Sintered Press-Fit Assembly for Concentric Gear-Shaft Joining
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Solution Overview
Problem
The production of press fit connections in mechanical engineering is costly due to the need for tight production tolerances and additional mechanical processing steps, such as turning, milling, or grinding, to achieve concentricity in gears and shafts.
Innovation Solution
The use of sintered components with net shape or near net shape quality in the annular component section, which eliminates the need for mechanical processing and allows for improved concentricity and bond strength through the plasticization of the sintered material during the press fit formation, enabling easier and more cost-effective production of gears with uniform tooth root circles and inner diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical processing methods (turning, milling, grinding) are used to achieve tight tolerances for press fit connections, then manufacturing precision is improved, but device complexity and production cost increase due to additional working steps
Solution Approach 1:
The sintering process is performed before mechanical processing, creating a green compact with predetermined geometry. The pressing operation in the sintering process preliminarily establishes the inner diameter and outer diameter dimensions, eliminating or reducing the need for subsequent mechanical machining operations to achieve the required tolerances for press fit connections.
Solution Approach 2:
The invention changes the material state from solid metal requiring mechanical machining to sintered compact that can be directly formed to near-net shape. By controlling sintering parameters (temperature, pressure, time) and green compact density, the inner diameter tolerance is improved to within ±30 μm without requiring traditional mechanical processing steps.
2Manufacturing precision
If tight production tolerances are required for press fit connections, then concentricity is improved, but productivity decreases due to additional mechanical processing steps
Solution Approach 1:
The sintering process preliminarily establishes the concentricity of the gear by forming the green compact with predetermined inner and outer diameters. The pressing operation creates a uniform density distribution that ensures concentricity within acceptable tolerances, eliminating the need for subsequent grinding or turning operations that would reduce productivity.
Solution Approach 2:
The invention extracts or removes the mechanical processing steps (turning, milling, grinding) from the production sequence. By achieving the required concentricity and tolerance directly through sintering, the time-consuming mechanical machining operations are eliminated, significantly improving production efficiency while maintaining quality standards.
3Manufacturing precision
If mechanical processing is used to achieve uniform tooth root circles, then manufacturing precision is improved, but production cost increases due to additional working steps
Solution Approach 1:
The invention changes the manufacturing approach from mechanical removal of material to sintering with controlled density distribution. By adjusting the green compact density and sintering parameters, uniform tooth root circles are achieved directly during the sintering process, eliminating the need for additional machining operations and improving ease of manufacture.
Solution Approach 2:
The pressing operation in sintering preliminarily establishes the uniform geometry of the tooth root circle by compacting the green metal powder to a controlled density distribution. This preliminary action ensures that the tooth root circles are uniform before the sintering process completes, eliminating the need for subsequent machining to achieve this geometry.
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 simplifies the production of press fit connections by reducing the need for mechanical processing, improving concentricity accuracy, and enhancing bond strength, while allowing for greater tolerance compensation, thus reducing production costs and improving the force fit's reliability.
Implementation Method 1
Due to the sintered material being plasticizable in the creation of the press fit, the surfaces of the two components can better adapt to one another, so that the bond strength can be improved
Implementation Method 2
When joining the force fit, the sintered material may also be compressed at the inner diameter
Data Source
AI summary
A method for connecting a first component to a second component to form an assembly forms a press fit connection between the first component and the second component, for which purpose the second component is produced having an annular component section. A recess is formed, in which the first component is at least partially arranged. At least the annular component section of the second component is produced as a sintered component and has net shape or near net shape quality at least in the region of the recess.