Stabilizer Tube End Forging With Molten Sealing Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional method for manufacturing stabilizers requires high pressing forces and can result in larger connecting plates, leading to deteriorated workability and potential size issues, while also risking the opening of pores on the connecting plate's end surface.
Innovation Solution
A method involving a forging step where both end portions of the material tube are crushed in a radial direction with a sealing metal plate heated above its melting point disposed inside, allowing the plate to spread and cover the inner surfaces, reducing pressing force requirements and preventing pore opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both end portions of the material tube are crushed together with a cylindrical insert material in the radial direction to form the connecting plate, then pores communicating with the inside of the main body bar are suppressed, but workability is deteriorated and the size of the connecting plate becomes larger
Solution Approach 1:
The invention changes the physical state of the sealing material from solid (cylindrical insert) to liquid (molten metal) by heating it above its melting point. This parameter change allows the sealing material to flow and fill pores effectively while reducing the pressing force needed, thus improving workability without compromising pore suppression capability
Solution Approach 2:
The invention utilizes the phase transition of the sealing material from solid to liquid state during the forging process. By heating the sealing material above its melting point, it transitions to a liquid state that can easily flow and fill pores in the connecting plate, achieving effective sealing with reduced forming forces and without increasing the connecting plate size
2Reliability
If both end portions of the material tube are crushed together with a cylindrical insert material in the radial direction to form the connecting plate, then pores communicating with the inside of the main body bar are suppressed, but the size of the connecting plate becomes larger
Solution Approach 1:
The invention changes the physical state of the sealing material from solid to liquid by heating it above its melting point. This allows the sealing material to flow into pores under lower pressure, achieving effective pore suppression without requiring excessive forming force that would increase the connecting plate dimensions
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 method effectively suppresses pore opening on the connecting plate's end surface while maintaining workability and the connecting plate's size, enhancing manufacturing efficiency and preventing deformation.
Implementation Method 1
a sealing metal plate heated to a temperature equal to or higher than a melting point is disposed inside both end portions of the material tube heated to a temperature lower than the melting point
Implementation Method 2
both end portions of the material tube are crushed in a radial direction to be formed into the connecting plate
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for manufacturing a stabilizer (1), the stabilizer (1) including a main body bar (11) that is elastically deformable, and a pair of connecting plates (12) that are separately connected to a pair of left and right suspension devices (50), the method including a forging step of forming the connecting plate (12) by forging both end portions of a material tube (W), in which in the forging step, both end portions of the material tube (W) are crushed in a radial direction to be formed into the connecting plate (12) in a state where a sealing metal plate (17) heated to a temperature equal to or higher than a melting point is disposed inside both end portions of the material tube (W) heated to a temperature lower than the melting point.