Friction-Welded Fastening Element With Melted Material Flute
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Solution Overview
Problem
Existing fastening elements for friction-welded joints with flat components lack a designated space to collect melted material, leading to potential deep penetration and instability in the joint, as they do not effectively manage the melted material during the friction-welding process.
Innovation Solution
A rotationally symmetrical fastening element with a conical lateral surface transitioning into a flute, surrounded by a shoulder that axially recesses and includes a design featuring an annular projection and concentric groove to collect and solidify melted material, preventing deep penetration and enhancing joint stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If no special space is provided to receive melted material, then the friction-welding operation can proceed quickly, but the melted material causes deep penetration and instability in the joint
Solution Approach 1:
The fastening element is segmented into distinct functional zones: the tip for initial engagement and centering, the conical lateral surface for friction-welding, the flute for collecting melted material, and the shoulder for limiting penetration depth. This segmentation allows each zone to perform its specific function effectively, preventing deep penetration while maintaining joint stability.
Solution Approach 2:
The flute acts as an intermediary structure between the tip and the component, collecting and containing the melted material that would otherwise cause instability. The shoulder serves as another intermediary, physically limiting the penetration depth of the tip into the component.
2Length of moving object
If the tip is made obtuse to prevent deep penetration, then penetration depth is controlled, but the tip cannot effectively center the fastening element during engagement
Solution Approach 1:
The tip is designed with a specific obtuse angle that provides local quality suited for centering - sharp enough to engage and center the fastening element accurately, but not so sharp that it penetrates too deeply. The conical lateral surface then takes over the friction-welding function, allowing the tip to maintain its optimal centering geometry without compromising penetration control.
3Adaptability or versatility
If the fastening element is allowed free movement during friction-welding, then the welding process can adapt to misalignment, but the tip penetrates too deeply into the component
Solution Approach 1:
The shoulder is positioned in advance to prevent the tip from penetrating too deeply into the component. This preliminary anti-action counteracts the tendency of the tip to penetrate excessively, even when the fastening element is allowed to move and adapt to misalignment during the friction-welding process.
4Strength
If the shoulder is included in the friction-welding operation, then the joint strength is increased, but the complexity of the fastening element design increases
Solution Approach 1:
The shoulder serves multiple functions: it limits the penetration depth of the tip, provides additional surface area for the friction-welding operation (increasing joint strength), and contributes to the overall structural integrity of the fastening element. By making the shoulder multi-functional, the design achieves increased joint strength without proportionally increasing complexity.
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 solution ensures the melted material forms a stable joining means around the tip, preventing deep penetration and strengthening the friction-welded joint, providing automatic centering and increased stability from the shoulder's involvement in the friction-welding process, resulting in a robust joint extending from the tip to the shoulder.
Implementation Method 1
the rounded tip is pressed onto a flat component until, because of the arising heat of friction, the material of the pin and, where applicable, also of the component melts
Implementation Method 2
because of the arising heat of friction
Implementation Method 3
the retaining of the pin and the ensuing cooling of the friction-welding site results in the welded joint with subsequent solidification
Data Source
AI summary
The invention relates to a rotationally symmetrical fastening element with an axially centralized rounded tip for a friction-welded joint with a flat component. The tip is adjoined by a conical lateral surface, the conical lateral surface transitioning into a flute for receiving a material melted during friction-welding, and by a shoulder, wherein the shoulder surrounds the flute, is axially recessed in relation to the tip and transitions into the friction-welded joint.