Friction Welding Fastener With Integrated Drilling for Thin Sheet Metal
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Solution Overview
Problem
Existing fastening methods for attaching elements to planar workpieces, such as sheet-metal parts, are inefficient and costly due to multiple process steps and lower tensile strength, particularly in vehicle construction where thin-walled parts pose challenges.
Innovation Solution
A fastening element with a nut head and integrated cutting device that allows for simultaneous drilling and friction welding, reducing process steps and enabling secure attachment to thin-walled sheet-metal parts by introducing a drilled hole and establishing a friction-welded connection in one step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a press nut with conical shaft element is pressed into the sheet-metal part, then the fastening element can be attached to the workpiece, but the tensile strength is lower and an additional anvil is required
Solution Approach 1:
The patent combines the cutting device and friction welding nut into a single integrated fastening element. The cutting device with cutting elements is merged with the nut head, eliminating the need for separate drilling and fastening operations and removing the requirement for an additional anvil, while achieving higher tensile strength through friction welding
2Reliability
If multiple process steps are used for fastening, then the attachment can be established, but the production time and costs increase
Solution Approach 1:
The patent merges drilling and friction welding into a single integrated process step. The fastening element performs both functions sequentially: the cutting device drills the hole while the friction welding face creates the welded connection, eliminating multiple process steps and reducing production time while maintaining reliable attachment
Solution Approach 2:
The cutting device is integrated into the fastening element itself, performing the preliminary drilling action before the friction welding takes place. This preliminary action is built into the fastening element structure, allowing seamless transition from drilling to welding without separate operations
3Strength
If a friction welding nut is rotated against the sheet-metal part, then a friction-welded connection is established, but a separate drilling operation is required first
Solution Approach 1:
The patent merges the cutting device and friction welding nut into a single integrated fastening element. The cutting device with cutting elements is combined with the nut head, allowing both drilling and friction welding to be performed by one element without requiring separate drilling operations
Solution Approach 2:
The fastening element is designed with multi-functionality, serving both as a cutting device for drilling holes and as a friction welding nut for creating welded connections. This universal design eliminates the need for separate specialized tools for each operation
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 significantly reduces production time and costs by integrating drilling and friction welding into a single process, enhancing attachment strength and preventing moisture ingress while allowing access from both sides.
Implementation Method 1
a cutting device for introducing a drilled hole into the workpiece is provided on that end side of the nut head having the friction welding face
Implementation Method 2
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
Implementation Method 3
A rotation apparatus rotates the anchor bolt, whereupon the resulting friction heat causes at least partial melting
Data Source
AI summary
A fastening element for friction welding onto a planar workpiece includes a nut head, a through-bore extending at least locally within the nut head, a friction welding face on one end side of the nut head, and a cutting device for introducing a drilled hole into the workpiece on the one end side of the nut head having the friction welding face.