Friction Joining Preheating for Reduced Load and Burr Discharge
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Solution Overview
Problem
In friction joining methods, increasing the joining load is necessary to achieve sufficient joint strength and burr discharge, which often results in a larger and more massive pressing mechanism, as the rigidity of the metal parts must be high to effectively join surfaces.
Innovation Solution
A friction joining method that preheats the joining surfaces to a temperature of 20% or greater of the material's melting point and maintains a heating depth of 1.0 mm or greater, allowing for quick softening and burr discharge without increasing the joining load, by using a combination of thermal analysis and controlled heating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If joining load is increased to achieve sufficient joint strength and burr discharge, then joint strength is improved, but the pressing mechanism becomes larger and more massive
Solution Approach 1:
The invention applies preliminary heating to the joining surfaces before the friction joining process. By preheating the surfaces to a temperature of 20% or greater of the material's melting point, the material becomes softer and more ductile, enabling effective burr discharge and joint formation at reduced joining loads, thus avoiding the need for large pressing mechanisms
Solution Approach 2:
The invention changes the temperature parameter of the joining surfaces by applying preliminary heat. This parameter change allows the material to undergo softening, which fundamentally alters the joining characteristics and enables the process to proceed with lower joining loads, resolving the contradiction between joint strength and pressing mechanism size
2Object-generated harmful factors
If joining load is increased to discharge burrs and activate joining surfaces, then burr discharge is improved, but the rigidity requirement of metal parts increases
Solution Approach 1:
Preliminary heating is applied before the friction joining process to soften the material at the joining surfaces. This pre-softening effect enables burrs to be discharged more easily during the joining process without requiring high joining loads, thus parts with lower rigidity can be effectively joined
Solution Approach 2:
The temperature parameter is changed through preliminary heating, which softens the material and changes its mechanical properties. This parameter change reduces the material's resistance to deformation, enabling effective burr discharge without requiring high joining loads or high part rigidity
3Temperature
If joining load is increased to soften joining surfaces through friction, then surface softening is improved, but the actuator size must be enlarged
Solution Approach 1:
The invention applies preliminary heating to raise the temperature of the joining surfaces before the friction joining process. This pre-heating reduces the additional temperature rise needed during friction, allowing the use of smaller actuators that can generate lower frictional heat while still achieving sufficient surface softening
Solution Approach 2:
The temperature parameter is advanced by preliminary heating, which reduces the thermal demand during the friction joining process. This parameter change allows smaller actuators to achieve the required surface softening effect, resolving the contradiction between surface temperature and actuator size
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 method enables efficient burr discharge and joint formation with reduced joining load, allowing for the joining of metal parts with lower strength or rigidity, and minimizes the size of the pressing mechanism and the joining apparatus.
Implementation Method 1
utilize frictional heat generated at each joining surface of a pair of metal parts to join the joining surfaces of the pair of metal parts to each other
Implementation Method 2
a heating process that heats at least one of the joining surfaces of the pair of metal parts
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
A heating process makes a temperature of joining surfaces Wa and Ta of a pair of metal parts W and T at the start of a first joining process equal to 20% or greater, preferably, 40% or greater of a melting point of material of the metal parts W and T. The heating process makes a heating depth h of the pair of metal parts W and T at the start of the first joining process equal to 1.0 mm or greater.