Friction Weld Assembly Slender Cone Connection Body
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Solution Overview
Problem
Existing friction weld assemblies lack sufficient strength and reliability in connecting superposed plates, particularly when dealing with thin or dissimilar materials, due to inadequate material interlock and friction distribution.
Innovation Solution
A special shape design for the connection body featuring a slender cone with a steeper short cone tip, which penetrates both plates to form a continuous friction welding zone, generating girders that interlock the plates and transfer forces through the pressed-out material, enhancing the connection strength and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connection body with a flat tip is used, then the penetration into plates is difficult and the friction welding zone is discontinuous, but the manufacturing is simpler
Solution Approach 1:
The connection body employs a conical shape with a rounded tip instead of a flat or sharp edge. This curved geometry allows the connection body to progressively penetrate the plates during friction welding, creating a continuous friction welding zone from the tip through the collar. The conical form facilitates material displacement and generates intimate contact between the connection body and both plates, significantly improving connection strength and reliability.
2Reliability
If pressure is applied to penetrate the connection body into plates, then the friction welding zone is generated, but the collar may abut the upper plate before complete penetration
Solution Approach 1:
The conical shape with progressive taper allows the connection body to penetrate the plates more easily under applied pressure. The angled surfaces of the cone guide material flow and distribute the penetration force, reducing the peak pressure required compared to a cylindrical form. This enables complete penetration and continuous friction welding zone formation without premature collar abutment.
3Strength
If the connection body penetrates deeply into both plates, then the connection strength is improved, but the collar abutment to the upper plate is delayed
Solution Approach 1:
The conical geometry creates a progressive contact sequence during penetration. The angled surfaces generate axial force components that push material ahead of the connection body while distributing the load. This allows deep penetration and strong girder formation without requiring excessive collar abutment force, as the cone shape itself provides mechanical advantage for material displacement.
4Reliability
If a slender cone shape is used for the connection body, then the friction welding zone extends to the tip, but the material melting and pushing requires high friction
Solution Approach 1:
The conical shape with its angled surfaces generates friction forces that efficiently melt and displace material in the axial direction. The geometry converts rotational friction into axial pushing force, enabling the connection body to penetrate deeply and create a continuous friction welding zone from collar to tip. The tapered form concentrates the frictional heating and material flow in a controlled manner along the cone 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
The solution provides a robust and reliable connection between plates by generating a continuous friction welding zone that distributes forces effectively, ensuring high strength and resistance to separation, and can be adapted for various materials including thin plates by using a hard tip or reinforcement.
Implementation Method 1
Because of the rotation of the connection body and the friction generated thereby between the connection body and the two plates, the material of the parts reaming one on the other, is plastified
Implementation Method 2
a friction weld assembly of a plurality of superposed plates, wherein girders which penetrate from the upper plate into the lower plate and a girder which protrudes from the lower plate, form, along the inner surfaces thereof, a friction welding region
Implementation Method 3
the material of the parts reaming one on the other, is plastified such that a friction weld zone is generated thereby
Data Source
AI summary
The invention relates to a friction weld assembly of a plurality of superposed plates, said plates being held together by a connection body which rests on the upper plate by means of a collar and is formed as a slender cone ending in a tip. The connection body comprises a driving element in the region of the collar thereof, for the attachment of a pressure and rotation tool. A girder formed from the slender cone and penetrating from the upper plate into the lower plate, and a girder protruding from the lower plate along the inner surfaces thereof, form a friction welding region extending onto the slender cone.