Solid Formed Suspension Leg Turret with Rigidity Structures
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Solution Overview
Problem
Conventional methods for producing spring strut domes, such as casting, result in components with internal defects and poor mechanical properties due to surface cracks, pores, and gas inclusions, while solid forming lacks the complexity and rigidity needed for optimal mechanical performance.
Innovation Solution
A method involving solid forming to create a spring strut dome with increased rigidity through the introduction of structures like ribs and increased wall thickness, combined with semi-finished product processes like rolling, forging, and pressing, which allows for reduced wall thickness and improved stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If casting processes are used to produce spring strut domes with complex structures, then weight is reduced and design freedom is increased, but internal defects such as cracks, pores, and gas inclusions occur which weaken the component
Solution Approach 1:
The patent replaces the casting process with a solid forming process (specifically deep drawing followed by localized plastic deformation). This substitution eliminates the harmful effects of gas inclusions, pores, and cracks inherent in casting, while achieving the desired complex geometries and rigidity-increasing structures through mechanical forming of solid metal sheets.
2Reliability
If solid forming is used to produce spring strut domes, then mechanical properties are improved and internal defects are eliminated, but the complexity of structures and rigidity are insufficient
Solution Approach 1:
The patent performs preliminary deep drawing to create a basic dome geometry, then subsequently introduces rigidity-increasing structures (such as ribs, beads, or localized thickening) through additional plastic deformation steps. This staged approach allows the build-up of structural complexity while maintaining the advantages of solid forming.
Solution Approach 2:
The patent applies localized plastic deformation to specific areas of the spring strut dome to create rigidity-increasing structures only where needed. This allows complex geometries and enhanced stiffness in critical regions while maintaining simpler forms in non-critical areas, optimizing the balance between structural complexity and mechanical performance.
3Strength
If local material doubling is used to meet mechanical properties in shell design, then strength is increased, but the number of parts and joining effort increase
Solution Approach 1:
The patent merges the dome shell and rigidity-increasing structures into a single integrated component formed through solid forming processes. This eliminates the need for separate reinforcement parts and their associated joining operations, while achieving the required strength through localized material thickening and geometric features created during forming.
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 enhances the mechanical properties of spring strut domes by reducing susceptibility to defects and increasing process reliability, achieving high strength and resilience with a reduced number of parts and wall thickness.
Implementation Method 1
massive forming of a semi-finished product (10; FIG. 1), in particular of a circuit board (11; FIG. 1), to the shape of a spring strut dome (2; FIG. 1), with a change taking place during the forming both with regard to the wall thickness and the shape of the cross section of the semi-finished product
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention concerns a method of producing a suspension leg turret (2) with a turret element (4) as a separate part of the bodywork. The semi-finished product is brought into the shape of the turret element (4) by solid forming, by means of which rigidity-enhancing structures are also incorporated into the turret element (4). The invention also concerns a suspension leg turret with a turret element (4), in particular produced by a method according to the invention, the turret element (4) being designed as a solid-formed part and an assembly consisting of a suspension leg turret according to the invention and at least one adjacent component of the motor vehicle.