Metal Sheath Pressing for Precise Contact on Ceramic Components
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Solution Overview
Problem
Existing methods for equipping electrical or electronic component elements with a metal sheath struggle with achieving precise mechanical contact and effective heat transfer while maintaining the shape and dimensional stability of the sheath, especially for components with ceramic structures.
Innovation Solution
A method using a radial press with an auxiliary sleeve to deform a plastically flexible metal sheath blank into a close-fitting sheath around a cylindrical electrical or electronic component element, preventing burr formation and allowing for precise control of the deformation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal sheath is equipped around an electrical or electronic component element to ensure good heat transfer ability and mechanical protection, then heat transfer ability is improved, but achieving precise mechanical contact and maintaining shape stability of the sheath becomes difficult
Solution Approach 1:
A mandrel is introduced as an intermediary tool during the sheath forming process. The mandrel is inserted into the component element and serves as a temporary support structure that maintains the internal geometry and provides a reference surface for the metal sheath. This ensures precise mechanical contact between the sheath and component element while allowing the sheath to be formed with accurate dimensional stability.
Solution Approach 2:
The mandrel is prepared and positioned in advance before the metal sheath is formed. By establishing the mandrel's position and geometry beforehand, the subsequent sheath forming process can proceed with predetermined precision, ensuring that the sheath will achieve the required mechanical contact and shape stability without requiring post-processing adjustments.
2Ease of manufacture
If conventional pressing methods are used to deform the metal sheath blank, then the sheath can be formed around the component element, but burr formation occurs and post-machining is required
Solution Approach 1:
The mandrel acts as a mediator between the pressing tool and the metal sheath blank. By providing a smooth, precisely dimensioned surface that the sheath forms against, the mandrel ensures that the deformation process produces a clean finish without burrs. The mandrel's surface quality is transferred to the sheath during forming, eliminating the need for post-machining operations.
Solution Approach 2:
The mandrel is prepared with the final desired surface quality and dimensional accuracy before the sheath forming process begins. This preliminary preparation ensures that when the metal sheath is deformed over the mandrel, it inherits these precise surface characteristics, achieving a burr-free finish directly from the forming operation without requiring subsequent machining.
3Temperature
If the metal sheath is tightly fitted around the component element to ensure mechanical contact, then heat transfer is improved, but the component element is vulnerable to mechanical overload
Solution Approach 1:
The mandrel is removed after the sheath is formed but before the component element is subjected to mechanical loads. This preliminary removal eliminates the constraint that would otherwise transmit mechanical overloads directly to the component element. The sheath retains its close-fitting geometry for heat transfer while being free from the mandrel's protective constraint during operation.
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 achieves a close-fitting metal sheath around the component with reduced manufacturing costs and without the need for post-machining, ensuring precise mechanical contact and heat transfer while safeguarding components from mechanical overload.
Implementation Method 1
closing the pressing tool at least one time with successively occurring bearing of the press jaws on the auxiliary sleeve, elastic radial contraction of the auxiliary sleeve until it bears on the sheath blank
Implementation Method 2
plastic radial contraction of the sheath blank until it bears on the electrical or electronic component element
Data Source
AI summary
A method is provided for equipping a component element with a sheath. A plastically deformable metal sheath blank has a large size relative to the component and an elastically deformable auxiliary sleeve has a large size relative to the sheath blank. The component, sheath blank, and auxiliary sleeve are introduced into a radial press having press jaws moved radially in the direction of a press axis. A pressing tool of the radial press is closed with successively occurring bearing of the press jaws on the auxiliary sleeve, elastic radial contraction of the auxiliary sleeve until it bears on the sheath blank and plastic radial contraction of the sheath blank until it bears on the component element. Upon opening the pressing tool, the elastically deformable auxiliary sleeve lifts away from the sheath produced from the sheath blank and the finished component part can be removed from the auxiliary sleeve.