Sheet Metal Spindle Nut Thread Forming Without Cutting
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Solution Overview
Problem
Existing methods for producing spindle nuts from sheet metal face challenges in forming internal threads efficiently, as they require cutting processes that result in high machining forces and moments, making it difficult to achieve good surface quality and strength benefits, especially in thin-walled designs.
Innovation Solution
A spindle nut produced using non-cutting shaping methods like deep drawing or extrusion, where a sheet metal blank is formed into a sleeve portion with a smooth outer surface and a thread is created on the inner face using a tool, allowing for material displacement within the wall to form a reliable thread without cutting, and optionally incorporating a flange or rim for additional functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cutting processes are used to form internal threads in sheet metal spindle nuts, then thread formation is possible, but machining forces are high and surface quality deteriorates
Solution Approach 1:
The patent replaces the traditional cutting-based mechanical thread formation system with a shaping-based system. Instead of using cutting tools that remove material through mechanical separation, the invention employs shaping processes that displace and redistribute material plastically to form threads. This substitution eliminates chip accumulation and reduces machining forces while improving surface quality and component strength.
Solution Approach 2:
The patent changes the fundamental parameter of thread formation from material removal (cutting) to material displacement (shaping). By altering the process mechanism from subtractive to formative, the invention achieves thread formation with significantly lower forces, better surface quality, and enhanced material strength retention in thin-walled sheet metal components.
2Ease of manufacture
If cutting processes are used to form internal threads in sheet metal spindle nuts, then threads can be created, but surface quality deteriorates and strength benefits are lost
Solution Approach 1:
The patent replaces the cutting-based mechanical system with a shaping-based system that displaces material rather than removing it. This substitution prevents surface degradation from chip removal and tool passes, maintaining the original material surface quality while creating precise thread forms through controlled plastic deformation in sheet metal spindle nuts.
Solution Approach 2:
The patent converts the potential harm of high machining forces and surface damage into benefits by using shaping processes. The material displacement mechanism, which initially presents challenges for thin-walled components, is optimized to create threads that enhance surface quality and maintain material strength, turning the complexity of sheet metal forming into a advantageous manufacturing approach.
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 enables the efficient production of spindle nuts with reliable threads and improved surface quality, achieving strength benefits and reduced machining forces, while allowing for the integration of features like flanges and rims, suitable for various screw drive applications, including non-returning ball screw drives and exhaust gas recirculation systems.
Implementation Method 1
a blank having a sleeve portion and a cylindrical outer surface is produced by non-cutting shaping, such as by deep drawing from sheet metal
Implementation Method 2
the thread, in particular in the form of a ball track, is formed on the inner face of the blank by a suitable tool, in particular a thread groover. This shaping takes place by material displacement within the wall of the sleeve-shaped blank
Data Source
AI summary
Methods for producing a spindle nut, and spindle nuts produced by such methods are disclosed. The method for producing a spindle nut may include producing a blank which has a sleeve portion and a cylindrical outer surface by non-cutting shaping from sheet metal; and forming a thread provided for cooperation with a threaded spindle in the blank by non-cutting shaping, while maintaining the cylindrical outer surface of the sleeve portion.