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Mechanical assembly-shaft press and cold drawing process

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Mechanical assembly-shaft press and cold drawing process

Shaft components, as the core parts of mechanical transmission systems, directly impact the overall performance and service life of equipment through their assembly accuracy and structural reliability. In over-travel fits, the rational selection and process control of press fitting and cold drawing techniques have become key technical challenges in the field of mechanical assembly. This article will systematically explore the control of assembly deformation in shaft components under high over-travel fits, alternative solutions for cold drawing, analysis of fit grades, definition of process windows, and measurement technology for tooling, aiming to enhance assembly quality and ensure equipment reliability.

Mechanical assembly-shaft press and cold drawing process

1 Principle and Assembly Method of Overrun Fits for Shaft Components An overrun fit is achieved by slightly exceeding the hole diameter with the shaft's outer diameter, forming a reliable connection through material deformation. This method is widely used in applications such as between gears, inner rings of bearings, hubs, and shafts, as well as between drive shafts and bearing housings.

2Analysis of Deformation Risks During High Overrun Shaft Pressing In high overrun assembly, improper process control can lead to several risks:

Axial Crush If the pressing force is too high or the fixture is unbalanced, plastic deformation may occur at the shaft end and step positions.

Loss of Roundness and Coaxiality Misalignment between the shaft and the mating hole can cause skewing during pressing, affecting assembly quality.

Assembly Cracks Insufficient material strength in the shaft or hole can result in local stress concentration, leading to micro-cracks or even structural damage.

Assembly Dimensional Deviation The elastic recovery of materials is difficult to control accurately, resulting in dimensional deviations. Therefore, for high overrun structures, it is essential to systematically analyze deformation risks, define a process window, and optimize the assembly process.

3Cold Drawing Process Technology and Its Advantages The cold drawing process controls the drawing force to uniformly pull out shaft components from the mating hole, making it widely used in applications such as structures with large overruns that pose high risks of forced disassembly, situations requiring strict control of hole and shaft diameter deformation, and the assembly and disassembly of high-precision bearings and gears. Compared to traditional press fitting, the cold drawing process offers significant advantages: It effectively avoids skewing and deformation during pressing; the operation is smooth, facilitating precise control; it can be integrated with hydraulic systems to achieve safe assembly of large-size, high-overrun structures.

4Assembly process window under different shaft materials and mating grades During the assembly of shaft parts, the material properties and mating grades determine the controllable process window:

Mechanical assembly-shaft press and cold drawing process

The fit grade and assembly window: The higher the fit grade, the greater the interference, and the difficulty of assembly and the risk of failure increase simultaneously. It is essential to strictly control the process parameters. 5⃣ Optimization of tooling design and measurement methods: High-quality assembly processes rely on scientifically sound tooling and precise, efficient measurement techniques:

Principles of tooling design: Reliable positioning: Ensure coaxiality between shaft components and tooling and equipment; Uniform force distribution: Use ring supports and evenly distributed guides to avoid local stress concentration; Convenient operation: Integrate hydraulic and pneumatic systems to enhance efficiency and safety.

Mechanical assembly-shaft press and cold drawing process

Measurement Method Recommendations: For measuring shaft diameters and hole diameters, it is recommended to use internal and external micrometers to ensure precise fitting. During the assembly process, dynamic monitoring should be conducted using displacement and force sensors to track the assembly status in real time. After assembly, use a roundness meter and coaxiality testing tools to ensure the quality of the assembly.

Mechanical assembly-shaft press and cold drawing process

6 Typical Application Cases and Process Optimization Suggestions �� Application Cases During major overhauls of gearboxes, high interference fits between the output shaft and gears; Cold drawing and disassembly of urban rail transit wheelset gears; Large-scale cold drawing processes for wind turbine spindles and ship drive shafts. �� Process Optimization Suggestions In the design phase, select appropriate fit grades to balance assembly difficulty and structural reliability; For high interference structures, prioritize cold drawing over traditional press fitting to minimize deformation risks; Tooling design should consider both assembly and disassembly functions to enhance maintenance efficiency; During process control, integrate force and displacement monitoring to prevent abnormal assembly; Regularly inspect the dimensions and geometric accuracy of mating parts to prevent early failure.

Pub Time : 2025-07-08 08:38:27 >> News list
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