CN113339155A - Preparation method of piston, piston and tool assembly - Google Patents
Preparation method of piston, piston and tool assembly Download PDFInfo
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- CN113339155A CN113339155A CN202110729237.3A CN202110729237A CN113339155A CN 113339155 A CN113339155 A CN 113339155A CN 202110729237 A CN202110729237 A CN 202110729237A CN 113339155 A CN113339155 A CN 113339155A
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- Prior art keywords
- piston
- wall
- cavity
- structural member
- protective layer
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- 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
- F02F3/10—Pistons having surface coverings
- F02F3/12—Pistons having surface coverings on piston heads
- F02F3/14—Pistons having surface coverings on piston heads within combustion chambers
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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
- F02M61/14—Arrangements of injectors with respect to engines; Mounting of injectors
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- 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
- F02F2200/00—Manufacturing
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Pistons, Piston Rings, And Cylinders (AREA)
Abstract
The invention provides a preparation method of a piston, the piston and a tool assembly, wherein the preparation method of the piston at least comprises the following steps: determining a first high thermal load area on the inner wall of a cavity of the piston body, and forming a groove on the first high thermal load area; forming a first protective layer on an inner wall of a chamber of a piston body; assembling the tool assembly on the piston body, placing the first structural member in a cavity of the piston, and enabling a projection area of the through hole in the first structural member on the inner wall to correspond to the groove; and forming a second protective layer in the first high heat load area so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body. The invention can reduce or avoid the phenomena of oxidation, ablation, damage and the like at the position with higher heat load on the surface of the combustion chamber of the aluminum piston, thereby avoiding large heat loss and improving the reliability of the piston to a certain extent.
Description
Technical Field
The invention relates to the technical field of mechanical assembly, in particular to a piston, a preparation method thereof and a tool assembly.
Background
The piston is the "heart" of an automobile engine, which is subjected to alternating mechanical and thermal loads, generally operates at high temperatures, is one of the most severe critical components of the engine, and is otherwise part of the combustion chamber. Because the piston heat load and mechanical load are larger, a heat barrier layer is generally required to be arranged on the piston for heat insulation treatment, on one hand, more heat can be left in the combustion chamber so as to facilitate work and post-treatment temperature improvement, on the other hand, the heat load of other parts can be effectively reduced, and the service life is prolonged.
For a steel piston, in the prior art, a plasma spraying method is generally adopted to coat the surface of a combustion chamber of the steel piston, specifically, a molded line structure of the combustion chamber is determined firstly, then the thickness of a thermal barrier layer is cut and reserved on the basis of the structure, and the thermal barrier layer is formed on the steel piston by a thermal spraying method.
However, in the above-described configuration, oxidation, ablation, and damage are likely to occur at a position where the thermal load on the combustion chamber surface of the aluminum piston is high, and a large amount of heat is lost.
Disclosure of Invention
In order to solve at least one problem mentioned in the background art, the invention provides a preparation method of a piston, the piston and a tool assembly, which can reduce or avoid the phenomena of oxidation, ablation, damage and the like at a position with higher heat load on the surface of a combustion chamber of an aluminum piston, thereby avoiding a large amount of heat loss and improving the reliability of the piston to a certain extent.
In order to achieve the above object, the present invention provides, in a first aspect, a method of manufacturing a piston, the method including: providing a tool assembly and a piston body made of steel materials, wherein the tool assembly comprises at least one first structural member, a through hole is formed in the first structural member, and a cavity is formed above the piston body; determining a first high thermal load area on the inner wall of the chamber of the piston body, and forming a groove on the first high thermal load area; forming a first protective layer on an inner wall of the chamber of the piston body; assembling the tool assembly on the piston body, wherein the first structural member is placed in a cavity of the piston and is matched with at least part of the inner wall of the cavity, and the projection area of the through hole on the inner wall corresponds to the groove; and forming a second protective layer in the first high heat load area so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body.
In a second aspect, the present invention provides a piston comprising at least: a piston body; a cavity is formed at the top of the piston body, at least one first high-heat-load area is arranged on the inner wall of the cavity, and a protective layer is arranged on the inner wall; the thickness of the protective layer at least one of the first high heat load regions is larger than the thickness of the protective layer at the remaining region of the inner wall except for the first high heat load region.
In the above piston, optionally, the piston body further includes: a fuel injector located within the chamber; the fuel injector comprises a fuel injector body and a fuel bundle connected with the fuel injector body, and the first high heat load area is located at the nozzle position of the fuel bundle.
In the above piston, optionally, the inner wall of the chamber further has at least one second high thermal load region; the thickness of the protective layer at least one of the second high heat load regions is larger than the thickness of the protective layer at the remaining region of the inner wall except for the first high heat load region and the second high heat load region.
In the piston described above, optionally, the second high thermal load region is at a throat position of the chamber.
In the above piston, optionally, a thickness of the protective layer at least one of the first high thermal load regions is the same as a thickness of the protective layer at least one of the second high thermal load regions.
In a third aspect, the present invention provides a tooling assembly for application to any one of the above pistons, comprising at least: at least one first structural member; the first structural member is placed in a cavity of the piston, and the first structural member is matched with at least part of the inner wall of the cavity; the first structural member is provided with at least one through hole, and the projection area of the through hole on the inner wall is positioned at the first high heat load area of the inner wall.
In the above tool assembly, optionally, the number of the first structural members is at least two, and the inner diameter of the through hole in each of the at least two first structural members is different.
In the above tool assembly, optionally, the method further includes: at least one second structural member; the second structural part is placed in a cavity of the piston, and the second structural part is matched with at least part of the inner wall of the cavity; the second structural member is provided with at least one annular opening, and the projection area of the annular opening on the inner wall is positioned at a second high heat load area of the inner wall.
In the above tool assembly, optionally, the number of the second structural members is at least two, and the size of the annular opening on each of the at least two second structural members is different.
In the above tool assembly, optionally, the second structural member includes: a first sub-structure and a second sub-structure; the annular opening is formed between the first substructure and the second substructure.
The invention provides a preparation method of a piston, which at least comprises the following steps: providing a tool assembly and a piston body made of steel materials, wherein the tool assembly comprises at least one first structural member, a through hole is formed in the first structural member, and a cavity is formed above the piston body; determining a first high thermal load area on the inner wall of the chamber of the piston body, and forming a groove on the first high thermal load area; forming a first protective layer on an inner wall of the chamber of the piston body; assembling the tool assembly on the piston body, wherein the first structural member is placed in a cavity of the piston and is matched with at least part of the inner wall of the cavity, and the projection area of the through hole on the inner wall corresponds to the groove; and forming a second protective layer in the first high heat load area so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body.
By the method, the thickness of the protective layer at the high heat load area on the inner wall of the chamber of the piston is larger than that of the protective layer at the residual area on the inner wall of the chamber of the piston, so that the phenomena of oxidation, ablation, damage and the like at the position with higher heat load on the surface of the combustion chamber of the piston can be reduced or avoided, the phenomenon of overlarge local heat dissipation caused by uneven heat load of the piston is effectively avoided, and the reliability of the piston is improved to a certain extent.
The construction of the present invention and other objects and advantages thereof will be more apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic diagram of a protective layer on the inner wall of a chamber of a piston in the prior art;
FIG. 2 is a schematic diagram of a piston of the prior art;
FIG. 3 is a schematic diagram of a heat load (temperature) distribution of a prior art piston;
FIG. 4 is a schematic diagram of a chamber of a piston according to an embodiment of the present invention;
fig. 5 is a schematic structural diagram of a tooling assembly according to an embodiment of the present invention;
FIG. 6 is a schematic view of an assembly structure of the tooling assembly and the piston according to an embodiment of the present invention;
FIG. 7 is a schematic diagram of a protective layer on an inner wall of a chamber of a piston according to an embodiment of the present invention;
FIG. 8 is a schematic view of another embodiment of a piston chamber;
fig. 9 is another schematic structural diagram of a tooling assembly according to an embodiment of the present invention;
fig. 10 is another structural diagram of a protective layer on an inner wall of a chamber of a piston according to an embodiment of the present invention.
Description of reference numerals:
100-a piston;
10-a piston body;
11-a chamber;
111-inner wall;
1111 — a first high thermal load region;
1112-a second high thermal load region;
112-a protective layer;
113-laryngeal opening;
101-fuel injector;
1011-fuel injector body;
1012-fuel bundles;
1013-nozzles;
200-a tooling assembly;
21-a first structural member;
211-a through hole;
22-a second structural member;
221-annular opening;
222-a first sub-structure;
223-second sub-structure.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below with reference to the accompanying drawings in the preferred embodiments of the present invention. In the drawings, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The described embodiments are only some, but not all embodiments of the invention. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.
In the description of the present invention, it should be noted that unless otherwise specifically stated or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning a fixed connection, an indirect connection through intervening media, a connection between two elements, or an interaction between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
Because the heat load and the mechanical load of the piston are large, the heat insulation treatment is generally carried out by coating a coating on the piston at present, on one hand, the heat insulation can retain more heat in a combustion chamber so as to improve the working and post-treatment temperature, on the other hand, the heat insulation can effectively reduce the heat load of other parts and components, and the service life is prolonged.
Aiming at the heat insulation requirement of the piston, a thermal barrier coating is generally adopted on the surface of a combustion chamber of the piston to protect a piston body. The thermal barrier coating comprises a functional layer and a bonding layer, wherein the functional layer of the thermal barrier coating is made of ceramic materials and is also called the functional layer, and a transition layer is arranged between the thermal barrier layer and the piston body and is also called the bonding layer. The overall thickness of the thermal barrier coating is typically within 1mm, with the bond coat having a thickness of 0.02mm to 0.2 mm. For steel pistons, the current thermal barrier coating is usually coated on the piston by plasma spraying, and the coating thickness after plasma spraying is uniform.
Fig. 1 is a schematic structural view of a protective layer on an inner wall of a chamber of a piston in the related art. Fig. 2 is a schematic structural diagram of a piston in the prior art. Fig. 3 is a schematic diagram of the heat load (temperature) distribution of a piston in the prior art.
In the prior art, the work flow of preparing the piston with the thermal barrier coating is generally as follows: firstly, determining the molded line structure of a combustion chamber of a piston, then cutting to reserve the thickness of a thermal barrier coating on the basis, wherein the bonding layer and the functional layer of a steel piston form the thermal barrier coating on the piston in a thermal spraying mode, and the specific address is as shown in figure 1, the thermal barrier coating of the combustion chamber of the piston is equal in thickness, and the thickness of the thermal barrier coating in figure 1 is 0.4 mm.
It will be readily appreciated that the fuel in the combustion chamber of the piston is typically injected by an injector, which is typically porous and therefore tends to cause non-uniform thermal loading in the combustion chamber, as shown in fig. 2 and 3, which may result from non-uniform thermal loading (temperature) distribution in the combustion chamber due to the distribution of high pressure fuel injected by the injector in the combustion chamber of the piston. Uneven distribution of the heat load easily causes inconsistent service lives of different positions in the piston combustion chamber, that is, oxidation, ablation, damage and the like easily occur in areas with high heat load. At the same time, there will be a large amount of heat lost in areas with high thermal load.
Based on this, the embodiment of the application provides a preparation method of a piston, a tool assembly is assembled on a piston body by forming a first protective layer on an inner wall of a cavity of the piston body, and a projection area of a through hole of at least one first structural member in the tool assembly on the inner wall is located at a first high heat load area of the inner wall. And then forming a second protective layer on the first high heat load area of the inner wall so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body. Therefore, the thickness of the protective layer at the high heat load area on the inner wall of the chamber of the piston is larger than that of the protective layer at the residual area on the inner wall of the chamber of the piston, so that the phenomena of oxidation, ablation, damage and the like at the position with higher heat load on the surface of the combustion chamber of the piston can be reduced or avoided, the phenomenon of overlarge local heat dissipation caused by the uneven heat load of the piston is effectively avoided, and the reliability of the piston is improved to a certain extent.
The specific structure of the piston and the tooling assembly will be described in detail below with reference to the accompanying drawings.
Fig. 4 is a schematic structural diagram of a chamber of a piston according to an embodiment of the present invention. Fig. 5 is a schematic structural diagram of a tooling assembly according to an embodiment of the present invention. Fig. 6 is a schematic view of an assembly structure of the tool assembly and the piston according to an embodiment of the present invention. Fig. 7 is a schematic structural diagram of a protective layer on an inner wall of a chamber of a piston according to an embodiment of the present invention. Fig. 8 is another schematic structural diagram of a chamber of a piston according to an embodiment of the present invention. Fig. 9 is another schematic structural diagram of a tooling assembly according to an embodiment of the present invention. Fig. 10 is another structural diagram of a protective layer on an inner wall of a chamber of a piston according to an embodiment of the present invention.
Referring to fig. 4 to 10, an embodiment of the present invention provides a piston 100, where the piston 100 may include at least: the piston comprises a piston body 10, a cavity 11 is formed at the top of the piston body 10, an inner wall 111 of the cavity 11 is provided with at least one first high heat load area 1111, a protective layer 112 is arranged on the inner wall 111, and the thickness of the protective layer 112 at the at least one first high heat load area 1111 is larger than that of the protective layer 112 at the rest area of the inner wall 111 except the first high heat load area 1111.
By designing the protective layer 112 with unequal thickness on the inner wall 111 of the chamber 11, the problems of oxidation ablation and large heat dissipation in the high heat load area of the thermal barrier coating with the equal thickness design in the prior art can be solved.
Wherein, in one possible implementation, the depth of the first high thermal load region 1111 (the relative depth between the first high thermal load region 1111 and the remaining region) is 0.1mm to 0.3 mm. For example, the depth of the first high thermal load region 1111 may be 0.15mm, 0.20mm, 0.25mm, or the like, which is not limited by the embodiment of the present application and is not limited to the above example.
It should be noted that the numerical values and numerical ranges referred to in this application are approximate values, and there may be some error due to the manufacturing process, and the error may be considered to be negligible by those skilled in the art.
In addition, the shape of the first high thermal load region 1111 in the depth direction may be a semicircle, an ellipse, or the like, which is not limited to the above example in the embodiment of the present application.
In the embodiment of the present application, as shown in fig. 2, the piston body 10 may further include: injector 101, injector 101 being located in chamber 11, injector 101 may include a fuel bundle 1012 having a fuel injector body 1011 connected to fuel injector body 1011, with a first high thermal load region 1111 located at a location of a nozzle 1013 of fuel bundle 1012.
Further, in some embodiments, the inner wall 111 of the chamber 11 also has at least one second high heat load region 1112, and the thickness of the protective layer 112 at the at least one second high heat load region 1112 is greater than the thickness of the protective layer 112 at the remaining region of the inner wall 111 except for the first high heat load region 1111 and the second high heat load region 1112.
As an alternative embodiment, the second high thermal load region 1112 may be at the throat 113 location of the chamber 11.
In addition, it is to be noted that, in the present embodiment, the thickness of the protective layer 112 at the at least one first high thermal load region 1111 is the same as the thickness of the protective layer 112 at the at least one second high thermal load region 1112.
Further, in the present embodiment, the piston 100 may be a steel piston.
The present invention provides a piston 100, wherein the piston 100 at least comprises: the piston comprises a piston body 10, a cavity 11 is formed at the top of the piston body 10, an inner wall 111 of the cavity 11 is provided with at least one first high heat load area 1111, a protective layer 112 is arranged on the inner wall 111, and the thickness of the protective layer 112 at the at least one first high heat load area 1111 is larger than that of the protective layer 112 at the rest area of the inner wall 111 except the first high heat load area 1111.
Through the arrangement, the thickness of the protective layer 112 at the high heat load area on the inner wall 111 of the chamber 11 of the piston 100 is greater than the thickness of the protective layer 112 at the residual area on the inner wall 111 of the chamber 11 of the piston 100, so that the phenomena of oxidation, ablation, damage and the like at the position with higher heat load on the surface of the combustion chamber of the piston 100 can be reduced or avoided, the phenomenon of overlarge local heat dissipation caused by uneven heat load of the piston 100 is effectively avoided, and the reliability of the piston 100 is improved to a certain extent.
The embodiment of the present invention further provides a tooling assembly 200, which is applied to the piston 100, where the tooling assembly 200 at least includes: the first structural member 21 is placed in the chamber 11 of the piston 100, the first structural member 21 is matched with at least part of the inner wall 111 of the chamber 11, at least one through hole 211 is formed in the first structural member 21, and the projection area of the through hole 211 on the inner wall 111 is located in the first high heat load area 1111 of the inner wall 111.
In the embodiment of the present application, the number of the first structural members 21 may be at least two, and the inner diameter of the through hole 211 on each of the at least two first structural members 21 is different.
Further, in some embodiments, the tooling assembly 200 provided in the embodiment of the present application may further include: at least one second structural member 22, the second structural member 22 is disposed in the chamber 11 of the piston 100, and the second structural member 22 is adapted to at least a portion of the inner wall 111 of the chamber 11, at least one annular opening 221 is opened on the second structural member 22, and a projection area of the annular opening 221 on the inner wall 111 is located at a second high thermal load area 1112 of the inner wall 111.
In the embodiment of the present application, the number of the second structural members 22 may be at least two, and the size of the annular opening 221 on each of the at least two second structural members 22 is different.
As an alternative embodiment, the second structural member 22 may include: the first sub-structure 222 and the second sub-structure 223 form an annular opening 221 therebetween.
The tooling assembly 200 provided in the embodiment of the present invention, the tooling assembly 200 is applied to the piston 100, and the tooling assembly 200 at least includes: the first structural member 21 is placed in the chamber 11 of the piston 100, the first structural member 21 is matched with at least part of the inner wall 111 of the chamber 11, at least one through hole 211 is formed in the first structural member 21, and the projection area of the through hole 211 on the inner wall 111 is located in the first high heat load area 1111 of the inner wall 111.
Through the arrangement, the first structural member 21 is placed in the cavity 11 of the piston 100, because the first structural member 21 is matched with at least part of the inner wall 111 of the cavity 11, and the first structural member 21 is provided with at least one through hole 211, and the projection area of the through hole 211 on the inner wall 111 is located in the high heat load area of the inner wall 111, when the protective layer 112 is sprayed on the inner wall 111 of the cavity 11, the first structural member 21 can play a role of blocking other areas except the high heat load area from being sprayed, so that the thickness of the protective layer 112 in the high heat load area on the inner wall 111 of the cavity 11 of the piston 100 is larger than that of the protective layer 112 in the residual area on the inner wall 111 of the cavity 11 of the piston 100, the phenomena of oxidation, ablation, damage and the like at the position with higher heat load on the surface of the combustion chamber of the piston 100 can be reduced or avoided, and the phenomenon of over-large local heat dissipation caused by the uneven heat load of the piston 100 can be effectively avoided, the reliability of the piston 100 is improved to some extent.
In addition, the tool assembly 200 includes at least one first structural member 21, and the inner diameters of the through holes 211 on the first structural members 21 are different, so that the high heat load region can be ensured to be in a thickness gradually changing state to match the design shape of the first high heat load region 1111.
The embodiments of the present application also provide a method of forming a protective layer 112 on the piston body 10. The tool assembly 200 including at least one first structural member 21 (when at least one first structural member 21 is applied to the piston 100) will be described as an example.
S101: the tool assembly 200 and the piston body 10 made of steel material are provided, and the tool assembly 200 includes at least one first structural member 21, a through hole 211 is formed on the first structural member 21, and a cavity 11 is formed above the piston body 10.
S102: a first high thermal load region 1111 is defined in an inner wall 111 of a chamber 11 of a piston body 10, and a groove is formed in the first high thermal load region 1111.
Specifically, the region of the inner wall 111 of the chamber 11 of the piston body 10 where the thermal load is large may be determined according to the position and range of the fuel injector fuel flow landing point.
During the machining process of the piston body 10, firstly, according to the simulation calculation result, a thickened space is reserved on the inner wall 111 of the cavity 11 of the piston body 10 in the area with larger heat load, namely, a groove is arranged on the inner wall 111 of the cavity 11 of the piston body 10 in the area with larger heat load. For example, the thickness of the protective layer 112 at the remaining region of the inner wall 111 excluding the first high heat load region 1111 may be 0.4mm, and the thickness of the protective layer 112 at the first high heat load region 1111 may be 0.5mm to 0.7 mm.
It should be noted that, when the space of the protective layer 112 is cut entirely on the inner wall 111 of the cavity 11, the first high thermal load region 1111 is determined to be deeper by 0.1mm to 0.3mm than the remaining region.
For example, fig. 4 is a cross-sectional view of the grooves in the first high thermal load region 1111, as shown in fig. 4, the grooves in the first high thermal load region 1111 may have various shapes such as a semicircular shape and an elliptical shape in the depth direction, and the size of the grooves in the first high thermal load region 1111 gradually changes in the depth direction, and the specific cutting depth and position of the first high thermal load region 1111 may be designed according to the temperature calculation result.
S103: a first protective layer is formed on the inner wall 111 of the chamber 11 of the piston body 10.
It should be noted that the overall spraying process may include spraying of the adhesive layer and spraying of the functional layer, and when the adhesive layer is sprayed on the inner wall 111 of the entire chamber 11, the thickness of the adhesive layer may be controlled to be between 0.08 mm and 0.12mm, and the thickness of each spraying process is increased by 0.02mm, so that the spraying process needs to be performed 4 to 6 times. The functional layer is integrally sprayed on the basis of the bonding layer, the thickness can be controlled to be about 0.4mm, and the thickness is increased by 0.04mm in each spraying process, so that the spraying needs to be performed for about 10 times.
S104: the tool assembly 200 is assembled on the piston body 10, the first structural member 21 is placed in the cavity 11 of the piston body 10, the first structural member 21 is matched with at least part of the inner wall 111 of the cavity 11, and the projection area of the through hole 211 on the inner wall 111 corresponds to the groove.
Specifically, the first structural member 21 is placed in the chamber 11, and the through hole 211 on the first structural member 21 corresponds to the first high heat load region 1111 on the inner wall 111 of the chamber 11, so that the first high heat load region 1111 (i.e., the recess region) is exposed.
Note that the first structural member 21 can block the remaining region other than the first high thermal load region 1111 from being painted.
S105: and forming a second protective layer in the first high-heat-load area of the inner wall so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body.
Specifically, local re-spraying is carried out on a region with a large heat load, the spraying thickness can be controlled within 0.1mm-0.3mm, and the principle of filling the original hollowed region is taken as a principle. The secondary spraying is generally realized by 3-8 times of spraying, and the thickness of each spraying is increased by about 0.04 mm. The thickness of the protective layer 112 in the heat load region (i.e., the first high heat load region 1111) can be gradually changed.
In addition, in order to ensure that the first high thermal load region 1111 has a gradually changing thickness, two or more different first structural members 21 may be used, and after the coating layer is thickened by 0.04 to 0.1mm every 1 to 3 times of spraying, the first structural member 21 having the larger aperture of the through hole 211 is replaced once to form the protective layer 112 shown in fig. 6 after spraying.
S106: and polishing the protective layer 112 after finishing spraying so as to make the surface of the protective layer 112 smoother and the whole body more beautiful.
The tool assembly 200 includes at least one second structural member 20 (when at least one second structural member 22 is applied to the piston 100) for illustration.
S101: the tool assembly 200 and the piston body 10 made of steel material are provided, and the tool assembly 200 includes at least one second structural member 22, an annular opening 221 is formed on the second structural member 22, and a chamber 11 is formed above the piston body 10.
S102: a second high thermal load area 1112 on the inner wall 111 of the chamber 11 of the piston body 10 is defined, and an annular groove is opened on the second high thermal load area 1112.
Specifically, it may be determined that the throat 113 of the chamber 11 is located in a region where the thermal load is large (i.e., the second high thermal load region 1112) according to the design of the chamber 11 of the piston body 10.
In the machining process of the piston body 10, firstly, according to the simulation calculation result, a thickened space is reserved on the region with larger heat load on the inner wall 111 of the cavity 11 of the piston body 10, namely, a second high heat load region 1112 is arranged on the region with larger heat load on the inner wall 111 of the cavity 11 of the piston body 10. For example, the thickness of the protective layer 112 at the remaining region of the inner wall 111 excluding the second high heat load region 1112 may be 0.4mm, and the thickness of the protective layer 112 at the second high heat load region 1112 may be 0.5mm to 0.7 mm.
It should be noted that, when the space of the protective layer 112 is cut integrally on the inner wall 111 of the chamber 11, it is first determined that the second high heat load region 1112 is 0.1mm to 0.3mm deeper than the space of the remaining region.
Specifically, the specific cutting cavity depth and location of the second high thermal load region 1112 may be designed based on empirical accumulation and simulation calculations.
S103: a first protective layer is formed on the inner wall 111 of the chamber 11 of the piston body 10.
Specifically, the inner wall 111 of the chamber 11 of the piston body 10 may be entirely coated.
It should be noted that the overall spraying process may include spraying of the adhesive layer and spraying of the functional layer, and when the adhesive layer is sprayed on the inner wall 111 of the entire chamber 11, the thickness of the adhesive layer may be controlled to be between 0.08 mm and 0.12mm, and the thickness of each spraying process is increased by 0.02mm, so that the spraying process needs to be performed 4 to 6 times. The functional layer is integrally sprayed on the basis of the bonding layer, the thickness can be controlled to be about 0.4mm, and the thickness is increased by 0.04mm in each spraying process, so that the spraying needs to be performed for about 10 times.
S104: the tool assembly 200 is assembled on the piston body 10, the second structural part 22 is placed in the cavity 11 of the piston body 10, the second structural part 22 is matched with at least part of the inner wall 111 of the cavity 11, and the projection area of the annular opening 221 on the inner wall 111 corresponds to the annular groove.
Specifically, the second structural member 22 is placed in the chamber 11, and the annular opening 221 of the second structural member 22 corresponds to the second high heat load region 1112 on the inner wall 111 of the chamber 11, so that the second high heat load region 1112 is exposed.
It should be noted that the second structural member 22 can block the remaining area other than the second high thermal load area 1112 from being painted.
S105: a second protective layer is formed on the second high thermal load region 1112 of the inner wall so that the protective layer 112 having a different thickness is formed on the inner wall 111 of the chamber 11 of the piston body 10.
That is, the second high heat load region 1112 is sprayed again. Specifically, local re-spraying is carried out on a region with larger heat load (namely the position of the throat 113), and the spraying thickness can be controlled within 0.1mm-0.3mm to fill the original hollowed region. The secondary spraying is generally realized by 3-8 times of spraying, and the thickness of each spraying is increased by about 0.04 mm. The thickness of the protective layer 112 in the heat load region (i.e., the second high heat load region 1112) can be gradually changed.
In addition, in order to ensure that the second high thermal load region 1112 is in a thickness gradient state, two or more different second structural members 22 can be used, after the coating is thickened by 0.04-0.1mm every 1-3 times by spraying, the second structural member 22 with the larger aperture of the through hole 211 is replaced once, and the protective layer 112 shown in fig. 6 after spraying is formed.
S206: and polishing the protective layer 112 after finishing spraying so as to make the surface of the protective layer 112 smoother and the whole body more beautiful.
In the description of the present invention, it is to be understood that the terms "upper", "lower", "front", "rear", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are only for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. In the description of the present invention, "a plurality" means two or more unless specifically stated otherwise.
The terms "first," "second," "third," "fourth," and the like in the description and in the claims of the present application and in the drawings described above, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the application described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "may include" and "have," as well as any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: the above embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the same, although the present invention is described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: it is to be understood that modifications may be made to the technical solutions described in the foregoing embodiments, or some or all of the technical features may be equivalently replaced, and the modifications or the replacements may not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. A method of making a piston, the method comprising:
providing a tool assembly and a piston body made of steel materials, wherein the tool assembly comprises at least one first structural member, a through hole is formed in the first structural member, and a cavity is formed above the piston body;
determining a first high thermal load area on the inner wall of the chamber of the piston body, and forming a groove on the first high thermal load area;
forming a first protective layer on an inner wall of the chamber of the piston body;
assembling the tool assembly on the piston body, wherein the first structural member is placed in a cavity of the piston and is matched with at least part of the inner wall of the cavity, and the projection area of the through hole on the inner wall corresponds to the groove;
and forming a second protective layer in the first high heat load area so as to form protective layers with different thicknesses on the inner wall of the cavity of the piston body.
2. A piston produced by the method for producing a piston according to claim 1, comprising at least:
a piston body;
a cavity is formed at the top of the piston body, at least one first high-heat-load area is arranged on the inner wall of the cavity, and a protective layer is arranged on the inner wall;
the thickness of the protective layer at least one of the first high heat load regions is larger than the thickness of the protective layer at the remaining region of the inner wall except for the first high heat load region.
3. The piston of claim 2 wherein said piston body further comprises: a fuel injector located within the chamber;
the fuel injector comprises a fuel injector body and a fuel bundle connected with the fuel injector body, and the first high heat load area is located at the nozzle position of the fuel bundle.
4. A piston according to claim 2 or 3, wherein the inner wall of said chamber further has at least one second region of high thermal load;
the thickness of the protective layer at least one of the second high heat load regions is larger than the thickness of the protective layer at the remaining region of the inner wall except for the first high heat load region and the second high heat load region.
5. The piston of claim 4 wherein said second high thermal load region is at the throat location of said chamber.
6. A tool assembly adapted for use in the method of manufacturing a piston according to claim 1, comprising at least: at least one first structural member; the first structural member is placed in a cavity of the piston, and the first structural member is matched with at least part of the inner wall of the cavity;
the first structural member is provided with at least one through hole, and the projection area of the through hole on the inner wall is positioned at the first high heat load area of the inner wall.
7. The tooling assembly of claim 6, wherein the number of the first structural members is at least two, and the inner diameter of the through hole of each of the at least two first structural members is different.
8. The tooling assembly of claim 6, further comprising: at least one second structural member; the second structural part is placed in a cavity of the piston, and the second structural part is matched with at least part of the inner wall of the cavity;
the second structural member is provided with at least one annular opening, and the projection area of the annular opening on the inner wall is positioned at a second high heat load area of the inner wall.
9. The tooling assembly of claim 8 wherein the number of second structural members is at least two, the annular openings on each of the at least two second structural members being of different sizes.
10. The tooling assembly of claim 9, wherein the second structural member comprises: a first sub-structure and a second sub-structure; the annular opening is formed between the first substructure and the second substructure.
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| CN202110729237.3A CN113339155B (en) | 2021-06-29 | 2021-06-29 | Preparation method of piston, piston and tool assembly |
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| CN202110729237.3A CN113339155B (en) | 2021-06-29 | 2021-06-29 | Preparation method of piston, piston and tool assembly |
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| US20130025561A1 (en) * | 2011-07-28 | 2013-01-31 | Dieter Gabriel | Bowl rim and root protection for aluminum pistons |
| WO2015110379A1 (en) * | 2014-01-24 | 2015-07-30 | Volkswagen Aktiengesellschaft | Piston for a piston machine |
| US20170328300A1 (en) * | 2015-09-30 | 2017-11-16 | Mazda Motor Corporation | Heat insulation structure of combustion chamber of engine |
| US20180179644A1 (en) * | 2016-11-04 | 2018-06-28 | Cummins Inc. | Pistons with thermal barrier coatings |
| WO2019049738A1 (en) * | 2017-09-06 | 2019-03-14 | 日立オートモティブシステムズ株式会社 | Internal combustion engine piston, method for measuring film thickness of internal combustion engine piston, and manufacturing method for internal combustion engine piston |
| CN110159415A (en) * | 2018-02-16 | 2019-08-23 | 丰田自动车株式会社 | Charge compression self-ignition type internal combustion engine |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20130025561A1 (en) * | 2011-07-28 | 2013-01-31 | Dieter Gabriel | Bowl rim and root protection for aluminum pistons |
| WO2015110379A1 (en) * | 2014-01-24 | 2015-07-30 | Volkswagen Aktiengesellschaft | Piston for a piston machine |
| US20170328300A1 (en) * | 2015-09-30 | 2017-11-16 | Mazda Motor Corporation | Heat insulation structure of combustion chamber of engine |
| US20180179644A1 (en) * | 2016-11-04 | 2018-06-28 | Cummins Inc. | Pistons with thermal barrier coatings |
| WO2019049738A1 (en) * | 2017-09-06 | 2019-03-14 | 日立オートモティブシステムズ株式会社 | Internal combustion engine piston, method for measuring film thickness of internal combustion engine piston, and manufacturing method for internal combustion engine piston |
| CN110159415A (en) * | 2018-02-16 | 2019-08-23 | 丰田自动车株式会社 | Charge compression self-ignition type internal combustion engine |
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| CN113339155B (en) | 2022-06-28 |
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