Piston Pin Hole Boring System with Multi-Axis Dynamic Cutting
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Solution Overview
Problem
Existing methods for forming pin holes in pistons often result in frictional wear due to imprecise formation of bores, requiring separate operations and tools, which can lead to reduced assembly life.
Innovation Solution
A piston pin hole boring system comprising a rotateable cutting member and a movable slide member with a fixture, allowing for precise formation of pin holes along multiple axes with controlled feedback, enabling the formation of pin holes of any peripheral profile in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate cutting tools are used to form pin holes at separate operations, then manufacturing flexibility is maintained, but manufacturing time and operational complexity increase
Solution Approach 1:
The patent combines multiple pin hole formation operations into a single machining operation by using a rotating cutting tool that can simultaneously or sequentially form multiple pin holes in different locations on the piston while the workpiece rotates, thereby reducing total manufacturing time and operational complexity
Solution Approach 2:
The invention employs dynamic positioning where the cutting tool and workpiece rotate relative to each other, allowing the same cutting tool to access multiple pin hole locations throughout the rotation cycle, enabling multi-location machining in one operation without complex repositioning
2Manufacturing precision
If a fixed cutting tool is used to form pin holes, then tool positioning is simple, but manufacturing precision deteriorates
Solution Approach 1:
The system employs relative rotation between the cutting tool and the piston workpiece, where both elements move in a controlled rotational manner to achieve precise bore formation. This dynamic approach allows the cutting edge to accurately trace the required bore geometry while maintaining simple tool positioning
Solution Approach 2:
The patent incorporates feedback control mechanisms that monitor and adjust the relative positions and speeds of the cutting tool and workpiece during machining, ensuring precise bore formation by continuously correcting any deviations from the intended cutting path
3Reliability
If pin holes are formed with imprecise geometry, then manufacturing complexity is reduced, but frictional wear increases
Solution Approach 1:
The dynamic rotational machining process ensures precise and consistent bore geometry by maintaining controlled relative motion between tool and workpiece, which minimizes frictional wear and extends assembly life through superior surface quality and dimensional accuracy
Solution Approach 2:
Feedback control systems monitor the machining process in real-time to ensure precise bore geometry is achieved, adjusting parameters as needed to maintain the quality required for minimizing frictional wear and maximizing component reliability
Data Source
AI summary
A piston pin hole boring system and method of forming pin holes therewith includes fixing a piston to a fixture supported by a slide member. Then, rotating a cutting member about a first axis and moving the slide member with the fixture thereon toward the cutting member along the first axis and bringing the piston into cutting contact with the cutting member. Further, moving the fixture along second and third axes, each extending transversely to the first axis and machining the desired pin hole contours in the piston with the cutting member.