GB2538239A - Method for producing a poppet valve, in particular a hollow head valve - Google Patents

Method for producing a poppet valve, in particular a hollow head valve Download PDF

Info

Publication number
GB2538239A
GB2538239A GB1507975.9A GB201507975A GB2538239A GB 2538239 A GB2538239 A GB 2538239A GB 201507975 A GB201507975 A GB 201507975A GB 2538239 A GB2538239 A GB 2538239A
Authority
GB
United Kingdom
Prior art keywords
valve
blank
poppet
poppet valve
foreign material
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.)
Withdrawn
Application number
GB1507975.9A
Other versions
GB201507975D0 (en
Inventor
Contarin Fabiano
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.)
Eaton SRL
Original Assignee
Eaton SRL
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 Eaton SRL filed Critical Eaton SRL
Priority to GB1507975.9A priority Critical patent/GB2538239A/en
Publication of GB201507975D0 publication Critical patent/GB201507975D0/en
Publication of GB2538239A publication Critical patent/GB2538239A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/20—Making machine elements valve parts
    • B21K1/22—Making machine elements valve parts poppet valves, e.g. for internal-combustion engines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/18—Making uncoated products by impact extrusion
    • B21C23/183—Making uncoated products by impact extrusion by forward extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/003—Selecting material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • 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
    • B23P15/001—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass valves or valve housings
    • B23P15/002—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass valves or valve housings poppet valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L3/00—Lift-valve, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces; Parts or accessories thereof
    • F01L3/02—Selecting particular materials for valve-members or valve-seats; Valve-members or valve-seats composed of two or more materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L3/00—Lift-valve, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces; Parts or accessories thereof
    • F01L3/12—Cooling of valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L3/00—Lift-valve, i.e. cut-off apparatus with closure members having at least a component of their opening and closing motion perpendicular to the closing faces; Parts or accessories thereof
    • F01L3/12—Cooling of valves
    • F01L3/14—Cooling of valves by means of a liquid or solid coolant, e.g. sodium, in a closed chamber in a valve
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2301/00—Using particular materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2303/00—Manufacturing of components used in valve arrangements

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Forging (AREA)

Abstract

A method for producing a hollow head poppet valve for an internal combustion engine comprises: providing a blank 20 with core material 2 such as sodium, tin or aluminium, and mantle material 3, such as a steel alloy, with melting point higher than the core; shaping the blank into a poppet having; cutting the tip of the poppet stem to expose the core material; heating to a temperature above the core material melting point and below that of the mantle material; removing the core material via the cut tip providing a hollow poppet; filling the hollow poppet with a material having a thermal conductivity higher than the mantle material; closing the cut valve tip. The blank may be cylindrical and have a diameter equal to that of the finished poppet stem, and the head may be further formed by upsetting a blank end (Figures 2a-c). Alternatively the blank may be extrusion forged to produce the stem (Figures 1a-c). In both embodiments the head may be further shaped in a die (7, 8). The heating step may form part of a precipitation or solution heat treating step. In use the sodium liquefies and the shaker effect occurs.

Description

Eaton Srl 15ECE229 GB Method for producing a poppet valve, in particular a hollow head valve The invention relates to a method for producing a poppet valve, in particular a hollow head valve.
Poppet valves are typically used as intake valves and exhaust valves in a combustion engine. Of such combustion engines, typically used in passenger cars, it is required to reduce the CO2 emission. This is for example achieved by downsizing the engine and by applying turbo charging. This results in combustion engines having a high specific power (over 100 hp/1). Typically such type of engines require valves which can withstand high temperature (>800°C) It is known to create a cylindrical cavity in the valve stem and partially fill it with sodium. The sodium (thanks to the high thermal conductivity and the convective motion in the cavity -shaker effect) transfers heat from the hot end of the valve to the cold end with greater efficiency than the solid valve material, hence reducing the peak temperature of the valve.
With the specific power growing even higher, additional cooling capacity is required. Providing a larger cavity in the valve head, connected to the cylindrical cavity in the valve stem, is an effective way to increase the cooling performance. Such valves are commonly named "Hollow Head Valve" (HHV). However, production of HHV poses significant manufacturing challenges which result in high cost.
Several of the existing technologies to manufacturing hollow head valves rely on welding to seal the cavity with a "cap" after it has been machined from the face-side of the valve head. Such a method is for example disclosed in US 6378543.
Forging and cold drawing can also be used for obtaining a cavity in the head, as disclosed in US 2013/0019474. However, the size of the cavity obtained by forging and cold drawing is still limited.
It is an object of the invention to reduce or even remove the above mentioned disadvantages.
This object is achieved with the method according to the invention, which method comprises the steps of: - providing a blank with a core of a foreign material and a mantle of a base material, wherein the melting point of the foreign material is lower than the melting point 15 of the base material; - shaping the blank into a poppet valve having a valve stem and a disc shaped valve head; -cutting the valve tip of the valve stem to expose the foreign material at the core of the shaped poppet valve; -heating the shaped poppet valve to a temperature above the melting point of the foreign material and below the melting point of the base material; - removing the foreign material via the cut valve tip providing a hollow poppet valve; -filling the hollow poppet valve with a material having a thermal conductivity higher than the base material; - closing the cut valve tip.
With the method according to the invention, the blank does not comprise any cavities, when it is shaped into a 30 poppet valve. This allows for using conventional techniques for shaping the blank, typically forging or upset forging. After shaping the poppet valve, the tip of the valve stem is cut, such that foreign material can be removed by heating the shaped poppet valve to a temperature above the melting point of the foreign material. The foreign material becomes liquid and can be poured out. It would even be possible to use a foreign material, which is already liquid at room temperature.
The advantage of using a foreign material as core in the blank, is that the blank can be shaped, while the foreign material will ensure that the volume of the core stays constant and that the mantle of the blank cannot unexpectedly collapse during the shaping process.
When the foreign material is solid at the shaping temperature, the foreign material can also transfer shear stresses, besides providing a hydrostatic pressure, which could be beneficial for controlling the wall thickness in valve stem and valve head.
Preferably, the blank is shaped into a poppet valve by forging. This is a typical shaping method for producing conventional valves, in which a blank of a single material is forged using different dies to arrive at the desired poppet valve shape. Usually, the blank is heated during forging to reduce the forces for shaping the blank. This could result in the foreign material being liquid during forging or having at least a low ductility. As a result, the blank could be forged more easily compared to a blank being of a solid base material only.
In a preferred embodiment of the method according to the invention, the blank is cylindrical and has a concentric, blind hole, wherein the blind hole is filled with foreign material after which the blind hole is closed by a plug or lid, which is preferably welded to the blank.
Such a cylindrical blank can easily be provided with a blind hole on a lathe. After filling the blind hole with foreign material, the blind hole can be closed by inserting a plug in the hole or by covering the hole with a lid. In order to withstand the forces of the shaping method, the plug or lid are preferably welded to the blank, for example by resistance welding or friction welding.
In a further preferred embodiment of the method according to the invention the diameter of the cylindrical blank corresponds to the diameter of the valve stem including a finishing thickness and wherein the disc shaped valve head is shaped by upset forging.
By having the diameter of the blank corresponding to the diameter of the valve stem including a finishing thickness, only the disc shaped valve head needs to be shaped and the valve stem needs to be finished, for example by grinding. The finishing thickness allows for the finishing step to remove a small amount of material to arrive at the desired valve stem diameter with the desired finishing. The shaping of the valve head is preferably done by upset forging, in which only one end of the cylindrical blank is heated and then shaped by suitable dies.
In another embodiment of the method according to the invention, the heating step and the step of removing the foreign material is continued in a heat treatment step providing a solution heat treatment or a precipitation heat treatment of the hollow poppet valve.
Such a heat treatment provides the hollow poppet valve with the required hardness for use as an inlet valve or outlet valve in a combustion engine.
Afterwards, the hollow poppet valve is filled with a thermal conductive material. Preferably, the cavity in the hollow poppet valve is not filled fully, such that the shaker effect can occur within the poppet valve.
In yet another embodiment of the method according to the invention, the foreign material is selected from the list of sodium, tin, and aluminum. These materials have a low melting point compare to a typical steel alloy used as the base material. As a result, the foreign material can easily be removed from the shaped poppet valve.
In yet a further embodiment of the method according to the invention the material having a thermal conductivity 10 higher than the base material is sodium.
Sodium provides a excellent thermal conductivity and becomes liquid at relative low temperatures, i.e. around 98°C.
Such temperatures are easily reached in poppet valves of a combustion engine. When the sodium becomes liquid, the shaker 15 effect can occur in the poppet valve, which contributes to a better heat transport from the valve head to the valve stem. Preferably, the base material of the poppet valve is a steel alloy.
These and other features of the invention, will be 20 elucidated in conjunction with the accompanying drawings. Figures lA -1E show the steps of a first embodiment of the method according to the invention.
Figures 2A -2C show a few steps of a second embodiment of the method according to the invention.
In figure 1A a blank 1 is shown having a core 2 of a foreign material, preferably sodium, and a mantle 3 of a base material, typically a steel alloy.
The blank 1 is arranged in a die 4. The die 4 has an extrusion channel 5, through which the blank 1 is at least 30 partially pressed (see figure 1B). As a result of the extrusion forging, a valve stem 6 is shaped on the blank 1. During the extrusion, the core material 2 will provide at least hydrostatic pressure, such that the mantle material 3 will maintain a more or less even thickness over the extruded parts.
Then the partially shaped blank 1 is positioned in a second die 7, 8, in which the valve head 9 is shaped by restrike forging. Again, due to the core material 2 the head 9 can be shaped, such that the mantle material 3 will have a more or less even thickness.
Now the poppet valve with the valve stem 6 and the valve head 9 is shaped, the valve tip 10 is cut off and the poppet valve 6, 9 is heated such that the foreign material 2 becomes liquid and can be poured out, leaving a hollow poppet valve with a mantle 3 and a cavity 11. (see figure 1D).
Finally, the hollow poppet valve is filled with sodium 12, as is common for hollow head valves (HHV) and the out off valve stem 6 is closed by welding a tip 13 to the free end (see figure 1E). Typically, a space 14 is left between the sodium 12 and the tip 13, such that when the sodium becomes liquid, the shaker effect can occur contributing to an improved heat transfer.
Figure 2A shows a first step of a second embodiment of the method according to the invention. A blank 20 is provided with a mantle 21 and a core 22. The diameter of the mantle 21 corresponds to the diameter of the valve stem of the poppet valve to be shaped out of the blank 20.
The blank 20 is arranged partially in a tool 23, while the free end of the blank 20 is heated and pressed against a second tool 24. As a result, the cylindrical blank 20 is provided on one end with a bulge.
Then the partially shaped blank 20 is arranged in a similar die 7, 8 as shown in figure 1C to further shape the valve head 25.
After the poppet valve is fully shaped out of the blank 20, the valve stem tip will be cut off, the core material 22 will be poured out and the hollow poppet valve will be filled with sodium and be closed similar to the steps shown in figures 1D and 1E.

Claims (8)

  1. Claims 1. Method for producing a poppet valve, in particular a hollow head valve, which method comprises the 5 steps of: - providing a blank with a core of a foreign material and a mantle of a base material, wherein the melting point of the foreign material is lower than the melting point of the base material; -shaping the blank into a poppet valve having a valve stem and a disc shaped valve head; - cutting the valve tip of the valve stem to expose the foreign material at the core of the shaped poppet valve; - heating the shaped poppet valve to a temperature 15 above the melting point of the foreign material and below the melting point of the base material; - removing the foreign material via the cut valve tip providing a hollow poppet valve; - filling the hollow poppet valve with a material 20 having a thermal conductivity higher than the base material; - closing the cut valve tip.
  2. 2. Method according to claim 1, wherein the blank is shaped into a poppet valve by forging.
  3. 3. Method according to claim 1 or 2, wherein the blank is cylindrical and has a concentric, blind hole, wherein the blind hole is filled with foreign material after which the blind hole is closed by a plug or lid, which is preferably welded to the blank.
  4. 4. Method according to claim 2 and 3, wherein the 30 diameter of the cylindrical blank corresponds to the diameter of the valve stem including a finishing thickness and wherein the disc shaped valve head is shaped by upset forging.
  5. 5. Method according to any of the preceding claims, wherein the heating step and the step of removing the foreign material is continued in a heat treatment step providing a solution heat treatment or a precipitation heat treatment of the hollow poppet valve.
  6. 6. Method according to any of the preceding claims, wherein the foreign material is selected from the list of sodium, tin, and aluminum.
  7. 7. Method according to any of the preceding claims, 10 wherein the material having a thermal conductivity higher than the base material is sodium.
  8. 8. Method according to claim 7, wherein the base material is a steel alloy.
GB1507975.9A 2015-05-11 2015-05-11 Method for producing a poppet valve, in particular a hollow head valve Withdrawn GB2538239A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1507975.9A GB2538239A (en) 2015-05-11 2015-05-11 Method for producing a poppet valve, in particular a hollow head valve

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1507975.9A GB2538239A (en) 2015-05-11 2015-05-11 Method for producing a poppet valve, in particular a hollow head valve

Publications (2)

Publication Number Publication Date
GB201507975D0 GB201507975D0 (en) 2015-06-24
GB2538239A true GB2538239A (en) 2016-11-16

Family

ID=53489398

Family Applications (1)

Application Number Title Priority Date Filing Date
GB1507975.9A Withdrawn GB2538239A (en) 2015-05-11 2015-05-11 Method for producing a poppet valve, in particular a hollow head valve

Country Status (1)

Country Link
GB (1) GB2538239A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107511645A (en) * 2017-09-29 2017-12-26 宝鸡市永盛泰钛业有限公司 A kind of oil drill rocker machining manufacture
CN108426072A (en) * 2018-03-26 2018-08-21 张元红 A kind of production technology of list depotition cock main body
DE102019123456A1 (en) * 2019-09-02 2021-03-04 Federal-Mogul Valvetrain Gmbh DISC VALVE WITH CORE AND PROCESS FOR THEIR PRODUCTION

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1980716A (en) * 1931-05-20 1934-11-13 Thompson Prod Inc Method of making inlaid metal valves
US2004528A (en) * 1933-12-30 1935-06-11 Wilcox Rich Corp Method of making valves
GB456028A (en) * 1935-10-02 1936-11-02 Enrico Ravera Method of stamping hollow-valves in a single piece
JPH03238139A (en) * 1990-02-16 1991-10-23 Daido Steel Co Ltd Production of hollow valve for engine

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1980716A (en) * 1931-05-20 1934-11-13 Thompson Prod Inc Method of making inlaid metal valves
US2004528A (en) * 1933-12-30 1935-06-11 Wilcox Rich Corp Method of making valves
GB456028A (en) * 1935-10-02 1936-11-02 Enrico Ravera Method of stamping hollow-valves in a single piece
JPH03238139A (en) * 1990-02-16 1991-10-23 Daido Steel Co Ltd Production of hollow valve for engine

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107511645A (en) * 2017-09-29 2017-12-26 宝鸡市永盛泰钛业有限公司 A kind of oil drill rocker machining manufacture
CN108426072A (en) * 2018-03-26 2018-08-21 张元红 A kind of production technology of list depotition cock main body
DE102019123456A1 (en) * 2019-09-02 2021-03-04 Federal-Mogul Valvetrain Gmbh DISC VALVE WITH CORE AND PROCESS FOR THEIR PRODUCTION

Also Published As

Publication number Publication date
GB201507975D0 (en) 2015-06-24

Similar Documents

Publication Publication Date Title
CN110869590B (en) Method for manufacturing hollow valve
JP5297402B2 (en) Manufacturing method of engine valve filled with sodium metal
CN110914519B (en) Hollow valve with optimized internal stem geometry and method of making same
WO2014054113A1 (en) Hollow poppet valve
GB2538239A (en) Method for producing a poppet valve, in particular a hollow head valve
US20140352385A1 (en) Apparatus for producing a hollow poppet valve
US8561297B2 (en) Method for producing engine valve in which sodium metal is sealed
CN203879566U (en) Plate end airtight hollow sodium-inflation valve
US2093771A (en) Method of making copper cooled valves
US2093773A (en) Method of making hollow valves
JPH07102917A (en) Sodium-enclosed hollow engine valve manufacturing method
US1984728A (en) Method of making hollow head valves
CN101817031A (en) Method for manufacturing titanium alloy guiding pipe for aircraft engine
CN107227982B (en) Engine valve and its manufacturing method
US4606730A (en) Bimetal electrodes for spark plugs or the like and method of making same
CN105171365A (en) Deep cavity thin-wall flange piece composite forging molding method
CN104801938A (en) Hollow sodium-filled valve forming process based on cross wedge rolling of billets
CN104801937B (en) A kind of forming technology of Novel hollow valve filled with sodium
US2093776A (en) Method of making valves
US1980716A (en) Method of making inlaid metal valves
JP2020527662A (en) A method of manufacturing an internal cooling valve having a cooling structure, and a valve manufactured by the manufacturing method.
US2131953A (en) Method of making valves
JP2008000768A (en) Method for production of engine valve
EP3406367A1 (en) Method and apparatus for producing a piston top with a cooling chamber
CN215746264U (en) Cooling water channel embedded in hub die

Legal Events

Date Code Title Description
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)