Friction-Welded Sheet Metal Connection Using Conical Annular Wall
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Solution Overview
Problem
Existing friction-welded connections between sheet metal elements and rotation bodies face challenges, particularly with thin sheet metals, as they require significant pressure and often necessitate counter-supports to prevent deformation, which can be difficult to implement, especially in automated production of large components like car bodies.
Innovation Solution
A protruding circular annular wall is integrated into the sheet metal element, providing increased stability and allowing the sheet metal to withstand pressure without a counter-support, by using a conical design that increases radial forces upon rotation, facilitating friction-welded connections without the need for external support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a friction-welded connection is made between a rotation body and a flat sheet metal element without a counter-support, then the process is simplified and accessibility is improved, but the sheet metal element deforms due to insufficient resistance to the applied pressure
Solution Approach 1:
The invention transitions from a flat 2D sheet metal surface to a 3D structured surface by adding an annular wall that protrudes from the sheet metal element. This dimensional change creates a raised platform that provides the necessary structural resistance to the rotation body during friction welding, eliminating the need for external counter-support while maintaining sheet metal stability.
Solution Approach 2:
The sheet metal element itself is modified to provide the counter-support function through its own annular wall structure. Instead of requiring an external counter-support device, the sheet metal element becomes self-sufficient by incorporating the supporting structure directly into its design, thereby simplifying the overall system.
2Strength
If pressure is applied to a thin sheet metal element during friction welding, then the friction-welded connection is formed, but the sheet metal element bows and becomes deformed
Solution Approach 1:
By adding the annular wall protruding from the sheet metal surface, the invention creates a three-dimensional structure that distributes the applied pressure across a larger area and provides geometric constraint. This prevents the thin sheet metal from bowing under pressure while still enabling the formation of a strong friction-welded connection between the rotation body and the sheet metal.
3Force
If a conical design is used for the annular wall or rotation body, then radial compressive forces are increased to improve welding, but the sheet metal element is exposed to higher pressure that could cause unacceptable bowing
Solution Approach 1:
The annular wall protruding from the sheet metal surface creates a three-dimensional platform that geometrically constrains the sheet metal during pressure application. This dimensional addition allows the conical design to generate high radial compressive forces for effective welding while the annular wall structure prevents unacceptable bowing by providing internal geometric support.
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 design enables the production of friction-welded connections on thin sheet metals without counter-supports, enhancing stability and allowing for efficient automated production by distributing radial forces effectively, thus improving the robustness and accessibility of the connection process.
Implementation Method 1
there being formed a friction-welded connection between rotation body and annular wall as a result of rotation of the rotation body
Data Source
AI summary
Friction-welded connection between a sheet metal element and a therein inserted rotation body. The sheet metal element is provided with a protruding, circular annular wall as a pressure face, which pressure face is adapted to be engaged by the rotation body with a counter-pressure face. At least one pressure face is of such conicity that the insertion of the rotation body loads the annular wall with increasing pressure, there being formed a friction-welded connection between rotation body and annular wall as a result of rotation of the rotation body.