Technology Pushed Process and Product Innovation – Joining by Linear Flow Splitting

In order to take full advantage of manufacturing technologies, designers have to use technology specific manufacturing-induced properties. An adequate selection and optimisation of the manufacturing technology and a consequent combination of product and process development can lead to product innovations. Linear flow splitting yields ultra fine grained (UFG) microstructures which are characterised by high hardness, ductility and fatigue strength. These manufacturing-induced properties are particularly suited for rolling contact areas of linear guiding systems. Multi-functional linear systems require an integration of additional functional elements. For the hereby necessary joining, using the mechanisms acting in the linear flow splitting process seems attractive. The paper introduces a mechanical joining process following this technology push approach. Thereby, manufacturing-induced properties and mechanisms induced during the linear flow splitting process are utilised to integrate additional functional elements. Necessary joining operations can be integrated into the continuous flow production, maintaining the technological potential to manufacture large quantities at low costs. Extensive experiments show the applicability of various joined elements and materials for process integrated mechanical joining. The potential for product innovations is illustrated by an innovative linear system. Its core component is an integrated rack as part of a rack and pinion drive of a facade cleaner.