Basic Property of High-precision Metal Flow Joining Method Without Need for any Specialized Punch

AbstractThe conventional metal flow joining method needs a specialized punch. In this study, a new metal flow joining method that enables a shaft and ring to be combined without the need for any specialized punch was examined. In this experiment, 20-mm-diameter solid shafts and 40-mm-outer-diameter rings having a 20-mm-inner-diameter step at the 18.5-mm-inner-diameter center hole were used. The material combinations of the shaft / ring were JIS S45C / SKD11, A5056 / S45C, and S45C / A5056. The experiment was performed as follows. The shaft was put on the ring and pressed. Then, metal plastically flowed between the joining faces. The gap between them was filled with the flowing metal, and then, they were joined by high clamping pressure. The primary results were as follows. This joining method was completed with small amounts of metal flow because of highly precise fitting between the shaft and ring. Therefore, they could be joined by small pressing strokes. In this experiment, the maximum joining efficiency (shaft return proof load / joining load) reached 25% - 35%. This new metal flow joining method appears to be highly useful in terms of low cost, high productivity, and non-mass production