Metal Jacket Press-Fitting for Burr-Free Ceramic Components
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Solution Overview
Problem
Existing methods for equipping cylindrical electrical or electronic components with a metallic coat require high manufacturing technology effort and often result in mechanical overload, burrs, and poor precision, especially when dealing with ceramic structures.
Innovation Solution
A procedure using a radial press with auxiliary sleeves made of spring steel to deform a plastically excess metallic coat blank, ensuring precise fitting and preventing material displacement, which includes synchronously movable press brakes and controlled deformation to avoid mechanical overload and burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pressing methods are used to fit a metallic jacket onto a cylindrical electrical or electronic component, then the component can be surrounded by the metallic jacket, but mechanical overload and burr formation occur, resulting in poor manufacturing precision and high manufacturing effort
Solution Approach 1:
A compression element is introduced as an intermediary between the pressing tool and the metallic jacket blank. This compression element transfers the pressing force uniformly distributed across the blank's entire surface area, preventing localized mechanical overload and burr formation while achieving precise fitting without excessive manufacturing effort
Solution Approach 2:
The pressing force is transformed from a localized concentrated load to a uniformly distributed load across the entire surface of the metallic jacket blank. This parameter change in force distribution prevents material displacement and burr formation while maintaining fitting precision
2Strength
If high pressing force is applied to deform the metallic coat blank, then the metallic coat can be fitted tightly, but material displacement occurs causing burrs and mechanical overload
Solution Approach 1:
The compression element acts as a mediator that distributes the pressing force uniformly across the metallic jacket blank's surface. This prevents localized material displacement and burr formation while still achieving the required tightness of fit through controlled elastic and plastic deformation
3Productivity
If conventional pressing tools are used, then the metallic jacket can be applied, but complex post-processing is required to remove burrs and defects
Solution Approach 1:
The compression element with its larger surface area than the component enables uniform force distribution during pressing, eliminating burr formation and mechanical overload. This results in a clean fit that requires no complex post-processing operations, maintaining high productivity while simplifying the overall manufacturing process
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
Achieves precise and efficient application of the metallic coat with reduced manufacturing effort, preventing mechanical overload and burr formation, allowing for high-precision fitting without complex post-processing, especially beneficial for ceramic structures.
Implementation Method 1
elastic radial narrowing of the auxiliary sleeve so that it rests on the casing blank
Implementation Method 2
plastic radial narrowing of the casing blank so that it rests on the electrical or electronic component
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
In a method for fitting a component (5) with a tightly surrounding jacket (7), the component (5), a plastically deformable metallic jacket blank (16) that has an excess of dimension compared to the component (5), and an elastically deformable auxiliary sleeve (17) that has an excess of dimension compared to the jacket blank (16) are assembled into a group that is inserted into the press tool (9) of a radial press (8), which has at least four press jaws (10) that are synchronously movable radially towards a press axis (X) by means of a drive device. The press tool (9) is closed at least once by successively applying the press jaws (10) to the auxiliary sleeve (17), elastically narrowing the auxiliary sleeve (17) radially to conform to the jacket blank (16), and plastically narrowing the jacket blank (16) radially to conform to the component (5).When the press tool (9) is opened, the elastically deformable auxiliary sleeve (17) lifts off from the jacket (6) which was formed from the jacket blank (16) by plastic deformation, so that the finished component can be removed from the auxiliary sleeve (17).