Laminated Mechanical Components Arc Segments Material Waste
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Solution Overview
Problem
Current manufacturing methods for circular mechanical components, such as transmission components, result in significant material wastage due to the need for multiple parts and interlocking geometries, which complicates the production of high-strength components like engine components.
Innovation Solution
A method involving stamping an inlet stock to form a line of arc segments with notches and interlocking ends, wrapping these segments into circular laminate layers, and stacking them to form a laminate disc, with optional features like pilot holes and dimples for alignment and fastening, to reduce material waste and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional stamping methods are used to manufacture circular mechanical components, then manufacturing simplicity is maintained, but material wastage increases significantly
Solution Approach 1:
The manufacturing process segments the circular component into multiple arc segments that are stamped separately and then assembled together using interlocking geometries. This segmentation allows for more efficient material utilization while maintaining manufacturing simplicity through standardized stamping operations.
Solution Approach 2:
Multiple arc segments are nested and interlocked together to form the complete circular component. The segments are positioned in a sequential manner, with each segment interlocking with its neighbors, creating an efficient assembly that reduces material waste while maintaining structural integrity.
2Loss of substance
If multiple parts are stamped and interlocked together to create circular components, then material usage efficiency improves, but manufacturing process complexity increases
Solution Approach 1:
Multiple stamped arc segments are merged together through interlocking geometries to form a complete circular component. The interlocking design integrates the segments into a unified structure that functions as a single component, reducing material waste while maintaining ease of manufacture through modular assembly.
Solution Approach 2:
The arc segments are pre-stamped with interlocking geometries and notches before assembly. This preliminary action prepares the segments for efficient assembly, reducing the complexity of the final assembly process while maximizing material utilization.
3Strength
If arc segments are wrapped and joined to form circular laminate layers, then structural strength is enhanced, but manufacturing process complexity increases
Solution Approach 1:
Multiple arc segments are assembled into a laminated structure where each segment acts as a layer in the composite. The interlocking geometries and notches create a composite structure that enhances structural strength through the arrangement and integration of multiple layers, while the modular nature maintains manufacturing feasibility.
Data Source
AI summary
Methods and apparatus for manufacturing a circular laminated component are disclosed herein. In one embodiment, a method comprises stamping an inlet stock of material to form a line of arc segments, the line of arc segments having: a plurality of notches along a first edge; a first longitudinal end; and a second longitudinal end opposite the first longitudinal end; wrapping the line of arc segments to form a circular segment having the first edge along an inner-circumferential diameter of the circular segment; joining the first longitudinal end to the second longitudinal end to form a circular laminate layer; and stacking a plurality of circular laminate layers to form a laminate disc.