Method for producing a piston for an internal combustion engine and piston produced by said method

• US 10,077,738 B2
• Filed: 03/18/2014
• Issued: 09/18/2018
• Est. Priority Date: 03/18/2013
• Status: Active Grant

• Current Assignee: Mahle International GmbH (MAHLE-STIFTUNG GmbH)
• Original Assignee: Mahle International GmbH (MAHLE-STIFTUNG GmbH)
• Inventors: Berr, Gerhard, Boczek, Sascha-Oliver, Mueller, Reiner, Scharp, Rainer
• Primary Examiner(s): Besler, Christopher
• Application Number:
  US14/778,076
• Publication Number:
  US 20160281637A1
• Time in Patent Office: 1,645 Days
• CPC Class Codes: B21K 1/18 pistons or plungers
• CPC Class Codes: B21K 1/185 with cooling channels
• CPC Class Codes: B23B 2215/245 Pistons
• CPC Class Codes: B23K 15/0053 Seam welding
• CPC Class Codes: B23K 15/0093 characterised by the properties of the materials to be welded
• CPC Class Codes: B23K 2101/003 Pistons
• CPC Class Codes: B23K 2103/04 Steel or steel alloys
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/282 of tube sections
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: B23P 15/10 pistons
• CPC Class Codes: F02F 2003/0061 by welding
• CPC Class Codes: F02F 2200/04 Forging of engine parts
• CPC Class Codes: F02F 3/003 the parts being connected by casting, brazing, welding or clamping
• CPC Class Codes: F02F 3/22 the fluid being liquid
• CPC Class Codes: F02F 3/28 Other pistons with specially-shaped head

Abstract

A method for producing a piston for an internal combustion engine may include the steps of: producing a piston main body from a first blank via a deformation process; producing a piston ring part from a second blank via at least one of a deformation process and a casting process; pre-machining the first blank and the second blank, and finish machining a welding surface of the first blank and a welding surface of the second blank; connecting the pre-machined first blank and the pre-machined second blank via a welding process to form a piston body; and performing at least one of a secondary machining and a finish machining of the piston body to produce the piston.

Claims

1. A method for producing a piston for an internal combustion engine, comprising the steps of:

a) producing a first blank of a piston main body via a deformation process, wherein producing the first blank includes forming a contour of a combustion depression outside of a dome region of the piston main body to completion where an excess material deposit is defined in the dome region of the combustion depression, the piston main body including a plurality of piston bosses together defining at least two boss bores, the plurality of piston bosses connected to one another via a running surface, and wherein the combustion depression includes a welding surface facing radially towards an outside with respect to a piston central axis;

b) producing a second blank of a piston ring part via at least one of a deformation process and a casting process, wherein the piston ring part includes a piston crown, an annular fire land and an annular ring section, and wherein the piston crown has a welding surface facing radially towards an inside with respect to the piston central axis;

c) pre-machining the first blank and the second blank, and finish machining the welding surface of the combustion depression and the piston crown;

d) connecting the pre-machined first blank of piston main body and the pre-machined second blank of the piston ring part via a welding process to form a piston body, wherein the piston main body and the piston ring part together define an annular cooling duct; and

e) performing at least one of a secondary machining and a finish machining of the piston body to produce the piston;

wherein step e) further includes removing an amount of the excess material deposit in the dome region of the combustion depression to define a predetermined volume of the combustion depression and inspecting the predetermined volume during the removal of the excess material deposit in the dome region, wherein inspecting the predetermined volume includes determining a lowest point of the combustion depression, and establishing a starting point for a finish machining of the piston crown based on a plane running perpendicularly to the piston central axis and extending through the lowest point.

2. The method as claimed in claim 1, wherein step c) further includes forming a first cooling duct region into the first blank and forming a second cooling duct region into the second blank.

3. The method as claimed in claim 1, wherein step c) further includes finish machining an interior space defined in the first blank of the piston main body and forming an inlet opening and an outlet opening for a cooling fluid into a cooling duct region of the first blank.

4. The method as claimed in claim 1, wherein step c) further includes pre-machining an outer diameter of at least one of the first blank of the piston main body and the second blank of the piston ring part.

5. The method as claimed in claim 1, wherein step e) further includes forming the at least two boss bores into the plurality piston bosses after performing the finish machining of at least the piston crown.

6. The method as claimed in claim 1, wherein step a) further includes forging the first blank of the piston main body via hot working at a temperature ranging from 1200°

C. to 1300°

C. and subsequently performing a cold calibration process to the first blank.

7. The method as claimed in claim 1, wherein step a) further includes forging the first blank of the piston main body via hot working at a temperature ranging from 1200°

C. to 1300°

C. and subsequently cold working the first blank at a temperature of 150°

C. or less.

8. The method as claimed in claim 1, wherein step a) further includes forging the first blank of the piston main body via working at a predetermined temperature.

9. The method as claimed in claim 8, further comprising cold working the first blank of the piston main body at a temperature of 150°

C. or less after forging the first blank.

10. The method as claimed in claim 1, wherein step a) further includes forging the first blank of the piston main body via cold working at a temperature of 150°

C. or less.

11. The method as claimed in claim 1, wherein step c) further includes at least one of pre-machining and finish machining the piston crown on the second blank of the piston ring part.

12. The method as claimed in claim 1, wherein step c) further includes pre-machining the plurality of piston bosses on the first blank of the piston main body.

13. The method as claimed in claim 2, wherein step c) further includes performing a finish machining on at least one of the first cooling duct region and the second cooling duct region.

14. The method as claimed in claim 1, wherein step e) of removing the amount of excess material deposit in the dome region includes providing the combustion depression with a defined geometry.

15. The method as claimed in claim 8, wherein the predetermined temperature ranges from 600°

C. to 900°

C.

16. The method of claim 1, wherein the annular fire land includes at least one annular groove configured to receive a first piston ring and the annular ring section includes at least one annular groove configured to receive at least one second piston ring.

18. The method as claimed in claim 14, wherein providing the combustion depression with the defined geometry includes forming the combustion depression radially offset with respect to the piston central axis.

19. The method as claimed in claim 14, wherein providing the combustion depression with the defined geometry includes forming the combustion depression inclined with respect to the piston central axis.

17. A method for producing a piston for an internal combustion engine, comprising:

a) deforming a first blank of a piston main body including a combustion depression having a dome, a plurality of piston bosses together defining at least two boss bores, a running surface connecting the plurality of piston bosses to one another, wherein the combustion depression has a welding surface facing radially towards an outside with respect to a piston central axis;

b) deforming or casting a second blank of a piston ring part including a piston crown, an annular fire land and an annular ring section, wherein the piston crown has a welding surface facing radially towards an inside with respect to the piston central axis;

c) pre-machining the first blank and the second blank, and finish machining the welding surface of the combustion depression and of the piston crown;

d) connecting the pre-machined first blank of piston main body and the pre-machined second blank of the piston ring part via a welding process to form a piston body, wherein the piston main body and the piston ring part together define an annular cooling duct; and

e) performing at least one of a secondary machining and a finish machining of the piston body to produce the piston;

wherein step a) includes forming a contour of the combustion depression for the piston outside of a dome region to completion where an excess material deposit is defined in the dome region, and wherein step e) further includes removing an amount of the excess material deposit in the dome region to provide a predetermined volume of the combustion depression without performing at least one of a secondary machining and a finish machining on the contour outside of the dome region.