Forged Iron Club Head Cavity Forming for Lower CG and Higher MOI
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Solution Overview
Problem
Current methods for manufacturing forged iron golf club heads with cavities are expensive and time-consuming, and they struggle to achieve advanced geometries and mass properties efficiently.
Innovation Solution
A multi-stage forging process that forms a forged iron golf club head with a rear cavity from a single billet, using a bent strike face technique to create a deep undercut cavity, and incorporating an elastomeric insert to optimize mass distribution and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional forging techniques are used to create an iron golf club head, then the manufacturing cost is reduced and production time is shortened, but the ability to create cavities and advanced geometries is limited
Solution Approach 1:
The forging process is divided into multiple stages: initial forging to create the basic club head shape, followed by a second forging operation to create the cavity. This segmentation allows each stage to optimize for its specific function, achieving both cost efficiency and geometric complexity.
Solution Approach 2:
The first forging operation preliminarily forms the club head body with prepared geometry before the second forging operation creates the final cavity shape. This preliminary action enables the subsequent cavity formation to be more efficient and precise.
2Adaptability or versatility
If casting or co-casting methods are used to create club heads with cavities, then advanced geometries and cavity designs can be achieved, but the manufacturing cost increases and production time extends
Solution Approach 1:
The patent replaces the chemical casting process with a mechanical forging process to create cavities. The second forging operation uses mechanical force to displace material and form the cavity, eliminating the need for casting molds and chemical processes while achieving similar geometric results.
Solution Approach 2:
The patent changes the physical parameters of the forging process, including applying controlled displacement and force during the second forging operation to create the cavity. By adjusting forging parameters such as pressure, temperature, and tooling geometry, the desired cavity shapes are achieved through mechanical means rather than casting.
3Manufacturing precision
If milling techniques are used to create club heads with cavities from a single block of material, then the desired geometries can be achieved, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent replaces the subtractive milling process with a formative forging process. Instead of removing material to create cavities, the second forging operation shapes the material directly into the desired cavity geometry, significantly reducing production time and material waste while maintaining precision.
Solution Approach 2:
The patent utilizes the plastic phase transition of metal during forging to transform the solid billet into the final club head shape with cavities. The heat treatment and forging processes exploit the ductile phase of metal to enable complex shape changes that would be inefficient through milling.
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 process results in a forged iron club head with a lower center of gravity and higher moment of inertia, providing improved performance and feel similar to casted cavity back club heads, while maintaining the benefits of forging such as a tighter grain structure.
Implementation Method 1
incorporating an elastomeric insert to optimize mass distribution and performance
Data Source
AI summary
An iron-type golf club head with a cavity formed via a multi-stage forging process. The forged iron-type golf club head is formed from a single billet of material. An intermediate step of the multi-stage forging process creates a cavity in the iron-type golf club head which can receive an insert. The resultant iron-type golf club head has a substantially lower center of gravity and higher moment of inertia when compared to a traditionally forged iron-type golf club head lacking a cavity. Additionally, the resultant iron-type golf club head has a more solid feel than a traditionally cast iron-type golf club head as a result of the tighter grain structure the forging process yields.