Metal Bonded Product With Step-Shaped Taper Surfaces
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Solution Overview
Problem
Existing metal bonding processes, such as ring mash bonding, face challenges in achieving high bonding strength and coaxial accuracy, especially when bonding different metals like cast iron and alloy steel, due to limited bonding area and increased unbonded portions with deeper press-fitting.
Innovation Solution
A metal bonded product is created by forming a first metal member with a circular opening and a second metal member with a cylindrical portion, both having taper portions with multiple step-shaped bonding surfaces, which undergo plastic flow when press-fitted and current is applied, increasing the bonding area and strength without the need for a positioning jig.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the press-fitting depth is increased to achieve high bonding strength, then the bonding area increases, but the unbonded portions increase and bonding strength decreases
Solution Approach 1:
The bonding interface is segmented into multiple step-shaped bonding surfaces at different radial positions. This segmentation allows the bonding area to be distributed across multiple levels, enabling deep press-fitting while maintaining uniform bonding through current application at each step, thus preventing unbonded portions even at increased depths.
2Strength
If the bonding area is increased to achieve high bonding strength, then more bonding area is available, but the coaxial alignment becomes more difficult
Solution Approach 1:
The stepped configuration of the bonding surfaces enables self-alignment during press-fitting. As the cylindrical member is pressed into the opening, the step surfaces naturally guide the components into coaxial alignment through their geometric configuration, eliminating the need for external positioning jigs while maintaining large bonding area.
3Productivity
If the current density is increased to achieve effective bonding, then the bonding speed increases, but the heat generation causes metal melting and loss of control
Solution Approach 1:
The current application is segmented to correspond with the multiple step-shaped bonding surfaces. Current is applied at each step level, distributing the heating effect across multiple zones rather than concentrating it at a single interface. This enables effective bonding at each step while controlling overall heat generation and preventing uncontrolled metal melting.
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 method enhances bonding strength and achieves coaxial accuracy without a positioning jig, suitable for bonding different metals by increasing the bonding area through plastic flow of step-shaped surfaces, addressing the limitations of existing processes.
Implementation Method 1
causing the contact portions of the cylindrical metal member 11 and the ring-shaped metal member 12 to undergo plastic flow to achieve bonding therebetween
Implementation Method 2
a current is applied between the cylindrical metal member 11 and the ring-shaped metal member 12, thereby causing the contact portions to undergo plastic flow
Implementation Method 3
a current is applied to a projection provided on one of a cylindrical metal member and a ring-shaped metal member until the metal is melted to achieve bonding
Implementation Method 4
a current is applied to a projection provided on one of a cylindrical metal member and a ring-shaped metal member until the metal is melted
Data Source
AI summary
To provide a metal bonded product wherein a large bonding area can be provided to achieve high bonding strength and coaxial accuracy can be easily achieved needing no positioning jig. A first taper portion 16 is formed on a side wall surface of the opening 13 of the ring-shaped metal member 12, and multiple step-shaped bonding surfaces are formed thereon. An end of the cylindrical portion 11 has a second taper portion 17 with the same chamfer angle as that of the first taper portion 16 of the ring-shaped metal member 12. The ring-shaped metal member 12 and the cylindrical metal member 11 are bonded to each other by press-fitting the cylindrical portion of the cylindrical metal member 11 in the opening 13 of the ring-shaped metal member 12 while applying a current to cause the side wall portion of the cylindrical portion of the cylindrical metal member 11 and the multiple step-shaped bonding surfaces of the first taper portion 16 to undergo plastic flow.