Tool Socket Production Method for Abrasion-Resistant Rib
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Solution Overview
Problem
The existing tool socket designs for handheld rotating and chiseling power tools face challenges with high mechanical loads and vibrations, requiring a durable connection between the rib and the main body, while current production methods like soldering and welding are laborious, and adhesives or press fits are unsuitable.
Innovation Solution
A production method involving a hollow spindle made of unalloyed or low-alloyed steel and an insert of high-alloyed tool steel, where the insert is soldered into the spindle above the steel's Ac3 temperature, followed by heat treatment in a carbon-containing atmosphere to carburize the spindle without affecting the insert, and a multi-stage hardening process to achieve abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to fix the rib to the main body, then the connection durability is improved, but the manufacturing complexity and labor required increase significantly
Solution Approach 1:
The rib is pre-hardened before assembly, and the main body is pre-prepared with recesses. The hardening process is completed in advance, allowing the rib to be simply pressed into the main body without requiring complex soldering or welding operations during final assembly.
Solution Approach 2:
The patent replaces the thermal joining processes (soldering, welding) with a mechanical press-fit system. The rib is forced into the recess of the main body through mechanical pressure, creating a durable connection without the need for thermal processes or additional materials.
2Reliability
If tool steel is used for the rib to achieve high abrasion resistance, then the rib durability is improved, but the material becomes difficult to process during production
Solution Approach 1:
The tool steel rib is hardened in advance through a preliminary heat treatment process before assembly. This allows the rib to achieve its full hardness and abrasion resistance properties before being installed, eliminating the need to process hard material during final assembly operations.
Solution Approach 2:
The patent changes the temperature parameter during processing - the rib is heated to austenitizing temperature for hardening, then cooled to achieve the desired hardness. This parameter control allows the material to be soft during forming operations but hard during service.
3Reliability
If high hardening temperature is applied to the tool steel rib, then the abrasion resistance is improved, but the material loses hardness and becomes soft during heat treatment
Solution Approach 1:
The rib undergoes preliminary hardening treatment before assembly, achieving the desired hardness. The main body is then heat treated at a lower temperature that does not affect the already-hardened rib, preserving its hardness while treating the main body material.
Solution Approach 2:
The patent applies different heat treatment conditions to different parts of the assembly. The rib receives high-temperature hardening treatment, while the main body receives a lower-temperature treatment that preserves the rib's hardness. This localized quality control ensures each component receives appropriate treatment.
4Ease of manufacture
If adhesives or press fit are used to fix the rib, then the manufacturing process is simplified, but the connection durability is insufficient for high mechanical loads
Solution Approach 1:
The rib and main body are pre-prepared with precise geometric features (rib dimensions and recess geometry) that enable a durable press-fit connection. This preliminary precision work allows simple assembly without adhesives while maintaining high connection strength.
Solution Approach 2:
The patent replaces chemical bonding (adhesives) with a mechanical interference fit system. The rib is designed with dimensions that create radial pressure and frictional engagement with the recess, providing a durable mechanical connection that can withstand high mechanical loads and vibrations.
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 results in an abrasion-resistant rib with improved durability and ease of production, effectively addressing the high mechanical loads and vibrations encountered during drilling.
Implementation Method 1
The insert is soldered into the hollow spindle at a temperature that is above the Ac3 temperatures of the steel grades employed
Implementation Method 2
The heat treatment in the combined structure is carried out at a temperature between 800° C. and 950° C. in an atmosphere that contains sufficient carbon to carburize the hollow spindle
Implementation Method 3
The combined structure is cooled down in a salt bath or liquid bath subsequent to the heat treatment
Implementation Method 4
The hardening process entails at least heating the steel up to a temperature at which carbides dissolve as well as a tempering procedure repeated three times at a temperature between 500° C. and 600° C.
Data Source
AI summary
A production method for a tool socket includes forming a hollow spindle An elongated recess is provided in the wall. The spindle includes unalloyed or low-alloyed steel grades. An insert includes a high-alloyed tool steel. The insert has a pedestal that is complementary to the recess and it also has a rib. The insert is placed into the hollow spindle in such a way that the pedestal rests in the recess and the rib projects into the interior of the spindle. The pedestal is soldered into the recess at a temperature that is above the Ac3 temperatures of the steel grades employed. The combined structure is cooled and then undergoes a heat treatment in an atmosphere containing sufficient carbon to carburize the hollow spindle but not sufficient to carburize the insert. The heat treatment of the combined structure is carried out at a temperature between 800° C. and 950° C. The combined structure is cooled down in a salt bath or liquid bath subsequent to the heat treatment.