Swaging Structure Grooves Reduce Load and Prevent Wrinkles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-pressure pressure switches require large swaging loads and are prone to wrinkle formation during the swaging process, leading to increased manufacturing costs and potential quality issues such as dimensional inaccuracies and plating cracks.
Innovation Solution
A swaging structure with grooves formed in the annular side wall of the holder member, allowing for reduced swaging load and preventing wrinkle generation, while maintaining high pressure-resistant performance by providing a deformation margin and increasing the contact area with the swaging tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the annular side wall is increased to enhance pressure-resistant performance, then the pressure-resistant performance is improved, but a large swaging load is required
Solution Approach 1:
Grooves are formed in the annular side wall before the swaging process to create preliminary deformation paths. This preliminary action allows the material to yield more easily during swaging, reducing the required swaging load while maintaining the necessary thickness for pressure resistance
Solution Approach 2:
The grooves create localized regions of reduced material density and strength in specific areas of the annular side wall. This local modification allows controlled deformation at the groove locations during swaging, facilitating the shaping process with lower loads while preserving overall structural integrity
2Strength
If the thickness of the annular side wall is increased to enhance pressure-resistant performance, then the pressure-resistant performance is improved, but the facility cost and manufacturing space are increased
Solution Approach 1:
By forming grooves beforehand, the swaging process becomes simpler and requires less complex equipment. The preliminary groove formation creates natural deformation zones that reduce the complexity of the swaging operation and the size of manufacturing facilities needed
Solution Approach 2:
The groove geometry parameters (depth, width, spacing) are optimized to achieve the desired deformation characteristics. By carefully controlling these parameters, the swaging process can be performed with simpler equipment and less manufacturing space while still achieving the required wall thickness for pressure resistance
3Strength
If the annular side wall is swaged with high load to achieve thick wall retention, then the pressure-resistant performance is improved, but wrinkles are formed on the swaged portion
Solution Approach 1:
The grooves are formed before swaging to create predetermined deformation paths. This preliminary action guides the material flow during swaging, preventing uncontrolled buckling and wrinkle formation that would otherwise occur with high-load swaging of thick walls
Solution Approach 2:
The grooves create localized deformation zones that concentrate the plastic flow in specific areas. This local modification of material properties allows the thick annular side wall to be swaged without generating wrinkles, as the grooves provide controlled yielding points that prevent material instability
4Strength
If the annular side wall is swaged with high load to achieve thick wall retention, then the pressure-resistant performance is improved, but the swaging die is quickly worn
Solution Approach 1:
By forming grooves before swaging, the required swaging load is significantly reduced. This preliminary groove formation protects the swaging die from excessive mechanical stress and rapid wear, extending die life and reducing manufacturing costs while still achieving thick wall retention for pressure resistance
Solution Approach 2:
The groove parameters are designed to optimize the deformation characteristics during swaging. This parameter optimization reduces the peak loads and stress concentrations on the die, minimizing wear and extending die life while maintaining the ability to produce thick-walled pressure-resistant components
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
Enables swaging with lower loads, reduces the risk of wrinkle formation, and allows for a thicker swaging portion to be formed with the same load, enhancing manufacturing efficiency and maintaining high pressure-resistant performance.
Implementation Method 1
a deformation margin at the time of plastic deformation of the swaging portion by swaging escapes to the groove, and thus resistance during swaging is small
Data Source
AI summary
A swaging structure for which swaging process is easy, generation of wrinkles can be prevented, and which has high pressure-resistant performance is provided. In a swaging structure including at least a to-be-swaged member required to have airtightness to a surrounding environment and a swaging member constituted to retain the to-be-swaged member by a swaging processing, the swaging member has an annular side wall surrounding the to-be-swaged member, and a groove is formed in the annular side wall.