Steering Spindle Hollow Shaft Sleeve Reshaping
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Solution Overview
Problem
The production of steering spindle parts for motor vehicles is labor-intensive and difficult to control due to the need for reshaping tubes with greater wall thickness over their entire length to achieve the required torque transfer, leading to increased weight and material inefficiency.
Innovation Solution
A method involving the use of a sleeve inserted into the end section of a hollow-cylindrical tube, which is then reshaped jointly with the tube to create a connection section with increased wall thickness, allowing for a strong force-closure connection and eliminating the need for reshaping the tube over its entire length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tube is reshaped over its entire length to achieve adequate wall thickness in the connection section, then the structural integrity for torque transfer is improved, but the manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The connection section is segmented from the remaining tube length by inserting a sleeve into the end section. This allows the sleeve to be reshaped independently with the tube end to create increased wall thickness only where needed, rather than reshaping the entire tube length. The segmentation enables focused manufacturing effort on the critical connection zone.
Solution Approach 2:
The sleeve provides localized wall thickness enhancement only in the connection section where adequate thickness is required for torque transfer and threaded joint formation. The remaining tube length maintains its original, thinner wall thickness, optimizing the overall weight while ensuring structural integrity at the critical connection point.
2Strength
If a tube with greater wall thickness is used to ensure adequate torque transfer, then the structural integrity is improved, but the weight of the steering spindle part increases
Solution Approach 1:
The sleeve creates a localized thick-walled connection section only where required for torque transfer and threaded joint formation. The remaining tube length maintains its original, thinner wall thickness, optimizing the overall weight while ensuring structural integrity at the critical connection point.
3Strength
If the tube is reshaped over its entire length, then the connection section achieves adequate wall thickness, but the material usage and production cost increase
Solution Approach 1:
The sleeve enables localized wall thickness enhancement only in the connection section through targeted reshaping. The remaining tube length requires no reshaping and maintains its original wall thickness, minimizing material usage while ensuring adequate thickness at the critical connection zone.
Solution Approach 2:
By segmenting the connection section from the rest of the tube using a sleeve, the reshaping process is confined to only the necessary portion. This prevents unnecessary material removal or addition in sections where adequate wall thickness already exists.
4Strength
If the tube is reshaped over its entire length, then the connection section achieves adequate wall thickness, but the production time and labor intensity increase
Solution Approach 1:
The sleeve segments the connection section, allowing the reshaping process to be applied only to the sleeve and tube end rather than the entire tube length. This significantly reduces the time and labor required for the reshaping operation.
Solution Approach 2:
The sleeve is inserted into the tube end before the reshaping process begins. This preliminary action prepares the connection section for localized reshaping, eliminating the need for lengthy full-length tube reshaping operations and improving production efficiency.
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 simplifies and cost-effectively produces steering spindle parts with a connection section of adequate wall thickness for torque transfer, reducing material usage and weight while maintaining structural integrity.
Implementation Method 1
wherein creeping of the material of the tube and of the sleeve takes place
Data Source
AI summary
A method for the production of a steering spindle part is provided. The method includes forming a section of a steering spindle for a motor vehicle and which is implemented in the form of a hollow shaft and includes at least a connection section adjoining one of its ends. The connection section has at least over a portion of its length a wall thickness (D) which, compared to a section of the steering spindle part adjoining the connection section, is increased, for the production of the steering spindle part as the starting produce is utilized an initially hollow-cylindrical tube, which is at least section-wise reshaped. For the formation of the connection section, a sleeve is set into an end section of the tube and the end section of the tube and of sleeve are subsequently jointly reshaped.