Tapered Stud for Ring Gear Flange Shear Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting the ring gear flange to the axle housing, such as spline and nut systems or bolt and bushing systems, are either expensive or unreliable, leading to material weakening and strength issues due to uniform material removal across identical bolt diameters, resulting in costly failures and shearing problems.
Innovation Solution
A tapered stud with a Morse taper structure is used to connect the ring gear flange to the axle housing, providing a self-holding mechanism that reduces shearing risk by decomposing force components and minimizing material removal, thus enhancing shear strength and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bolt and bushing system is used to connect the ring gear flange to the axle housing, then the connection is simpler and cheaper than a spline and nut system, but the reliability is poor and material weakening occurs due to uniform material removal across identical bolt diameters
Solution Approach 1:
The stud diameter varies along its length, with a larger diameter at the shear-critical section and a smaller diameter at the threaded section. This non-uniform diameter distribution optimizes the shear strength where it is most needed while reducing material removal in less critical areas, thereby improving connection reliability without excessive manufacturing complexity
Solution Approach 2:
The stud geometry transitions from a uniform diameter bolt to a tapered stud with varying diameter along its length. This parameter change in the stud's cross-sectional area allows for optimized mechanical properties at different locations, improving both reliability and manufacturing efficiency
2Ease of operation
If multiple bolts with identical diameter are used to connect the ring gear flange, then the connection is straightforward, but significant material removal is required in every section which weakens the material and causes strength problems
Solution Approach 1:
Different sections of the stud have different diameters optimized for their specific functions. The larger diameter section provides the necessary shear strength, while the smaller diameter threaded section reduces material removal requirements, thereby maintaining material strength while ensuring connection simplicity
Solution Approach 2:
The stud is divided into distinct sections with different diameters - a larger unthreaded section for shear resistance and a smaller threaded section for engagement. This segmentation allows each part to perform its optimal function without compromising overall strength
3Strength
If a tapered stud with varying diameter is used, then material removal is minimized and shear strength is enhanced, but the manufacturing process becomes more complex than using standard identical bolts
Solution Approach 1:
The stud manufacturing process incorporates a tapering operation that gradually changes the diameter from the larger end to the smaller end. This controlled parameter change achieves the desired strength optimization while using standard machining processes, keeping manufacturing complexity manageable
Solution Approach 2:
The tapered geometry concentrates material where it is most needed for shear resistance, creating local quality variations that optimize strength without requiring complex manufacturing. The taper angle and length are designed to achieve the desired strength-to-manufacturing-complexity ratio
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
The tapered stud connection offers a reliable and robust attachment with reduced material weakening and increased shear strength, eliminating shearing issues and maintaining structural integrity even with multiple bolts, while minimizing material removal and preventing loosening or displacement.
Implementation Method 1
The force that the bolt threads apply when engaged with the threads on the material is decomposed into vertical and horizontal components with respect to the tapered part and the holding characteristic is provided by the parallel one of said force components
Implementation Method 2
The diameter gradually decreases towards the interior part of the axle, thus, the amount of material removed and the weakening of the material is reduced
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a tapered stud (7) utilized during fixing the ring gear flange (4), used to connect the ring gear (3) located in the axle part of the motor vehicles to the hub swivel (11) provided in the axle housing part, to the axle housing.