Friction Weld Setting Tool With Controlled Bead Break Point
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Solution Overview
Problem
Existing tools and methods for setting a setting element in a component using friction welding often result in a bead that damages the component surface, making it difficult to achieve a smooth surface finish, which is crucial for flat connections between components.
Innovation Solution
A tool with a predetermined breaking point generating element that creates a controlled breaking point in the bead, allowing for easy removal of the bead without damaging the component surface, featuring an axially movable and spring-loaded breaking point element with an oblique deflection surface to manage the melt and facilitate smooth surface preservation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cutting means are used to remove the bead surrounding the setting element, then the bead can be removed, but the component surface is damaged
Solution Approach 1:
A predetermined breaking point is created in the bead during the setting process itself, before removal is needed. This breaking point is formed by the geometry of the setting element or tool, creating a natural separation point that allows easy bead removal without requiring aggressive cutting operations that would damage the component surface
Solution Approach 2:
The bead, which is initially a harmful factor damaging the surface, is converted into a beneficial feature by creating a predetermined breaking point. The bead material itself becomes the tool for removal, as it can be cleanly separated at the breaking point without requiring external cutting means that would harm the component surface
2Strength
If the setting element is pressed onto the component with axial force during rotation, then friction weld connection is created, but a bead forms that damages the surface
Solution Approach 1:
The predetermined breaking point is created during the friction welding process itself, as the setting element is pressed onto and rotated against the component. This breaking point is formed in advance in the bead material, allowing subsequent easy removal without damaging the component surface
Solution Approach 2:
The breaking point creates a localized weakness in the bead at a specific position, while the rest of the bead remains intact during welding. This localized modification allows selective removal of only the necessary portion without affecting the overall weld strength or component surface
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
Enables a smooth component surface by generating a predetermined breaking point in the bead, allowing for easy removal of the bead without damaging the surface, thus ensuring a flat and undisturbed surface for subsequent connections.
Implementation Method 1
the rotating setting element is pressed by the rotary feed unit onto the component, e.g., the cover layer made of fiber-reinforced plastic, with an axial force acting in the direction of the rotation axis, so that the setting element and the cover layer heat up through friction
Implementation Method 2
When the cover layer and core cool down again, a friction weld is created between the setting element and the component
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
The invention relates to a tool (10, 10') for setting a setting element (42) in a component (44) by generating a friction weld connection between the setting element (42) and the component (44) with a drive shaft (12) which can be rotated about a drive axis (14) for transmitting a torque to the setting element (42) and a predetermined breaking point generating element (20) which extends at least partially around the drive axis (14).The invention also relates to a method for setting a setting element (42) in a component (44) by generating a friction weld connection between the setting element (42) and the component (44), comprising the steps of: introducing the setting element (42) into the component (44) by generating a relative rotational movement between the setting element (42) and the component (44) and a relative axial feed movement between the setting element (42) and the component (44) and generating a predetermined breaking point (26) in a bead (56) which is formed around the setting element (42) when the setting element (42) is set.