Rolled Thread Screw End Geometry to Minimize Burr Formation
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Solution Overview
Problem
In-feed thread rolling methods often result in burrs and sharp edges on rolled thread screws, which complicates post-processing and reduces production yield.
Innovation Solution
The solution involves a rolled thread screw design with salient excess-thickness portions, such as columnar and truncated cone parts, that are formed through thread rolling to create first and second concave surfaces and a salient part, preventing end-part wall surfaces from becoming burrs and allowing for flat axial end surfaces, thereby reducing burr formation and simplifying deburring processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If in-feed thread rolling is used to manufacture rolled thread screws, then the manufacturing process is simple and production efficiency is high, but burrs and sharp edges are generated on the rolled thread screws
Solution Approach 1:
The patent applies preliminary action by forming salient excess-thickness portions (columnar parts and truncated cone parts) on the blank before thread rolling. These pre-formed structures serve as sacrificial material that prevents wall surface collapse during thread rolling, thereby preventing burr formation on the final product while maintaining the simplicity of in-feed thread rolling
2Ease of manufacture
If in-feed thread rolling is used to manufacture rolled thread screws, then manufacturing cost is reduced, but post-processing such as deburring is required
Solution Approach 1:
The patent converts the potential harm of excess material into a benefit by deliberately forming salient excess-thickness portions on the blank. These portions act as a protective mechanism during thread rolling, preventing wall surface collapse and burr formation, thereby eliminating the need for deburring post-processing while maintaining low manufacturing costs
3Speed
If in-feed thread rolling is used to manufacture rolled thread screws, then manufacturing speed is high, but burr generation increases
Solution Approach 1:
The patent applies preliminary action by pre-forming salient excess-thickness portions (columnar parts and truncated cone parts) on the blank before high-speed thread rolling. These pre-formed structures prevent wall surface collapse during the rapid plastic deformation process, thereby preventing burr generation even when manufacturing at high speeds
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 effectively minimizes burr generation, reduces the need for deburring operations, and enhances the production yield by ensuring flat axial end surfaces and longer effective screw lengths.
Implementation Method 1
a processing step of plastically deforming the blank into a rolled thread screw
Data Source
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AI summary
A rolled thread screw includes: a screw part having, on an outer circumferential part of the screw part, thread crests and thread grooves disposed alternately along an axial direction of the rolled thread screw; and a columnar part adjoining at least one of both sides of the screw part in the axial direction. An axial end surface of the columnar part is provided with: a first concave surface concave in the axial direction; a second concave surface positioned to an outer circumference of the first concave surface and being concave in the axial direction; and a salient part positioned on a boundary between the first concave surface and the second concave surface and projecting further than a bottom of the first concave surface and a bottom of the second concave surface, the salient part extending in an arc-like shape along a circumferential direction of the columnar part as viewed in the axial direction.