Hexagonal Spoke Reinforcement for Lateral Stress
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Solution Overview
Problem
Conventional spokes exhibit fractures due to inadequate testing methods that do not account for lateral forces and tilt angles, leading to premature failure and increased risk of accidents, especially in high-speed vehicles, as the existing reinforcement methods fail to distribute stress evenly and result in a fatigue hot zone with inconsistent metal density.
Innovation Solution
A spoke reinforcing method involving forging a hexagonal columnar reinforced section to replace the cylindrical structure at the neck, ensuring optimal compressive and flexural strength by maintaining continuous grain density and reducing the likelihood of fractures through a multi-step process including straightening, first and second forging, clamping, bending, and hobbing, which enhances the structural integrity and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If forge processing method is used to reinforce the neck of spokes, then tensile strength and fatigue resistance are improved, but lateral force resistance deteriorates due to inconsistent metal density and grain boundary interface faults
Solution Approach 1:
The patent changes the geometric parameters of the reinforced section from cylindrical to hexagonal columnar shape. This parameter change allows for more uniform stress distribution under lateral forces while maintaining tensile strength. The hexagonal cross-section provides better grain flow alignment and reduces the formation of fatigue hot zones compared to the traditional cylindrical reinforcement
Solution Approach 2:
The patent transitions from simple cylindrical reinforcement (one-dimensional symmetry) to hexagonal columnar reinforcement (multi-dimensional geometry). This dimensional change in cross-sectional shape creates more favorable stress distribution patterns in multiple directions, particularly improving resistance to lateral forces while maintaining tensile properties
2Ease of manufacture
If conventional cylindrical reinforcement is used, then manufacturing process is simple, but stress distribution is uneven leading to fatigue fractures
Solution Approach 1:
The patent modifies the geometric parameters of the reinforced section from cylindrical to hexagonal columnar shape. This parameter change creates more uniform stress distribution and eliminates fatigue hot zones while remaining compatible with existing forging processes, thus maintaining ease of manufacture while improving fatigue resistance
3Device complexity
If standard vertical angle testing is used, then test procedure is simple, but test results do not reflect actual service conditions with tilt angles
Solution Approach 1:
The patent introduces dynamic testing conditions by incorporating tilt angles that simulate actual service environments. Rather than using static vertical-only loading, the testing system dynamically adjusts to include lateral force components, providing more accurate reliability data while the hexagonal reinforcement design compensates for the increased testing complexity
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
The method significantly reduces the probability of fatigue fractures and extends the lifespan of spokes by providing enhanced compressive and flexural strength, improving performance under both standard and tilt angle conditions, thereby minimizing the risk of accidents and improving the structural integrity of spokes.
Implementation Method 1
a hexagonal columnar reinforced section (4) is stamped by a stamping unit (104) to form a head (2), a neck (3) and a reinforced part (4)
Data Source
AI summary
The present invention relates generally to a spoke reinforcing method and reinforced structure of spokes, the method includes a main body of spoke with a head end and a thread part on two ends respectively, a neck is disposed below the head end, the neck is forged at least twice to enlarge the cross-section area of the neck, and to increase the density and strength of the metal grains therein; a hexagonal columnar reinforced structure is forged below this high density neck, and the high frequency lateral stress on the lower part of the high density neck is buffered by the optimal compressive strength and flexural strength of the hexagonal column, the reinforced structure of spokes produced by this method can reduce the spoke fracture probability and prolong the spoke lifetime.