Ribbed Aluminum Insertion Hole for Steel Pipe Press-Fit Joining
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Solution Overview
Problem
The existing electromagnetic forming joining method for high-tension steel and aluminum parts results in insufficient joining strength due to small contact area and potential cracking, with increased manufacturing costs from required post-fabrication processes like burring.
Innovation Solution
A press-fit joining method where a first member with an insertion hole and a rib at its edge is used to increase the contact area with a second member, allowing for effective planar contact and reduced curvature at the joining point, thereby enhancing joining strength without additional fabrication steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electromagnetic forming joining is used for high-tension steel and aluminum parts, then joining of multiple materials is achieved, but the contact area is small resulting in insufficient joining strength
Solution Approach 1:
The insertion hole is preliminarily formed with a rib structure at its edge part before the joining process. This preliminary structural preparation increases the contact area between the first and second members during electromagnetic forming, thereby improving joining strength without requiring additional post-fabrication steps
Solution Approach 2:
The rib is provided at a specific local position (edge part of the insertion hole) rather than uniformly across the entire surface. This localized structural modification concentrates the contact area enhancement where it is most needed for joining strength, while maintaining the overall simplicity of the component design
2Reliability
If the joining part has small curvature, then the structure is simple, but cracking may occur at the joining part
Solution Approach 1:
The rib structure is preliminarily formed at the edge part of the insertion hole to increase curvature at the joining part before the electromagnetic forming process. This preliminary curvature enhancement prevents stress concentration and potential cracking during the joining operation, while the rib itself is integrated into the original molding process
3Strength
If burring fabrication is applied to increase joining area, then joining strength is improved, but manufacturing cost and man-hours increase
Solution Approach 1:
The rib structure is merged into the original molding process of the first member, combining the formation of the insertion hole and the rib into a single manufacturing step. This eliminates the need for separate burring fabrication operations, thereby maintaining improved joining strength while reducing manufacturing cost and man-hours
Solution Approach 2:
The rib structure serves dual purposes: it increases the contact area for improved joining strength, and simultaneously acts as a built-in feature that eliminates the need for additional burring fabrication. The structure essentially serves itself by providing both the geometric enhancement and the manufacturing efficiency
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 method achieves increased joining strength and prevents cracking of the second member, reducing manufacturing costs and man-hours by providing a rib during molding and allowing for deformation of the second member to enhance contact area and curvature.
Implementation Method 1
a solenoid formed coil is inserted into a pipe component fitted to a mating component, and followed by applying impact current to the coil so that induced current is induced in the conductive pipe by change in a magnetic field generated by applying impact current
Implementation Method 2
Electromagnetic force is generated between magnetic field generated by the primary current of the coil and induced current flowing in the opposite direction along the circumferential direction of the pipe
Data Source
AI summary
The joining method for members according to the present invention includes: providing an aluminum component including an insertion hole provided with a rib in at least part of an edge part, and a hollow steel pipe; inserting the steel pipe into the insertion hole of the aluminum component; and expanding and deforming the steel pipe to join the steel pipe to the aluminum component by press-fitting.