Stabilizer Tube-End Forging With Molten Sealing Plate
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Solution Overview
Problem
Conventional methods for manufacturing stabilizers require high pressing forces and can result in larger connecting plates, compromising workability and the suppression of pore openings on the end surface of the connecting plate.
Innovation Solution
A method involving a forging step where both end portions of a 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 openings.
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 can be suppressed, but workability is deteriorated by requiring large pressing force
Solution Approach 1:
The invention changes the physical state of the insert material from solid (cylindrical) to liquid (molten metal) by heating it above its melting point. This parameter change allows the metal to flow and fill pores more effectively while reducing the force required for forming, thus resolving the contradiction between pore suppression and workability
Solution Approach 2:
The invention utilizes the phase transition of the insert material from solid to liquid state during the forging process. The cylindrical insert material is heated above its melting point to become molten metal, which then fills and seals pores in the connecting plate during radial crushing, achieving effective pore suppression with reduced pressing force
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 can be suppressed, but the size of the connecting plate becomes larger than current ones
Solution Approach 1:
By changing the insert material from solid cylindrical form to molten metal state, the material can conform precisely to the desired connecting plate dimensions during forging. The liquid metal fills the mold cavity exactly to the required size, preventing over-forming and ensuring the connecting plate maintains its current compact size while still achieving pore suppression
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 openings on the end surface of the connecting plate while maintaining workability and the size of the connecting plate, 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
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
Data Source
AI summary
A method for manufacturing a stabilizer, the stabilizer including a main body bar that is elastically deformable, and a pair of connecting plates that are separately connected to a pair of left and right suspension devices, the method including a forging step of forming the connecting plate by forging both end portions of a material tube, in which in the forging step, both end portions of the material tube are crushed in a radial direction to be formed into the connecting plate in a state where 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.