Golf Club Striking Face Variable Geometry Manufacturing
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Solution Overview
Problem
Current manufacturing techniques for golf club striking faces with variable face geometry suffer from issues such as waviness, machine marks, material inconsistency, and grain growth, which affect precision and material strength, especially when creating asymmetrical geometries.
Innovation Solution
A method involving stamped forging to create a non-planar rear surface and machining to create a planar frontal surface, allowing for precise geometry without melting the material, thus avoiding phase transformation and oxidation, and enabling the use of different materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional forging process is used to create variable face geometry, then the striking face can be formed with complex shapes, but the resulting geometry exhibits waviness and requires extensive machining to achieve precise geometry
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first, a pre-form is created using conventional forging to achieve the basic variable thickness geometry; second, the frontal surface is machined to precise tolerances. This segmentation allows each process to optimize for its specific function, reducing overall waviness while maintaining complex geometry.
Solution Approach 2:
The pre-forming stage performs preliminary shaping of the variable face geometry before final precision machining. By pre-establishing the thickened central region and transition regions, the subsequent machining requires less material removal and achieves better final precision.
2Shape
If conventional forging process is used to create variable face geometry, then complex geometries can be formed, but machine marks and material inconsistency occur affecting surface quality
Solution Approach 1:
The process separates forming operations from finishing operations. The forging process creates the complex variable thickness shape, while the subsequent machining process independently addresses surface quality and eliminates machine marks from the forging stage.
Solution Approach 2:
The patent applies controlled heating parameters to the pre-form before machining, optimizing the material's machinability and surface finish quality while maintaining the complex geometry established during forging.
3Shape
If material is melted and plastically deformed during forging, then complex geometries can be formed, but grain growth and oxidation occur lowering material strength
Solution Approach 1:
The patent applies controlled heating parameters to the pre-form before machining, optimizing the material's machinability and surface finish quality while maintaining the complex geometry established during forging. The heating is controlled to avoid excessive grain growth and oxidation.
Solution Approach 2:
The heating and forging processes are conducted in a controlled atmosphere environment that prevents oxidation of the metal surface, thereby maintaining material strength while allowing the necessary plastic deformation for complex geometry formation.
4Manufacturing precision
If extensive machining is used to correct waviness and achieve precise geometry, then manufacturing precision can be improved, but device complexity and manufacturing time increase
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first, a pre-form is created using conventional forging to achieve the basic variable thickness geometry; second, the frontal surface is machined to precise tolerances. This segmentation allows each process to optimize for its specific function, reducing overall waviness while maintaining complex geometry.
Solution Approach 2:
The pre-forming stage performs preliminary shaping of the variable face geometry before final precision machining. By pre-establishing the thickened central region and transition regions, the subsequent machining requires less material removal and achieves better final precision with reduced process complexity.
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 results in a more precise and consistent striking face with improved material strength and the ability to create complex geometries without the need for extensive machining, optimizing weight distribution and performance.
Implementation Method 1
compressing the top punch against the bottom cavity to alter a shape of the pre-form face insert to create a substantially non-planar rear surface
Data Source
AI summary
An improved striking face of a golf club head and a method of manufacturing thereof is disclosed herein. More specifically, the present invention discloses an improved method of stamped forging variable face geometry onto the rear surface of a striking face from a frontal portion of the striking face; wherein the improved process allows for more precise finished parts with less need for complicated machining. The resulting striking face of a golf club head comprises of a substantially planar frontal surface and a substantially non-planar rear surface, wherein the substantially non-planar rear surface is created via a stamped forging process while the substantially planar frontal surface is created via a machining process.