Laser Welded Vehicle Axle Chamfer Design
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Solution Overview
Problem
Conventional welding technologies for attaching shaft journals to the intermediate element of vehicle axles result in precision issues and the formation of droplike structures within the welds, leading to high stress concentrations and potential detachment risks.
Innovation Solution
The method involves chamfering the contact surfaces of the shaft journals and intermediate element to create a smoother transition during laser welding, reducing droplike formations and stress concentrations by forming a V-shaped recess, thereby enhancing the strength and durability of the weld seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser welding is used to attach shaft journals to the intermediate element, then welding precision is improved and further processing is eliminated, but droplike formations occur on the inside of the weld leading to high stress concentrations
Solution Approach 1:
The chamfer is created on the shaft journal before the laser welding process begins. This preliminary geometric modification prepares the surface to receive the weld material in a controlled manner, preventing droplike formations during welding while maintaining the high precision benefits of laser welding.
Solution Approach 2:
The chamfer is applied locally only at the specific region where the weld will be deposited - the transition zone between the internal surface and contact surface of the shaft journal. This localized geometric modification improves weld quality without affecting other parts of the component.
2Device complexity
If conventional welding technology is used to attach shaft journals, then manufacturing complexity is reduced, but welding precision is insufficient requiring further processing
Solution Approach 1:
The invention changes the geometric parameters of the weld joint by introducing a chamfer with specific dimensions (angle and depth). This parameter modification allows laser welding to achieve the required precision in a single pass, eliminating the need for post-weld processing while maintaining manufacturing simplicity.
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 results in reduced notching and stress concentrations, leading to improved strength and reliability of the vehicle axles, capable of handling heavy loads without compromising structural integrity.
Implementation Method 1
each shaft journal is connected to the respective end of the intermediate element by a weld seam made by laser welding
Implementation Method 2
The laser welding is executed with electric power exceeding 10 kW and laser beams with focusing of between 0 and 4 mm within the outer surface of the material
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a vehicle axle (1) comprising an intermediate element (10) with a shaft journal (30) at each of the two ends of the intermediate element, which intermediate element and respective shaft journal have mutual contact surfaces (12, 32) with substantially the same material thickness, each shaft journal being connected to the respective end of the intermediate element by a weld seam (50) made by laser welding, and at least one out of the respective shaft journal's contact surface and the intermediate element's contact surface having at least one chamfer (18, 38, 20, 40). The invention relates also to a motor vehicle.