Swaging Tool Lattice Structure for Lightweight Strength
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Solution Overview
Problem
Existing swaging tools are often heavy, inefficient, and costly, and there is a need for lightweight, efficient, and cost-effective solutions for connecting fluid conduits with fittings.
Innovation Solution
The method involves manufacturing swaging tools using additive manufacturing, incorporating lattice structures and recesses within the body and jaw, and conducting stress analysis to optimize material distribution, resulting in a lightweight and efficient tool design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional manufacturing methods are used for swaging tools, then structural integrity is maintained, but weight and manufacturing cost increase
Solution Approach 1:
The patent applies lattice structures (porous material arrangement) within the swaging tool body to reduce weight while maintaining structural integrity. The lattice structure provides a framework that distributes mechanical loads throughout the tool, preventing catastrophic failure while using significantly less material than solid construction.
Solution Approach 2:
The patent utilizes additive manufacturing technology to change the manufacturing parameters and material distribution within the tool. This enables complex internal lattice structures and optimized material placement that would be impossible with traditional subtractive manufacturing methods, achieving weight reduction without compromising strength.
2Weight of moving object
If material is removed to reduce weight, then swaging tool weight decreases, but manufacturing complexity increases
Solution Approach 1:
Instead of starting with solid material and removing portions (traditional subtractive manufacturing), the patent inverts the approach by building the tool layer-by-layer using additive manufacturing. This allows direct creation of complex lattice structures and internal geometries without requiring complex machining or material removal operations.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive to additive processes. This enables the direct fabrication of complex internal lattice structures and optimized material distributions that would be extremely difficult or impossible to achieve through traditional material removal methods.
3Ease of manufacture
If uniform material distribution is used, then manufacturing is simplified, but stress resistance and efficiency decrease
Solution Approach 1:
The patent applies local quality by varying material distribution throughout the tool body based on stress analysis. High-stress areas receive denser material concentration while low-stress areas have reduced material content. This non-uniform distribution optimizes both stress resistance and weight efficiency, with each local region having the appropriate material density for its functional requirements.
Data Source
AI summary
A method of manufacturing a swaging tool includes forming a body of the swaging tool via additive manufacturing, forming a jaw of the swaging tool, and connecting the jaw with the body. Forming the body may include providing a portion of the body with a lattice structure. The portion may be internal and may not be externally accessible. Forming the body may include adding material to form at least one recess in an outer surface of the body. The method may include conducting a stress analysis. The at least one recess may be formed based on or according to the stress analysis.