Nylon Alignment Disk for Mandrel Coaxial Seating
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Solution Overview
Problem
Existing methods for installing structural members, such as bushings, often result in misalignment due to the weight of installation tools and lack of initial contact reaction, leading to gaps and non-uniform residual stresses, which affect the structural integrity and flushness of the installation.
Innovation Solution
An alignment device, typically a nylon disk with a passageway smaller than the mandrel's expansion portion, is used to coaxially align the mandrel and structural member with the workpiece, ensuring the radial flange is seated correctly and uniformly expanding the structural member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard mandrel of an installation tool is used to radially expand a structural member, then the structural member can be installed into the workpiece, but the weight of the installation tool causes misalignment of the expansion mandrel relative to the structural member and opening
Solution Approach 1:
An alignment device is introduced as an intermediary component between the installation tool and the structural member. This alignment device includes an alignment feature that interfaces with the expansion mandrel to maintain coaxial alignment during the radial expansion process, thereby compensating for misalignment caused by tool weight
Solution Approach 2:
The alignment device is positioned and engaged with the expansion mandrel before the radial expansion process begins. This preliminary positioning ensures that the mandrel is properly aligned with the opening and structural member from the start of the operation, preventing misalignment during expansion
2Ease of operation
If the installation tool is used to pull the mandrel through the structural member, then the mandrel can be positioned, but there is no reaction force until the expansion portion contacts the structural member, causing misalignment
Solution Approach 1:
The alignment device provides preliminary counteraction to the misalignment tendency by maintaining a reaction force path through its alignment feature. This prevents the mandrel from deviating from coaxial alignment during the critical phase before expansion contact occurs
Solution Approach 2:
The alignment device acts as a mediator that establishes mechanical contact and alignment between the installation tool and the structural member before the expansion portion makes contact, ensuring proper positioning throughout the process
3Productivity
If the structural member is expanded in a misaligned orientation, then the installation can be completed, but gaps occur between the radial flange and the workpiece surface
Solution Approach 1:
The alignment device ensures that the structural member is properly aligned and positioned before the radial expansion begins. This preliminary alignment prevents gaps from forming between the radial flange and workpiece surface during the expansion process
Solution Approach 2:
The alignment device serves as a mediator that maintains proper orientation between the structural member and workpiece throughout the expansion process, ensuring the radial flange remains aligned with the workpiece surface to prevent gap formation
4Ease of operation
If misalignment occurs during expansion, then the installation proceeds, but non-uniform residual stresses are induced in the workpiece
Solution Approach 1:
The alignment device establishes proper coaxial alignment before expansion begins, ensuring that the structural member is correctly positioned relative to the opening. This preliminary positioning ensures uniform distribution of residual stresses during the radial expansion process
Solution Approach 2:
The alignment device acts as a mediator that maintains consistent orientation between the structural member and workpiece during expansion, ensuring uniform contact and stress distribution that results in uniform residual stresses throughout the workpiece
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
The alignment device ensures proper alignment and seating of the structural member, reducing the need for post-installation adjustments and achieving uniform residual stresses, thereby enhancing the structural integrity and fatigue resistance of the installation.
Implementation Method 1
the alignment device is a nylon disk having a passageway extending through the disk, where the passageway is sized to be slightly smaller than a major diameter of an expansion portion of the mandrel. As an expansion portion of the mandrel radially expands the disk...
Data Source
AI summary
An alignment device is located on a mandrel of an installation tool and is used to align a structural member in an opening of a workpiece while seating a radial flange of the structural member against a first surface of the workpiece. The alignment device comprises a disk-shaped device having an outer surface, an inner surface forming an opening through the alignment device, and where the opening is sized to be at least slightly smaller than a major diameter of an expansion portion of the mandrel. In one embodiment, the alignment is nylon to allow the inner surface of the alignment device to be repeatedly, radially expanded and yet the opening formed by the inner surface returns to its original size.