Description:TECHNICAL FIELD
[001] This disclosure relates generally to physical components having a lattice structure, and more particularly to extrusion die and extrusion process for manufacturing the physical components with a lattice structure.
BACKGROUND
[002] Many physical components, such as connecting rods for internal combustion engines, are typically produced using forging process. For example, a substrate (typically alloy of steel, etc.) is subjected to localized compressive forces using a forging die to form a forged component. The forged component further undergoes additional machining and treatment processes, thereby yielding the physical component as a finished product.
[003] However, traditional forging methods present intricate challenges. Forming physical components with distinctive shapes encounters efficiency hurdles, and the energy utilization in the forging procedure increases with the number of dies involved. For instance, shaping a complex component may necessitate the use of multiple dies. Moreover, the component forged in one die requires reheating before being processed in another die. Additionally, after the forging process, extensive machining processes are frequently required to attain the desired surface appearance.
[004] Additionally, there is an increasing need to form physical components that are structurally strong, and yet lightweight.
SUMMARY
[005] In an embodiment, a method of manufacturing a physical component is disclosed. The method may include a step in which a substrate may be extruded through an extrusion die to form a body of the physical component. In an embodiment, the extrusion die may include a die input surface, a die output surface, and a plurality of openings running through at least a portion of the extrusion die from the die input surface to the die output surface. In an embodiment, at least one set of the plurality of openings may be shaped to allow formation of at least one corresponding calcite lattice in at least one portion of the body of the physical component.
[006] In an embodiment, an extrusion die for forming a physical component is disclosed. The extrusion die may include a die input surface, a die output surface, and a plurality of openings running through at least a portion of the extrusion die from the die input surface to the die output surface. In an embodiment, the at least one set of the plurality of openings may be shaped to allow formation of at least one corresponding calcite lattice in at least one portion of the body of the physical component.
[007] In an embodiment, a physical component is disclosed. The physical component may include a body. The body may further include a first surface, a second surface, and at least one calcite lattice running through at least one portion of the body, from the first surface and the second surface.
[008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[009] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
[010] FIG. 1 illustrates a perspective view of a physical component, in accordance with an embodiment of the present disclosure;
[011] FIG. 2 illustrates a perspective view of an extrusion die, in accordance with an embodiment of the present disclosure; and
[012] FIGS. 3A-3B illustrate a process flow for manufacturing the physical component, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[013] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope being indicated by the following claims. Additional illustrative embodiments are listed.
[014] References will now be made to exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, the same numerals have been used to refer to the same or like parts.
[015] As explained earlier, traditional forging methods, specifically related to forming physical components such as connecting rods, require higher energy utilization with multiple dies, reheating between processes, and the need for post-forging machining. Further, there is a need for physical components that are structurally strong, and yet lightweight.
[016] To mitigate such challenges, the present disclosure relates to the manufacturing of physical components (for example, connecting rods for internal combustion engine) using an extrusion process. Physical components formed through the extrusion process require low machining, and may exhibit high strength and durability. Additionally, the physical component formed may include a calcite lattice, due to which the connecting rod exhibits high durability while being light in weight. As will be described in detail below, the calcite lattice has repeating pattern of interconnected trigonal crystal structure (calcite units), thereby ensuring lower material weight while still being structurally strong. The following paragraphs detail the physical component (e.g., connecting rod) and the method of manufacturing thereof, with reference to FIGs. 1, 2, and 3A - 3B.
[017] Now, referring to FIG. 1, which illustrates a perspective view of a physical component 102 in accordance with an embodiment of the present disclosure. In the illustrated embodiment, the physical component 102 may be a connecting rod for an engine. The physical component 102 may include a body having a first end 104 and a second end 106. When assembled in a vehicle, such as a passenger vehicle or a commercial vehicle, the first end 104 may be coupled to a crankshaft, while the second end 106 may be connected to the piston of the engine of the vehicle. In an embodiment, a first surface 108 may be disposed between the first end 104 and the second end 106, and a second surface 110 disposed opposite (e.g., diametrically opposite) to the first surface 108. In an embodiment, the first surface 108 may represent a top surface of the body of the physical component 102, and the second surface 110 may represent a bottom surface of the body of the physical component 102.
[018] In an embodiment, the physical component 102 may include a calcite lattice structure 112. The calcite lattice structure 112 may be formed on at least one portion of the body of the physical component 102 and may extend from the first surface 108 to the second surface 110. In an embodiment, the calcite lattice structure 112 may be formed as an arrangement of a plurality of calcite units 114. The plurality of calcite units 114 may be sequentially arranged in a predefined arrangement, for example, in a cross arrangement. In an embodiment, each calcite unit may be connected to a sequential calcite unit using one or more connectors 116. The one or more connectors 116 may extend from the surface of a calcite unit, and terminate at the surface of the sequential calcite unit or at the edge of the physical component 102. It should be noted that, in an embodiment, the one or more connectors 116 may be absent from the calcite lattice structure 112. Thus, in such embodiment, the calcite lattice structure 112 may just comprise of the plurality of calcite units 114. In an embodiment, the plurality of calcite units 114, and/or the one or more connectors 116 may be formed as hollow regions on at least one portion of the body of the physical component 102. In an embodiment, at least one region 118 may be formed between the plurality of calcite units 114 and/or the one or more connectors 116. Further, at least one region 118 may include a solid region formed between the plurality of calcite units 114 and/or the one or more connectors 116. In an embodiment, each calcite unit from the plurality of calcite units 114 may include a rhombohedron or a six-face polygon with rhombus-shaped faces. Alternatively, each calcite unit may include a prismatic shape or a scalenohedral shape.
[019] In an embodiment, the physical component 102 may be formed using an extrusion process, using a substrate such as a metal having a density lower than a density of iron (about 7.874 g/cm³ at room temperature), for example, aluminum. Alternatively, a metal alloy having a density lower than a density of iron may also be selected as the substrate. The physical component 102 formed with the substrate with a density less than about 7.874 g/cm³, along with the calcite lattice structure 112 formed therein, may exhibit high strength and durability. For example, the physical component 102 formed for small-capacity internal combustion engine (e.g., up to 800 cc) may exhibit high strength and durability when subjected to an inertial force up to 4200 N at about 5000-6000 RPM for about 4-6 million cycles until failure. Further, it should be noted that the choice of substrate material and dimensions of the calcite lattice structure 112 in the physical component 102 may be based on the size of the engine. For example, in an embodiment, the physical component 102 and the associated calcite lattice structure 112 may be formed to withstand higher inertial forces for example for higher-capacity internal combustion engines (e.g., up to 10,000cc). Moreover, in some embodiments, such high strength and durability may be achieved with a material weight up to 50% lower than the material weight used for manufacturing connecting rods using the forging process (with cast iron as a metal substrate).
[020] As explained earlier, the physical component 102 may be formed using an extrusion process, by subjecting the substrate through an extrusion die. The extrusion die may include an inner die profile, through which the substrate may be forced to yield the physical component 102. The extrusion die along with the inner die profile is explained in detail in conjunction with FIG. 2.
[021] Now referring to FIG. 2, which illustrates a perspective view 200 of the extrusion die in accordance with an embodiment of the present disclosure. The extrusion die may include an input die 202 and an output die 204. In an embodiment, the input die 202 may be assembled into the output die 204 to form the extrusion die. In an embodiment, during the extrusion process, the substrate may be forced into the input die 202, and the physical component 102 may be discharged from the output die 204. Such extrusion die may be formed as a single die assembly, thereby eliminating the need for reheating the substrate between the processes involved in manufacturing the physical component 102.
[022] In an embodiment, the input die 202 may include a die input surface 206. The die input surface 206 may include an input die profile. The input die profile may further include an upper profile portion 208, a bottom profile portion 210, and a middle profile portion 212. In an embodiment, the upper profile portion 208 may include a crankshaft hole generator, and the bottom profile portion 210 may include a piston shaft hole generator. The crankshaft hole generator may be shaped to allow formation of a crankshaft hole in the body of the physical component 102 during extrusion. Further, the piston shaft hole generator may be shaped to allow formation of the piston rod hole in the body of the physical component 102 during extrusion.
[023] In an embodiment, the middle profile portion 212 may include an inverse calcite lattice 214. The inverse calcite lattice 214 may include a plurality of openings 216. The plurality of openings may be surrounded by a solid portion 218. Further, the solid portion 218 may run throughout the middle profile portion 212. In an embodiment, the solid portion 218 may include one or more solid calcite-shaped units 220 and/or one or more solid connector units 222. In an embodiment, the one or more solid calcite-shaped units 220 may be sequentially connected by the one or more solid connector units 222, i.e., a solid calcite shaped unit may be connected to a sequential solid calcite shaped unit using the one or more connector units 222. It should be noted that, in an embodiment, the one or more connectors 222 may be absent from the inverse calcite lattice 214. Thus, the inverse calcite lattice 214 may just include one or more solid calcite-shaped units 220.
[024] In an embodiment, the inverse calcite lattice 214 may be shaped to allow formation of the calcite lattice structure 112 on the physical component 102 during the extrusion process. The substrate may be forced through the die input surface 206, and the substrate may be forced into the inverse calcite lattice 214, particularly into the plurality of openings 216 and the solid portion 218. Accordingly, one or more portions of the substrate may pass through the plurality of openings 216, and no portion of the substrate may pass through the solid portion 218. Therefore, the plurality of openings 216 and the solid portion 218 may form the calcite lattice structure 112 in the physical component 102, i.e., hollow structure of the plurality of calcite units 114 optionally connected by hollow structure of one or more connectors 116 (Refer to FIG. 1). Moreover, the plurality of openings 216 may also form the at least one region 118 on the physical component 102.
[025] In an embodiment, as explained earlier, the output die 204 may be assembled to the input die 202. Further, the output die 204 may include a die output surface 220. In an embodiment, as the substrate may be continuously forced into the extrusion die, the body of the physical component 102 formed by the input die profile may be discharged through the die output surface 220.
[026] In an embodiment, after extrusion, the body of the physical component 102 may be prone to deformities such as but not limited to corrosion, low durability, and the like. Therefore, the discharged physical component 102 may be subjected to a surface treatment process, which is explained in detail hereinafter.
[027] In an embodiment, as explained earlier, the physical component 102 after being extruded may be subjected to a surface treatment process. The surface treatment process may include subjecting the physical component 102 to a cold working process, followed by a ceramic coating process, and finally exposing the physical component 102 to a liquid inert gas.
[028] In an embodiment, the cold working process may include a shot peening process. The shot peening process may include subjecting the surface of the extruded physical component 102 to high-speed bombardment with spherical beads made of materials such as steel, ceramic, or glass. In an embodiment, the spherical beads, upon bombardment, may be configured to generate one or more dimples or detents on the body of the physical component 102. These detents on the physical component 102 may be configured to remove residual stresses present therein. Furthermore, the detents can establish an additional layer of compressive stress on the physical component 102. As may be appreciated, the compressive stress layer facilitates an enhancement in fatigue resistance for the physical component 102. As a result, a hardened physical component 102 may be formed.
[029] In an embodiment, the size of the spherical beads may be selected based on the size of the plurality of calcite units 114 formed on the extruded physical component 102. For example, the size of the spherical beads may range between about 0.5A to about 0.8A, where A represents the dimension (e.g., minimum width) of each calcite unit. In an embodiment, the size of the spherical beads may be less than the dimension (e.g., minimum width) of the calcite unit. Such size may allow the passage of the spherical beads through the plurality of calcite units 114. Therefore, the extruded physical component 102 may be effectively bombarded by the spherical beads.
[030] Further, the hardened physical component 102 may be subjected to a ceramic coating process at a predefined temperature. The hardened physical component 102 may be coated with a ceramic coating material, such as but not limited to ceramic nanoparticles, sol-gel coating, polymer-ceramic composites, plasma-sprayed ceramics, metal-ceramic coatings, and the like.
[031] In an embodiment, the ceramic coating material may be coated on the hardened physical component 102 at a temperature ranging between about 15? to about 20°C, using any coating methods known in the art. As a result, a layer of ceramic material with a thickness ranging between about 15 µm to about 25 µm may be coated on the hardened physical component 102, thereby forming a ceramic-coated hardened physical component 102. The ceramic-coated hardened physical component 102 may exhibit enhanced hydrophobic characteristics, and anti-corrosive properties, along with resistance to scratch and abrasion.
[032] Finally, the ceramic-coated hardened physical component 102 may be exposed to a plurality of droplets of liquid inert gas. The liquid inert gas may include gases possessing low thermal conductivity, such as argon. In an embodiment, a plurality of droplets of argon may be deposited on the ceramic-coated surface of the ceramic-coated hardened physical component 102. As a result, an insulation layer may be formed on the ceramic-coated surface. The insulation layer may form a thermal barrier on the ceramic-coated hardened physical component 102, thereby reducing heat conduction therefrom. Accordingly, a finished physical component 102 may be formed.
[033] As will be appreciated, in an alternative embodiment, the calcite lattice structure 112 may be formed as a solid calcite lattice structure on the body of the physical component 102. Particularly, the plurality of calcite units 114 and/or the one or more connectors 116 may be formed as solid portions, and the regions 118 therebetween may be formed as hollow portions. Accordingly, to achieve such structure, the inverse calcite lattice 214 in the middle profile portion 212 of the input die 202 (refer to FIG. 2) may be designed as hollow portions. For example, the plurality of openings 216 may be designed as one or more hollow calcite shaped structures, which may be optionally connected by one or more hollow connector units. Moreover, the portion between the hollow calcite shaped structures and/or the one or more hollow connector units may be formed as a solid portion. As may be appreciated, the substrate metal when extruded through such extrusion die will discharge a physical component where the calcite lattice structure may be formed as a solid calcite lattice structure.
[034] Now, referring to FIGS. 3A-3B, which illustrates a process flow 300A-300B for manufacturing the physical component 102, in accordance with an embodiment of the present disclosure.
[035] At step 302, a substrate 304 may be forced through an extrusion die formed by an assembly of the input die 202 and the output die 204. In an embodiment, the substrate 304 may be initially heated up to a predefined temperature and then forced through the extrusion die. The substrate 304 may be forced into the die input surface 206, and as a result, an extruded physical component 102 may be discharged through the output die 204. The extruded physical component 102 may include a calcite lattice structure 112, which may be formed as the substrate 304 may progress through the input die profile of the input die 202. The input die profile may include inverse calcite lattice 214, which may further include solid portion 216, and a plurality of openings 218 which may be shaped to allow formation of the calcite lattice structure 112 on the physical component 102.
[036] Further, at step 306, the extruded physical component 102 may be subjected to a surface treatment process, to enhance durability, anti-corrosive properties, scratch, and abrasion resistance, and also add an insulation layer thereon. For example, in some embodiments, at step 306-1, the extruded physical component 102 may be subjected to the cold working process (e.g., shot peening process) to form a hardened physical member. Further, at step 306-2, the hardened physical member may be subjected to a ceramic coating process, in which a ceramic material on the hardened physical member to form a ceramic-coated hardened physical component. Additionally, in some embodiments, at step 306-3, the ceramic-coated hardened physical component may be exposed to the liquid inert gas to create a thermal barrier thereon. These surface treatment processes 306-1 to 306-3 have already been explained in detail in conjunction with FIGs. 1-2.
[037] The physical component 102 formed through the extrusion process using a single extrusion die assembly, and after being treated with the surface treatment may exhibit enhanced strength, resistance to fatigue, hydrophobic characteristics, and anti-corrosive properties, along with resistance to scratch and resistance. The finished physical component 102 may also exhibit excellent durability with lower material composition, as compared to physical components manufactured using the forging process.
[038] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for the sake of clarity.
[039] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
[040] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
, Claims:1. A method (300) of manufacturing a physical component (102), the method (300) comprising:
extruding a substrate (304) through an extrusion die to form a body of the physical component (102), wherein the extrusion die comprises:
a die input surface (206);
a die output surface (220); and
a plurality of openings (218) running through at least a portion of the extrusion die from the die input surface (206) to the die output surface (220), and wherein at least one set of the plurality of openings (218) is shaped to allow formation of at least one corresponding calcite lattice (112) in at least one portion of the body of the physical component (102).
2. The method (300) as claimed in claim 1, wherein the substrate (304) comprises one of:
a metal, or
a metal alloy.
3. The method (300) as claimed in claim 2, wherein the metal or the metal alloy has a density lower than a density of iron.
4. The method (306) as claimed in claim 1, comprising:
treating the body of the physical component (102) with a surface treatment process, the surface treatment process comprising:
subjecting (306-1), the physical component to a cold working process to form a hardened physical component (102);
coating (306-2), a ceramic material on the hardened physical component to form a ceramic-coated hardened physical component (102); and
creating (306-3), a thermal barrier on the ceramic-coated hardened physical component (102) by exposing the ceramic-coated hardened physical component (102) to a liquid inert gas.
5. The method (300) as claimed in claim 4, wherein the cold working process comprises a shot peening process.
6. The method (300) as claimed in claim 1, wherein the physical component (102) comprises:
a connecting rod for an engine.
7. A extrusion die for forming a physical component, the extrusion die comprising:
a die input surface (206);
a die output surface (220); and
a plurality of openings (218) running through at least a portion of the extrusion die from the die input surface (206) to the die output surface (220), wherein at least one set of the plurality of openings (218) is shaped to allow formation of at least one corresponding calcite lattice (112) in at least one portion of a body of the physical component (102).
8. A physical component (102), comprising:
a body, comprising:
a first surface (108);
a second surface (110); and
at least one calcite lattice (112) running through at least one portion of the body from the first surface (108) to the second surface (110).
9. The physical component (102) as claimed in claim 8, wherein the body is formed by extruding a substrate (304) through an extrusion die, and wherein the substrate comprises one of:
a metal, or
a metal alloy.
10. The physical component (102) as claimed in claim 8, wherein the physical component (102) comprises a connecting rod for an engine.