Forged Iron Golf Club Head Cavities via Multi-Stage Forging
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Solution Overview
Problem
Current methods for manufacturing forged iron golf club heads with cavities are limited in achieving complex geometries quickly and cheaply, as existing techniques are either expensive and time-consuming or restrict the achievable geometries.
Innovation Solution
A multi-stage forging process involving rough forging, hot pressing, and precision forging to create a deep undercut cavity within a single solid billet, allowing for the formation of a forged golf club head with a cavity, and the option to attach an insert within the cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional forging techniques are used to create an iron golf club head, then production cost and time are reduced, but the ability to create complex cavity geometries is limited
Solution Approach 1:
The forging process is divided into multiple stages: initial forging to create a blank, then subsequent forging operations to form the cavity. This segmentation allows complex geometries to be achieved through sequential shaping operations rather than requiring a single complex die, thus maintaining cost-effectiveness while achieving geometric complexity.
Solution Approach 2:
An initial forging stage creates a prepared blank with preliminary shape characteristics before the final cavity-forming operations. This preliminary action simplifies subsequent forging steps by pre-positioning material flow paths and reducing the complexity of the final forming operation.
2Shape
If milling techniques are used to create club heads with cavities from a single block, then complex geometries are achieved, but production cost and time increase
Solution Approach 1:
The patent replaces the milling process (subtractive manufacturing) with a forging process (formative manufacturing). Instead of removing material to create cavities, the material is shaped and formed through controlled deformation, achieving similar geometric complexity with lower cost and higher material efficiency.
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from material removal (milling) to material deformation (forging). This parameter change enables the creation of complex cavity geometries through plastic flow and forming operations, which are more cost-effective and time-efficient than subtractive processes.
3Shape
If casting or co-casting methods are used to achieve advanced cavity geometries, then complex shapes are obtained, but material density and grain structure are compromised
Solution Approach 1:
The patent replaces casting methods with forging processes. Forging maintains the material's metallic structure and grain integrity through controlled plastic deformation, whereas casting creates potential defects like porosity and weak grain structures. This substitution achieves complex geometries while preserving superior material properties.
Solution Approach 2:
The invention effectively creates a composite structure where the forged metal body maintains its superior grain structure and density, while the cavity geometry provides the desired performance characteristics. The integration of complex cavity shapes within a densely-grained forged structure achieves both geometric complexity and material integrity.
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 method enables the production of durable, high-performance golf club heads with a tighter grain structure, improved durability, and reduced production costs, while maintaining or enhancing ball speed, workability, spin rates, and feel characteristics compared to casted club heads.
Implementation Method 1
rough forging a solid block billet to create an intermediate club head body
Implementation Method 2
hot pressing the intermediate club head to create a cavity in the body
Implementation Method 3
precision forging the intermediate club head to create a golf club body
Data Source
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AI summary
A method of manufacturing an iron type golf club head with a cavity. Other embodiments are disclosed.