Spherical Cross-Bore Intersection for Pump Fluid End Stress Relief
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Solution Overview
Problem
The cross-bore intersection in reciprocating pumps experiences high stresses due to non-uniform curves and intersecting edges in the transition surfaces, which existing designs fail to adequately address for stress relief and manufacturing ease.
Innovation Solution
The design incorporates a spherical geometry for the cross-bore intersection with circumferential transition surfaces and edges that form continuous, circular paths, allowing for easier manufacturing and stress distribution, using CNC milling for precise creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cross-bore intersection geometry with non-uniform curves and intersecting edges is used, then the pump can be manufactured with conventional methods, but high stress concentrations occur at the bore intersections
Solution Approach 1:
The patent applies spherical geometry to the cross-bore intersection, replacing the traditional non-uniform curved surfaces with a spherical surface that has uniform curvature in all directions. This spherical geometry eliminates stress concentrations by distributing stresses evenly across the intersection area, while the uniform curvature allows for easier manufacturing using spherical milling tools and CNC programming.
2Strength
If spherical geometry is used for the cross-bore intersection, then stress concentrations are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces complex manual machining operations with CNC automated milling. The spherical geometry is created using computer-controlled milling tools that can accurately follow spherical toolpaths, eliminating the need for manual fitting and blending operations. This substitution of manual mechanical work with automated CNC processes achieves high geometric precision while simplifying the manufacturing workflow.
3Volume of moving object
If multiple bores intersect at a single point, then the fluid end structure is compact, but the transition surfaces create intersecting edges that form stress concentration points
Solution Approach 1:
The spherical surface at the cross-bore intersection eliminates intersecting edges by providing a continuous, smooth transition between all bores. The sphere's uniform curvature ensures that no sharp corners or edge intersections exist, thereby eliminating stress concentration points while maintaining the compact multi-bore structure.
Data Source
AI summary
A fluid end of a high-pressure pump having a power end bore, a discharge bore, a suction bore, an access bore, and a cross-bore intersection formed in portions of the fluid end is provided. A transitional open area opens into the cross-bore intersection from the power end bore; a transitional open area opens into the cross-bore intersection from the access bore; a transitional open area opens into the cross-bore intersection from the suction bore; and a transitional open area opens into the cross-bore intersection from the discharge bore. A spherical geometry is created in the cross-bore intersection. A spherical surface forms an outer boundary of the cross-bore intersection.