Steering Shaft Connection with Deformed Tube-Sleeve Torque Lock
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Solution Overview
Problem
The existing methods for producing steering spindle parts require additional machining steps to create positive-locking elements, increasing manufacturing complexity and cost, particularly in forming a highly loadable connection portion for transmitting torque.
Innovation Solution
A method where a smooth cylindrical tube and sleeve are jointly deformed during the connection process, forming positive-locking elements without pre-existing structures, reducing the need for separate machining and enhancing the connection's loadability by creating non-circular cross-sectional shapes with projections and depressions that engage in a circumferential direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sleeve is inserted into the tube and non-detachably connected by pressure deformation to generate large wall thickness in the connecting portion, then the connection becomes highly loadable for torque transmission, but additional machining steps are required to create positive-locking elements, increasing manufacturing complexity
Solution Approach 1:
The invention combines the pressure deformation process with the formation of positive-locking elements into a single integrated operation. The grooves and protrusions are created directly during the sleeve insertion and deformation process, eliminating the need for separate machining steps and reducing manufacturing complexity while maintaining high loadability.
Solution Approach 2:
The pressure deformation process itself serves dual purposes: it creates the non-detachable connection between sleeve and tube while simultaneously forming the positive-locking elements (grooves and protrusions). The process is self-sufficient, generating both the connection strength and the locking features without requiring external machining operations.
2Stability of the object's composition
If the tube is plastically deformed by pressure deformation method at cold temperatures to create non-positively locking connection, then the sleeve and tube are permanently connected, but no positive locking is generated in the circumferential direction
Solution Approach 1:
The invention introduces asymmetric features (grooves and protrusions) into the otherwise symmetric cylindrical components. These asymmetric elements engage with each other to provide positive locking in the circumferential direction, preventing relative rotation between the sleeve and tube while maintaining the permanent connection established by pressure deformation.
Solution Approach 2:
The grooves and protrusions are formed in advance on the sleeve and tube surfaces before the final assembly and pressure deformation. This preliminary structuring ensures that when the components are pressed together, the positive-locking elements are already positioned to engage correctly, providing immediate circumferential locking upon connection.
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 simplifies the manufacturing process by eliminating the need for pre-machining positive-locking elements, resulting in a more economical and highly loadable connection that effectively transmits torque without local force peaks, while maintaining the cylindrical shape outside the connecting portion.
Implementation Method 1
the tube to be plastically deformed by means of a pressure deformation method performed at cold temperatures
Implementation Method 2
the tube is pressed with its inner surface from the outside, that is to say radially with respect to the longitudinal axis, against the outer surface of the sleeve
Data Source
AI summary
A method may be utilized to produce a steering spindle part configured as a hollow shaft and having a connecting portion at its end. At least a part of the connecting portion includes increased wall thickness relative to a portion of the steering spindle part adjoining the connecting portion. The method may involve providing a circular, hollow cylindrical tube with an inner surface that is smooth in a circumferential direction, providing a circular, hollow cylindrical sleeve with an outer surface that is smooth in a circumferential direction, inserting the sleeve into an end portion of the tube, and jointly deforming the end portion of the tube and the sleeve such that a flow of material occurs. This flow may form positively locking elements on the tube and the sleeve that engage into one another in the circumferential direction and generate positive locking in the circumferential direction.