Laser-Cut Washer Forming to Preserve Sliding Area

Solution Overview

Problem

Conventional methods for manufacturing washers result in the formation of droops and burrs, which reduce the sliding area and lead to material waste, detachment of metal components, and increased costs due to finishing requirements.

Innovation Solution

A method involving laser cutting of a panel-shaped member into longitudinal members, followed by forming these into an arc shape to create a washer with right-angled edge portions and molten portions for improved sliding and bonding, reducing curvature differences and material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal material is stamped into a ring shape by use of a forming die, then the washer can be manufactured, but droops and burrs are formed on the sliding portion reducing the sliding area

Engineering Contradiction:

Improvemanufacturing processVSAvoidsliding area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent replaces the mechanical stamping process with a laser cutting process. The laser cutting method uses optical energy instead of mechanical force to cut the metal plate, thereby avoiding the formation of droops and burrs that reduce the sliding area. The laser beam melts or vaporizes the material along the cutting path, producing clean edges without mechanical deformation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing method from mechanical stamping to laser cutting, fundamentally altering the process parameters. Instead of applying mechanical pressure through a forming die, the process uses laser energy with controlled power, speed, and focal position to achieve clean cutting edges that preserve the full sliding area.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If stamping is used to form the washer, then the manufacturing process is simple, but material waste occurs due to droop formation

Engineering Contradiction:

Improvemanufacturing processVSAvoidmaterial yield

Core Design Contradiction:

Device complexityVSLoss of substance

Solution Approach 1:

The patent replaces the mechanical stamping process with a laser cutting process. The laser cutting method uses optical energy instead of mechanical force to cut the metal plate, thereby avoiding the formation of droops and burrs that reduce the sliding area. The laser beam melts or vaporizes the material along the cutting path, producing clean edges without mechanical deformation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing method from mechanical stamping to laser cutting, fundamentally altering the process parameters. Instead of applying mechanical pressure through a forming die, the process uses laser energy with controlled power, speed, and focal position to achieve clean cutting edges that preserve the full sliding area.

Inventive Principle:

Principle #35Parameter changes

3Shape

If droops are formed on the sliding portion, then the washer structure is created, but the sliding portion cannot slide against the other member at the droop areas

Engineering Contradiction:

Improvewasher structureVSAvoidsliding function

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent replaces the mechanical stamping process with a laser cutting process. The laser cutting method uses optical energy instead of mechanical force to cut the metal plate, thereby avoiding the formation of droops and burrs that reduce the sliding area. The laser beam melts or vaporizes the material along the cutting path, producing clean edges without mechanical deformation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of edge irregularities by using laser cutting to produce precisely controlled edges. The laser process can create specific edge geometries (such as slight bevels or smooth finishes) that actually improve sliding performance by eliminating the harmful droops and burrs that would otherwise prevent proper sliding contact.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach suppresses the reduction in sliding area, enhances material yield, prevents detachment of metal components, and simplifies the manufacturing process by eliminating the need for extensive finishing, thereby reducing costs and improving wear resistance.

Implementation Method 1

a cutting step of cutting the panel-shaped member with a laser to thereby obtain a longitudinal member

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11339828B2Method of manufacturing washer and washer

Publication Date: 2022.05.24 TAIHO KOGYO CO LTD

AI summary

There is provided a method of manufacturing a washer capable of suppressing reduction in a sliding area, which includes: a preparing step of preparing a panel-shaped member N; a cutting step of cutting the panel-shaped member N with a laser L2 to thereby obtain a longitudinal member N1; and a forming step of obtaining an arc-shaped washer by using the longitudinal member N1. The panel-shaped member N has an equal width to a longitudinal width of the longitudinal member N1. The cutting step is a step of cutting the panel-shaped member N from one end to the other end in a width direction to thereby obtain the longitudinal member N1 and the forming step is a step of deforming the longitudinal member N1 into an arc shape so that cut faces of the longitudinal member N1 form an outer peripheral face and an inner peripheral face.