Double-Sided Piston Drilling Fixture for Accurate One-Clamp Machining
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Solution Overview
Problem
Existing drilling devices for die-forged pistons are inefficient and inaccurate due to the need for two separate clamping and fixation processes, leading to quality issues and size deviations, especially when dealing with the complex geometrical shape of the internal cavity.
Innovation Solution
A double-sided drilling fixture and process that includes a fixture base assembly, upper and lower load-resisting assemblies, and left and right pressing block assemblies, which provide simultaneous clamping and fixation from multiple directions, allowing for simultaneous drilling on both sides of the die-forged piston using hydraulic cylinders and expansion pins to secure the piston firmly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drilling is performed on one side at a time using existing drilling devices, then the device complexity is low, but the productivity is low and the manufacturing precision deteriorates due to repeated clamping and fixation errors
Solution Approach 1:
The fixture is divided into multiple independent clamping assemblies (upper load-resisting assembly, lower expansion-resisting assembly, left pressing block assembly, right pressing block assembly) that can simultaneously clamp the piston from different sides, enabling parallel drilling operations while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple clamping functions are merged into a single integrated fixture that can simultaneously perform clamping and fixation from multiple directions, eliminating the need for separate clamping operations and enabling double-sided drilling in one setup
2Manufacturing precision
If repeated clamping and fixation are performed for double-sided drilling, then the device complexity remains simple, but the manufacturing precision deteriorates due to workpiece fixation error and size deviation
Solution Approach 1:
The clamping system is segmented into multiple specialized assemblies (load-resisting, expansion-resisting, pressing block assemblies) each designed for specific clamping directions, ensuring precise positioning and fixation without requiring complex multi-step clamping procedures
Solution Approach 2:
The fixture performs preliminary clamping and fixation of the piston in a predetermined position before drilling begins, ensuring that the workpiece remains securely positioned throughout the double-sided drilling process without requiring re-clamping, thus maintaining high alignment accuracy
3Manufacturing precision
If clamping plates are used to fix the internal cavity during drilling, then the device complexity is low, but the manufacturing precision deteriorates due to difficulty in controlling assembly accuracy
Solution Approach 1:
The internal cavity fixation is achieved through segmented expansion pins and pressing blocks that can independently adjust to the cavity geometry, ensuring accurate fixation without requiring complex pre-assembled clamping plates
Solution Approach 2:
Hydraulic cylinders are used to actuate the expansion pins and pressing blocks, providing controlled and precise movement for clamping the internal cavity, which ensures high assembly accuracy while maintaining relatively simple fixture structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables quick and accurate simultaneous drilling on both sides of the die-forged piston, reducing processing time, improving alignment accuracy, and increasing production efficiency by eliminating the need for repeated clamping and fixation.
Implementation Method 1
The lower expansion-resisting assembly comprises a lower hydraulic cylinder installed on the fixture base assembly with a lower piston rod facing the die-forged piston
Implementation Method 2
an upper hydraulic cylinder is installed on the pressing plate, the upper piston rod of the upper hydraulic cylinder faces the die-forged piston and is located above the die-forged piston
Implementation Method 3
a left hydraulic cylinder installed therein, a left piston rod of the left hydraulic cylinder faces longitudinal center line of the fixture base assembly, and a left pressing head is fixedly installed on the left piston rod
Data Source
AI summary
The invention relates to a double-sided drilling fixture for die-forged pistons and a double-sided drilling process thereof. It overcomes the defects of low efficiency and accuracy of the double-sided drilling operation for die-forged pistons in the prior art. The invention comprises a die-forged piston, a fixture base assembly, an upper load-resisting assembly and a lower expansion-resisting assembly. The upper load-resisting assembly is installed on the fixture base assembly and disposed above the die-forged piston. A fixation base, whose upper surface shape is the same as internal surface shape of the die-forged piston, is installed above the fixture base assembly. The die-forged piston is sleeved on the fixation base. The invention achieves simultaneous drilling on both sides of the two rear skirt surfaces of die-forged pistons and delivers quick clamping and automatic fixation, significantly reducing the difficulty in the assembly of drilling plate and workpiece and increasing the alignment accuracy.