Hollow Shaft End Joining Using Threaded Diffusion Bonding
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Solution Overview
Problem
Existing methods for manufacturing hollow shafts with linking members joined by friction welding are inefficient and lack quality control in mass production, particularly in reducing weight for applications like electric vehicle motors.
Innovation Solution
A method involving the formation of male threaded portions on a cylindrical member, screwing on female threaded linking members, and diffusion-joining the opposing end surfaces under pressure, allowing for efficient joining of linking members at both ends of a cylindrical member without the need for additional jigs, while maintaining the cylindrical shape through engagement parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If friction welding is used to join linking members to cylindrical member ends, then joining strength is achieved, but manufacturing efficiency is low and quality control is difficult in mass production
Solution Approach 1:
Male threaded portions are formed on the cylindrical member ends in advance before the joining operation. This preliminary preparation enables subsequent linking members to be screwed on easily and ensures consistent joining quality without requiring complex real-time control during the joining process itself, thereby improving both productivity and quality control.
2Shape
If semicylindrical members are joined together before diffusion-joining, then the cylindrical shape is formed, but additional joining steps and jigs are required
Solution Approach 1:
The linking members themselves serve as the means to maintain the cylindrical shape during diffusion-joining. By screwing the linking members onto the male threaded portions, they automatically hold the semicylindrical members in the correct position and shape, eliminating the need for separate jigs or fixtures. This self-service approach simplifies the device complexity while maintaining shape accuracy.
3Strength
If linking members are screwed onto male threaded portions and then diffusion-joined, then both screwing strength and diffusion-joining strength are achieved, but the process complexity increases
Solution Approach 1:
The screwing operation and diffusion-joining operation are merged into a single integrated process. The linking members are screwed onto the male threaded portions, and then the entire assembly undergoes diffusion-joining in one heating step. This combines two joining mechanisms (mechanical threading and thermal diffusion) into a unified process that achieves both screwing strength and diffusion-joining strength without requiring separate, complex equipment for each step.
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 method enables efficient and high-quality manufacturing of hollow shafts with improved diffusion-joining strength and screwing strength, ensuring consistent quality and reducing production time and costs by eliminating the need for pre-joining semicylindrical members.
Implementation Method 1
a diffusion-joining step in which opposing end surfaces of the linking members 11 and the cylindrical member 10 are heated in a state of being pressed against each other by the tightening produced by the screwed-on linking members 11, and the opposing end surfaces are diffusion-joined
Data Source
AI summary
A method for manufacturing a shaft, whereby a hollow shaft in which linking members are joined at both ends of a cylindrical member (a pipe member) can be manufactured more efficiently. A method for manufacturing a shaft in which linking members are provided to end parts of a cylindrical member, wherein the method comprises: a preparation step for preparing the cylindrical member, in which male threaded portions are formed at the end parts; a screwing step in which the linking members, which have female threaded portions to be screwed onto the male threaded portions, are screwed onto the male threaded portions; and a diffusion-joining step in which opposing end surfaces of the linking members and the cylindrical member are heated in a state of being pressed against each other by the tightening produced by the screwed-on linking members, and the opposing end surfaces are diffusion-joined.