Channel Intersection Stress Reduction via Segmented Pockets
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Solution Overview
Problem
Existing methods for reducing stress at intersections of channels in high-pressure fuel injection systems are complex and difficult to manufacture, often concentrating stress at critical areas.
Innovation Solution
The implementation of easily manufacturable axial or inclined pockets on both sides of the junction between channels, which can be precisely incorporated using a spherical drill, effectively redistributes stress away from critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If annular grooves or kidney-shaped depressions are used to reduce stress at channel intersections, then stress reduction is achieved, but manufacturing complexity increases significantly
Solution Approach 1:
The continuous annular groove or kidney-shaped depression is segmented into discrete pockets positioned at specific locations around the channel intersection. This segmentation simplifies manufacturing by allowing each pocket to be drilled independently using standard drilling equipment, eliminating the need for complex etching processes required for continuous grooves.
Solution Approach 2:
Instead of creating complex continuous grooves that are difficult to manufacture, the invention inverts the approach by using simple discrete pockets that are easier to produce. The pockets achieve the same stress redistribution function through a simpler geometric form that is more amenable to conventional manufacturing methods.
2Strength
If complex etching processes are used to create stress-reducing features, then stress distribution improves, but production time and cost increase
Solution Approach 1:
The stress management function is achieved through multiple discrete pockets rather than a single complex continuous feature. This segmentation allows each pocket to be manufactured independently and quickly using standard drilling operations, significantly reducing production time compared to complex etching processes.
Solution Approach 2:
The invention replaces complex chemical etching processes with simpler mechanical drilling operations. The pockets can be produced using program-controlled machine tools with spherical drills, which are faster and more economically viable than the etching processes previously required for stress reduction.
3Strength
If pockets are positioned at critical stress areas, then local stress values are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The pockets are positioned at predetermined locations around the channel intersection that are optimized for stress redistribution. These positions are determined in advance through stress analysis, allowing manufacturers to use standard positioning fixtures and program-controlled drilling to achieve the required precision without excessive complexity.
Solution Approach 2:
The invention optimizes the geometric parameters of the pockets (size, shape, depth, and spacing) to achieve effective stress reduction with reasonable positioning tolerances. By carefully selecting pocket parameters, the design achieves stress management effectiveness while maintaining manufacturability with standard precision drilling capabilities.
Data Source
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AI summary
Method and apparatus for reducing stress at the intersection of two intersecting channels 9, 10 in a body 11 made of a metallic material, wherein a medium under high pressure is guided in the channels 9, 10, and a second channel 9 opens into a first channel 10. According to the invention, a method for reducing the stress at the intersection of two intersecting channels 9, 10 is provided, which, with simple manufacturability, effectively reduces the stresses or shifts them to system-non-critical areas. This is achieved by arranging a pocket 13a, 13b, 13bb on both sides of the opening 12 of the second channel 9 into the first channel 10.