Splined Powder Metal Joint Using Dissimilar-Material Race and Gear
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Solution Overview
Problem
There is a need for powder metal parts, such as toroids, gears, and bearing races, that are stronger and more durable to meet stringent performance requirements without increasing costs or compromising part tolerances and uniformity, which existing methods struggle to achieve efficiently.
Innovation Solution
A method involving attaching a powder forged or wrought outer splined plate with a female ID profile to a sintered powder metal inner splined connection gear using sinter brazing, laser brazing, laser welding, or staking, allowing for the use of different materials and precision machining to achieve high strength and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If powder metal parts are made using traditional one-piece design, then manufacturing cost is reduced, but part strength and durability are insufficient to meet stringent performance requirements
Solution Approach 1:
The part is divided into multiple components (outer race and inner gear) that can be manufactured separately using different material systems and then assembled together. This allows each component to be optimized for its specific functional requirements while maintaining manufacturing efficiency.
Solution Approach 2:
The invention uses composite construction by combining different material systems (wrought metal and powder metal) in a single part. The outer race can be made from wrought metal for superior strength and durability, while the inner gear can be made from powder metal for cost-effective manufacturing of intricate geometries.
2Strength
If full density metal is used throughout the entire part, then strength is improved, but manufacturing cost increases significantly
Solution Approach 1:
Different material densities and properties are applied to different regions of the part based on local functional requirements. The outer race receives full density wrought metal for areas requiring high strength, while the inner gear uses lower density powder metal where intricate geometry is the primary requirement.
3Manufacturing precision
If precision machining is performed after heat treatment, then part tolerances are improved, but heat treatment distortion causes poor tolerance achievement
Solution Approach 1:
Precision machining operations are performed on the outer race before heat treatment to establish accurate dimensional relationships. By machining beforehand, the critical tolerances are set before the heat treatment process that could cause distortion, ensuring that final part tolerances are achieved without relying on post-heat treatment machining.
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 results in superior, cost-effective parts with improved performance and tolerances by incorporating full density metal where needed and lower density metal where strength is not required, enabling the production of high-strength, durable parts with reduced costs.
Implementation Method 1
the external component and the internal component are affixed together by a sinter braze
Implementation Method 2
the external component and the internal component are affixed together by a sinter braze
Implementation Method 3
the external component and the internal component are affixed together by a laser braze
Implementation Method 4
the external component and the internal component are affixed together by a laser braze
Implementation Method 5
the external component and the internal component are affixed together by a laser weld
Implementation Method 6
the external component and the internal component are affixed together by a stake
Data Source
AI summary
This invention relates to a method for manufacturing a metal part which comprises attaching a powder forged or wrought outer raced ID splined plate to a powdered metal inner splined connection gear, wherein the outer raced ID splined plate incorporates a female ID profile on the race, wherein the inner splined connection gear contains a mail OD profile on the exterior of the part, and wherein the splined plate and the splined connection gear are attached together by (1) sinter brazing, (2) laser brazing, (3) laser welding, (4) sintering a mechanical joint, or (5) staking. In practicing this method a tight mechanical joint is formed between the splined plate and the splined connection gear which can be made of highly dissimilar materials, such as a wrought metal and a sintered powder metal.