Friction Riveting Tool with Integrated Deburring Shoulder
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Solution Overview
Problem
Existing techniques for inserting components into workpieces, particularly those made of soft metallic materials like aluminum alloys, face challenges in achieving strong and flexible attachments without requiring additional machining operations or parts, and existing friction riveting methods struggle with uniformity and flash removal.
Innovation Solution
A rotary tool system that uses a component with a harder outer surface to insert into a workpiece through friction-induced plasticity, featuring a shoulder portion with a deburring device for efficient attachment and surface preparation, allowing for flexible and strong component integration without pre-drilling, and maintaining axial force during a setting time to ensure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction riveting method is used to join metal components, then joining strength is achieved, but flash removal is incomplete and scraping uniformity cannot be maintained
Solution Approach 1:
The patent combines the joining function and flash removal function into a single rivet insertion tool. The anvil portion of the tool serves dual purposes: it provides the friction riveting action for joining while simultaneously acting as a scraping surface to remove flash during the same operational cycle, eliminating the need for separate scraping operations
Solution Approach 2:
The patent introduces an intermediary scraping surface on the anvil that mediates between the joining process and flash removal. This scraping surface is positioned to contact the workpiece surface during insertion, automatically removing flash as the rivet is driven home, thereby achieving uniform scraping without requiring separate scraping tools or operations
2Strength
If harder material is used for component insert portion, then insertion strength into soft workpiece is improved, but deburring of workpiece surface becomes more difficult
Solution Approach 1:
The patent applies local quality by making only the insert portion of the component harder than the workpiece material, while the head portion remains softer. This localized hardness distribution allows the insert portion to achieve strong insertion and anchoring in the soft workpiece, while the softer head portion can be easily deburred and finished after insertion
Solution Approach 2:
The patent segments the component into distinct portions with different material properties: a harder insert portion for anchoring and a softer head portion for deburring. This segmentation allows each portion to be optimized for its specific function without compromising the other
3Productivity
If axial force is increased during insertion, then insertion speed is improved, but insertion precision and surface quality deteriorate
Solution Approach 1:
The patent employs periodic action by controlling the rivet insertion process in distinct phases: an initial higher-force phase to quickly drive the rivet into the workpiece, followed by a reduced-force phase to precisely set the rivet and allow the anvil to scrape the surface. This periodic variation in force application achieves both high insertion speed and high precision
Solution Approach 2:
The patent applies preliminary action by first driving the rivet to a predetermined depth using controlled axial force, then maintaining that position while applying scraping action through the anvil. This preliminary positioning followed by surface scraping ensures both accurate insertion depth and clean surface finish
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 rotary tool system provides strong and flexible attachment comparable to conventional mechanical joining techniques, with improved insertion quality and reduced axial force requirements, while effectively deburring the workpiece surface, enhancing assembly accuracy and efficiency.
Implementation Method 1
inserting a component through a surface of a workpiece made of a first material showing friction-induced plasticity
Implementation Method 2
produce insertion of the insert portion along said axis by plasticizing the first material through friction
Data Source
AI summary
A rotary tool (11) for use with a rotary driving unit (12) for inserting a component (14,14′,14″) through a surface of a workpiece made of a material showing friction-induced plasticity such as aluminum, includes a tool body (22) having a working end (24) defining a shoulder portion (26) and a securing device (28,28′) for selectively engaging the component to impart rotation thereof in a first direction while applying an axial force of a sufficient magnitude onto the component to produce insertion thereof by plasticizing the material through friction. The shoulder portion is provided with a deburring device (34) capable of being displaced from an inoperative position upon rotation of the tool body (22) in the first rotation direction (30), to an operative position whenever the tool body is caused to rotate in an opposite direction (30′), to provide deburring of the workpiece surface.