Abstract:
A method for manufacturing a gear, which may be utilized as a side gear in a vehicle differential, with the method including the steps of selecting a first billet of low carbon steel and producing an annular gear wheel therefrom, and selecting a second billet of low carbon steel and making an annular gear hub therefrom. The method further comprises the step of bonding the gear wheel to the gear hub. Both the producing and making steps may comprise the step of forging a gear wheel and gear hub, respectively, near net forming the hub and wheel, or net forming the hub and wheel. The step of joining may be accomplished by laser welding or alternatively, by applying adhesives to mating surfaces of the hub and wheel. Due to the use of separate billets of low carbon steel to produce or make the wheel and hub, the wheel and hub may be made of different materials.
Abstract:
Method and system for designing and producing a lightweight automobile or vehicle body. Structural performance targets are selected, a beam model analysis is conducted, and a body-in-white design is developed. A shell model is created and analyzed and material gauges and manufacturing processes for the body components are selected. A structural analysis is conducted to determine whether the shell model meets the selected structural performance targets. A crash model is created, analyzed, and modified until satisfactory crash requirements are met. A final structural analysis is conducted to determine whether the shell model meets the selected structural performance targets.
Abstract:
A method and apparatus for automatically welding and handling mash welded tailored blank composites. The method comprises the steps of transferring first and second sheet component parts from respective input stacks to an assembly table of a mash welding machine. The sheet components are disposed in an overlapping lap joint configuration and the lap joint is welded along a linear weld seam thus defining a welded blank. The welded blank is conveyed in a timed step manner from the welding machine to an output stacking machine via a magnetic stepping conveyor and the blank is transferred from the conveyor to an output stack of completed blanks with a stacking machine. An apparatus is provided to carry out the method.
Abstract:
A method produces hollow gas exchange valves, in particular with a cooling medium introduced into the hollow valve stem. The hollow of the valve stem is preferably drilled from the valve head side and, after the introduction of the cooling medium, sealed again by surfacing. A thin filling piece is inserted to a defined depth into the drilled hole temporarily holding the weld pool of the surfacing weld. By means of surfacing, it is possible to achieve cost savings over other sealing methods. The surfacing is preferably performed by a welding method in which the workpiece is not part of an electric circuit through which the welding energy flows. Preferable methods include gas welding, electron beam welding or laser welding. With these methods, so-called edge effects can be avoided.
Abstract:
The invention relates to a laser beam welding method for carbon steels applied to laser beam welding of carbon steels of different carbon content, and in order to improve uniformity of fused metal in the welded region, a laser beam is applied obliquely to the joint region between the carbon steels from the side of the carbon steel having the lower carbon content. When manufacturing a vehicle wheel 1 by this method, the laser beam is applied obliquely from the side of the hub 3 of rolled steel plate which contains about 0.1% of carbon to the joint region with the boss 2 of carbon steel for machine structural use which contains about 2% of carbon so as to fuse the end of the hub 3 and cause it to penetrate into the welded region.
Abstract:
A method of welding at least two sheets using a high energy density radiation beam that preferably is a laser beam or an electron beam for producing a welded lap joint that is substantially completely fused across the width of overlap of the sheets preferably for enabling shaping or forming to be performed such that at least one of the sheets and at least portion of a weld line defined between the overlapped sheets are bent or three dimensionally contoured. In practicing a preferred embodiment of the method, the sheets are overlapped and welded by directing at least one radiation beam toward the overlapped sheets having sufficient power density and for a sufficient amount of time to weld the sheets such that they are substantially completely fused from front to back in the overlap region. As a result, the sheets form a blank that preferably is formed or shaped, such as by shaping, deep drawing, hydro-forming or roll forming, such that at least one of the sheets and a portion of the weld line of the sheets are bent or three dimensionally contoured. After shaping or forming, the sheets preferably form at least part of an article of manufacture.
Abstract:
Galvanized steel sheets or a galvanized steel sheet and a sheet of another metal are welded to each other by a laser beam. An intermediate layer for suppressing evaporation of zinc is formed between the galvanized steel sheets (1, 4) or the galvanized steel sheet (1) and the sheet of another metal. A laser beam (8) is applied to the galvanized steel sheet (1) or the sheet of another metal, thereby welding the sheets with the laser beam. As a result, porosity is prevented from being formed in a weld bead (9), and the weld bead (9) has a constant width.
Abstract:
A spot welding device for welding car bodies at a plurality of different positions without the need to move the car body to the welding device for each weld position. The device comprises a polyhedron shaped rotating member having a plurality of electrodes disposed on surfaces of the rotating member. The member is rotated to select a desired surface and the configuration of electrodes thereon to thereby perform a plurality of welds with the electrodes on the selected surface.