Towing Hook Ball Part Forging and Bending Design
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Solution Overview
Problem
Existing methods for manufacturing ball parts of vehicle towing hooks face challenges in achieving cost-effectiveness and sufficient mechanical properties, particularly due to the need for unique forging dies for each vehicle configuration and issues with fatigue strength in assembled connections.
Innovation Solution
The method involves shaping the attachment part by forging while keeping the cross-sectional shape similar, allowing for variable lengths and shapes of the connecting part, with the attachment part being forged independently and the connecting part subjected to bending, ensuring a single continuous metallic structure with high strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the entire ball part is produced by forging, then sufficiently good mechanical properties are achieved, but it is hardly cost-effective to produce a separate forging die for each vehicle configuration
Solution Approach 1:
The ball part is divided into two segments: the attachment part (ball and connecting part) and the connecting part. The attachment part is forged using a universal die, while the connecting part is produced separately by bending a rod, allowing customization without requiring custom forging dies for each configuration.
Solution Approach 2:
The attachment part and connecting part are joined together through welding or other connection methods, combining the advantages of forged strength in the attachment part with the flexibility and cost-effectiveness of bent rod construction for the connecting part.
2Ease of manufacture
If joining techniques are used to assemble the ball part, then cost-effectiveness is improved, but fatigue strength problems still occur
Solution Approach 1:
The ball part is segmented into a forged attachment part and a separately formed connecting part, allowing each segment to be optimized for its specific function while maintaining overall reliability through proper connection methods.
Solution Approach 2:
The connection between the attachment part and connecting part is achieved through controlled welding or other reliable joining methods, with attention to connection parameters such as weld quality, geometry, and material matching to ensure fatigue strength is maintained.
3Strength
If the connecting part is produced by separate forging, then mechanical properties are improved, but the cross-sectional shape cannot be easily adapted for different vehicle configurations
Solution Approach 1:
The ball part is divided into the attachment part (forged) and the connecting part (bent rod), allowing the connecting part to be easily adapted to different shapes and lengths for various vehicle configurations without compromising the mechanical properties of the forged attachment part.
Solution Approach 2:
The connecting part is produced by bending a rod, which allows for dynamic adjustment of shape and length to suit different vehicle configurations, providing versatility while maintaining structural integrity.
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 approach allows for the production of ball parts with adaptable connecting parts and improved mechanical properties, enabling easy manufacturing and ensuring high strength and durability, while maintaining a smooth external surface on the connecting part and a forging seam on the attachment part.
Implementation Method 1
shaping the latter by forging
Implementation Method 2
the ball is produced by upsetting the material part from which the ball part is made
Data Source
Figure 1~2
Figure 3a~3d
AI summary
Method for manufacturing a ball part of a towing hook. The ball part is composed as is customary of a ball (5) and attachment part (8) to the remainder of the towing hook, a connecting part (7) extending between the ball and the attachment part. Depending on the application, the length and shape of the connecting part vary in each case. The invention proposes to produce the unit by forging. In order to avoid the use of different dies, a material part (15) which is cut to size, depending on the desired shape, is used to which the ball (5) is forged. The shape of the material part (15) corresponds to the shape of the connecting part (7). The end of the material situated opposite the ball is turned into the connecting part (8) by forging.