Pipe Joining Body with Concave Wire Rod for Strong Swaged Connections
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Solution Overview
Problem
Conventional swaging processes for joining wire rods and pipes often result in insufficient joining force due to limited deformation of the pipe member, which can lead to weak connections, especially when the pipe member has a lower hardness than the wire rod.
Innovation Solution
A pipe joining method where a wire rod with a concave portion is formed by plastic deformation, and a tubular member with a deformed portion is created to fit into the concave portion, using a transfer mold to ensure the maximum displacement of the tubular member does not exceed that of the wire rod, thereby maintaining strength and achieving a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional swaging processing is used to join wire rod and pipe, then the joining process is simple, but the joining force is insufficient due to small biting amount of pipe member into wire rod
Solution Approach 1:
The wire rod is pre-formed with concave portions before the joining process. This preliminary action creates receptacles that guide and enhance the deformation of the tubular member during swaging, ensuring the deformed portions properly enter and interlock with the concave portions, thereby achieving sufficient joining force without excessive processing complexity
Solution Approach 2:
The invention changes the geometric parameters of the wire rod by forming concave portions with specific dimensions and shapes. These parameter changes create optimal receptacles that match the deformation characteristics of the tubular member, enabling effective interlocking and enhanced joining force while maintaining manageable processing complexity
2Strength
If the tubular member is pressed to enter the concave portion, then the joining force is improved, but the tubular member may be excessively deformed if its hardness is lower than the wire rod
Solution Approach 1:
The concave portions are pre-formed in the wire rod with dimensions and geometries that account for the hardness difference between the wire rod and tubular member. This preliminary action ensures that during the pressing operation, the tubular member deforms to the appropriate extent to enter the concave portions without being excessively deformed, maintaining manufacturing precision while achieving strong joining force
Solution Approach 2:
The invention applies local quality by creating specific geometric features (concave portions) at precise locations on the wire rod. These localized features are designed with specific dimensions and shapes that match the deformation characteristics of the tubular member, enabling controlled deformation and proper interlocking without causing excessive deformation of the softer tubular member
3Manufacturing precision
If a transfer mold is used to form concave portions on the wire rod, then the shape precision is improved, but the device complexity increases
Solution Approach 1:
The transfer mold is designed with a convex transfer surface that can form multiple concave portions on the wire rod in a single operation. This multi-functional design achieves high shape precision for all concave portions while reducing the need for multiple separate forming operations, thereby limiting the increase in device complexity
Solution Approach 2:
The transfer mold uses a convex transfer surface that is a precise copy or inverse of the desired concave portion geometry. This copying approach ensures that the concave portions are formed with high shape precision by directly transferring the mold geometry to the wire rod, achieving manufacturing precision without requiring complex multi-step processes
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 enhances the joining force between the wire rod and tubular member, ensuring a strong and durable connection without compromising the strength of the tubular member, even when the tubular member has lower hardness than the wire rod, and allows for precise deformation using a swaging processing machine.
Implementation Method 1
at least one concave portion formed by plastically deforming a part of an outer periphery of the wire rod
Implementation Method 2
pressing a portion of the tubular member covering the at least one concave portion from an outer periphery of the tubular member toward the at least one concave portion to plastically deform the portion
Data Source
AI summary
Provided is a pipe joining body in which a wire rod and a tubular member are joined. The wire rod includes a concave portion formed by plastically deforming a part of an outer periphery of the wire rod. The tubular member includes a deformed portion that is formed so as to enter the concave portion by inserting the wire rod into the tubular member and by pressing a portion of the tubular member covering the concave portion toward the concave portion to plastically deform the portion. A maximum displacement amount of the tubular member when the deformed portion is formed is not larger than a maximum displacement amount of the wire rod by the plastic deformation when the concave portion is formed. The concave portion is formed by bringing a mold having a convex surface into contact with the part of the outer periphery of the wire rod to press.