Powder Metallurgy Joint Member Assembly Without Mold Buckling
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Solution Overview
Problem
Existing methods for producing a joint member with coaxially arranged male and female engaging portions using powder metallurgy face issues such as buckling of protrusions, uneven powder density, and excessive force requirements due to axial load concentration, leading to production inefficiencies and potential cracks.
Innovation Solution
Separately form a male member with a male engaging portion and a female member with a female engaging portion using powder metallurgy, then combine them in a non-rotatable manner to avoid axial protrusions, allowing for easy production of a high-quality joint member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a joint member with coaxially arranged male and female engaging portions is produced by integral powder metallurgy using a male mold with an axial protrusion, then the engaging portions can be formed in one piece, but the protrusion buckles under axial compression load
Solution Approach 1:
The joint member is divided into two separate components: a male member containing the male engaging portion and a female member containing the female engaging portion. These are produced separately by powder metallurgy and then assembled together, eliminating the need for axial protrusions in the mold and preventing buckling issues while maintaining the coaxial arrangement of engaging portions.
2Ease of manufacture
If a male mold with an axial protrusion is used to form the female engaging portion, then the female engaging portion can be defined by the protrusion, but excessive force is required to enter the female mold due to powder fluidity issues
Solution Approach 1:
By separating the joint member into male and female members produced in different molds, the design eliminates the need for axial protrusions that disrupt powder flow. This allows the male mold to enter the female mold smoothly with reduced closing force, as there are no protrusions to concentrate axial loads or impede powder fluidity.
3Ease of manufacture
If powder is compressed using a male mold with axial protrusion, then the female engaging portion is formed, but uneven density distribution occurs leading to cracks during sintering
Solution Approach 1:
The joint member is produced as separate male and female components using各自的 molds, eliminating axial protrusions that cause non-uniform powder compression. This ensures homogeneous density distribution throughout each component during the powder metallurgy process, preventing cracks during sintering while still achieving the required coaxial engaging portions through subsequent assembly.
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 enables the production of a high-quality joint member with coaxially arranged engaging portions without the issues associated with integral production, ensuring stability and efficiency.
Implementation Method 1
the interior of the female mold is filled with a powder, and then, the male mold is made enter the female mold so as to compress the powder, whereby a compact is formed
Implementation Method 2
Later, the compact is taken out from the molding die and sintered
Data Source
AI summary
Provided is a novel producing method for enabling to easily produce a high-quality joint member by powder metallurgy, where the joint member has a male engaging portion and a female engaging portion arranged coaxially at different positions in the axial direction. A male member (14) having a male engaging portion (10) and a female member (16) having a female engaging portion (12) are formed separately by powder metallurgy, and then, the male member (14) and the female member (16) are combined in a relatively non-rotatable manner.