling effective biting into the opposite surface and achieving high slip torque without precision-dependent issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser processing is used to form protrusions on the end face, then protrusions that bite into the opposite surface can be formed, but the process requires precise adjustment of laser output and hardening conditions, increasing device complexity and manufacturing difficulty
Solution Approach 1:
The patent replaces laser processing (thermal field) with forging (mechanical field) to form the corrugated rib parts. This substitution eliminates the need for precise laser output adjustment and hardening condition control, while still achieving protrusions that bite into the opposite surface to increase slip torque
Solution Approach 2:
The patent changes the formation method from laser-induced melting to forging-induced plastic deformation. This parameter change allows for larger protrusion dimensions (height and width) without requiring precise control of thermal parameters, thereby increasing slip torque while reducing processing complexity
2Strength
If laser processing is used to form protrusions, then anti-slip effect is improved, but the protrusions are minute due to difficulty in increasing protuberance amount, limiting the friction coefficient increase
Solution Approach 1:
By replacing laser processing with forging, the patent enables creation of larger protrusions (corrugated rib parts with greater height and width) through plastic deformation. This mechanical approach overcomes the limitation of minute protrusions achieved by laser processing, thereby significantly increasing the friction coefficient and slip torque
3Productivity
If simultaneous laser processing of both sides of the boss part is performed, then productivity is improved, but the process becomes complex and time-consuming
Solution Approach 1:
The patent combines the formation of corrugated rib parts on both axial end faces into a single forging operation. By applying radial compressive forces simultaneously or sequentially in one manufacturing step, the patent achieves what would otherwise require separate laser processing operations, thereby improving productivity while simplifying the overall process
4Strength
If shot peening is used to form irregularities on the surface, then the friction coefficient increases, but protrusions that would bite into the opposite surface cannot be formed
Solution Approach 1:
The patent replaces shot peening (impact-induced surface roughening) with forging (compressive force-induced plastic deformation). This substitution transforms the surface profile from mere irregularities to structured corrugated rib parts with protrusions that actively bite into the opposite surface, thereby achieving both increased friction coefficient and mechanical interlocking
Solution Approach 2:
The patent changes the surface modification approach from creating random irregularities (shot peening) to forming structured corrugated patterns (forging). This parameter change enables the formation of protrusions with controlled geometry that can bite into the opposite surface, significantly enhancing the anti-slip effect beyond what shot peening alone can achieve
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 corrugated rib design enhances slip torque by allowing ridges to bite into the opposite surface effectively, providing consistent anti-slip effect in all directions and reducing production costs and complexity, while being adaptable to varying surface conditions.
Implementation Method 1
the corrugated rib parts including a main groove and at least one auxiliary groove extending parallel to the main groove, with a ridge protruding higher than the anti-slip surface between the main groove and the auxiliary groove
Data Source
AI summary
To provide a rotating member and a forming method thereof that allow formation of protrusions biting into an opposite surface to achieve high slip torque with a simple configuration. The rotating member includes a boss part and an anti-slip surface at least on one of both axial end faces of the boss part. The anti-slip surface has a plurality of corrugated rib parts, which includes a main groove and at least one auxiliary groove extending parallel to the main groove, with a ridge protruding higher than the anti-slip surface between the main groove and the auxiliary groove.