I-Shape Oil Ring Wire Remelting Laser Dross Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming oil holes in I-shape oil rings using laser beam processing face issues with dross adhesion, where solidified residues can reattach or pass through holes, compromising hole shape and engine performance.
Innovation Solution
Forming a remelted and solidified portion at the outlet side of each through hole, extending up to 200µm from the periphery but not exceeding 100µm in depth, to integrate dross with the wire and prevent reattachment, while maintaining the predetermined hole shape and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser beam processing is used to form oil holes, then productivity is improved and adaptability is enhanced, but dross adhesion occurs on the wire surface
Solution Approach 1:
The patent applies a remelting laser to melt and re-solidify the dross on the wire surface, converting the harmful dross into a smooth, integrated surface. The remelting process causes the dross to fuse with the base material, eliminating the harmful adhesion effect and transforming it into a beneficial surface finish that prevents future dross accumulation.
Solution Approach 2:
The patent changes the thermal parameters by applying a second laser beam with different energy characteristics (remelting laser) to the already-formed holes. By controlling the remelting laser's power, speed, and focal position, the dross is melted and re-solidified into a smooth surface without damaging the underlying structure, thus resolving the dross adhesion problem while maintaining production efficiency.
2Object-generated harmful factors
If high thermal energy density processing is used with oxygen or air assist gas, then dross can be blown out, but dross may reattach or pass through holes to adhere to back surface
Solution Approach 1:
Instead of attempting to blow out the dross (which causes reattachment or passage through holes), the patent uses a remelting laser to melt and re-solidify the dross in place. This converts the harmful dross into a smooth, integrated surface, preventing reattachment and ensuring reliability by eliminating the dross rather than relocating it.
Solution Approach 2:
The patent replaces the mechanical blowing-out method (using high pressure gas) with a thermal remelting process. By using laser energy to melt and re-solidify the dross, the system achieves more reliable dross removal without the mechanical forces that cause dross to reattach or pass through the holes.
3Object-generated harmful factors
If sufficient thermal energy and gas pressure are exerted to blow out dross, then dross removal is achieved, but through hole shape deviates from predetermined shape
Solution Approach 1:
The patent replaces the mechanical gas pressure method with a controlled thermal remelting process. The remelting laser precisely melts and re-solidifies the dross without exerting mechanical forces that would distort the hole shape, thereby maintaining manufacturing precision while achieving effective dross removal.
Solution Approach 2:
The patent changes the approach from mechanical ejection to thermal processing by applying a remelting laser with carefully controlled parameters (power, speed, focal position). This allows the dross to be melted and re-solidified into a smooth surface without deviating the hole shape from its predetermined geometry, thus preserving manufacturing precision.
4Object-generated harmful factors
If dross is removed by melting and blowing out with high pressure gas, then some dross is eliminated, but dross adheres again in other locations or on back surface
Solution Approach 1:
The patent uses a remelting laser to melt and re-solidify the dross in place, converting the harmful dross into a smooth, integrated surface. This process eliminates the dross completely rather than relocating it, preventing reattachment in other locations or on the back surface, and ensuring a reliable dross-free surface.
Solution Approach 2:
The patent replaces the mechanical blowing-out method with a thermal remelting process that fundamentally eliminates the dross by fusing it into the base material. This substitution ensures complete dross elimination without the risk of dross reattachment or migration to other locations, thereby achieving reliable dross-free surfaces.
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 effectively reduces dross influence, ensuring oil holes with predetermined shapes and dimensions, enhancing the wire's performance as an oil ring by preventing dross exfoliation and maintaining toughness and strength.
Implementation Method 1
piercing by stamping... laser beam processing has been proposed as means for formation of oil holes... a laser for forming the through holes is incident
Implementation Method 2
forming a remelted and solidified portion at an outlet side of each through hole... formed by integrating the wire for an I-shape oil ring and solidified residues
Implementation Method 3
a melted and solidified region formed on an inner side of each of the through holes... a remelted and solidified portion formed by integrating
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a wire rod for an I-type oil ring, which includes right and left rail portions and a web portion connecting the rail portions, which has an oil hole or a molten through hole formed in the web portion, and which has a circumscribing circle diameter of 10 mm or less in its transverse contour. The molten through hole has such a remolten portion formed on its exit side as encloses the exit of the molten through hole. The remolten portion exceeds such a molten portion in the transverse section along the center of the molten through hole as is formed in the molten through hole, and is formed to have 200 µm or less from the outer circumference of the molten through hole and 100 µm or less in the depth direction of the molten through hole.