Metal Injection Molded End Cap for Linear Motion Guide
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Solution Overview
Problem
Conventional linear motion guide devices experience deformation and abrasion issues at high-speed operations due to increased energy from rolling elements colliding with the scooping portion of the end cap, especially when the hardness is enhanced through quenching, which compromises dimensional stability and toughness.
Innovation Solution
The linear motion guide device employs end caps formed by injection molding using metal powders with particle diameters of 20 μm or less, subjected to Hot-Isostatic-Pressing (HIP) and thermal processes, enhancing density and carbide distribution, and adjusting quenching hardness to improve adhesion and toughness at the scooping portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the hardness of the scooping portion is increased through quenching, then abrasion resistance is improved, but dimensional stability deteriorates
Solution Approach 1:
The end cap is constructed with different materials for different portions: the scooping portion uses high-hardness metal powder material for abrasion resistance, while the main body uses austenitic stainless steel material for dimensional stability. This local differentiation allows each portion to have the properties needed for its specific function.
Solution Approach 2:
The end cap combines two different metal powder materials: austenitic stainless steel material for the main body and high-hardness metal powder material for the scooping portion. This composite structure integrates the advantages of both materials to resolve the contradiction between hardness and dimensional stability.
2Productivity
If the feeding speed is increased to improve throughput, then productivity is improved, but energy of collision increases
Solution Approach 1:
The metal powder material for the scooping portion is designed with specific physical properties (hardness, density, adhesion) to withstand the increased collision energy resulting from higher feeding speeds, enabling throughput improvement without excessive wear.
3Strength
If metal powder material with higher carbon content is used to increase hardness, then abrasion resistance is improved, but dimensional stability deteriorates
Solution Approach 1:
High carbon content metal powder material is used only for the scooping portion where hardness is needed for abrasion resistance, while the main body uses low-carbon austenitic stainless steel material that maintains excellent dimensional stability. This localized material selection resolves the contradiction.
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 effectively suppresses abrasion and deformation, enabling the device to operate in high-temperature and vacuum environments with fast speeds, maintaining dimensional stability and preventing chipping at the scooping portion.
Implementation Method 1
the end cap has, to form the endless circulation channel, a scooping portion (tang portion) that scoops the rolling elements rolling over the load raceways... the end caps are each formed by injection molding (MIM: Metal Injection Molding) using metal powders having a particle diameter of equal to or less than 20 μm as a raw material. The scooping portion is subjected to an Hot-Isostatic-Pressing (HIP) process and a thermal process.
Implementation Method 2
The scooping portion is subjected to an Hot-Isostatic-Pressing (HIP) process and a thermal process... adjusting quenching hardness to improve adhesion and toughness at the scooping portion
Data Source
AI summary
In a linear motion guide device suitably applicable to applications under high-temperature and vacuum environments where no plastic end cap is applicable, and having an end cap formed by injection molding using metal powders as a raw material, the degree of adhesion of the metal powders is improved at a thin and keen portion like the scooping portion of the end cap, thereby suppressing an abrasion and a deformation. The end cap (7) is formed by injection molding (MIM: Metal Injection Molding) using metal powders of equal to or less than 20 μm as a raw material, and has a scooping portion (9) having undergone an HIP (Hot-Isostatic-Pressing) process and a thermal process.