Cooling Duct Piston Inlet Angle Optimization
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Solution Overview
Problem
The existing production method for cooling duct pistons is costly due to the need for countersinking and tool changes when creating overflow bores, as the axis of the overflow bore is not aligned at a right angle to the cooling space wall, requiring two tools and successive production steps.
Innovation Solution
Shaping the inner surface of the internal cooling duct to have an inlet angle of between 85° and 95°, eliminating the need for countersinking and reducing the number of production steps and time by allowing direct introduction of overflow bores without tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the overflow bore axis is not aligned at a right angle to the cooling space wall, then the cooling duct design can be optimized for heat dissipation, but the production process becomes more complex requiring countersinking and tool changes
Solution Approach 1:
The patent changes the geometric parameter of the cooling space wall by providing it with a specific contour that creates a substantially right-angled inlet angle (85°-95°) for the overflow bore. This parameter change allows the overflow bore to be introduced at a right angle to the wall, eliminating the need for countersinking and tool changes while maintaining effective heat dissipation through the overflow passage.
2Adaptability or versatility
If countersinking is performed before boring the overflow bore, then the overflow bore can be introduced at an angle, but the production time and costs increase due to two successive production steps
Solution Approach 1:
The patent applies preliminary action by pre-shaping the contour of the cooling space wall before the overflow bore is introduced. The wall is contoured in advance to provide a substantially right-angled inlet angle, which eliminates the need for subsequent countersinking operations. This preliminary preparation allows the overflow bore to be directly introduced at the correct angle in a single production step, significantly improving production efficiency.
3Strength
If the cooling space wall has a constant wall thickness, then the structural integrity is maintained, but the overflow bore cannot be introduced at a right angle without additional production steps
Solution Approach 1:
The patent applies local quality by providing the cooling space wall with a specific localized contour only in the region where the overflow bore is introduced. The wall maintains constant thickness in other areas to preserve structural integrity, but has a modified contour at the overflow bore introduction point to create a substantially right-angled inlet angle. This localized contour change enables simple single-step bore introduction without compromising overall structural strength.
Data Source
AI summary
The arrangement relates to a method for producing a cooling duct piston for an internal combustion engine, having the steps of producing a top piston part by introducing a combustion bowl, a cooling space of a part of a cooling duct and overflow ducts, producing a bottom piston part by introducing a part of a cooling duct, and joining the piston parts, wherein at least one transfer duct is created by bores. A cooling duct piston produced by the method is disclosed.