Near-Net Piston Blank Forging for Closed Cooling Channels
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Solution Overview
Problem
Conventional piston blank forging methods result in heavy, top-heavy flanges that require substantial machining to form cooling channels, making it difficult to achieve a near-net shape piston blank with predictable and repeatable dimensions.
Innovation Solution
A forging process that involves heating and shaping a cylindrical steel billet to form a near-net shape piston blank with a reduced mass, using induction heating to deform the pre-flange portion and forming a flange without removing material from the core, allowing for spin bending to create a closed cooling channel with minimal machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional forging methods are used to create piston blanks, then the forging process is simple and robust, but the resulting blank has a heavy top-heavy flange requiring substantial machining
Solution Approach 1:
The method performs preliminary shaping of the flange and collar features during the forging process itself, before machining operations. The forging process is designed to pre-form the blank geometry close to the final shape, reducing subsequent material removal requirements while establishing predictable dimensions for the flange and collar structures.
Solution Approach 2:
The invention changes the forging parameters including temperature ranges, pressure application sequences, and die design to achieve near-net shape formation. By optimizing these parameters, the process produces consistent, predictable dimensions in the forged blank that reduce or eliminate the need for extensive machining while maintaining dimensional accuracy.
2Loss of substance
If near-net shape forging is attempted with existing equipment, then material usage is reduced, but substantial challenges and difficulties arise in the process
Solution Approach 1:
The forging process is divided into multiple sequential stages with distinct objectives. The method segments the deformation process into initial shaping, flange formation, and collar formation stages, each with controlled temperature and pressure parameters. This segmentation makes the complex near-net shape forging achievable with existing equipment by breaking down the challenging single-step process into manageable steps.
Solution Approach 2:
The invention maintains continuous heating and forging action throughout the process to keep the material in a deformable state. The continuous application of heat and pressure without interruption allows the material to flow continuously into the desired near-net shape, reducing the difficulty associated with stopping and restarting the process multiple times.
3Strength
If high temperatures and brute force are applied in forging, then material deformation is achieved, but predictable piston shape with repeatable dimensions becomes difficult to obtain
Solution Approach 1:
The invention implements precise control of temperature parameters throughout the forging process, maintaining the material within specific temperature ranges that optimize both deformability and dimensional control. By carefully managing thermal parameters and applying pressure in controlled sequences, the process achieves repeatable dimensions while maintaining adequate deformation capability.
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 achieves a near-net shape piston blank with reduced material usage and minimal machining, enabling consistent production with potential savings and improved efficiency.
Implementation Method 1
the pre-flange portion is heated by induction heating to bring that portion of the steel billet to temperatures where steel can be deformed
Implementation Method 2
the heated pre-flange portion is upset to form a flange over a recess in the skirt
Data Source
AI summary
A one-piece piston blank of near-net shape wherein the piston blank has a flange disposed opposite a skirt, the flange being spin-bendable to form a cooling channel with reduced preliminary removal of material relative to conventional forged piston blanks.