Muffler Shell Flared Part Laser Welding
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Solution Overview
Problem
Conventional muffler manufacturing methods involve complex and inefficient press molding processes that result in low manufacturing efficiency and require multiple stages to minimize gaps between parts for laser welding, limiting the diversity of technology in achieving a reliable connection.
Innovation Solution
A muffler shell is formed by creating a flared part with a projecting flange on one metallic half-body and a peripheral wall with a cut tip on the other, allowing for smooth press-fitting and laser welding along the peripheries, eliminating the need for additional press molding steps and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flared parts are formed by press molding at both opening end portions and additional press molding is performed to form tapered opening parts, then dimension accuracy and fit quality are improved, but manufacturing efficiency deteriorates due to multiple press molding steps
Solution Approach 1:
The patent extracts and eliminates the unnecessary additional press molding step for forming tapered opening parts. Instead, it uses a cutting process to remove excess material and form the tapered opening parts, thereby reducing the number of manufacturing steps while maintaining the required dimension accuracy and fit quality.
Solution Approach 2:
The patent replaces the mechanical press molding process with a cutting process for forming tapered opening parts. This substitution reduces manufacturing complexity and improves efficiency while achieving the same functional result of creating precise tapered openings for proper fitting.
2Reliability
If the opening end portion is reduced in diameter through press molding to eliminate wrinkles and minimize gaps, then connection quality for laser welding is improved, but manufacturing efficiency deteriorates due to additional press molding steps
Solution Approach 1:
The patent extracts and eliminates the additional press molding step for reducing diameter. Instead, it uses a cutting process to remove excess material and form the tapered opening parts, thereby reducing the number of manufacturing steps while maintaining the required connection quality for laser welding.
Solution Approach 2:
The patent replaces the mechanical press molding process with a cutting process for forming tapered opening parts. This substitution reduces manufacturing complexity and improves efficiency while achieving the same functional result of creating precise tapered openings for proper fitting and welding.
3Manufacturing precision
If flared parts are formed by press molding and then subjected to additional press molding with conical punch and die, then fit quality between parts is improved, but device complexity increases due to multiple processing stages
Solution Approach 1:
The patent extracts and eliminates the additional press molding stage with conical punch and die. Instead, it uses a simpler cutting process to form tapered opening parts, thereby reducing device complexity and the number of processing stages while maintaining the required fit quality between parts.
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 configuration ensures a reliable connection by minimizing gaps between parts, enhances manufacturing efficiency, and provides a novel approach that increases dimension accuracy and durability, while preventing rainwater retention and reducing air resistance.
Implementation Method 1
The peripheral wall at the opening end portion of the second finished article is press fitted inside the peripheral wall of the flared part of the first finished article to fit into the peripheral wall of the flared part
Implementation Method 2
A part of the peripheral wall of the flared part of the first finished article and a part of the peripheral wall at the opening end portion of the second finished article that are fitted into each other are laser welded along their entire peripheries
Data Source
AI summary
A muffler has a first flared part provided at an opening end portion of an upper half body of a muffler shell. A flange is provided at a tip of a peripheral wall extending substantially vertically and belonging to the first flared part. The flange is bent to project outwardly. A second flared part is provided at the opening end portion of the lower half body of the shell. A peripheral wall of the second flared part is press fitted inside the peripheral wall of the first flared part to fit into the peripheral wall so as to extend substantially along the peripheral wall. A part of the peripheral wall of the first flared part and a part of the peripheral wall of the second flared part that fit into each other are laser welded along their entire peripheries, thereby forming a welded part.