Extrusion-Type Connecting Rod with Split Seam Big End
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Solution Overview
Problem
Conventional connecting rod manufacturing methods, such as casting, forging, or sintered powder molding, face challenges with low productivity, high costs, and weight due to processing characteristics, and require additional cutting steps for big end connection, increasing manufacturing time and defect rates.
Innovation Solution
An extrusion-type connecting rod and apparatus that uses high-strength aluminum for large-scale production, incorporating seam line splitting planes for easy division of the big end without additional cutting, and a connecting rod extrusion apparatus with front and rear dies to generate crankshaft holes and seam line splitting planes, allowing for integral molding and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods (casting, forging, sintered powder molding) are used, then the connecting rod has sufficient strength and toughness, but productivity is low, manufacturing costs are high, and product weight is increased
Solution Approach 1:
The patent changes the material parameter from traditional iron-based alloys to lightweight aluminum alloys with high strength properties. By modifying the material composition and applying extrusion processing parameters, the connecting rod achieves both reduced weight and sufficient mechanical strength, resolving the contradiction between weight reduction and productivity improvement
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods (casting, forging, sintered powder molding) with an extrusion-based manufacturing system. This substitution enables continuous high-volume production while maintaining structural integrity, thereby improving productivity without increasing weight
2Reliability
If conventional manufacturing methods are used, then the connecting rod has required mechanical properties, but the defect rate is high due to structural defects and porosity
Solution Approach 1:
The patent replaces traditional casting and forging processes with extrusion molding, which eliminates porosity and structural defects inherent in conventional methods. The extrusion process produces dense, defect-free structures with consistent mechanical properties, improving reliability while maintaining high production efficiency
Solution Approach 2:
By changing the manufacturing process parameters from batch-based casting/forging to continuous extrusion, the patent achieves uniform material distribution and eliminates common defects like porosity and structural inconsistencies, thereby reducing defect rates while improving productivity
3Ease of manufacture
If the big end is connected using cutting devices in conventional methods, then the connecting rod structure is formed, but manufacturing costs and manufacturing time are increased
Solution Approach 1:
The patent incorporates the big end connection structure directly into the extrusion mold design, creating integrated seam line splitting planes during the initial extrusion process. This preliminary action eliminates the need for subsequent cutting operations, reducing manufacturing time and costs while maintaining ease of assembly
Solution Approach 2:
The patent merges the big end connection formation with the main body extrusion process by integrating the seam line splitting plane design into the mold. This combines multiple operations (body formation and connection creation) into a single extrusion step, eliminating separate cutting processes and reducing overall manufacturing time
4Strength
If iron-based alloys are used in conventional manufacturing, then toughness and fatigue resistance are excellent, but product weight is increased and economic feasibility is reduced
Solution Approach 1:
The patent changes the material parameter from heavy iron-based alloys to lightweight aluminum alloys with optimized composition and microstructure. By controlling alloying elements and heat treatment parameters, the aluminum alloy achieves toughness and fatigue resistance comparable to iron-based materials while significantly reducing weight
Solution Approach 2:
The patent employs composite aluminum alloy materials with enhanced mechanical properties through controlled microstructure and phase distribution. This composite approach provides both lightweight characteristics and the necessary toughness and fatigue resistance, resolving the contradiction between strength and weight
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 approach enables high-quality, defect-free connecting rods to be produced in large quantities, reducing product weight and manufacturing time, while improving economic feasibility and productivity by eliminating the need for additional cutting processes.
Implementation Method 1
a connecting rod extrusion apparatus with front and rear dies to generate crankshaft holes and seam line splitting planes
Data Source
AI summary
The present invention relates to an extrusion-type connecting rod which is installed between a piston and a crank and can convert the reciprocating motion of the piston into the rotary motion of a crank shaft, an extrusion apparatus for a connecting rod, and a manufacturing method for the extrusion-type connecting rod. The extrusion-type connecting rod may comprise: a first big end having a portion of a crank shaft hole formed on one side and having a seam-line divided surface, which comprises a seam line formed at the time of extrusion, formed on the other side; a second big end, being extrusion-molded simultaneously with the first big end, having the other portion of the crank shaft hole formed on one side, and having a seam-line divided surface, which comprises a seam line formed at the time of extrusion, formed so as to contact the seam-line divided surface of the first big end; a connection part which is extrusion-molded integrally with the second big end; and a small end which is extrusion-molded integrally with the connection part.