Extruded Axial Piston Blank for Low-Machining Precision Forming
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Solution Overview
Problem
Existing production methods for axial piston machines are costly and complex, requiring extensive machining to achieve high surface quality and component accuracy, which increases production costs and time.
Innovation Solution
A production method involving extrusion to create a piston blank with a shaft, ball head, and sealing portions, followed by machining to incorporate a through-opening, reducing the need for extensive finishing and allowing for cost-effective production with improved component strength and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to produce piston blanks, then high surface quality and component accuracy can be achieved, but production costs and machining complexity increase significantly
Solution Approach 1:
The extrusion process performs preliminary shaping of the piston blank, creating the basic geometry and surface quality before final machining. This preliminary action reduces the amount of material removal and finishing work required in subsequent machining operations, thereby reducing machining complexity while maintaining high surface quality and precision
2Manufacturing precision
If traditional machining methods are used to produce piston blanks, then component accuracy can be achieved, but production time and costs increase
Solution Approach 1:
The extrusion process creates a near-net-shape piston blank with predetermined geometry and high surface quality, significantly reducing the amount of subsequent machining required. This preliminary forming action accelerates production by minimizing the time-consuming machining operations while maintaining component accuracy through controlled extrusion parameters and tooling design
Solution Approach 2:
The extrusion process utilizes controlled parameters such as extrusion speed, temperature, and die geometry to directly achieve the desired component accuracy and surface quality in the blank formation stage, eliminating the need for multiple iterative machining operations and thereby improving production efficiency
3Manufacturing precision
If extensive machining is performed to achieve high surface quality, then component accuracy is improved, but production costs increase
Solution Approach 1:
The extrusion process performs the surface quality formation in advance during blank creation, rather than requiring extensive post-machining. This preliminary surface formation through controlled extrusion reduces the need for costly finishing operations such as grinding and polishing, thereby lowering production costs while maintaining high surface quality standards
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
The method significantly reduces machining complexity, achieves high surface quality and accuracy, and lowers production costs by creating a piston blank with a high surface quality and directed fiber orientation, enhancing component strength and operational efficiency.
Implementation Method 1
In a method step, in a first method step, of the production method an intermediate blank (7) is produced by extrusion. In particular, for this purpose a raw part, such as a solid body, is shaped by an extrusion tool.
Data Source
AI summary
A method of producing a piston blank, comprising producing an intermediate blank of a piston for an axial piston machine by extrusion wherein the intermediate blank includes a shaft portion, a ball head portion, and a sealing portion, wherein the shaft portion connects the ball head portion to the sealing portion. The method also includes producing a piston blank of the piston from the intermediate blank and machining a through-opening in the intermediate blank, wherein the through-opening extends within the piston blank in the longitudinal direction.