Hydroformed Coupling Structure for Vehicle Suspension Buckling Strength
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Solution Overview
Problem
Existing coupling structures for vehicle suspensions face challenges in achieving sufficient buckling strength against compressive stress while reducing weight and cost, and improving productivity, particularly due to limitations in material selection and processing complexity.
Innovation Solution
A coupling structure featuring a hollow rod section with fastening sections formed by plastic deformation of a metal pipe, including base and front end sections with specific geometric configurations and reinforcing beads, which allows for improved buckling strength and reduced weight, and a manufacturing method that integrates slit-forming and plastic deformation processes to create complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the rod section and fastening sections, then the strength is improved, but the productivity decreases and weight increases
Solution Approach 1:
The rod section and fastening sections are merged into a single integrated component formed by hydroforming, eliminating the need for welding connections. This combining approach simultaneously improves productivity by removing the welding process and maintains strength through the continuous metal structure created during forming.
Solution Approach 2:
The welding process (thermal/mechanical system) is replaced with hydroforming (fluid pressure system). By using high-pressure fluid to plastically deform the metal tube into the final shape with integrated fastening sections, the patent eliminates welding operations while achieving equivalent or superior structural integrity.
2Strength
If welding is used to connect the rod section and fastening sections, then the strength is improved, but the weight increases
Solution Approach 1:
The rod section and fastening sections are merged into a single integrated component formed by hydroforming, eliminating the need for welding connections. This combining approach simultaneously improves productivity by removing the welding process and maintains strength through the continuous metal structure created during forming.
Solution Approach 2:
The patent changes the geometric parameters of the fastening sections during hydroforming, creating optimized shapes with varying wall thicknesses. The forming process allows for strategic thickening of material in high-stress areas while maintaining thinner sections elsewhere, achieving sufficient strength with reduced overall weight compared to uniform thickening required for welding.
3Productivity
If hydroforming is used to shape the coupling member, then the weight and cost are reduced and productivity is improved, but the buckling strength against compression is insufficient
Solution Approach 1:
The patent applies local quality by creating varying wall thicknesses within the hydroformed structure. The fastening sections have strategically thickened areas at critical locations to resist buckling under compression, while other portions maintain thinner walls for weight reduction. This localized material distribution optimizes both buckling strength and productivity.
Solution Approach 2:
The hydroforming process inherently creates curved and rounded geometries in the coupling member. These curved surfaces, particularly in the fastening sections, provide better stress distribution and resistance to buckling compared to sharp corners, enhancing compressive strength while maintaining the productivity benefits of hydroforming.
4Weight of moving object
If aluminum is used as the material, then the weight is reduced, but the strength and buckling strength are insufficient
Solution Approach 1:
The patent changes the material parameter from aluminum to steel, fundamentally altering the strength-to-weight characteristics. Steel provides superior strength and buckling resistance while the hydroforming process ensures optimized geometry to minimize weight, achieving a balance that aluminum cannot provide through geometric optimization alone.
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 solution enhances buckling strength against compressive stress, reduces the weight and cost of the coupling member, and improves productivity by enabling the use of high-strength metal pipes like steel, while allowing for easier processing of complex shapes.
Implementation Method 1
fastening sections formed by plastic deformation of the metal pipe so as to be connected with end sections of the hollow rod section
Data Source
AI summary
A coupling structure includes a hollow rod section formed of a metal pipe and fastening sections formed by plastic deformation of the metal pipe so as to be connected with end sections of the hollow rod section. The fastening section includes a pair of base end sections which are each connected with a peripheral wall section forming a closed cross-section at the end section of the hollow rod section, and are separated from each other, and a bottom wall including a flat surface connected with the pair of the base end sections, and a pair of front end sections including a pair of side walls curving inwards from at least widthwise end sections of the bottom wall on a base end section side.