A joining technique with high accuracy and reliability is required in mechatronics parts. However, sufficient accuracy and joining strength can not be achieved by conventional methods such as staking and fitting.
A joining technique called Metal Flow Joining has been developed and applied to several mechatronics parts and car parts. In principle two parts are joined together by plastic metal flow into circumferential grooves on the surface of once part during pressing the other with a punch.
The effects of the position and the number of the grooves on the plastic flow formability and the strength of the joints have been studied by FEM analysis and some experiments.
The joining strength equal to the shear strength of the base metal can be obtained in the range of the ratio L/B (L: the distance between the loading surface and the circumferential grooves, B: the loading width) from 0.5 to 0.75.
It is also found that optimum number of the grooves is two or three.
The coaxiality and the parallelism of the joints made by the Metal Flow Joining are less than 0.02mm and in the range from 0.005 to 0.015mm respectively.
Higher accuracy of the joints can be also assured compared with those made by the conventional staking.
It is concluded that the designing die and the controll of the joining conditions are very important to achieve higher accuracy and reliability, and wide application of this technique can be expected.
View full abstract