Hollow Shaft Flange Forming Using Radial Spreader Ring
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Solution Overview
Problem
Existing methods for manufacturing hollow shafts with integral flanges made of fiber composite face challenges such as complex processes, reduced fiber structure quality, and non-uniform wall thickness, which affect the strength and usability of the flanges.
Innovation Solution
A method involving intersecting windings of fiber material deposited onto a core with a radial spreader ring for shaping the flanges, where inserts are used to adjust the wall thickness and ensure the fibers are under tension, preventing folds and optimizing the fiber structure, and a stripper is used to form the flanges while maintaining the core's stationary nature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If spreader disks are displaced during manufacturing to form flanges, then the flange shape is achieved, but the method becomes complicated and fiber structure quality deteriorates
Solution Approach 1:
The core is divided into a shaft portion and a spreader ring portion that can be independently positioned. The spreader ring is displaced axially relative to the shaft portion to form the flange, while the shaft portion remains stationary. This segmentation allows the flange formation without complicating the entire manufacturing process.
Solution Approach 2:
The spreader ring is pre-positioned on the stationary shaft portion at the desired flange location before fiber winding begins. This preliminary positioning eliminates the need for complex displacements during manufacturing, as the flange shape is predetermined by the spreader ring's initial position.
2Shape
If the core is moved during manufacturing, then flange formation is possible, but manufacturing precision and fiber structure uniformity deteriorate
Solution Approach 1:
Instead of moving the core to form the flange, the invention keeps the core stationary and uses the pre-positioned spreader ring to define the flange geometry. The flange is formed by the interaction between the stationary core and the displaced spreader ring, reversing the conventional approach and maintaining manufacturing precision.
3Strength
If wall thickness reduction is compensated by metallic closing plates, then structural integrity is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention changes the geometric parameters of the spreader ring (outer diameter, axial position) to directly control the flange wall thickness and compensate for thinning without requiring additional metallic components. This parameter adjustment maintains structural integrity while avoiding increased device complexity.
4Ease of manufacture
If fiber material is laid without tension control, then the winding process is simple, but folds and load-free portions occur reducing flange strength
Solution Approach 1:
The stationary spreader ring with its specific geometry automatically maintains fiber tension during the winding process. The ring's outer circumferential area and axial bearing surface create natural tension zones that prevent folds and load-free portions without requiring complex tension control mechanisms, achieving both simplicity and strength.
Data Source
AI summary
For a method for manufacturing a hollow shaft with at least one integral flange made of fiber composite, a plurality of intersecting windings of fiber material are applied onto a core. Moreover, the core has, for each flange, a radial spreader ring with an axial bearing surface. The windings are laid over an outer circumferential portion of the respective spreader ring and fixed. One or several inserts made of fiber material are inserted in the area of the spreader ring between the windings. The fixing of the wound fiber material is released, but is first still held on the spreader ring. Portions of the windings are then pulled off from the outer circumferential portion of the spreader ring and brought to rest on the axial bearing surface of the spreader ring in order to form a partial portion of a flange.