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WO2008016921A2 - bielle avec zones usinables localisÉes - Google Patents

bielle avec zones usinables localisÉes Download PDF

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Publication number
WO2008016921A2
WO2008016921A2 PCT/US2007/074857 US2007074857W WO2008016921A2 WO 2008016921 A2 WO2008016921 A2 WO 2008016921A2 US 2007074857 W US2007074857 W US 2007074857W WO 2008016921 A2 WO2008016921 A2 WO 2008016921A2
Authority
WO
WIPO (PCT)
Prior art keywords
connecting rod
composition
zone
sintered material
bore
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2007/074857
Other languages
English (en)
Other versions
WO2008016921A3 (fr
Inventor
Richard P. Mccorry
Timothy E. Geiman
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.)
GKN Sinter Metals LLC
Original Assignee
GKN Sinter Metals LLC
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 GKN Sinter Metals LLC filed Critical GKN Sinter Metals LLC
Publication of WO2008016921A2 publication Critical patent/WO2008016921A2/fr
Publication of WO2008016921A3 publication Critical patent/WO2008016921A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/003—Articles made for being fractured or separated into parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C7/00—Connecting-rods or like links pivoted at both ends; Construction of connecting-rod heads
    • F16C7/02—Constructions of connecting-rods with constant length
    • F16C7/023—Constructions of connecting-rods with constant length for piston engines, pumps or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/245—Making recesses, grooves etc on the surface by removing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • This invention relates to connecting rods, for example of the type used in reciprocating piston engines, and in particular to connecting rods that are made of powder metal, whether forged or not.
  • Connecting rods used in reciprocating piston and internal combustion engines have great stresses imposed upon them in operation of the engine and therefore must be very strong, and preferably of light weight. Sufficiently strong and lightweight metal materials are typically also very hard.
  • the ends of the connecting rod must be machined for the bearing bores, one for the crank pin and the other for the wrist pin of the piston, and also typically the crank end of the connecting rod also must be drilled and tapped so as to provide bolt holes for securing the crankshaft cap section of the connecting rod to the remainder of the connecting rod with bolts.
  • connecting rods Forming the connecting rod with traditional materials that possess the required combination of strength and weight has resulted in difficult machining of the connecting rod, and in particular in increased wear and tear on the tools and tooling used in the machining operations.
  • the typical solution in prior art connecting rods was to compromise strength and weight for machinability.
  • the invention provides an integral multi-material powder metal connecting rod with localized zones of high strength and high machinability materials tailored to match product performance demands within the connecting rod.
  • the central beam section, the piston end, and the crank end of the connecting rod are made of one powder metal material of a relatively high strength and the zones of the connecting rod that are machined during manufacture are made of one or more powdered metal materials that are more machinable.
  • the central beam section, the piston end, and the crank end where the highest stresses tend to occur are of high strength material to resist such stresses, and the zones of the connecting rod that are machined during manufacture are made from lower strength more machinable material, but still of a requisite strength.
  • machinability refers to the relative ease of machining a metal, and various machinability indexes are well known that provide a relative measure of the machinability of an engineering material under specified standard conditions.
  • the invention provides a connecting rod including a central beam section, a first end integrally connected to the beam section, and a second end integrally connected to the beam section opposite the first end.
  • the first end has a central bore and a first material zone adjacent the central bore of the first end.
  • the second end has a central bore and a second material zone adjacent the central bore of the second end.
  • the beam section includes a first sintered material having a first machinability, and the first end other than the first material zone includes the first sintered material, and the second end other than the second material zone includes the first sintered material.
  • At least one of the first material zone and the second material zone includes a second sintered material having a second machinability wherein the second machinability is greater than the first machinability.
  • the first sintered material has a first chemical composition
  • the second sintered material has a second chemical composition wherein the first chemical composition and the second chemical composition are different.
  • the first sintered material has a first density
  • the second sintered material has a second density wherein the first density is greater than the second density.
  • the first sintered material has a first hardness
  • the second sintered material has a second hardness wherein the first hardness is greater than the second hardness.
  • the first material zone and the second material zone include the second sintered material.
  • the invention provides a connecting rod including a central beam section, a first end integrally connected to the beam section, and a second end integrally connected to the beam section opposite the first end.
  • the first end has a central bore and a central material zone adjacent the central bore of the first end.
  • the second end has a central bore, a first longitudinal bore on a side of the central bore of the second end, and a second longitudinal bore on an opposite side of the central bore of the second end.
  • the second end has a first material zone adjacent the first longitudinal bore, a second material zone adjacent the second longitudinal bore, and a third material zone adjacent the central bore of the second end.
  • the beam section includes a first sintered material having a first machinability, the first end other than the central material zone includes the first sintered material, and the second end, other than the first material zone, the second material zone and the third material zone, includes the first sintered material. At least one of the first material zone and the second material zone includes a second sintered material having a second machinability wherein the second machinability is greater than the first machinability.
  • the central material zone may include the second sintered material, the first material zone and the second material zone may include the second sintered material, and the third material zone may include the second sintered material.
  • the first sintered material has a first chemical composition
  • the second sintered material has a second chemical composition, wherein the first chemical composition and the second chemical composition are different.
  • the first sintered material has a first density
  • the second sintered material has a second density wherein the first density is greater than the second density.
  • the first sintered material has a first hardness and the second sintered material has a second hardness wherein the first hardness is greater than the second hardness.
  • the invention provides a connecting rod including a central beam section, a first end integrally connected to the beam section, and a second end integrally connected to the beam section opposite the first end.
  • the first end has a central bore and a central material zone adjacent the central bore of the first end.
  • the second end has a central bore, a first longitudinal bore on a side of the central bore of the second end, and a second longitudinal bore on an opposite side of the central bore of the second end.
  • the second end has a first material zone adjacent the first longitudinal bore, a second material zone adjacent the second longitudinal bore, and a third material zone adjacent the central bore of the second end.
  • the beam section includes a first sintered material having a first composition
  • the first end other than the central material zone includes the first sintered material
  • the second end other than the first material zone, the second material zone and the third material zone, includes the first sintered material.
  • At least one of the central material zone and the third material zone includes a second sintered material having a second composition
  • at least one of the first material zone and the second material zone includes a third sintered material having a third composition wherein the first composition is different than the second composition, the second composition is different than the third composition, and the first composition is different than the third composition.
  • the first material zone and the second material zone include the third sintered material.
  • the second sintered material has a machinability greater than the first sintered material.
  • the third sintered material has a machinability greater than the first sintered material.
  • the central material zone includes the third sintered material.
  • the first composition is chemically different than the second composition, the second chemical composition is chemically different than the third composition, and the first composition is chemically different than the third composition.
  • the first composition has a different density than the second composition
  • the second chemical composition has a different density than the third composition
  • the first composition has a different density than the third composition.
  • the invention provides a connecting rod including a central beam section, a first end integrally connected to the beam section, and a second end integrally connected to the beam section opposite the first end.
  • the first end has a central bore and a central material zone adjacent the central bore of the first end.
  • the second end has a central bore, a first longitudinal bore on a side of the central bore of the second end, and a second longitudinal bore on an opposite side of the central bore of the second end.
  • the second end has a first material zone adjacent the first longitudinal bore, a second material zone adjacent the second longitudinal bore, and a third material zone adjacent the central bore of the second end.
  • the beam section includes a first sintered material having a first composition
  • the first end other than the central material zone includes the first sintered material
  • the second end other than the first material zone, the second material zone and the third material zone, includes the first sintered material.
  • the central material zone may include a second sintered material having a second composition
  • the third material zone may include a third sintered material having a third composition wherein the first composition is different than the second composition, the second composition is different than the third composition, and the first composition is different than the third composition.
  • the first material zone and the second material zone comprise the second sintered material.
  • the second sintered material has a machinability greater than the first sintered material.
  • the third sintered material has a machinability greater than the first sintered material.
  • the first composition is chemically different than the second composition
  • the second chemical composition is chemically different than the third composition
  • the first composition is chemically different than the third composition.
  • the first composition has a different density than the second composition
  • the second chemical composition has a different density than the third composition
  • the first composition has a different density than the third composition.
  • the invention provides a connecting rod including a central beam section, a first end integrally connected to the beam section, and a second end integrally connected to the beam section opposite the first end.
  • the first end has a central bore and a first material zone adjacent the central bore of the first end.
  • the second end has a central bore and a second material zone adjacent the central bore of the second end.
  • the second material zone extends laterally from the central bore of the second end to a first outer surface of the second end, and the second material zone also extends laterally from the central bore of the second end to a second outer surface of the second end opposite the first outer surface of the second end.
  • the beam section includes a first sintered material having a first machinability, and the first end other than the first material zone includes the first sintered material, and the second end other than the second material zone includes the first sintered material.
  • the second material zone includes a second sintered material having a second machinability wherein the second machinability is greater than the first machinability.
  • the first sintered material has a first chemical composition
  • the second sintered material has a second chemical composition wherein the first chemical composition and the second chemical composition are different.
  • the first sintered material has a first density
  • the second sintered material has a second density wherein the first density is greater than the second density.
  • the first sintered material has a first hardness
  • the second sintered material has a second hardness wherein the first hardness is greater than the second hardness.
  • the first material zone includes the second sintered material.
  • the first material zone includes a third sintered material.
  • the second end has a first longitudinal bore on a side of the central bore of the second end, and the second end has a second longitudinal bore on an opposite side of the central bore of the second end, and the second material zone surrounds the first longitudinal bore and the second longitudinal bore.
  • the second end includes regions of the first sintered material on opposite sides of the central bore of the second end wherein one or more of the regions may be arcuate.
  • FIG. 1 is a perspective view of a connecting rod according to the invention before separation into two parts.
  • Fig. 2 is a top plan view of a connecting rod according to the invention.
  • Fig. 3 is a cross-sectional view of the connecting rod of Fig. 2 taken along line 3-3 of Fig. 2.
  • Fig. 4 is another cross-sectional view of the connecting rod of Fig. 2 taken along line 4-4 of Fig. 2.
  • Fig. 5 is another cross-sectional view of the connecting rod of Fig. 2 taken along line 5-5 of Fig. 2.
  • FIG. 6 is another cross-sectional view of the connecting rod of Fig. 2 taken along line 6-6 of Fig. 2.
  • FIG. 7 is a top plan view of a second embodiment of a connecting rod according to the invention.
  • a connecting rod 10 of the invention is shown in a sintered condition before separation of the connecting rod 10 into two pieces.
  • the connecting rod 10 has a central beam section 12 having at a first end thereof an integrally connected piston end 14 and at the opposite second end thereof an integrally connected crank end 16.
  • integrally connected we mean the central beam section 12, the piston end 14 and the crank end 16 are formed as a unit.
  • the piston end 14 has a smaller piston bore 18 therethrough for receiving the wrist pin (and bearing if applicable) of a piston (not shown).
  • the piston bore 18 has an annular machinable zone 19 extending inward into the piston end 14 from the inner surface of the piston bore 18.
  • the material of the machinable zone 19 varies from the rest of the piston end 14 as will be detailed below.
  • the crank end 16 has a larger crank bore 20 therethrough for receiving a journal of a crank shaft and a bearing (not shown).
  • the crank bore 20 has an annular machinable zone 21 extending inward into the crank end 16 from the inner surface of the crank bore 20.
  • the material of the machinable zone 21 varies from the rest of the crank end 16 as will be detailed below.
  • the crank end 16 can also be provided with opposed separation notches 24 at the sides of the crank bore 20.
  • the connecting rod 10 of Fig. 1 is formed by pressing various powdered metal alloys into the general shape of Fig. 1. After pressing, the connecting rod 10 is sintered in a sintering furnace. The sintered connecting rod 10 may then be removed directly from the furnace and forged. The forging step may be followed by a cooling step.
  • the notches 24 may be incorporated as a forged notch (see, for example, U.S. Patent No. 4,923,674), or the notches 24 may be machined (e.g., broached) or laser cut. After initial machining that includes drilling and tapping of the bolt holes, a fracturing step is then used to separate the connecting rod 10 into two individual parts.
  • the separation of the individual parts may be accomplished by inserting a separating tool (e.g., a wedge) into the crank bore 20 of the crank end 16.
  • the notches 24 permit initiation of fracture and propagation of the crack perpendicular to the direction of tension provided by the separating tool.
  • the piston bore 18 and the crank bore 20 are machined to their final dimension.
  • Another method for separating the connecting rod 10 into two individual parts would be to saw it (where the material modifications make sawing easier).
  • Figs. 2-6 the connecting rod 10 is shown in an assembled condition after all manufacturing steps.
  • the crank end 16 includes a crankshaft cap 28 having an arcuate central section 29 between a first side section 30 and a second side section 33.
  • the first side section 30 has a machined fastener bore 31 therethrough having a machinable zone 32 extending inward into the first side section 30 from the inner surface of the fastener bore 31.
  • the second side section 33 has a machined fastener bore 34 therethrough having a machinable zone 35 extending inward into the second side section 33 from the inner surface of the fastener bore 34.
  • the material of the machinable zones 32, 35 varies from the rest of the crank end 16 as will be detailed below.
  • the crank end 16 also includes a crank end base 38 having a first side section 39 and a second side section 42.
  • the first side section 39 has a machined fastener bore 40 therethrough having a machinable zone 41 extending inward into the first side section 39 from the inner surface of the fastener bore 40.
  • the second side section 42 has a machined fastener bore 43 therethrough having a machinable zone 44 extending inward into the second side section 42 from the inner surface of the fastener bore 43.
  • the material of the machinable zones 41 , 44 varies from the rest of the crank end 16 as will be detailed below.
  • the crankshaft cap 28 and the crank end base 38 are connected with one another by a bolt 46 (and possibly a corresponding nut 47) and a bolt 48 (and possibly a corresponding nut 49).
  • the connecting rod 10 of Figs. 1-6 includes potentially six zones that are machined when manufacturing the connecting rod 10.
  • the connecting rod 10 includes (i) annular machinable zone 19 for the piston bore 18, (ii) annular machinable zone 21 for the crank bore 20, (iii) machinable zone 32 for the fastener bore 31 , (iv) machinable zone 35 for the fastener bore 34, (v) machinable zone 41 for the bore 40, and (vi) machinable zone 44 for the fastener bore 43.
  • the central beam section 12, the piston end 14, and the crank end 16 where the highest stresses tend to occur are of high strength material to resist such stresses, and the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 that are machined during manufacture are made from lower strength material so as to be more machinable, but still of a requisite strength.
  • first material which may be a steel powder material including iron (typically at least 90 wt.%), nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon 0.10- 0.90 wt.%.
  • beam section 12 is made of MPIF (Metal Powder Industries Federation) P/F-4660 Modified low alloy steel material which has iron, nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • MPIF Metal Powder Industries Federation
  • P/F-4660 Modified low alloy steel material which has iron, nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-4660 Modified in the preferred finished part is approximately HRC 45 (and may be in the range of HRC 40-50), and the tensile strength of MPIF P/F-4660 Modified in the preferred finished part is approximately 1650 MPa (and may be in the range of 1400-1900 MPa).
  • the density of MPIF P/F-4660 Modified in the preferred finished part is approximately 7.80 g/cc (about 99% theoretical density). Theoretical densities above 95% are preferred.
  • the sintered material of the beam section 12, the piston end 14 (except for the machinable zone 19), and the crank end 16 (except for the machinable zones 21 , 32, 35, 41 , 44) is of uniform composition throughout the beam section 12, the piston end 14, and the crank end 16.
  • the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 are made of a second material, which may be a steel powder material including iron (typically at least 90 wt.%), copper 1.8-2.2 wt.%, manganese sulfide 0.3-0.5 wt.%, manganese 0.10-0.25 wt.%, and carbon 0.30-
  • a steel powder material including iron (typically at least 90 wt.%), copper 1.8-2.2 wt.%, manganese sulfide 0.3-0.5 wt.%, manganese 0.10-0.25 wt.%, and carbon 0.30-
  • the machinable zones 19, 21 , 32, 35, 41 , 44 are all made of MPIF P/F-11C60, which is a copper steel powder metal material suitable for connecting rods, thus quite machinable.
  • MPIF P/F-11 C60 includes iron, copper 1.8-2.2 wt.%, manganese sulfide 0.3-0.5 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-11C60 in the preferred finished part is approximately HRC 25 (and may be in the range of HRC 20-30), and the tensile strength of MPIF P/F-11C60 in the preferred finished part is approximately 900 MPa (and may be in the range of 700-1100 MPa).
  • the density of MPIF P/F-11 C60 in the preferred finished part is approximately 7.80g/cc (about 99% theoretical density). Theoretical densities above 95% are preferred.
  • the beam section 12, the piston end 14 (except for the machinable zone 19), and the crank end 16 (except for the machinable zones 21 , 32, 35, 41 , 44) are made of a first material (e.g., MPIF P/F- 4660 Modified low alloy steel material), the machinable zones 19, 21 are made of a second material (e.g., MPIF P/F-11C60 material), and the machinable zones 32,
  • a first material e.g., MPIF P/F- 4660 Modified low alloy steel material
  • the machinable zones 19, 21 are made of a second material (e.g., MPIF P/F-11C60 material)
  • the machinable zones 32 are made of a first material (e.g., MPIF P/F- 4660 Modified low alloy steel material)
  • the machinable zones 19, 21 are made of a second material (e.g., MPIF P/F-11C60 material)
  • the third material may be a steel powder material including iron (typically at least 90 wt.%), 0.10 nickel wt.% max., molybdenum 0.05 wt.% max., manganese 0.10-0.25 wt.%, copper 0.30 wt.% max., chromium 0.10 wt.% max., sulfur 0.025 wt.% max., silicon 0.03 wt.% max., phosphorus 0.03 wt.% max., and carbon 0.30-0.90 wt.%.
  • all of the machinable zones 32, 35, 41 , 44 are made of MPIF P/F-1060 carbon steel material which has iron, 0.10 nickel wt.% max., molybdenum 0.05 wt.% max., manganese 0.10-0.25 wt.%, copper 0.30 wt.% max., chromium 0.10 wt.% max., sulfur 0.025 wt.% max., silicon 0.03 wt.% max., phosphorus 0.03 wt.% max., and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-1060 in the machinable zones 32, 35, 41 , 44 in the preferred finished part is approximately HRC 25 (and may be in the range of HRC 20-30), and the tensile strength of MPIF P/F-1060 in the preferred finished part is approximately 860 MPa (and may be in the range of
  • the density of MPIF P/F-1060 in the preferred finished part is approximately 7.81 g/cc (about 99% theoretical density). Theoretical densities above 95% are preferred.
  • the machinable zones 32, 35, 41 , 44 is of uniform composition throughout the machinable zones 32, 35, 41 , 44.
  • the beam section 12, the piston end 14 (except for the machinable zone 19), and the crank end 16 (except for the machinable zones 21 , 32, 35, 41 , 44) are made of a first material (e.g., MPIF P/F- 4660 Modified low alloy steel material), the machinable zone 21 is made of a second material (e.g., MPIF P/F-11 C60 material), and the machinable zones 19,
  • a first material e.g., MPIF P/F- 4660 Modified low alloy steel material
  • the machinable zone 21 is made of a second material (e.g., MPIF P/F-11 C60 material)
  • the beam section 12, the piston end 14 (except for the machinable zone 19), and the crank end 16 (except for the machinable zones 21 , 32, 35, 41 , 44) are made of a first material (e.g., MPIF P/F- 4660 Modified low alloy steel material), the machinable zone 19 is made of a second material (e.g., MPIF P/F-11 C60 material), and the machinable zones 21 , 32, 35, 41 , 44 are made of a third material (e.g., MPIF P/F-1060 material).
  • a first material e.g., MPIF P/F- 4660 Modified low alloy steel material
  • the machinable zone 19 is made of a second material (e.g., MPIF P/F-11 C60 material)
  • the machinable zones 21 , 32, 35, 41 , 44 are made of a third material (e.g., MPIF P/F-1060 material).
  • the preferred finished connecting rod 10 is approximately 7.80 g/cc, and the density of MPIF P/F-11 C60 in the machinable zones 19, 21 , 32, 32, 41 , 44 of the connecting rod 10 is below 7.80g/cc.
  • the lower density in the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 allows for greater machinability of the piston bore 18 and the crank bore 20 and also the fastener bores 31 , 34, 40 and 43.
  • Another possibility is applying lower densities for the sintered material of the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 compared to the metal powder used in forming the beam section 12, the piston end 14, and the crank end 16.
  • the preferred finished connecting rod 10 is approximately 7.80 g/cc, and the density of MPIF P/F-11 C60 in the machinable zones 19, 21 of the connecting rod 10 is below 7.80 g/cc, and the density of MPIF P/F-1060 in the machinable zones 32, 35, 41 , 44 of the connecting rod 10 is below 7.80 g/cc.
  • the lower density in the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 may allow for greater machinability of the piston bore 18 and the crank bore 20 and also the fastener bores 31 , 34, 40 and 43.
  • the beam section 12 is of increased strength due to the choice of materials.
  • the piston end 14 except for the machinable zone 19
  • the crank end 16 except for the machinable zones 21 , 32, 35, 41 , 44
  • the machinable zones 19, 21 , 32, 35, 41 , 44 of the connecting rod 10 are a softer material to allow machining of the piston bore 18 and the crank bore 20, and also for drilling and/or tapping of the fastener bores 31 , 34, 40 and 43. It is also advantageous to manufacture the machinable zones
  • machinable zones 32, 35, 41 , 44 of different materials in order to tailor the material to the machining operation.
  • the machining of the fasteners bores 31 , 34, 40 and 43 can be improved when using a different material than the regions of the piston bore 18 and the crank bore 20.
  • Various means of filling a die for pressing the connecting rod 10 before sintering may be employed to make a multi-material connecting rod according to the invention.
  • the powder to powder boundaries between the machinable zone 19 and the rest of the piston end 14 of the connecting rod 10 could be defined by thin powder separating segments in the tool set or feeder box to keep the material in the sections separate from one another as the die is filled.
  • the powder to powder boundaries between the machinable zone 21 and the rest of the crank end 16 of the connecting rod 10 could also be defined by thin powder separating segments in the tool set or feeder box.
  • the powder to powder boundaries between the beam section 12 and the piston end 14 and between the beam section 12 and the crank end 16 of the connecting rod 10 could also be defined by thin powder separating segments in the tool set or feeder box. Then, after the die is filled, the segments could be retracted, allowing the powder metal material of adjacent sections to come into contact with each other. [0044]
  • 35, 41 , 44 and the rest of the crank end 16 of the connecting rod 10 could also be formed using thin powder separating segments in the tool set or feeder box to keep the material in the sections separate from one another as the die is filled.
  • a first material can be loaded in the die to a predetermined depth, then thin powder separating segments could be placed in the tool set to control location of a second material forming the machinable zones 32, 35, 41 , 44.
  • the thin powder separating segments could then be removed, and more first material could loaded into the die. It is believed that the formation of rectangular machinable zones 32, 35, 41 , 44 would be easiest using this method.
  • FIG. 7 a second embodiment of a connecting rod 110 is shown in an assembled condition after all manufacturing steps.
  • the connecting rod 1 10 has a central beam section 112 having at a first end thereof an integrally connected piston end 114 and at the opposite second end thereof an integrally connected crank end 116.
  • integrally connected we mean the central beam section 112, the piston end 114 and the crank end 116 are formed as a unit.
  • the piston end 114 has a smaller piston bore 118 therethrough for receiving the wrist pin (and bearing if applicable) of a piston (not shown).
  • the piston bore 118 has an annular machinable zone 119 extending inward into the piston end 114 from the inner surface of the piston bore 118.
  • the material of the machinable zone 119 varies from the rest of the piston end 1 14 as will be detailed below.
  • the crank end 116 has a larger crank bore 120 therethrough for receiving a journal of a crank shaft and a bearing (not shown).
  • the crank end 116 can also be provided with opposed separation notches 124 at the sides of the crank bore 120.
  • the crank end 116 includes a crankshaft cap 128 having an arcuate central section 129 between a first side section 130 and a second side section 133.
  • the first side section 130 has a machined fastener bore 131 therethrough.
  • the second side section 133 has a machined fastener bore 134 therethrough.
  • the crank end 116 also includes a crank end base 138 having a first side section 139 and a second side section 142.
  • the first side section 139 has the machined fastener bore 140 therethrough and the second side section 142 has the machined fastener bore 143 therethrough.
  • the crankshaft cap 128 and the crank end base 138 are connected with one another by a bolt 146 (and possibly a corresponding nut 147) and a bolt 148 (and possibly a corresponding nut 149).
  • the bolt 146 is inserted through bores 131 and 140
  • the bolt 148 is inserted through bores 134 and 143.
  • the connecting rod 110 of Fig. 7 includes potentially two zones that may be machined when manufacturing the connecting rod 110.
  • the first zone is the annular machinable zone 119 around the piston bore 118.
  • the second machinable zone 150 is located between material interfaces 160 and 180 that both extend from one side to the other side of the connecting rod 110.
  • the second machinable zone 150 includes potentially five areas that may be machined: (i) an annular machinable zone around the crank bore 120, (ii) an annular machinable zone in section 130 around the fastener bore 131 , (iii) an annular machinable zone in section 133 around the fastener bore 134, (iv) an annular machinable zone in section 139 around the bore 140, and (v) an annular machinable zone in section 142 around the fastener bore 143.
  • the machinable zones 119 and 150 of the connecting rod 110 that may be machined during manufacture are made from lower strength material so as to be more machinable, but still of a requisite strength.
  • the beam section 112, the piston end 114 (except for the machinable zone 119), and the crank end 116 (except for the machinable zone 150) are made of a first material which may be a steel powder material including iron (typically at least 90 wt.%), nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon 0.10-
  • beam section 112 the piston end 114 (except for the machinable zone 119), and the crank end 116 (except for the machinable zone 150) are made of MPIF (Metal Powder Industries Federation) P/F-4660 Modified low alloy steel material which has iron, nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • MPIF Metal Powder Industries Federation
  • P/F-4660 Modified low alloy steel material which has iron, nickel 1.75-2.00 wt.%, molybdenum 0.50-0.60 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-4660 Modified in the preferred finished part is approximately HRC 45 (and may be in the range of HRC 40-50), and the tensile strength of MPIF P/F-4660 Modified in the preferred finished part is approximately 1650 MPa (and may be in the range of 1400-1900
  • the density of MPIF P/F-4660 Modified in the preferred finished part is approximately 7.80 g/cc (about 99% theoretical density). Theoretical densities above 95% are preferred.
  • the sintered material of the beam section 112, the piston end 114 (except for the machinable zone 119), and the crank end 116 (except for the machinable zone 150) is of uniform composition throughout the beam section 112, the piston end 114, and the crank end 116.
  • the machinable zones 119, 150 of the connecting rod 110 are made of a second material, which may be a steel powder material including iron (typically at least 90 wt.%), copper 1.8-2.2 wt.%, manganese sulfide 0.3-0.5 wt.%, manganese 0.10-0.25 wt.%, and carbon 0.30- 0.70 wt.%.
  • the machinable zones 119, 150 are all made of MPIF P/F-11C60, which is a copper steel powder metal material suitable for connecting rods, thus quite machinable.
  • MPIF P/F-1 1C60 includes iron, copper 1.8-2.2 wt.%, manganese sulfide 0.3-0.5 wt.%, manganese 0.10-0.25 wt.%, and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-11 C60 in the preferred finished part is approximately HRC 25 (and may be in the range of HRC 20-30), and the tensile strength of MPIF P/F-11C60 in the preferred finished part is approximately 900 MPa (and may be in the range of 700-1100 MPa).
  • the density of MPIF P/F-11 C60 in the preferred finished part is approximately 7.80g/cc
  • the beam section 112, the piston end 114 (except for the machinable zone 119), and the crank end 116 (except for the machinable zone 150) are made of a first material (e.g., MPIF P/F-4660 Modified low alloy steel material), the machinable zone 119 is made of a second material (e.g., MPIF P/F-1 1C60 material), and the machinable zone 150 is made of a third material.
  • a first material e.g., MPIF P/F-4660 Modified low alloy steel material
  • the machinable zone 119 is made of a second material (e.g., MPIF P/F-1 1C60 material)
  • the machinable zone 150 is made of a third material.
  • the third material may be a steel powder material including iron (typically at least 90 wt.%), 0.10 nickel wt.% max., molybdenum 0.05 wt.% max., manganese 0.10-0.25 wt.%, copper 0.30 wt.% max., chromium 0.10 wt.% max., sulfur 0.025 wt.% max., silicon 0.03 wt.% max., phosphorus 0.03 wt.% max., and carbon 0.30-0.90 wt.%.
  • the machinable zone 150 is made of MPIF P/F-1060 carbon steel material which has iron, 0.10 nickel wt.% max., molybdenum 0.05 wt.% max., manganese 0.10-0.25 wt.%, copper 0.30 wt.% max., chromium 0.10 wt.% max., sulfur 0.025 wt.% max., silicon 0.03 wt.% max., phosphorus 0.03 wt.% max., and carbon (as graphite approximately 0.60 wt.%).
  • the hardness of MPIF P/F-1060 in the machinable zone 150 in the preferred finished part is approximately HRC 25 (and may be in the range of HRC 20-30), and the tensile strength of MPIF P/F-1060 in the preferred finished part is approximately 860 MPa (and may be in the range of 700-1000 MPa).
  • the density of MPIF P/F-1060 in the preferred finished part is approximately 7.81 g/cc (about 99% theoretical density). Theoretical densities above 95% are preferred.
  • the machinable zone 150 is of uniform composition throughout the machinable zone 150. [0053] In yet another version of the invention, the density of MPIF P/F-4660
  • the piston end 114 (except for the machinable zone 119), and the crank end 116 (except for the machinable zone 150) of the preferred finished connecting rod 110 is approximately 7.80 g/cc, and the density of MPIF P/F-11 C60 in the machinable zones 119, 150 of the connecting rod 110 is below 7.80g/cc.
  • the lower density in the machinable zones 119, 150 of the connecting rod 110 allows for greater machinability of the piston bore 118 and the crank bore 120 and also the fastener bores 131 , 134, 140 and 143.
  • Another possibility is applying lower densities for the sintered material of the machinable zones 119, 150 of the connecting rod 110 compared to the metal powder used in forming the beam section 112, the piston end 114, and the crank end 116.
  • Lower densities can be achieved by use of, for example, a lower powder compaction pressure.
  • the beam section 112 is of increased strength due to the choice of materials.
  • the piston end 114 except for the machinable zone 119), and the crank end 116
  • the machinable zones 119, 150 of the connecting rod 110 are a softer material to allow machining of the piston bore 118 and the crank bore 120, and also for drilling and/or tapping of the fastener bores 131 , 134, 140 and 143.
  • Various means of filling a die for pressing the connecting rod 1 10 of Fig. 7 before sintering may be employed to make a multi-material connecting rod according to the invention.
  • the powder to powder boundaries between the machinable zone 119 and the rest of the piston end 114 of the connecting rod 110 could be defined by thin powder separating segments in the tool set or feeder box to keep the material in the sections separate from one another as the die is filled.
  • the powder to powder boundaries between the machinable zone 150 and the rest of the crank end 116 of the connecting rod 110 could also be defined by thin powder separating segments in the tool set or feeder box. Then, after the die is filled, the segments could be retracted, allowing the powder metal material of adjacent sections to come into contact with each other.
  • a connecting rod exemplifying the invention has been described in considerable detail. Many modifications and variations to the preferred embodiment described will be apparent to persons of ordinary skill in the art. For example, different materials could be used for the beam section, or different materials could be used for the end sections (other than the machinable zones). Also, there could be any number of different sections, for example, the center beam section could itself have sections of different materials or densities, as well as the thrust faces adjacent to the crank and piston pin bores.
  • the part could be sintered powder metal (P/M) material or powder forged (P/F) material, and as used herein the term "powder metal” or "sintered material” includes powder metal material whether it is forged or not (for example if it was only sintered).
  • the beam section could be made of an air hardening powder metal material, or not, and the end sections could be of non-air hardening powder metal material, or not.
  • An example air-hardening powder metal material is a powder steel containing sufficient carbon and other alloying elements to harden fully during cooling in air or other gaseous mediums from a temperature above its transformation range. Such steels attain their martensitic structure without going through the quenching process. Additions of chromium, nickel, molybdenum, copper, manganese, and other hardenability-enhancing elements are effective toward this end. [0057] Therefore, the invention should not be limited to the preferred embodiment described, but should be defined by the claims which follow.
  • This invention relates to connecting rods, for example of the type used in reciprocating piston and internal combustion engines.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)

Abstract

Bielle en métal pulvérulent fritté comprenant (i) une section formant poutre médiane, une extrémité côté piston, et une extrémité côté vilebrequin, faites en un matériau de métal pulvérulent doté d'une résistance relativement élevée, et (ii) des zones de la bielle qui sont usinées pendant la fabrication, comme par exemple l'alésage du piston, l'alésage du vilebrequin, et les alésages pour les vis à tête du côté vilebrequin, faites en un ou plusieurs matériaux de métal pulvérulent qui sont plus facilement usinables. Les matériaux de métal pulvérulent des zones usinées peuvent être rendus plus facilement usinables par l'utilisation de différentes compositions chimiques, de différentes densités frittées, et/ou de différentes valeurs de dureté frittée dans les zones, par exemple.
PCT/US2007/074857 2006-08-02 2007-07-31 bielle avec zones usinables localisÉes Ceased WO2008016921A2 (fr)

Applications Claiming Priority (2)

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US83503406P 2006-08-02 2006-08-02
US60/835,034 2006-08-02

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WO2008016921A3 WO2008016921A3 (fr) 2008-12-04

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JP3389590B2 (ja) * 1995-11-09 2003-03-24 日産自動車株式会社 コンロッドの製造方法
US7299715B2 (en) * 2004-05-27 2007-11-27 International Engine Intellectual Property Company, Llc Non-homogeneous engine component formed by powder metallurgy

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