Forging Device with Slanted Lateral Jaws for Piston Cooling Pockets
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Solution Overview
Problem
Existing forging technologies cannot mold circumferential cooling pockets radially outside the box walls of a piston blank due to the design of the forging mold, which prevents the mold from being opened after the forging process.
Innovation Solution
The forging apparatus features two lateral jaws mounted at a slant relative to the longitudinal axis, allowing for the molding of radially outer surfaces and a circumferential cooling pocket by moving the jaws in directions that enclose an acute angle with the longitudinal axis, enabling the formation of slanted box walls during the forging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional two-half forging mold is used, then the mold structure is simple and easy to manufacture, but it is impossible to mold cooling pockets that run radially outside of the box walls because these cooling pockets would prevent the forging mold from being pulled apart in the radial direction
Solution Approach 1:
The forging mold is divided into three independent parts: a bottom half, a top half, and two lateral jaws that can move separately. This segmentation allows the lateral jaws to be extracted along a slanted path after forging, enabling the ejection of piston blanks with radially outer cooling pockets that would be impossible with a traditional two-half mold design.
Solution Approach 2:
The lateral jaws are mounted to move in directions that enclose an acute angle with the longitudinal axis of the forging apparatus, rather than moving strictly vertically like traditional molds. This dimensional change in the extraction path allows the mold to release the piston blank without requiring radial separation, thereby enabling cooling pockets to be molded in regions that would otherwise block mold opening.
2Adaptability or versatility
If the lateral jaws are mounted at a slant relative to the longitudinal axis, then cooling pockets can be molded radially outside the box walls, but the device complexity increases due to the slanted mounting and movement mechanism
Solution Approach 1:
The lateral jaws are designed with dynamic movement capability along slanted paths rather than fixed vertical movement. This dynamic configuration allows the jaws to adapt their extraction trajectory, enabling them to clear radially outer cooling pockets while maintaining a relatively simple overall device structure through straightforward slanted mounting.
3Shape
If the lateral jaws move in directions that enclose an acute angle with the longitudinal axis, then slanted box walls are formed during forging, but the extraction of the lateral jaws becomes more complex
Solution Approach 1:
Instead of extracting the lateral jaws vertically upward after forging (the conventional approach), the invention inverts the extraction direction by moving the lateral jaws along slanted paths that enclose an acute angle with the longitudinal axis. This inverted extraction method simultaneously forms the desired slanted box walls during forging and enables successful ejection of the finished piston blank.
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 solution allows for the successful molding of a circumferential cooling pocket outside the box walls, resulting in a piston blank with slanted box walls that can withstand greater stress compared to traditional designs.
Implementation Method 1
introduction of a heated billet from which the piston blank is to be forged into an essentially cylindrical recess of a forging apparatus, in such a manner that it comes to lie on a forging base disposed on the one side of the recess
Implementation Method 2
introduction of a heated billet from which the piston blank is to be forged
Data Source
AI summary
A forging device for producing a piston blank has a forging mold that has an essentially cylindrical cavity matching the radial outer surface of the piston blank, a forging base delimiting the cavity, and a central die consisting of a mandrel that has a conically tapering extension which is mounted on the mandrel and the shape of which matches the inner surface of the piston blank. In order to form the radially outer surfaces of the piston slipper walls and a peripheral cooling pocket located radially outside the slipper walls in the piston head, the forging device has two lateral jaws which are mounted in the forging device so as to be movable at an angle to the longitudinal axis of the forging device.