Gas Generator Holder Forging for Burr-Free Crimping
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Solution Overview
Problem
The existing methods for manufacturing gas generator holders often result in burrs during the crimping process, which can lead to failures such as short circuits due to burrs adhering to terminal pins, and require careful operation to remove these burrs.
Innovation Solution
The gas generator holder is designed using a stepwise combination of forging, punching, and machining processes, with second forging processing finish shaping the igniter and cup fixing engagement parts to prevent peeling or curling, ensuring a continuous metal flow that maintains mechanical strength and prevents burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining processing is used for finish shaping the engagement parts, then manufacturing precision can be achieved, but burrs occur during crimping and mechanical strength decreases
Solution Approach 1:
The invention changes the processing method from machining to forging, which fundamentally alters the metal flow characteristics. Forging creates continuous metal flow that follows the engagement part contours, whereas machining removes material and creates discontinuous metal flow. This parameter change in the manufacturing process eliminates burr formation while maintaining dimensional precision through controlled forging parameters.
Solution Approach 2:
The engagement parts are pre-shaped during the forging process before the crimping operation. By forming the engagement part geometry and metal flow pattern in advance during forging, the structure is prepared to withstand crimping forces without generating burrs, eliminating the need for post-processing burr removal.
2Manufacturing precision
If machining processing is used for finish shaping, then detailed configuration can be achieved, but burr removal requires careful operation reducing productivity
Solution Approach 1:
The forging process is designed to be self-sufficient in creating burr-free engagement parts. The continuous metal flow inherent in forging automatically forms smooth surfaces and proper geometry without requiring subsequent burr removal operations. The process serves itself to eliminate defects rather than requiring additional corrective operations.
Solution Approach 2:
The invention extracts the burr formation problem from the manufacturing process by eliminating the machining step that causes discontinuous metal flow. By removing the machining operation entirely and relying on forging alone, the source of burrs is eliminated, and productivity is improved by reducing the number of processing steps.
3Strength
If forging processing is used for finish shaping, then continuous metal flow is achieved improving strength, but manufacturing precision may be insufficient
Solution Approach 1:
The forging process applies localized quality control by optimizing forging parameters specifically for the engagement part regions. Different areas of the holder receive different forging conditions - the engagement parts are forged with controlled pressure and temperature to achieve both continuous metal flow for strength and precise dimensional control, while other areas may use different parameters.
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 approach effectively prevents burrs from occurring during crimping, enhancing the mechanical strength of the engagement parts, reducing the risk of failures, and simplifying the burr removal process, thereby improving productivity and reliability.
Implementation Method 1
The igniter fixing engagement part (15) and cup fixing engagement part (16) are bent, so that portions of the igniter (20) and cup (30) are sandwiched between the igniter fixing engagement part (15) and cup fixing engagement part (16) and the body part (11)
Data Source
Figure 1
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Figure 4~5
AI summary
A gas generator includes a holder (10) made of metal having assembled thereto a cup filled with a gas generating agent and an igniter for burning the gas generating agent. The holder (10) includes a body part (11), and an igniter fixing engagement part (15) and a cup fixing engagement part (16) projecting from the body part (11). These engagement parts (15, 16) are bent, so that the igniter and the cup are fixed by crimping to the holder (10). The engagement parts (15, 16) are both finish shaped by forging processing. A metal flow appearing in superficial layers of the engagement parts (15, 16) extends continuously from the body part (11) through the engagement parts (15, 16) to return to the body part (11), without being divided in surfaces of the engagement parts (15, 16).