Planetary Gear Carrier Assembly Using Brazed Dissimilar Metals
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Solution Overview
Problem
The existing methods for manufacturing metal components, such as planetary gear carriers, often require compromises between using steel and powdered metal due to factors like geometric complexity, hardness requirements, and cost considerations, leading to suboptimal solutions that balance these factors.
Innovation Solution
A method involving the use of dissimilar metals for the components of a planetary gear carrier, where one part is made of powdered metal and the other of non-powdered metal, with brazing material placed between them to mechanically couple the parts, allowing for targeted hardening and reduced processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel is used as raw material, then hardness and strength are improved, but manufacturing cost and processing complexity increase
Solution Approach 1:
The planetary gear carrier is divided into multiple components (plate portion and spider portion) made of different materials. The plate portion requiring high hardness is made of steel, while the spider portion is made of powdered metal, allowing each component to be optimized for its specific functional requirements without incurring the cost of hardening the entire assembly.
Solution Approach 2:
Different materials are selected for different portions of the carrier based on local requirements. The plate portion with splines and gear teeth that require high hardness is made of steel, while the spider portion is made of powdered metal, providing locally optimized material properties where needed rather than uniformly across the entire component.
2Ease of manufacture
If powdered metal is used as raw material, then manufacturing cost is reduced, but hardness and strength deteriorate
Solution Approach 1:
The carrier is segmented into components where only the powdered metal spider portion requires cost-effective manufacturing, while the steel plate portion provides the necessary hardness. This segmentation allows powdered metal to be used where high hardness is not critical, reducing overall manufacturing cost.
Solution Approach 2:
Powdered metal is applied locally to the spider portion where geometric complexity benefits from its manufacturing capabilities, while steel is used for the plate portion requiring high hardness. This local application of different materials optimizes both cost and performance.
3Strength
If steel is used for complex geometries, then strength is maintained, but manufacturing complexity and processing steps increase
Solution Approach 1:
The complex geometry is distributed across two components: the plate portion made of steel with simpler geometry, and the spider portion made of powdered metal that incorporates the geometric complexity during sintering. This segmentation eliminates the need for complex machining steps on the steel component.
Solution Approach 2:
Geometric complexity is localized to the spider portion where powdered metal manufacturing provides inherent advantages, while the plate portion maintains simpler geometry suitable for steel manufacturing. This local differentiation reduces overall processing complexity.
4Strength
If dissimilar metals are joined, then material strengths are optimized, but bonding reliability must be ensured
Solution Approach 1:
A brazing material acts as an intermediary between the steel plate portion and powdered metal spider portion, facilitating reliable bonding between the dissimilar metals. The brazing material is applied to mating surfaces and heated to create a strong metallurgical bond that ensures the reliability of the joint.
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 enables the production of metal components with improved mechanical coupling and reduced costs by leveraging the strengths of both materials, allowing for targeted hardening and complex geometries while minimizing additional processing steps.
Implementation Method 1
brazing material disposed between the first and second mating surfaces so as to mechanically couple the first and second components
Implementation Method 2
heating the brazing material to at least its melting point temperature
Implementation Method 3
heating the brazing material to at least its melting point temperature
Implementation Method 4
cooling the brazing material so as to mechanically couple the first and second components
Data Source
AI summary
An article of manufacture comprises a first component having a first mating surface and a second component having a second mating surface. The first component may include an aperture having internal splines or gear teeth, and/or an outer perimeter having external splines or gear teeth. The first and second components are disposed such that a gap is provided between the first and second mating surfaces. Brazing material is disposed between the first and second mating surfaces so as to mechanically couple the first and second components. The first component may be made of a powdered metal or a non-powdered metal, and the second component may be made of the other of such two metals. In one embodiment, the first component may be a planetary carrier plate portion having internal splines and the second component may be a planetary carrier spider portion.