Pulsed Hydraulic Rolling Tool for Metal Sealing Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical surface processing techniques lack the ability to effectively treat sealing surfaces of metallic components, particularly in terms of achieving a favorable balance between wear resistance, friction, and sealing effectiveness.
Innovation Solution
A surface treatment tool with a tubular housing containing a hydraulic medium and a piezoelectric actuator that generates targeted pressure pulses, allowing for controlled and adjustable forces on the rolling body to create stochastic indentations on the workpiece surface, enhancing wear resistance and sealing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling tools are used with constant pressure, then the tool structure is simple, but the surface treatment quality and sealing effectiveness are insufficient
Solution Approach 1:
The patent applies periodic pressure pulses to the rolling element through a vibration generator, transforming constant pressure rolling into pulsating pressure rolling. This periodic action creates stochastic indentations on the sealing surface that improve sealing effectiveness and wear resistance while maintaining a relatively simple tool structure.
Solution Approach 2:
The patent incorporates a vibration generator that applies mechanical vibrations to the rolling element, causing it to exert pulsating pressure on the workpiece surface. This mechanical vibration approach enables precise control of contact pressure and creates the desired surface structure for improved sealing performance.
2Force
If hydraulic pressure is applied to control rolling force, then the contact pressure is controllable, but pressure fluctuations reduce process stability
Solution Approach 1:
The patent uses periodic pressure pulses generated by a vibration generator rather than continuous hydraulic pressure. This periodic action provides controllable contact pressure while avoiding the stability issues associated with hydraulic pressure fluctuations, as the vibration generator directly controls the pulsating pressure without hydraulic system variability.
Solution Approach 2:
The patent replaces the hydraulic pressure system with a vibration generator that directly applies mechanical vibrations to the rolling element. This substitution eliminates hydraulic fluid compliance and pressure fluctuations, providing more stable and predictable contact pressure control.
3Productivity
If the rolling element is pressed firmly against the workpiece, then material removal is effective, but the sealing surface quality deteriorates
Solution Approach 1:
The patent applies periodic pressure pulses rather than continuous firm pressure. During each pulse cycle, the rolling element briefly contacts the workpiece to remove material, then separates to allow chip evacuation and prevent surface damage. This periodic action maintains high material removal efficiency while preserving sealing surface quality.
Solution Approach 2:
The vibration generator pre-excites the rolling element before contact with the workpiece, ensuring optimal contact conditions are established beforehand. This preliminary action allows for controlled material removal while maintaining surface integrity, as the rolling element is already in the correct vibrational state for precise surface treatment.
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 tool achieves a uniform and structured surface finish that improves wear resistance and sealing effectiveness on metallic components, such as bearing rings, by applying pulsating pressure that is synchronized with the workpiece's rotation, ensuring a consistent distribution of indentations.
Implementation Method 1
a piezoelectric actuator (3) that is arranged in a cavity (5) of the housing (2) and is designed to generate targeted pressure pulses in the hydraulic medium
Implementation Method 2
a cavity (5) for filling with a hydraulic medium, wherein a base pressure of the hydraulic medium is selectively increased by pulses
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a tool for mechanical surface treatment, comprising a housing (2), in which a cavity (5) for filling with a hydraulic medium is formed, and rolling element (10), which is exposed to the base pressure of the hydraulic medium and is provided for rolling on a workpiece surface to be treated. Furthermore, an oscillator (4) is provided, which is designed to produce specific pressure pulses in the hydraulic medium. The invention further relates to a method using the tool and to the use of the tool to treat a sealing surface of a metal component.