Friction-Welded Fastening Element With Integrated Hole Drilling
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Solution Overview
Problem
Existing fastening methods for attaching elements to planar workpieces, such as sheet-metal parts, are inefficient and require multiple process steps, leading to increased production time and costs.
Innovation Solution
A fastening element with a built-in cutting device that allows for simultaneous drilling of a hole and friction welding to the workpiece in a single process step, reducing the number of steps and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separate process steps (drilling then welding) are used to attach fastening elements to workpieces, then the attachment can be achieved, but the production time and process complexity increase
Solution Approach 1:
The patent combines the drilling function and friction welding function into a single integrated fastening element. The cutting device and friction welding face are integrated into one component that performs both hole drilling and welding operations simultaneously during a single attachment process, eliminating the need for separate drilling and welding steps.
Solution Approach 2:
The fastening element is designed with multi-functionality, serving both as a drilling tool (with cutting device) and as a welding component (with friction welding face). This single component performs multiple functions that previously required separate tools and process steps, thereby reducing production time and process complexity.
2Ease of manufacture
If a press nut with conical shaft element is used to attach to sheet-metal parts, then attachment is achieved, but the tensile strength is lower compared to friction-welded connections
Solution Approach 1:
The patent merges the drilling and welding operations into a single integrated process using one fastening element. This combination allows the workpiece material to be directly welded to the friction welding face during the same operation that creates the mounting hole, producing a stronger connection than separate pressing operations.
Solution Approach 2:
The patent changes the attachment process parameters by using friction welding instead of mechanical pressing. The friction welding process generates localized heat that melts and fuses the workpiece material to the fastening element, creating a metallurgical bond with superior tensile strength compared to mechanical press connections.
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 solution enables rapid and cost-effective attachment of fastening elements to workpieces, reducing production time and costs while maintaining a strong, durable friction-welded connection.
Implementation Method 1
a cutting device (4) is set with a force against a surface (17) of the workpiece (2), whereupon the cutting device (4) introduces a drilled hole (15) into the workpiece (2)
Implementation Method 2
the anchor bolt is set on a surface of the anchor rail and is pressed with a contact force against the surface. A rotation apparatus rotates the anchor bolt, whereupon the resulting friction heat causes at least partial melting of the annular ring and/or of the surface of the anchor rail. The subsequent cooling process and the associated solidification of the melts establishes the friction-welded connection
Data Source
AI summary
An assembly includes a workpiece and a fastening element. The fastening element is configured to drill a hole in the workpiece and allow the fastening element to be friction-welded to the workpiece.