One-Piece Axle Radial Forging Hollow Shaft
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Solution Overview
Problem
Existing axle manufacturing methods require multiple pieces and assembly steps, which can lead to gaps, corrosion, and reduced strength, and do not efficiently utilize material for torsional strength and weight reduction.
Innovation Solution
A one-piece axle is forged from a single piece of material using a sequence of forging steps and radial forging processes to integrate a hollow shaft with a flange, eliminating separate components and assembly steps, and allowing for material removal to achieve desired dimensions and features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a multi-piece axle is used, then manufacturing flexibility is improved, but assembly gaps and corrosion risk increase
Solution Approach 1:
The patent merges the flange and shaft into a single integrated axle component, eliminating the joint between separate pieces. This integration removes assembly gaps that would otherwise trap moisture and cause corrosion, directly resolving the reliability issue while maintaining manufacturing capability through controlled material removal processes
2Loss of substance
If a solid rod is used to make hollow pipe, then material utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary material removal by machining the forged axle to the desired hollow dimensions. This approach starts with a solid forged blank (efficient material use) and removes material only where needed, rather than attempting to form a hollow shape directly during forging, thus balancing material utilization with manufacturing simplicity
3Ease of manufacture
If separate flange and shaft components are assembled, then manufacturing ease is improved, but structural strength decreases
Solution Approach 1:
The patent combines the flange and shaft into a monolithic forged structure, eliminating the assembly joint that would create a stress concentration point. The integrated design provides continuous material grain flow and uniform stress distribution, significantly improving torsional strength while the final machining operations provide the necessary dimensional precision
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 one-piece axle design enhances durability, torsional strength, and weight reduction, eliminating assembly gaps and potential corrosion sites, while simplifying manufacturing and potentially improving vehicle fuel economy.
Implementation Method 1
a first radial forging process is performed on the single piece of material to forge a hollow shaft with a first diameter
Implementation Method 2
The one-piece axle blank is forged using a sequence of forging steps and radial forging processes to integrate a hollow shaft with a flange
Data Source
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AI summary
A one-piece axle and a method of manufacture. The method may include providing a one-piece axle blank that has a shaft and a flange. The shaft may have a hole that may extend along an axis. The flange may extend radially outward from an end of the shaft. The shaft may be radially forged against a first mandrel to axially elongate the shaft.