FRP Insert Manufacturing Reducing Dry Machining Time
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing FRP members with inserts require lengthy dry machining times, especially when multiple inserts are involved, leading to reduced productivity and increased manufacturing costs due to the need for multiple machining steps.
Innovation Solution
A method that forms a threaded hole in the insert through wet machining, followed by molding the FRP member with the insert and then creating a communication hole using dry machining, which reduces the number of post-molding machining steps and minimizes dry machining time, while using sealing materials and tapes to prevent resin entry into the threaded hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dry machining is performed to form threaded holes in inserts after molding FRP members, then the threaded holes can be formed without cutting oil, but the machining time becomes extremely long
Solution Approach 1:
The threaded hole is formed in the insert before the FRP molding step, rather than after. This preliminary action allows the use of fast wet machining with cutting oil to create the threaded hole, significantly reducing machining time while ensuring the threaded hole is formed in a clean, oil-free environment that prevents contamination of the FRP member
Solution Approach 2:
The manufacturing process is segmented into distinct steps: insert preparation (with threaded hole formation), FRP molding, and post-molding boring. This segmentation allows each step to be optimized independently, with the threaded hole formed in advance when fast machining is possible, and only minimal post-molding machining required
2Strength
If multiple inserts are provided in an FRP member, then the functionality and strength of the member are improved, but the machining time becomes extremely long when dry machining is performed on all inserts
Solution Approach 1:
Multiple inserts are prepared in advance with their threaded holes formed before assembly into the FRP member. This preliminary preparation of multiple inserts parallel to each other eliminates the need for sequential post-molding machining of each insert, reducing total machining time while maintaining the strength benefits of multiple inserts
Solution Approach 2:
The manufacturing process is segmented so that insert preparation and FRP molding occur as separate, potentially parallel operations. This allows multiple inserts to be prepared simultaneously before assembly, and the FRP member to be molded around them, avoiding sequential machining of each insert after molding
3Productivity
If wet machining is used to form threaded holes, then the machining speed is fast, but cutting oil may attach to the FRP member and reduce its strength or inhibit adhesive bonding
Solution Approach 1:
The threaded hole is formed in the insert before the FRP molding step, allowing the use of wet machining with cutting oil without risking contamination of the final FRP member. The insert serves as a separate preparation zone where fast machining can occur, and the FRP is molded around the already-prepared insert, preventing oil attachment to the FRP surface
Solution Approach 2:
The threaded hole formation operation is extracted from the post-molding process and performed separately on the insert before assembly. This extraction isolates the wet machining operation from the FRP member, allowing cutting oil to be used without risking attachment to or contamination of the FRP, while the FRP molding step creates a barrier that prevents any oil migration
Data Source
AI summary
Provided is a method for manufacturing an FRP member with insert which enables to reduce a machining time to improve productivity. First, a threaded hole 11 is formed in an insert 3. An FRP member 2 where at least the threaded hole 11 of the insert 3 is covered with a coating 4 made of FRP is molded. A counter-bored hole 31 that penetrates the coating 4 of the FRP member 2 to communicate with the threaded hole 11 of the insert 3 is formed, to thereby obtain an FRP component 1 with insert. Accordingly, a machining step after molding the FRP member 2 in which dry machining is required includes only the boring step of forming the counter-bored hole 31 in the FRP member 2. Thus, the machining time can be reduced, and the productivity can be improved.