WO2018092088A1 - Piston léger - Google Patents

Piston léger Download PDF

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Publication number
WO2018092088A1
WO2018092088A1 PCT/IB2017/057224 IB2017057224W WO2018092088A1 WO 2018092088 A1 WO2018092088 A1 WO 2018092088A1 IB 2017057224 W IB2017057224 W IB 2017057224W WO 2018092088 A1 WO2018092088 A1 WO 2018092088A1
Authority
WO
WIPO (PCT)
Prior art keywords
piston
magnesium alloy
cylindrical shaped
alloy
magnesium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2017/057224
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English (en)
Inventor
Oded DAHAN
Amnon Regev
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CN201780084242.5A priority Critical patent/CN110520618B/zh
Publication of WO2018092088A1 publication Critical patent/WO2018092088A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/10—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass pistons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 

Definitions

  • the embodiments herein is generally related to automobile industry.
  • the embodiments herein is particularly related to fluid pressure translating devices of the reciprocating type.
  • the embodiments herein is more particularly related to a system and method for manufacturing lightweight piston for internal combustion engines with increased engine efficiency.
  • Piston is one of the main components used in internal combustion engines.
  • the primary function of a piston is to suck the air-fuel mixture in order to compress the said mixture.
  • the pistons are designed to tolerate a sudden rise in temperature caused by an ignition of compressed air-fuel mixture and expulsion of the exhaust gases.
  • piston is the most active part of a combustion engine and needs to withstand heat, friction, inertia and vibrations caused by the crankshaft and rods.
  • the pistons are usually designed to minimize inertia in a high-speed engine and also designed to satisfy the above-mentioned attributes/qualities like heat dissipation etc. Therefore, standard pistons are made of high density, high strength, gas permeable steel or cast iron. Because of the use of thick steel or cast iron, the pistons are substantially heavy in weight.
  • the pistons are made of combination of steel and aluminium.
  • the aluminium is added as a material for making piston to greatly benefit the manufacturers with weight reduction.
  • the piston head is exposed to heavy pressure when the engine is operated under load due to the constant forces exhibited by the expanding the gases generated out of combustion of air-fuel mixture.
  • the upper portion of the piston is usually made of high density steel and the lower portion is made of aluminium alloy to withstand high temperature and pressure and to reduce an overall weight of the piston.
  • the use of combination of high density steel and aluminium still poses the problem of piston being thick and heavy.
  • typically pistons are casted completely with aluminium alloy to further reduce the piston weight.
  • Replacing cast iron (density 7.8) with aluminum (density 2.8) saves about 8% of fuel consumption simply because of its weight reduction.
  • the heavy weight of piston exhibits high inertia during combustion leading to decreased engine efficiency thereby decreasing horse power, increasing fuel consumption and causing air pollution.
  • the primary object of the embodiments herein is to provide a lightweight piston device for use in an internal combustion engine.
  • Another object of the embodiments herein is to provide an improved piston which is efficient in operation, relatively inexpensive and simple to manufacture.
  • Yet another object of the embodiments herein is to develop an improved piston with reduced fuel consumption of the automobile.
  • Yet another object of the embodiments herein is to develop a lightweight piston device using special magnesium alloy for use in an internal combustion engine.
  • Yet another object of the embodiments herein is to provide a system and method for manufacturing piston to achieve thinner wall cross section of the piston.
  • Yet another object of the embodiments herein is to manufacture a connecting rod for the piston using magnesium alloy.
  • Yet another object of the embodiments herein is to provide a piston with reduced inertial forces exhibited by the mass of the piston within the engine.
  • Yet another object of the embodiments herein is to provide an improved piston with increased fuel efficiency of the automobile.
  • Yet another object of the embodiments herein is to provide an improved piston with reduced pollution.
  • the embodiments herein provide a method for manufacturing a lightweight piston from magnesium alloy.
  • the method comprises forming a cylindrical shaped piston from magnesium alloy.
  • the method also comprises preparing a hole in the cylindrical shaped piston for inserting a piston pin using die punching technique.
  • the method further comprises performing external and internal turning to remove unwanted material from the internal and external surface of the cylindrical shaped piston.
  • the method still further comprises connecting a piston rod using a hole pin matching technique and performing lubricant hole drilling and performing a quality check on the cylindrical shaped piston to satisfy a plurality of desired parameters.
  • the step of forming the cylindrical shaped piston from magnesium alloy further comprises cold welding a steel or aluminium alloy metal sheet with magnesium alloy to form a disk as an input material for making the piston.
  • the cylindrical shaped piston is formed from the input material either by using metal spinning technique or extrusion technique.
  • the step of forming the cylindrical shaped piston from magnesium alloy using extrusion technique further comprises cutting one or more magnesium alloy rods into a plurality of billets.
  • the plurality of billets are heated and pressed against a dummy block through a die to form the piston.
  • the step of forming the cylindrical shaped piston from magnesium alloy using metal spinning technique further comprises rotating the magnesium alloy disk along with a mandrel and applying pressure on the disk by a tool with every passing rotation.
  • the method further comprises coating the external surface of the cylindrical shaped piston with a corrosion and heat resistant coating for protecting against corrosion and heat.
  • the step of forming the cylindrical shaped piston form magnesium alloy further comprises fabricating piston rings onto the cylindrical shaped piston body.
  • the step of preparing a hole in the cylindrical shaped piston further comprises punching the piston head on both sides using die punching for making hole to insert the piston pin.
  • the piston pin is inserted through the hole to connect the piston with a connecting rod.
  • the method further comprises manufacturing the connecting rod using magnesium alloy.
  • the embodiments herein provide a lightweight piston device for use in an internal combustion engine.
  • the piston is made from a magnesium alloy.
  • the piston made from magnesium alloy is lighter in weight thereby reducing the inertial forces within the cylinder which are directly proportional to the weight of the piston. By reducing the inertial forces, the efficiency of the engine increases which eventually increases the horse power.
  • a method for manufacturing piston from magnesium alloy comprises, manufacturing a piston from magnesium alloy using metal spinning technique.
  • the magnesium alloy is spun to a cylinder shape.
  • Die punching of the cylinder shaped magnesium alloy is carried out to make a hole for piston pin.
  • External and internal turning is performed using machining.
  • the piston rod is then connected matching hole pin and the lubricant hole drilling is performed.
  • a method for manufacturing piston from magnesium alloy comprises cutting the magnesium alloy rods into pieces as billets. These aluminium or magnesium billets are used as input pieces for extrusion. The billets are heated and then loaded into the container in the press. A dummy block is placed behind the billet. The billet is pushed out of the die with a ram. Based on the required properties, the piston is either heat treated or cold worked.
  • a method for reducing the inertial forces of the piston is provided by manufacturing the piston from magnesium alloy.
  • the magnesium alloy piston is lighter in weight and thereby reducing the inertia forces. By reducing the inertia forces, the efficiency of the engine increases which eventually increases the horse power.
  • a method for increasing a fuel efficiency of the internal combustion engine is provided.
  • a lightweight piston composition comprises a magnesium metal alloy, and wherein the magnesium meatal alloy is cladded or reinforced with a steel alloy sheet or aluminium alloy sheet, and wherein the magnesium alloy is a heat resistant magnesium alloy and wherein the heat resistant magnesium alloy is a magnesium alloy cladded with steel alloy sheet or aluminium alloy sheet coated with a heat resistant and corrosive resistant coating.
  • FIG. 1 illustrates a side view of a magnesium alloy sheet used as base material for manufacturing the piston, according to one embodiment herein.
  • FIG. 2 illustrates a flowchart explaining a method of manufacturing a piston using metal spinning technique, according to one embodiment herein.
  • FIG. 3 illustrates a front view of a piston manufactured using metal spinning technique, according to one embodiment herein.
  • FIG. 4 illustrates a side view of a piston depicting a process of making a hole for inserting a piston pin, according to one embodiment herein.
  • FIG. 5 illustrates a flowchart explaining a method of manufacturing a piston using extrusion technique, according to one embodiment herein.
  • FIG. 6 illustrates a cross sectional view of the internal structure of a piston, according to one embodiment herein.
  • FIG. 7 illustrates a piston movement when placed inside a cylinder, according to one embodiment herein.
  • the embodiments herein provide a method for manufacturing a lightweight piston from magnesium alloy.
  • the method comprises forming a cylindrical shaped piston from magnesium alloy.
  • the method also comprises preparing a hole in the cylindrical shaped piston for inserting a piston pin using die punching technique.
  • the method further comprises performing external and internal turning to remove unwanted material from the internal and external surface of the cylindrical shaped piston.
  • the method still further comprises connecting a piston rod using a hole pin matching technique and performing lubricant hole drilling and performing a quality check on the cylindrical shaped piston to satisfy a plurality of desired parameters.
  • the step of forming the cylindrical shaped piston from magnesium alloy further comprises cold welding a steel or aluminium alloy metal sheet with magnesium alloy to form a disk as an input material for making the piston.
  • the cylindrical shaped piston is formed from the input material either by using metal spinning technique or extrusion technique.
  • the step of forming the cylindrical shaped piston from magnesium alloy using extrusion technique further comprises cutting one or more magnesium alloy rods into a plurality of billets.
  • the plurality of billets are heated and pressed against a dummy block through a die to form the piston.
  • the step of forming the cylindrical shaped piston from magnesium alloy using metal spinning technique further comprises rotating the magnesium alloy disk along with a mandrel and applying pressure on the disk by a tool with every passing rotation.
  • the method further comprises coating the external surface of the cylindrical shaped piston with a corrosion and heat resistant coating for protecting against corrosion and heat.
  • the step of forming the cylindrical shaped piston form magnesium alloy further comprises fabricating piston rings onto the cylindrical shaped piston body.
  • the step of preparing a hole in the cylindrical shaped piston further comprises punching the piston head on both sides using die punching for making hole to insert the piston pin.
  • the piston pin is inserted through the hole to connect the piston with a connecting rod.
  • the method further comprises manufacturing the connecting rod using magnesium alloy.
  • the embodiments herein provide a lightweight piston device for use in an internal combustion engine.
  • the piston is made from a magnesium alloy.
  • the piston made from magnesium alloy is lighter in weight thereby reducing the inertial forces within the cylinder which are directly proportional to the weight of the piston. By reducing the inertial forces, the efficiency of the engine increases which eventually increases the horse power.
  • a method for manufacturing piston from magnesium alloy is provided. The method comprises, manufacturing a piston from magnesium alloy using metal spinning technique.
  • the magnesium alloy is spun to a cylinder shape. Die punching of the cylinder shaped magnesium alloy is carried out to make a hole for piston pin. External and internal turning is performed using machining.
  • the piston rod is then connected matching hole pin and the lubricant hole drilling is performed.
  • a method for manufacturing piston from magnesium alloy comprises cutting the magnesium alloy rods into pieces as billets. These magnesium billets are used as input pieces for extrusion. The billets are heated and then loaded into the container in the press. A dummy block is placed behind the billet. The billet is pushed out of the die with a ram. Based on the required properties, the piston is either heat treated or cold worked.
  • a method for reducing the inertial forces of the piston is provided by manufacturing the piston from magnesium alloy.
  • the magnesium alloy piston is lighter in weight and thereby reducing the inertia forces. By reducing the inertia forces, the efficiency of the engine increases which eventually increases the horse power.
  • a method for increasing a fuel efficiency of the internal combustion engine is provided.
  • a lightweight piston composition comprises a magnesium metal alloy, and wherein the magnesium meatal alloy is cladded or reinforced with a steel alloy sheet or aluminium alloy sheet, and wherein the magnesium alloy is a heat resistant magnesium alloy and wherein the heat resistant magnesium alloy is a magnesium alloy cladded with steel alloy sheet or aluminium alloy sheet coated with a heat resistant and corrosive resistant coating.
  • FIG. l illustrates a side view of a magnesium alloy sheet used as a base material for manufacturing the piston, according to one embodiment herein.
  • Steel or aluminium alloy metal sheet such as aluminium clad Alclad metal sheet (102) is obtained by cold welding aluminium alloy with magnesium alloy (104) to form a disk as an input material for making the piston either by using metal spinning technique or extrusion technique.
  • tough steel or tough aluminium alloy material is used to provide the desired capability of corrosion resistance and to meet the heat dissipation demands of the piston as magnesium is susceptible to corrosion and does not fulfil the desired heat dissipation criteria.
  • FIG. 2 illustrates a flowchart explaining a method of manufacturing a piston using metal spinning technique, according to one embodiment herein.
  • the method comprises the steps of manufacturing a piston from magnesium alloy using metal spinning technique (202).
  • Metal spinning technique is employed using a rotating mandrel to form a symmetric part across an axis.
  • a force is applied using a tool with smooth edges such as rounded end or the roller.
  • the process is started with withholding a magnesium alloy disk along with mandrel.
  • the required pressure is applied on the disk by the tool to gradually move up the mandrel with every passing rotation. This causes the disk to slowly take over the shape as desired and final shape is dictated by the shape of the mandrel.
  • punching is carried out on the cylindrical shaped magnesium alloy piston for making hole to insert piston pin (204).
  • a punch tool is pressed on the workpiece to create a hole.
  • the punch is passed through the workpiece in a die.
  • the die is located on the opposite side of the piston.
  • the material is supported around the perimeter of the hole to localize the shearing forces for a cleaner edge.
  • There is a small amount of clearance between the punch and the die to prevent the punch from sticking in the die thereby requiring lesser force to make the hole.
  • the punch is forced through the workpiece to produce the hole that has a diameter equivalent to the punch or slightly smaller after the punch is removed.
  • turning is carried out to remove unwanted material from the internal or external surface of the piston (206).
  • a cutting tool is moved linearly while the piston is rotated to produce tubular components and to achieve precise diameters and depths.
  • the piston rod is then connected using a hole pin matching technique and the lubricant hole drilling is performed (208).
  • hole pin machining is performed to enable connecting piston rod to the piston. Further drilling is performed to make lubrication holes on to the piston. Further, the quality of the piston thus manufactured is checked to satisfy the desired parameters. Further, a quality check is performed on the piston thus manufactured to satisfy desired parameters (210).
  • FIG. 3 illustrates a front view of a piston manufactured using metal spinning technique, according to one embodiment herein.
  • the magnesium alloy is spun into a cylinder shape using the metal spinning technique.
  • the piston rings are also fabricated onto the piston body.
  • FIG.4 illustrates a side view of a piston explaining a process of making a hole for inserting a piston pin, according to one embodiment herein.
  • the piston head is punched on both sides (402) using die punching for making holes to insert the piston pin.
  • the piston pin is inserted through these holes to connect the piston with the connecting rod to provide a bearing for the connecting rod to pivot upon as the piston moves, after the punching of the hole.
  • the connecting rod is also manufactured using magnesium alloy that in-turn further reduces the overall weight of the piston.
  • FIG.5 illustrates a flowchart explaining a method of manufacturing a piston using extrusion technique, according to one embodiment herein.
  • the magnesium alloy disk/rods are used as an extrusion log (502). Firstly, the magnesium alloy rods are cut into pieces as billets (504). These aluminium or magnesium billets are used as input pieces for extrusion.
  • objects of a fixed cross-sectional profile are extruded.
  • the magnesium alloy billets are pushed through a die of the desired cross-section (506).
  • the billets are heated (for hot or warm extrusion).
  • the billet is then loaded into a container in the press.
  • a dummy block is placed behind the billet and a ram is used to press the billet to push the billet out of the die.
  • the piston is either heat treated or cold worked.
  • An excellent surface finish process is applied for the piston.
  • the outcome of extrusion is very close to the desired shape of the piston.
  • the piston is then put through turning process as explained above followed by a hole pin machining process (508). Further, lubrication holes are formed within the piston.
  • the weight of the piston is reduced by 40% by using extrusion method for the manufacturing of piston in comparison with existing die casting methods. Further, a quality check is performed on the piston thus manufactured to satisfy desired parameters (510).
  • FIG. 6 illustrates a cross sectional view of the piston formed using magnesium alloy through either the metal spinning technique or extrusion technique, according to one embodiment herein
  • the cross section view highlights the hollow piston with thin magnesium alloy walls along with lubrication holes.
  • the cross section view additionally highlights the piston pin placement within the piston head.
  • other materials such as silicon is added to the magnesium alloy die casting to further enhance the properties of the piston.
  • FIG 7 illustrates a piston movement when placed inside a cylinder, according to one embodiment herein.
  • the piston is moved front and back inside the cylinder.
  • the inertial forces within the cylinder are directly proportional to the weight of the piston, high inertial forces are developed during a change in the piston movement direction.
  • Magnesium piston is lighter in weight and thus reduces the inertia forces. By reducing the inertia forces, the efficiency of the engine is increased thereby eventually increasing the horse power.
  • the embodiments herein provide a lightweight piston.
  • the piston is manufactured using magnesium alloy through metal spinning or extrusion technique.
  • the piston made from magnesium alloy is lighter in weight since the density of magnesium (1.7) is less as compared to aluminium (2.8) and thus reduces the inertia forces within the cylinder which are directly proportional to the weight of the piston. By reducing the inertia forces, the efficiency of the engine increases which eventually increases the horse power.
  • weight reduction of upto about 60% is achieved when the piston is manufactured using magnesium alloy through metal spinning technique. Further, weight reduction of upto about 40% is achieved when the piston is manufacture using magnesium through extrusion technique. In both the cases, the weight reduction is quite substantial as compared to the weight reduction of piston manufactured from aluminium alloy which is usually only about 20% to 30%.
  • the metal spinning technique is used for manufacturing the magnesium alloy piston. Metal spinning technique is performed to manufacture pistons with walls having thin cross section area. Due to thinner cross sectional area and due to use of low density magnesium alloy, substantially lightweight pistons are manufactured.
  • the extrusion technique is additionally used for manufacturing of the magnesium alloy piston.
  • the advantages of extrusion process over other manufacturing processes is its ability to create very complex cross-sections with an excellent surface finish.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Forging (AREA)

Abstract

Les modes de réalisation de la présente invention concernent un dispositif de piston léger destiné à être utilisé dans un moteur à combustion interne. Selon un mode de réalisation, le piston est constitué d'un alliage de magnésium. Le piston en alliage de magnésium présente un poids réduit, ce qui permet de réduire les forces d'inertie à l'intérieur du cylindre. La réduction des forces d'inertie, permet d'accroître le rendement du moteur, ce qui permet d'accroître la puissance en HP. L'invention concerne en outre un procédé de fabrication d'un piston à partir d'un alliage de magnésium mettant en œuvre une technique de repoussage au tour ou d'extrusion. Un poinçonnage est effectué sur la forme cylindrique de l'alliage de magnésium afin de réaliser un trou pour l'axe de piston. Un tournage externe et interne est effectué par usinage. La tige de piston est ensuite reliée à l'axe de trou correspondant et la perforation du trou de lubrifiant est effectuée.
PCT/IB2017/057224 2016-11-20 2017-11-17 Piston léger Ceased WO2018092088A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN201780084242.5A CN110520618B (zh) 2016-11-20 2017-11-17 由镁合金制造轻重量活塞的方法和轻重量活塞

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201641035882 2016-11-20
IN201641035882 2016-11-20

Publications (1)

Publication Number Publication Date
WO2018092088A1 true WO2018092088A1 (fr) 2018-05-24

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2017/057224 Ceased WO2018092088A1 (fr) 2016-11-20 2017-11-17 Piston léger

Country Status (2)

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CN (1) CN110520618B (fr)
WO (1) WO2018092088A1 (fr)

Citations (5)

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Publication number Priority date Publication date Assignee Title
GB1306470A (en) * 1970-09-23 1973-02-14 Porsche Kg Internal combustion engine piston
US5063894A (en) * 1989-11-11 1991-11-12 Kolbenschmidt Aktiengesellschaft Pressure-diecast light-alloy piston for internal combustion engines
DE10233263A1 (de) * 2002-07-23 2004-02-12 Ks Kolbenschmidt Gmbh Pleuelstange
JP4290059B2 (ja) * 2004-04-26 2009-07-01 本田技研工業株式会社 鍛造ピストンの製造方法および鍛造ピストン
US20120160206A1 (en) * 2010-12-28 2012-06-28 Hitachi Automotive Systems, Ltd. Piston of Internal Combustion Engine, Producing Method of Piston, and Sliding Member

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GB685289A (en) * 1948-08-04 1952-12-31 Denzil Dyne Fenton Smith A reciprocating piston and slide engine and pump and the like
GB1254884A (en) * 1968-12-30 1971-11-24 Ass Eng Ltd Improvements in or relating to a method of manufacturing pistons and to pistons produced by the method
JPH11264078A (ja) * 1998-03-18 1999-09-28 Hitachi Ltd Ｍｇ合金部材及びその用途とその処理液及びその製造法
JP2008036699A (ja) * 2006-08-09 2008-02-21 Univ Of Fukui 金属薄肉構造体並びに金属薄板の鍛造成形加工方法及び装置
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WO2012140219A1 (fr) * 2011-04-15 2012-10-18 Ks Kolbenschmidt Gmbh Piston pour moteur à combustion interne, fait d'un alliage d'aluminium à teneur en magnésium réduite
CN102240791B (zh) * 2011-06-30 2013-02-13 哈尔滨工业大学 铝镁合金熔炼后液压压射充型挤压铸造成形装置及方法
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DE102012008947A1 (de) * 2012-05-05 2013-11-07 Mahle International Gmbh Verfahren zur Herstellung eines Kolbens für einen Verbrennungsmotor
CN102676888A (zh) * 2012-05-17 2012-09-19 天津立中合金集团有限公司 一种车用发动机共晶铝硅合金活塞材料
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Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1306470A (en) * 1970-09-23 1973-02-14 Porsche Kg Internal combustion engine piston
US5063894A (en) * 1989-11-11 1991-11-12 Kolbenschmidt Aktiengesellschaft Pressure-diecast light-alloy piston for internal combustion engines
DE10233263A1 (de) * 2002-07-23 2004-02-12 Ks Kolbenschmidt Gmbh Pleuelstange
JP4290059B2 (ja) * 2004-04-26 2009-07-01 本田技研工業株式会社 鍛造ピストンの製造方法および鍛造ピストン
US20120160206A1 (en) * 2010-12-28 2012-06-28 Hitachi Automotive Systems, Ltd. Piston of Internal Combustion Engine, Producing Method of Piston, and Sliding Member

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Publication number Publication date
CN110520618B (zh) 2022-04-29
CN110520618A (zh) 2019-11-29

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