Asymmetric Valve Core Geometry for Support-Free 3D Printing
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Solution Overview
Problem
Traditional manufacturing methods for aircraft fuel pumps are costly and result in poor surface finishes, while additive manufacturing faces challenges with support structure removal and surface quality.
Innovation Solution
An additively manufactured self-supporting valve core design with chamfered upper portions and annular ring lower portions, allowing for perpendicular orientation during manufacturing without internal supports, which reduces costs and improves surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional molding and machining methods are used for fuel pumps, then manufacturing precision and surface finish are improved, but manufacturing cost and production time increase
Solution Approach 1:
The patent changes the geometric parameters of the valve groove from a traditional cylindrical shape to an asymmetric shape with a chamfered upper portion and annular ring lower portion. This parameter change allows the part to be additively manufactured without support structures while achieving functional equivalence to traditionally manufactured parts.
Solution Approach 2:
Instead of using traditional subtractive manufacturing methods (molding and machining) to achieve good surface finish, the patent inverts the approach by using additive manufacturing with a specially designed geometry that eliminates the need for support structures, thereby achieving both cost reduction and functional performance.
2Ease of manufacture
If additive manufacturing is used for fuel pump parts, then manufacturing cost is reduced, but support structure removal and surface quality deteriorate
Solution Approach 1:
The patent extracts and eliminates the support structure requirement from the additive manufacturing process by redesigning the valve groove geometry. The asymmetric shape with chamfered upper portion and annular ring lower portion allows the part to stand on its own during manufacturing, removing the need for additional support structures that would otherwise require post-processing removal.
Solution Approach 2:
The patent applies asymmetry by designing the valve groove with different geometries at different heights: the upper portion has a chamfered shape with varying diameter, while the lower portion has an annular ring shape. This asymmetric design provides self-supporting characteristics during additive manufacturing without compromising the functional performance of the valve groove.
3Productivity
If additive manufacturing is used for fuel pump parts, then production time is reduced, but defect rates increase due to support structure removal
Solution Approach 1:
The patent performs preliminary action by designing the valve groove geometry in advance to be self-supporting during additive manufacturing. The asymmetric shape with chamfered upper portion and annular ring lower portion is pre-configured to eliminate the need for support structures, preventing defects before they can occur during the manufacturing process.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An additively manufactured asymmetric self-supporting valve core can include a plurality of valve interfaces (404) and a plurality of valve grooves (402). The valve core can be manufactured such that a major axis of the valve core is oriented within 5 degrees of being perpendicular to a build plate during additive manufacturing. The valve grooves can each include an upper portion (406) and a lower portion (408), where the upper portion is a chamfer and the lower portion is an annular ring. Based on such a design and orientation during manufacturing, the valve core does not require internal support structures, the valve core maintains flow characteristics, and the valve core can have a smooth surface finish without overhanging radii.