Patent Application
20200300283
The present invention relates to a connecting element for the non-detachable joining of at least two components by means of friction welding, as well as a composite arrangement with at least one connecting element which connects at least two components by means of friction welding.
In the automated joining technology of metallic materials or components, the processing time or processing speed represents an essential productivity and cost factor. The demand for shorter processing times is therefore widespread. However, this demand can collide with technical boundary conditions, such as a high axial force on the joining element when joining by friction welding, which results in an increase in the processing time, or with the demand for a reduction in the quantity of metal chips when the joining element is turned.
From DE 10 2009 006 775 A1, a joining element for joining two workpieces attached to each other is known. A penetration section of the joining element has a spherical protrusion with a shape that is intended to facilitate penetration of the joining element into the first workpiece, such as an annular edge, a cutting edge or a gap-shaped recess.
The protrusion formation of the penetrating section causes the workpieces to be processed. Problems are associated with such processing, such as an increase in the amount of metal chips when turning the joining element and an insufficient strength of the connection produced.
From DE 10 2010 017 550 A1 discloses a connecting element for producing a friction welded connection of at least two plate-like components. The connecting element has a thread-shaped non-circular profile, through which displaced material is to be led away in a targeted manner.
Problems are associated with such processing, such as an increase in the amount of metal chips when the connecting element is turned and an increase in processing time required to an increase in the force applied and required for the connecting element.
It is therefore the object of the present invention to eliminate or at least partially eliminate the disadvantages described above with regard to a connecting element or joining element. In particular, it is the object of the present invention to provide a connecting element for the non-detachable joining of at least two components by means of friction welding as well as a composite arrangement with at least one connecting element, whereby a strength of the produced connection is improved and/or the production of the connection becomes more efficient and preferably a reduction of the material waste and/or the processing time resulting from the connection is achieved.
The preceding object is solved by the independent patent claims. Accordingly, the object is solved by a connecting element for the non-detachable joining of at least two components by means of friction welding with the features of claim 1 and by a composite arrangement with at least one connecting element, which connects at least two components by means of friction welding, with the features of claim 10. Further features and details of the invention are located in the dependent claims, the description and the drawings. Features and details which are described in connection with the connecting element are also valid in connection with the composite arrangement and vice versa, so that with regard to disclosure, reference is or can always be made to the individual aspects of the invention.
According to a first aspect, the object is solved by a connecting element for the non-detachable connection of at least two, in particular plate-shaped, components by means of friction welding when the connecting element is rotated about a longitudinal axis of the connecting element. The connection is to be understood as joining and the connecting element is a joining element or a friction-welded connecting element.
The connecting element comprises:
The stem face has a stem end face facing an outer area, which has a convex envelope and/or a convex shape. The envelope has a blunt shape or the shaft end face has a blunt shape.
In the present case, the terms “stem face” and “stem end face” are used equivalently with regard to the shape of the stem face or the stem end face or denote the same object. In addition, however, the front of the stem face may, unlike the stem end face, designate an inner area of the subject in question. If a reference is made to a course of the stem end face, a spatial 2D course is designated.
The envelope of the stem end face is to be understood as a surface which envelops the stem end face and whose points connect relative maxima of the stem end face. A relative maximum of the stem end face is preferably a mountain shaped or mound shaped elevation of the stem end face, wherein the stem end face may have a plurality of relative maxima. The relative maxima are preferably support points of a 2D interpolation surface, preferably the interpolation is linear or formed by splines. The 2D interpolation surface preferably connects the relative maxima or support points with each other and can thus form the envelope.
The envelope of the stem end face is convex if the envelope can be represented by a convex function in a section plane through the envelope. The section plane is preferably a longitudinal section plane comprising the longitudinal axis or a section plane perpendicular to the longitudinal axis. A function is convex if the following conditions are met for the entire range of the function:
A surface, preferably the stem end face or its envelope, has a blunt shape if it is not pointed or not angular or not sharp-edged. Preferably, a surface has a blunt shape if, in the longitudinal or cross-sectional plane, the surface is represented or can be represented by a continuous function, the first derivative of which is continuous between the edges of the function.
A surface with a blunt shape can be regarded as a blunt surface. A stem end face with a projection having an annular edge, a cutting edge or a gap-shaped recess can be regarded as angular or sharp-edged, respectively, and does not have a blunt shape. In particular, the envelope of such a stem end face is not blunt.
According to a second aspect, the object is solved by a composite arrangement comprising at least two components and at least one connecting element according to the first aspect, by which the components are inseparably connected by friction welding.
The components are preferably plate-shaped and/or sheet metal shaped. However, the components may also be of a different configuration. For example, a first component, which is the first to be penetrated by the connecting element, may be plate-shaped. A second component, on which the first component is placed flat and joined by the connecting element, can be cuboid or cube-shaped or can be of any shape, provided it has a flat surface in some areas, against which the first component can rest.
When producing the connection, the connecting element can first be turned into at least one first component by rotation and axial pressure, moved through it and pressed into a subsequent component without penetrating it. The friction generated by the twisting and indentation causes the connecting element and the contacted surrounding component material to become hot, which makes the component material deformable, and to be displaced by the advancing connecting element, so that the connecting element is connected to the corresponding components by material adhesion while the components are held in contact with each other.
The formation of the connecting element surface which contacts, rubs against, softens, deforms and penetrates the components, in particular the formation of the stem end face and/or an external stem surface of the penetrating stem area, is largely responsible for generating the friction between the connecting element and the components and thus for the efficiency of the friction welding. The feature where the stem end face has i) a convex shape with an obtuse course and/or ii) a convex envelope with an obtuse course advantageously causes:
In a preferential further development of the invention, the stem end face has a blunt surface shape which has a surface structure deviating from a spherical shell segment with friction-enhancing elements. The stem end face preferably comprises at least one of the following friction-enhancing elements:
The described surface structures or surface shapes increase the friction or the coefficient of friction between the stem end face and the components. The increased friction, in turn, causes increased heat development at the contact surface or friction surface and/or a stronger abrasion effect and can advantageously facilitate the penetration of the connecting element and cause an increased efficiency of the friction welding as well as a reduction of the processing time or cycle time without producing material waste, e.g. chips.
In a preferential further development of the invention, the envelope of the stem end face has a round or arc-shaped outline in the longitudinal section plane. This has the advantage of reducing the amount of material waste produced during the manufacture of the connection, because the absence of edges, especially sharp edges, or of points reduces or even avoids the generation of chips when the connecting element is screwed in.
Overall, the round or blunt shape of the penetrating portions of the connecting element, including the stem end face and the outer surface of the forming area and the friction-enhancing elements provided in these portions, ensures that increased friction and, consequently, increased efficiency of the friction welding is achieved while avoiding entanglement of the penetrating portions.
According to a further preferential further development of the invention, the envelope of the stem end face is rotationally symmetrical about the longitudinal axis and/or has a circular outline in the cross-sectional plane. This can advantageously facilitate production and reduce production costs (a rotationally symmetrical element is easier and cheaper to produce than a non-rotationally symmetrical element).
In a further preferential further embodiment of the invention, the envelope of the stem end face has a circular or parabolic or elliptical outline in the longitudinal plane. In combination with the rotationally symmetric shape, such an outline has the advantageous effect of good friction and at the same time avoiding waste of material, while at the same time the production is easy and the production costs are low.
According to a preferential further embodiment of the invention, the stem comprises at least two sections including a mold section starting from the free end of the stem and a retaining section starting from the head of the stem. The retaining section forms an upper part of the stem which retains the head, and the mold section forms a lower part of the stem which adjoins the stem face and which, together with the stem face, contributes to the generation of increased friction between connecting element and components and thus to an increased friction welding effect.
In a preferential further development of the invention, the mold section has in the cross-sectional plane a polygonal, i.e. polygonal or polygonal, outline with rounded corners, preferably the distances between the corners i) being of equal length in order to cause a uniform rotary movement during friction welding, and/or ii) being straight and/or curved in some areas in order to cause increased friction between connecting element and components while at the same time avoiding waste.
According to a further preferential further embodiment of the invention, the polygon-shaped outline of the mold section has at least three, four or six corners. This is advantageous in that it increases the friction between the connecting element and the components while at the same time reducing waste and lowering the production costs of the connecting element.
In a preferential further embodiment of the invention, an outer surface of the mold section is flat in certain areas, preferably the outer surface of the mold section comprising at least three flat or approximately flat surface sections. An approximately flat shape is to be understood as a slightly curved shape which deviates only slightly from the flat shape. This will advantageously result in a blunt course of the outer surface or contact surface and at the same time in increased friction between the connecting element and components, while at the same time avoiding waste.
In case of a preferred further embodiment of the invention, the mold section is cylindrical or approximately cylindrical in shape. In this context, a cylindrical form is to be understood as a form in which, in a longitudinal sectional plane, the outline of the mold section runs parallel or approximately parallel to the longitudinal axis, where the mold section does not necessarily have to be rotationally symmetrical with respect to the longitudinal axis.
Furthermore, according to a preferred further embodiment of the invention, the mold section has an outline in the cross-sectional plane which is arc-shaped or rectilinear in certain areas. Preferably, the mold section in the cross-sectional plane has an outline which is alternately rectilinear and arc-shaped in areas. The largely round shape, which nevertheless deviates from a circular shape, can advantageously result in increased friction while at the same time reducing the material waste produced during the manufacture of the connection.
In the case of a preferred further embodiment of the invention, the outer surface of the mold section is profiled around the longitudinal axis in the circumferential direction and exhibits in particular radial grooves, notches or depressions. Such a profile is characterized in the cross-sectional plane by corresponding radial variations of the circumferential contour. The profiling including recesses of any kind preferably has a rounded shape or contour in the cross-sectional plane. The largely round shape, which nevertheless has friction-enhancing elements, can advantageously result in increased friction and at the same time reduce the amount of material waste produced when producing the connection.
Alternatively, the outer surface of the mold section is preferably smooth around the longitudinal axis in the circumferential direction. In this way an additional reduction of the material waste produced during the manufacture of the connection and/or a uniform transmission of force over the outer surface of the mold section and a reliable friction-welded connection with short cycle times can be achieved.
According to a further preferred further embodiment of the invention, the outer surface of the mold section is tripolygonal in shape. Tripolygonal here means in particular that the outer surface of the mold section comprises three polygonal surfaces, preferably four corner surfaces or rectangular surfaces. This is advantageous for rolling in the first component and thus for increased frictional heat and improved screw-in behavior of the connecting element. In addition, it may preferably be provided that the connecting element, excluding the tip, i.e. the stem end face, is electroplated.
In a preferred further embodiment of the invention, an outer surface of the retaining section is cylindrical or approximately cylindrical or conical and in particular smooth. This is advantageous in order to facilitate the screwing in or penetration of the connecting element and the transfer of the plasticized component material.
Furthermore, according to a preferred further embodiment of the invention, a transition between i) the stem face and the outer surface of the mold section and/or ii) between the mold section and the retaining section is rounded. This additionally causes a rounded or blunt shaping of the sections of the connecting element penetrating into the components. This is advantageous in ensuring that there are no edges or points in the relevant area of the stem external face.
In a preferred further embodiment of the invention, a lower surface of the head facing the stem has a circumferential groove. This configuration corresponds to a groove and enables the accommodation of component material displaced or formed during the manufacture of the connection so that an outer edge on the bottom of the head lies flat on the upper of the interconnected components and additionally seals the resulting friction-welded connection against moisture penetration.
In a further preferred embodiment of the invention, an upper side of the head facing away from the stem features a torque coupler for transmitting the torque from the rotary tool to the head of the connecting element during friction welding. Preferably, the torque coupler has radial grooves, recesses or projections. This is advantageous for efficient torque transmission to the head and for simple and cost-effective production of the entire connecting element. Such a torque coupler is particularly suitable for automated applications, because the rotary tool does not need to be positioned very precisely when it is lowered onto the connecting element head to provide effective torque transmission to the connecting element.
In a preferential further embodiment of the invention, the connecting element is formed of a steel alloy, preferably of a screw-quenching and tempering material, or of a manganese- and/or boron-containing steel, in particular 20MnB4, 23MnB4 or 22MnB5. Alternatively, the connecting element is made of a Ti alloy. In particular, the connecting element has a martensitic structure. Alternatively, the connecting element has an austenitic microstructure, which is known to have a high strength. The surface of the connecting element is preferably hardened, for example by carburization, which creates a particularly resistant penetration layer.
A connecting element with a surface coating is also preferred. This is preferably applied by means of electroplating, or by a chemical nickel method, by plasma spraying, kinetic cold gas compacting, flame spraying, hard chromium plating, or by physical vapor deposition. For a particularly high hardness, the connecting element comprises at least in some areas high-carbon steel, in particular with a cementitious structure.
In accordance with a further preferred further embodiment of the invention, at least the stem end face, if necessary, also the stem including the mold area and retaining section, is electrogalvanized, preferably a layer of a material comprising zinc or a zinc-nickel compound being electrochemically applied at least to the stem end face. It is advantageous to produce a particularly hard or resistant layer on the stem end face and/or the mold area. Ideally, the complete connecting element is completely electroplated. A bare tip, i.e. a stem end face that is not electroplated, also enables a reliable welding method.
In a preferred further embodiment of the invention, a length of the mold section is about two to three times smaller than a length of the stem. This allows advantageously short cycle times to be achieved in friction welding, with a reliable seal being ensured by the retaining section with a circular cross-section.
After a preferential further embodiment of the invention, a respective component is formed from a metal or a metal alloy. Friction welding is thus advantageously made possible at all.
According to a further preferred further embodiment of the invention, at least one of the components, in particular at least a first component penetrated by the connecting element, is formed from a material which comprises a non-ferrous metal, preferably copper, aluminum or brass and/or has a lower material hardness than the connecting element. It is equally preferred if at least one of the components is made of plastic, in particular of thermoplastic or thermosetting plastic. This is advantageous because it facilitates the penetration of the connecting element into the components, friction welding can be made more efficient and cycle times can be shortened.
In a preferential further embodiment of the invention, the components are each configured as metal sheets or metal plates. Preferably, the components may each be unperforated or may have holes smaller in diameter than i) the largest diameter of the mold section and/or ii) the diameter of the retaining section. The advantage of this is that a hole created during friction welding and/or filled by the connecting element is reliably sealed by the retaining section of the stem starting from the head after completion of the friction welded connection. For this purpose, the retaining section may have a larger diameter than a maximum diameter of the mold section.
After a preferential further embodiment of the invention, the material of the at least one first component has a lower hardness than the material of the other components. This advantageously facilitates the penetration of the connecting element into the components, friction welding can be made efficient and cycle times can be shortened.
Furthermore, after a preferential further embodiment of the invention, at least one of the components not arranged as the first component is made of steel. This is advantageous in order to achieve an increased strength of the composite arrangement, while still not hindering or impairing the penetration of the connecting element during friction welding.
According to a preferential further embodiment of the invention, a total thickness of the components is at most as large as a length, i.e. axial extension, of the retaining section of the connecting element. This is advantageous to ensure complete penetration of the components by the connecting element in case the front part of the connecting element, including the stem face and mold section, is abraded or melted off during friction welding.
Connecting elements according to the invention are explained in more detail below on the basis of drawings. They each show schematically:
Elements with the same function and mode of operation are each provided with the same reference signs in the
The connecting element 10 comprises:
The stem face 10.2 has a stem end face 10.21 which has a convex envelope 10.22 with a blunt course. The envelope 10.22 of the stem end face 10.21 is to be understood as a surface which envelops the stem end face 10.21 and whose points connect relative maxima of the stem end face 10.21 (see
In the front view of the connecting element 10 shown in
In the plan view of the connecting element 10 shown in
In the view from below of the connecting element 10 shown in
The stem end face 10.21, shown as an example in
The embodiment of the connecting element 10 shown in
In the side view of the connecting element 10 shown in
The stem face 10.2 shown in
The retaining section 10.4 shown in
In the cross-sectional plane sectional views through the retaining section 10.4 (section A-A) and through the mold section 10.3 (section B-B) shown in
In the longitudinal sectional plane sectional view through the connecting element 10 shown in
In the case of the
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2017 221 681.6 | Dec 2017 | DE | national |
This application claims the benefit under 35 U.S.C. § 119(a) of German Application No. 10 2017 221 681.6 filed on Dec. 1, 2017 and is a national stage application under 35 U.S.C. § 371, of PCT/EP2018/080685, filed on Nov. 8, 2018, the contents of both are incorporated by reference herein in their entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2018/080685 | 11/8/2018 | WO | 00 |
