Fluid End Transition Surface Geometry for Reciprocating Pumps

Solution Overview

Problem

High stress concentrations at the intersection corners of intersecting bores in fluid ends of high pressure reciprocating pumps lead to reduced fatigue life and increased manufacturing costs due to the need for hand finishing, which introduces irregularities and is physically demanding.

Innovation Solution

A machinable transition feature that overlaps both intersecting bores to soften the transition between them, reducing the need for hand finishing and improving consistency, while maintaining or reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hand finishing is used to create a radiused shape at intersecting corners, then stress concentration is reduced, but manufacturing consistency deteriorates and physical demand on workers increases

Engineering Contradiction:

Improvefatigue lifeVSAvoidconsistency

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces the manual hand finishing process with an automated machining process using a ball end mill tool. The machining process uses programmed toolpaths to automatically create the radiused transition surfaces at intersecting bore corners, eliminating the need for manual intervention while improving consistency and reducing physical demand on workers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If hand finishing is used to soften the transition at intersecting corners, then stress concentration is reduced, but manufacturing cost and time increase

Engineering Contradiction:

Improvefatigue lifeVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the manual hand finishing process with an automated machining process using a ball end mill tool. The machining process uses programmed toolpaths to automatically create the radiused transition surfaces at intersecting bore corners, eliminating the need for manual intervention while improving consistency and reducing physical demand on workers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The transition surfaces are machined as part of the initial bore creation process rather than requiring a separate hand finishing step. The ball end mill tool automatically creates the radiused transition zones at the intersecting corners during the same machining operation that creates the bores themselves, integrating the stress-reduction feature into the primary manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If a machinable transition feature is used to overlap intersecting bores, then manufacturing consistency improves, but the complexity of the machining process increases

Engineering Contradiction:

ImproveconsistencyVSAvoidmachining complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the manual hand finishing process with an automated machining process using a ball end mill tool. The machining process uses programmed toolpaths to automatically create the radiused transition surfaces at intersecting bore corners, eliminating the need for manual intervention while improving consistency and reducing physical demand on workers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20240401587A1Fluid end with transition surface geometry

Publication Date: 2024.12.05 GD ENERGY PRODUCTS LLC

AI summary

A fluid end of a reciprocating pump includes multiple bores formed therein, and adjacent bores intersect each other. The intersection of two adjacent bores forms an intersection corner, which is where a concentration of high stress occurs during operation of the pump. A novel geometrical shape or geometry of the intersection corner reduces the concentration of stress on the intersection corners. By improving the shape and geometry of the intersection corner, the impact and concentration of the stress can be reduced, thereby improving or lengthening the lifetime of the material in that intersection corner of the fluid end.