Hemi is the Greek word for half. That makes a hemisphere exactly half of a perfectly round bubble. Unfortunately, the engineers who created Chrysler’s FirePower V-8 didn’t need that much bubble. In lieu of a full hemisphere, they capped each cylinder with a spherical shape whose height is significantly less than half its diameter. Prompted to explain what they had wrought, the Chrysler motor maestros must have been at a loss for words. While the shape depicted on their blueprints is best described as a spherical cap or dome, those terms lack cachet. Instead, the engineers chose the more evocative Hemi name, even though it’s not strictly correct.

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DeSoto tried harder by labeling its version of this V-8 FireDome. According to Chrysler Corp. veterans we contacted, no sleep was lost worrying about the legitimacy of the Hemi name. Over the decades, these V-8s were such potent weapons in the horsepower wars that the company trademarked its vaunted nickname for the third-generation version, which arrived in . Two decades later (and with no hint of a hemisphere remaining in any Chrysler engine), the Hemi thrives as one of the most beloved V-8s money can buy.

Imagine being a fly on the wall at GM headquarters in when news of Chrysler’s FirePower V-8 arrived. In many respects, this newcomer copied the Cadillac V-8 born two years earlier; the bore, stroke, and compression-ratio specs were an exact match. Yet, somehow, GM’s crosstown rival managed to squeeze 20 more horsepower, or 180, out of its 331-cubic-inch V-8.

The boardroom erupted, engineers were dispatched to their labs, and dynos howled in an earnest attempt to raise output at any cost. Motown’s horsepower war was on. The following year, Cadillac added a four-barrel carburetor to retaliate with 190 horsepower, topping Chrysler’s 180. By , Chrysler had upped the ante all the way to an impressive 390 horsepower with more displacement, higher compression, larger valves, and electronic fuel injection. By then, every Detroit brand had crashed the horsepower party.

Turns out Chrysler was wielding a not-so-secret weapon in the form of a more efficient combustion chamber design. While every carmaker had modernized its engines with shorter piston strokes to boost rpm, and more compression to exploit the high-octane gasoline developed during World War II, Chrysler dusted off a technology invented at the dawn of the 20th century to build the truly better mousetrap. What Chrysler had in that competitors lacked were hemispherical combustion chambers.

During WWII, the U.S. Army Air Forces hired Chrysler to design and develop a -cubic-inch, -hp V-16 for use in the forthcoming P-47 Thunderbolt fighter. Like nearly every aircraft engine of the era, Chrysler’s XI- featured hemispherical combustion chambers with boost provided by both a turbocharger and a supercharger. Though development wasn’t finished by war’s end (especially after it became clear that jet engines would soon replace piston power), one test flight to 20,000 feet did top 380 mph. Calculations projected that 414 mph might be achievable at 30,000 feet.

Knowledge gained from this program was instrumental in Chrysler’s use of hemispherical combustion chambers in its FirePower V-8, which was offered in a range of cars starting with the Chrysler New Yorker, identifiable by its large “V” on the hood and trunk. Barely a year later, Briggs Cunningham bolted the new Hemi (as the FirePower came to be known) into his C4R sports car because it was the most powerful domestic V-8 then available and earned a fourth-place finish at the 24 Hours of Le Mans.

Topping each cylinder with a machined dome instead of the wedge shapes used by GM and others expedited the flow of fuel and air into the combustion chamber and the exit of burned gas out of each cylinder. Engineers use the term “volumetric efficiency” to gauge this flow. Pumping 300 cubic inches of fuel-air mix into a 300-cubic-inch engine in one complete cycle constitutes 100 percent volumetric efficiency. Most engines pump less. Adding a turbo- or supercharger to overfill the cylinders is the easiest way to achieve significantly more than 100 percent volumetric efficiency, but at the price of weight, cost, and complexity.

Of all the possible combustion chamber shapes, from wedge to flat to pent-roof, a hemi provides the minimum surface area relative to the total volume of the chamber. This is a good thing in engineering because less surface area means more of the fuel’s heat energy stays in the cylinder, where it presses down on the piston to maximize the torque produced. Heat transferred out of the combustion chamber to the cooling system is simply dumped to the atmosphere by the radiator.

Using hemi chambers enabled Chrysler to arrange intake and exhaust valves in a pattern distinctly different from the contemporary Cadillac and Oldsmobile V-8s. In the GM engines, all the intake and exhaust valves stood next to each other in a line, like a rank of soldiers at attention. Chrysler instead rotated each pair of valves 90 degrees, so that the intake and exhaust valves now were opposite of each other above the cylinder. Also, both of the valves were canted at angles to align better with their ports. The resulting fluid flow was less restricted by tight corners, significantly increasing volumetric efficiency.

The third advantage of the dome shape is that it allows positioning the spark plug closer to the geometric center of the combustion chamber to minimize flame travel during ignition.

Of course, there are always a few downsides. The Chrysler V-8’s cylinder head width and weight were significantly greater than those of the Cadillac and Oldsmobile V-8s. Also, centering the spark plugs in the combustion chambers required long tubes through the valve covers, which created sealing challenges. Operating valves that were splayed 58.5 degrees apart were another challenge; instead of the single long shaft supporting eight rocker arms that GM used, Chrysler V-8s required two such shafts per head. In addition, the long pushrods and rocker arms needed to open exhaust valves positioned far from the camshaft added weight to the valve-train that hampered high-rpm operation. To address these issues, Chrysler introduced lighter, simpler, and lower-cost V-8s for several models with what engineers dubbed “polyspherical” combustion chambers.

That same year, Chrysler commenced a four-year run of 300 “letter” cars powered by Hemi V-8s with two four-barrel carburetors and 300 or more horsepower—what some historians consider the first true muscle car.

Marine magnate Carl Kiekhaefer built NASCAR’s first truly professional stock car team around an armada of C300 super coupes. His star driver, Tim Flock, won 18 races and the championship in , followed by Buck Baker with 14 wins and season laurels in ’56. In only its second year, this team scored an amazing 16 straight wins. The clever Kiekhaefer also invented dry-paper air filters for his race engine, which remain in use today. In , drag racer Don Garlits bolted a Hemi he found in a salvage yard into his slingshot dragster.

Chrysler supplied only advice and spare parts because Kiekhaefer had deep pockets and sponsorship from his lucrative outboard-motor business, which became Mercury Marine. But early in the third season of Kiekhaefer’s campaign, GM president Harlow Curtice waved a red flag. At a meeting of the Automobile Manufacturers Association, Curtice urged Detroit execs to cease their direct motorsports participation out of fear that the federal government might step in with regulations that would make their lives miserable. Whether this was a clever ploy on his part or a truly valid concern isn’t clear, but by June of that year, every car company had signed on to the AMA ban.

Satisfied with its achievements on and off the track, Chrysler sent its first-generation Hemis to the retirement home after the model year. Their 361-426-cubic-inch replacements all had wedge-shaped combustion chambers similar to GM’s designs. But, like distant thunder, the racing rumble never subsided.

Gen II: Race and Street Hemis

Instead of overt racing participation, Chevy and Pontiac soon created low-profile ways to grab checkered flags while Chrysler and Ford watched and waited. After five years of suffering, Chrysler had a belly full of defeat. As the company’s chief engine engineer, Willem Weertman, noted in a technical paper, “In December , engineering staff was requested to develop an engine and vehicle combination capable of winning stock car competitive closed-circuit track events. In addition, a version of this engine was desired for use in timed vehicle acceleration drag events.”

With only 15 months between the above memo and NASCAR’s Daytona 500 race, Chrysler engineers had no time to dither. The decision was quickly made to retain the existing Chrysler 426 V-8 block. To better support the crankshaft, the block’s side skirts were extended 3 inches and cross-bolted main bearings were added. When cracks appeared in the cylinder walls, their material thickness was increased to 0.30 inches.

The new Hemi head designs—first cast iron, then aluminum—developed from the previous lessons learned. Like Gen I, the Gen II design lacked a truly hemispherical combustion chamber. Weertman listed a dome diameter of 4.84 inches with a center depth of 1.34 inches. However, were it a true hemisphere, the depth would have equaled the dome’s radius, or 2.42 inches.

The previous 58.5-degree angle between each intake and exhaust valve was retained, and volumetric efficiency was improved by straightening the intake ports. They were as large as possible—a full 3 square inches in cross-section—while a cross-section of the exhaust ports had an area of 2.24 square inches. Spark plugs were spotted as close as possible to each combustion chamber’s center.

A creative measure used to improve head retention with five instead of the previous four fasteners per cylinder necessitated screwing a stud into the floor of every intake port. That stud extended down through the block’s deck into its center valley, where a nut was added and tightened.

To comply with rules, a 426-cubic-inch displacement (with a 4.25-inch bore and 3.75-inch stroke) was selected along with single four-barrel induction for NASCAR events and two four-barrels for drag-racing. Experimental engines were running by December , and plans were laid to produce a few hundred of the new Hemis for the and ’65 racing seasons.

Weertman recalled witnessing the new engine’s trial by fire at Daytona: “I was one of the few Chrysler people present aware of a disastrous failure that occurred during durability testing.” Likely the failure was the previously mentioned cylinder-wall cracking. Unfortunately, the engineers lacked the time to prove that the fix was totally effective, “so it was a huge relief when three Mopars finished the 500-mile race one, two, and three.” Richard Petty won with an engine block that had been cast only 13 days before the race, Weertman said.

Want more information on Hemi Valve Balls? Feel free to contact us.

Naturally, the race engines were loaded with premium materials. The rocker arms and crankshaft were steel forgings, the cranks heat-treated and shot-peened. After machining, a dip in a nitride solution hardened the working surfaces. Finally, the crank journals were hand-lapped. Camshafts were made of heat-treated cast iron and the aluminum pistons were impact-extruded.

The twin-rocker-shaft valvetrain actuated 2.25-inch-diameter intake valves and 1.94-inch exhaust valves. A special fixture that spun that hardware to rpm used a stroboscope to freeze motion so that natural frequencies, vibration, and surge characteristics could be studied.

According to Weertman, the open-plenum single four-barrel intake manifold used in NASCAR achieved an impressive 102 percent volumetric efficiency at rpm, meaning that cylinders were nicely overfilled during the intake stroke. A transistor ignition system triggered by a dual-point distributor fired the spark plugs.

Fed by two Carter four-barrel carburetors atop a dual-plane aluminum intake manifold, the Street Hemi achieved 90 percent volumetric efficiency to deliver 425 horsepower at rpm and 490 lb-ft of torque at rpm in model-year Dodge and Plymouth intermediates. The single four-barrel oval track engine produced 550 horsepower at rpm. Revving to rpm, the two four-barrel drag Hemi delivered 600 horsepower.

To support a speed record attempt by the Summers brothers of Ontario, California, Chrysler engineering equipped four Hemi V-8s with fuel injection, low-profile intake manifolds, and shallow oil pans to fit inside the Goldenrod’s 23-inch-high streamlined body. Tested in the Caltech wind tunnel, this bullet boasted a modest 8.5-square-foot frontal area and an extremely slick 0. drag coefficient. Each Hemi V-8 was tuned to 600 horsepower, and two of them powered each axle. On November 12, , driver Bob Summers averaged 409.3 mph across the Bonneville Salt Flats to bring the wheel-driven land speed record home to America.

As with its predecessor, the second-gen Hemi lasted eight years (–71). Tightening emissions controls and rising insurance premiums finally retired this Mighty Misnomer mighty warrior after nearly 11,000 of them—far more than anticipated—had been sold.

Gen III 5.7-Liter “HEMI” V-8

Midway through the ill-fated DaimlerChrysler marriage (–), the need for a fresh, affordable, and efficient V-8 cropped up. Even though everything associated with Hemis was oh-so-last-century, some unsung Chrysler hero had the bright idea of trademarking America’s most prestigious engine nameplate.

So, the new 5.7-liter V-8 manufactured in Saltillo, Mexico, initially for Dodge Ram pickups (before they became RAMs under their own brand), rolled forth as a HEMI®. Forgive us for not honoring the all-caps style plus registered trademark symbol from here on.

This new V-8 was another shrewd design but not enough to prevent Chrysler’s bankruptcy. It did uphold one long-standing tradition: As in its ancestors, the third-gen combustion chamber is anything but a hemisphere. In fact, close examination reveals a very shallow bowl with two sides partially filled in to encourage quench. The term refers to the tight squeeze between a rising piston and the cylinder head that generates mixture turbulence and speedy combustion after ignition. Twin plugs fired simultaneously lit the flame. The chamber volume is barely half that of the Gen II Hemi.

Other carryover artifacts in the new Hemi include pushrods, two rocker shafts per head, and splayed valves lying in planes perpendicular to the crankshaft. In the new compressed combustion chamber design, the angle between the valves is a modest 34.5 degrees (versus the 58.5 degrees used previously). This new Hemi followed in-depth examination of two-, three-, and four-valve-per-cylinder designs operated by pushrods and overhead cams (including Porsche’s flat-six!). Advanced computer-aided design and engineering tools were extensively employed.

The cast-iron block has a so-called “dry valley” between the cylinder banks, meaning no oil passes through here to the crankcase. Its cam is elevated above the crank by a greater than normal distance to shorten pushrod and rocker arm lengths to reduce the valvetrain weight. For manufacturing simplicity, a single aluminum casting is used for the heads of both sides of the block, with machining operations employed to modify the casting into left- and right-hand parts. The tunnels through the aluminum die-cast valve covers for the spark plug leads are cast in place to avoid oil leakage. Cast-iron exhaust manifolds, which resemble headers, were carefully tuned to optimize flow efficiency. Forged powdered-metal connecting rods tie the cast-aluminum pistons to the crankshaft. The camshaft is an assembly of forged-steel lobes and powdered-metal journals. The oil pan consists of two laminated steel sheets sandwiching an inner plastic layer to cut noise, vibration, and harshness (NVH). A tray skims oil off the crankshaft to minimize windage losses.

What Chrysler calls “an integrated air-fuel module” tops this V-8. This complex part is composed of seven chunks of injection-molded nylon plastic welded together. The savings over an aluminum intake manifold are an impressive 13.7 pounds. A built-in three-chamber Helmholtz resonator reduces NVH. The throttle is electronically controlled.

Delivering 345 horsepower at rpm, Chrysler’s new 5.7-liter V-8 topped the outgoing 5.9-liter engine’s output by a fruitful 41 percent. The torque plot was even more impressive: The new engine peaked at 375 lb-ft at rpm, a 12 percent gain, while its torque curve whipped the retired engine soundly from rpm. Compared with the 5.9 engine’s molehill, the 5.7’s torque mountain soars much higher to rpm. The best news: This was only the beginning for an engine that’s still thriving today.

Over the next three model years (–), this Hemi began powering more trucks, Jeep’s Grand Cherokee, and large Chrysler and Dodge sedans. Tech changes started arriving in when some applications began using a multi-displacement system (MDS) which switched from eight- to four-cylinder operation in only 1/25-second for improved light-load efficiency. Early durability issues were addressed and more changes came in a V-8 code-named Eagle: new cylinder heads with improved flow, plus variable valve timing and a dual-mode intake manifold to boost torque. Revised output ratings ranged from 360 to 399 horsepower, and torque peaked between 390 and 410 lb-ft depending on the application.

A new 6.1-liter edition with a larger bore, revised cooling, a forged-steel crankshaft, stronger rods, and lighter pistons cooled by oil jets came in for SRT8 applications. The plastic intake manifold and MDS were both omitted here. Power climbed to 425 horses at rpm and the torque peak was 420 lb-ft at rpm. Marcus Braun of Vancouver, British Columbia, Canada, won Chrysler’s “What Can You Hemi?” contest by building a Big Wheel powered by a Hemi V-8.

To salute the original Hemi of the s, a new 392 V-8 was introduced in for the Dodge Challenger SRT8 and subsequent Charger SRT8, Chrysler 300C, and Jeep Grand Cherokee models. With a 4.09-inch bore and 3.72-inch stroke, the actual displacement was 391 cubic inches (6.4 liters) yielding 470 to 485 horsepower and 470 to 475 lb-ft of torque. Cylinder deactivation and variable cam valve timing were used only in models equipped with an automatic transmission. Code-named Apache, this Hemi was also sold as a crate engine.

Hell Yes! Cat

Chrysler’s now-we’re-talkin’ move for was the 6.2-liter V-8 appropriately named Hellcat, with a nod toward the WWII-era Grumman F6F fighter of the same name. Combining the Apache’s bore with the Eagle’s stroke and adding an intercooled IHI-brand supercharger inflated output to 707 horses at rpm while hiking torque to a stout 650 lb-ft at rpm. The power peak topped the Chevrolet Corvette Z06 by 57 horses thanks to 11.6 psi of maximum boost.

Hellcat applications included the Dodge Challenger and Charger SRTs and the Jeep Grand Cherokee’s SRT Trackhawk. A crate version of this engine came in .

And there’s more: For , Dodge rolled forth its mean Demon edition of the Challenger SRT with a 15 percent larger huffer, recalibrated valve timing, and tougher internal components. Pump the tank full of 100-octane fuel and you’ve got 840 horsepower on tap according to Dodge—or 808 horsepower if you can only afford 91-octane premium. Either way, bragging rights over the 755-hp C7 Corvette ZR1 are yours. Only cars were built and sold with a $1 kit of wheels and tires intended solely for drag strip use. Guinness World Records certified this beast’s ability to wheelie during launch. Without ever testing one, Car and Driver guessed this Dodge would clock 60 mph in about 2.5 seconds and the quarter-mile in less than 10 seconds. The manufacturer claimed launch acceleration of 1.8 g’s while a YouTube video whisked you down the Kennedy Space Center’s 3-mile straightaway to 211 mph. We’re talking Porsche 918 Spyder performance for one-tenth the price.

Whether or not you believe the hemi designation is valid for any of these engines, what Chrysler achieved beginning in and continuing well into the 21st century is astonishing. These race-winning, tire-burning, and grocery-getting V-8s power cars that mere mortals can afford. It’s not Greek to us that the Hemi deserves everyone’s respect and adulation.

USB1 - Manufacturing process to make a valve ball - Google Patents

Manufacturing process to make a valve ball Download PDF

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Publication number

USB1

USB1 US10/852,564 USA USB1 US B1 US B1 US B1 US A US A US A US B1 US B1 US B1

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US

United States

Prior art keywords

ball valve

circular

semi

shaped

manufacturing process

Prior art date

-05-25

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Expired - Fee Related

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US10/852,564

Inventor

Chiang Hsiang-Hui

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-05-25

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-05-25

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-05-31

-05-25 Application filed by Individual filed Critical Individual

-05-25 Priority to US10/852,564 priority Critical patent/USB1/en

-05-31 Application granted granted Critical

-05-31 Publication of USB1 publication Critical patent/USB1/en

-05-25 Anticipated expiration legal-status Critical

Status Expired - Fee Related legal-status Critical Current

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• USPTO PatentCenter
• USPTO Assignment
• Espacenet
• Global Dossier
• Discuss

• manufacturing process Methods 0.000 title claims abstract description 17
• indentation Methods 0.000 claims abstract description 10
• method Methods 0.000 claims description 23
• punching Methods 0.000 claims description 9
• product Substances 0.000 claims description 7
• semifinished product Substances 0.000 claims description 6
• polishing Methods 0.000 claims description 3
• welding Methods 0.000 claims description 3
• solidification Methods 0.000 claims description 2
• solidification Effects 0.000 claims description 2
• trimming Methods 0.000 claims description 2
• FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims 1
• substance Substances 0.000 description 4
• Steel Inorganic materials 0.000 description 3
• forging Methods 0.000 description 3
• steel Substances 0.000 description 3
• deficient Effects 0.000 description 2
• coupling Effects 0.000 description 1
• coupling process Methods 0.000 description 1
• coupling reaction Methods 0.000 description 1
• cutting process Methods 0.000 description 1
• effects Effects 0.000 description 1
• epidermis Anatomy 0.000 description 1
• modification Methods 0.000 description 1
• modification Effects 0.000 description 1
• XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1

Images

Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B11/00—Machines or devices designed for grinding spherical surfaces or parts of spherical surfaces on work; Accessories therefor
• • 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
  • B21K1/02—Making machine elements balls, rolls, or rollers, e.g. for bearings
• • 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
• • 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
• • 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
  • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
  • F16K27/00—Construction of housing; Use of materials therefor
  • F16K27/06—Construction of housing; Use of materials therefor of taps or cocks
  • F16K27/067—Construction of housing; Use of materials therefor of taps or cocks with spherical plugs

Definitions

• the present invention relates to hydroelectric apparatus and more particularly to a manufacturing process to make a ball valve which is capable of rapidly and precisely to make shape of a ball valve.
• FIG. 10 shows a prior art manufacturing process of a ball valve 70 which is adapting the roller ramming process by forging a pair of semi-spherical shapes 71 and welding them together into a ball shape and then making a central passageway by a punching bar.
• this process costs more than others because it has to deal with epidermis chemical disposal and the spherical trimming procedure.
• the residual chemical remained on the surface of the ball valve may harm human health. So that this process is now being abandoned.
• FIGS. 11 , 12 and 13 indicate another prior art process which is adapted a steel plate 81 and punches the steel plate 81 into pieces of small arcuate sheet 81 ′ at first, secondly, punches the small arcuate sheet 81 ′ into a large arcuate sheet 81 ′′ and then presses the large arcuate sheets 81 ′ into the hemi-spherical shapes 80 by an upper and a lower molds. Finally, weld their coupling rims 82 together on pair by pair basis. This process is somewhat complicated due to its repeated punching activities and has to weld the hemispherical shapes together before removing of the upper and lower molds.
• FIGS. 14 to 17 show still another prior art process which punches a plate into a cup shaped semi-finished product 91 at first and punches the semi-finished products into a similar spherical shapes 92 . Then make an upper, a lower openings 921 and a lateral through hole 922 by punching or drill method. Due to that the openings 921 punched by the upper and lower molds may create protrudent stripes and the lower rim of the cup shape semi-finished product becomes thinner than the other portions of the ball valve that causes the ball valve in uneven thickness in addition to that the protrudent stripes are to be dealt with. So that this process always cause great defective proportion, than other process.
• FIGS. 18 to 22 a further prior art process of manufacturing a ball valve is shown.
• This process is to punch a plate 1 into a hollow cylindrical shape 2 and a flap 3 which must be removed later, to accomplish a hollow cylindrical shape 2 and a bottom which is then cut off to remain the hollow cylindrical shape 2 only, next step is to make the cylindrical shape 2 into a ball shape 4 by roller ramming method. Finally makes a rectangular through hole 5 in a periphery of the ball shape 4 . So that a ball valve is therefore finished.
• this process requires twice cutting procedures and the thickness of the ball is not so even. Besides, the circular measure is always not symmetrical such that the result is not qualified.
• connection hole for linking a valve stem is punched after the configuring of the ball valve that may cause a deformation of the ball valve that not only affects a perfect connection of the valve stem with the ball valve but also face the leakage of the water and/or the air.
• the present invention has a main object to provide a manufacturing process to make a ball valve which process is rapid and precise. The result will be in good quality in uniform thickness and circular measure. Therefore, a high qualified proportion in addition to a ready assembly become feasible.
• the manufacturing process to make a ball valve of the present invention comprises generally the following steps:
• FIG. 1 is a perspective to show a flat circular plate of the present invention
• FIG. 2 is a sectional view to show an upper and a lower mold in a punch machine
• FIG. 3 is a sectional view to show that the flat circular plate is punched into an indented bowl shape
• FIG. 4 is a perspectively view of FIG. 3 .
• FIG. 5 is a sectional view to show the flat bottom of the bowl shape being punched off
• FIG. 6 is a perspective view to show that the semi-product of the present invention is punched into a hemi-spherical shape
• FIG. 7 is a perspective view to show that a pair of corresponding hemi-spherical shape semi-products are welded into a ball valve
• FIG. 8 is a sectional view to show that the connection seam on the valve is polishing by a grinder
• FIG. 9 is a perspective view to show a finished ball valve of the present invention.
• FIG. 10 is a perspective view to show a prior art ball valve is made up with forging process
• FIGS. 11 to 13 are the plane views and a perspective view to show another prior art ball valve made up with punching process
• FIGS. 14 to 17 are the sectional views to show a still another prior art ball valve made up with punching process.
• FIGS. 18 to 22 are the sectional and perspective views to show a further prior art ball valve made up with roller ramming process.
• the manufacturing process to make a ball valve of the present invention comprises the following steps:
• the ball valve 10 c of the present invention is combined with a pair of corresponding semi-spherical shaped configuration 10 b . So that the result should be in uniform arc and thickness which insures a good quality and reliability.
• manufacturing processes that use only one piece of steel plate and manufactured through repeated strokes to form a valve ball that must be in uneven thickness and different arc, especially the high defective products are unavoidable.
• some of the producers previously forge a pair of corresponding hemi-spherical shaped pieces and then weld them together to finish a ball valve (as shown in FIG. 10 ). But a forged product has to finish through chemical disposal. That the residual chemical still remains in the surface of the ball valve.
• the rectangular retaining through hole 11 c of the ball valve 10 c of the present invention is formed at the beginning. So it don't have to be punched after the accomplishment of the ball valve 10 c . Thus, avoid a deformation of the products in comparison with the prior art manufacturing process.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Taps Or Cocks (AREA)

Abstract

A manufacturing process to make a ball valve of the present invention includes the following steps: a) prepare flat circular metallic plates each of which has a rectangular indentation in a circumference; b) mold those plates into bowl shape; c) remove the circular bottom of the bowl shapes to reform a hemi-spherical shape by another mold; d) weld each pair of the hemi-spherical shapes into a spherical shape each of which has a pair of aligned openings and a lateral rectangular through hole; e) trim and grind the uneven connection seam; and f) polish and smooth the outer surface to finished a qualified ball valve which has uniform arc and thickness.

Description

BACKGROUND OF THE INVENTION The present invention relates to hydroelectric apparatus and more particularly to a manufacturing process to make a ball valve which is capable of rapidly and precisely to make shape of a ball valve. As we know that the ball valve is popularly used to the switches. The manufacturing process of the ball valve is categorized as forging, punching and/or roller ramming. FIG. 10 shows a prior art manufacturing process of a ball valve 70 which is adapting the roller ramming process by forging a pair of semi-spherical shapes 71 and welding them together into a ball shape and then making a central passageway by a punching bar. However, this process costs more than others because it has to deal with epidermis chemical disposal and the spherical trimming procedure. Besides, the residual chemical remained on the surface of the ball valve may harm human health. So that this process is now being abandoned. FIGS. 11, 12 and 13 indicate another prior art process which is adapted a steel plate 81 and punches the steel plate 81 into pieces of small arcuate sheet 81′ at first, secondly, punches the small arcuate sheet 81′ into a large arcuate sheet 81″ and then presses the large arcuate sheets 81′ into the hemi-spherical shapes 80 by an upper and a lower molds. Finally, weld their coupling rims 82 together on pair by pair basis. This process is somewhat complicated due to its repeated punching activities and has to weld the hemispherical shapes together before removing of the upper and lower molds. FIGS. 14 to 17 show still another prior art process which punches a plate into a cup shaped semi-finished product 91 at first and punches the semi-finished products into a similar spherical shapes 92. Then make an upper, a lower openings 921 and a lateral through hole 922 by punching or drill method. Due to that the openings 921 punched by the upper and lower molds may create protrudent stripes and the lower rim of the cup shape semi-finished product becomes thinner than the other portions of the ball valve that causes the ball valve in uneven thickness in addition to that the protrudent stripes are to be dealt with. So that this process always cause great defective proportion, than other process. Referring to FIGS. 18 to 22, a further prior art process of manufacturing a ball valve is shown. This process is to punch a plate 1 into a hollow cylindrical shape 2 and a flap 3 which must be removed later, to accomplish a hollow cylindrical shape 2 and a bottom which is then cut off to remain the hollow cylindrical shape 2 only, next step is to make the cylindrical shape 2 into a ball shape 4 by roller ramming method. Finally makes a rectangular through hole 5 in a periphery of the ball shape 4. So that a ball valve is therefore finished. However, this process requires twice cutting procedures and the thickness of the ball is not so even. Besides, the circular measure is always not symmetrical such that the result is not qualified. The above discussed prior art manufacturing processes have a common disadvantage that the connection hole for linking a valve stem is punched after the configuring of the ball valve that may cause a deformation of the ball valve that not only affects a perfect connection of the valve stem with the ball valve but also face the leakage of the water and/or the air. SUMMARY OF THE PRESENT INVENTION The present invention has a main object to provide a manufacturing process to make a ball valve which process is rapid and precise. The result will be in good quality in uniform thickness and circular measure. Therefore, a high qualified proportion in addition to a ready assembly become feasible. Accordingly, the manufacturing process to make a ball valve of the present invention comprises generally the following steps:

• • a) prepare a pair of circular flat metallic plate and punch a rectangular indentation in a predetermined position of the circumference of the plate;
  • b) put the circular plate onto an upper and a lower molds and punches by a punching means to form a bowl shaped configuration;
  • c) punch the bowl shaped configuration again to remove the flat portion and form it into an indented hemi-spherical shape;
  • d) combine two indented hemi-spherical shaped member together by welding means to make a ball valve and their indentations are aligned with each other to form a rectangular retaining through hole which is provided to connect a valve stem;
  • e) polish the connection seam on the valve.

Therefore, a ball valve of uniform thickness is rapidly and precisely finished. The present invention will become more fully understood by reference to the following detailed description thereof when read in conjunction with the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective to show a flat circular plate of the present invention, FIG. 2 is a sectional view to show an upper and a lower mold in a punch machine, FIG. 3 is a sectional view to show that the flat circular plate is punched into an indented bowl shape, FIG. 4 is a perspectively view of FIG. 3, FIG. 5 is a sectional view to show the flat bottom of the bowl shape being punched off, FIG. 6 is a perspective view to show that the semi-product of the present invention is punched into a hemi-spherical shape, FIG. 7 is a perspective view to show that a pair of corresponding hemi-spherical shape semi-products are welded into a ball valve, FIG. 8 is a sectional view to show that the connection seam on the valve is polishing by a grinder, FIG. 9 is a perspective view to show a finished ball valve of the present invention, FIG. 10 is a perspective view to show a prior art ball valve is made up with forging process, FIGS. 11 to 13 are the plane views and a perspective view to show another prior art ball valve made up with punching process, FIGS. 14 to 17 are the sectional views to show a still another prior art ball valve made up with punching process, and FIGS. 18 to 22 are the sectional and perspective views to show a further prior art ball valve made up with roller ramming process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT With reference to FIGS. 1 and 2 of the drawings, the manufacturing process to make a ball valve of the present invention comprises the following steps:

• • a) prepare a pair of flat circular metallic plates 10 and each of the plates 10 has a roughly rectangular indentation 11 in a predetermined position of its circumference;
  • b) put the flat circular metallic plate 10 on one by one basis, on a lower mold 21 which has a punch 23 slidably disposed in the center and incorporates with an upper mold 20 which is moving downward onto the plate 10. Then striking the punch 23 upward to form the circular plate into a bowl shape piece 10 a due to that a bowl shaped depression 22 formed in the upper mold 20. The bowl shape piece 10 a has an indentation 11 in a lower rim and a circular bottom 12 on the specific surface (as shown in FIGS. 3 and 4);
  • c) place the bowl shape piece 10 a into a semi-circular mold 30 (as shown in FIGS. 5 and 6), and use a sharp punch bar 31 to punch the bottom 12 of the bowl shaped piece becoming a circular opening 12 b. The bowl shape piece 10 a which is already punched into hemi-spherical shaped configuration that will not be deformed due to the inner semi-circular depression of the semi-circular mold 30 which has the function of stability;
  • d) combine two hemi-spherical shaped configurations 10 b with their indentations 11 engaged with each other. Then weld them together to complete a spherical ball valve 10 c. Meanwhile, the two indentations 11 are aligned together to form a rectangular retaining through hole 11 c (as shown in FIG. 7) which is provided to connect a valve stem (not shown);
  • e) trim and grind the uneven connection seam 13 and perform a global shaped solidification method disposal;
  • f) polish the outer surface of the ball valve 10 c by inserting a rotatable cylindrical bar 40 through the aligned openings 12 b and use a polish machine 50 which has an inward curved semi-circular surface 51 on a lateral side engaged with the outer surface of the ball valve 10 c. When rotates the bar 40, the ball valve 10 c is being polished until the outer surface of the ball valve 10 c becoming smooth (as shown in FIG. 8). Then removes the cylindrical bar 40, a qualified ball valve 10 c of the present invention is therefore finished (as shown in FIG. 9).

Base on the above process, the ball valve 10 c of the present invention is combined with a pair of corresponding semi-spherical shaped configuration 10 b. So that the result should be in uniform arc and thickness which insures a good quality and reliability. Not as the prior arts manufacturing processes that use only one piece of steel plate and manufactured through repeated strokes to form a valve ball that must be in uneven thickness and different arc, especially the high defective products are unavoidable. Nevertheless, though some of the producers previously forge a pair of corresponding hemi-spherical shaped pieces and then weld them together to finish a ball valve (as shown in FIG. 10). But a forged product has to finish through chemical disposal. That the residual chemical still remains in the surface of the ball valve. Further, the rectangular retaining through hole 11 c of the ball valve 10 c of the present invention is formed at the beginning. So it don't have to be punched after the accomplishment of the ball valve 10 c. Thus, avoid a deformation of the products in comparison with the prior art manufacturing process. Note that the specification relating to the above embodiment should be construed as an exemplary rather than as a limitative of the present invention, with many variations and modifications being readily attainable by a person of average skill in the art without departing from the spirit or scope thereof as defined by the appended claims and their legal equivalents.

Claims (5)

1. A manufacturing process to make a ball valve comprising the following steps: a) preparing a pair of flat circular metallic plates each of which has a rectangular indentation in a predetermined position along a circumferential edge thereof; b) putting said plates on one by one basis between an upper mold and a lower mold in a punching machine, said plate being punched into a bowl shaped semi-finished product each of which has a rectangular indentation in a rim and a circular bottom on specific surface; c) placing each of said bowl shaped semi-finished products in a semi-circular shaped mold and using a sharp punch bar to punch said circular bottom of each bowl shaped semi-product into a circular opening and said bowl shaped semi-products into a piece of hemi-spherical shaped semi-finished products; d) combining each pair of said hemi-spherical shapes together to complete a spherical shaped ball valve by welding means and their indentations being aligned with each other to form a rectangular retaining through hole which is provided to connect a valve stem; e) trimming and grinding uneven connection seam of each ball valve and performing a global shaped solidification method; f) polishing outer surface of each of said ball valve by inserting a rotatable cylindrical bar through aligned circular openings and adapting a polish machine which has an inward curved semi-circular surface in a lateral side engaged with outer surface of said ball valve and rotating said bar to polish said ball valve until that the surface of said ball valve becomes smooth, then removes said bar; whereby, a qualified valve ball is therefore finished. 2. The manufacturing process as cited in claim 1, wherein said upper mold in step b has a bowl shaped depression in center. 3. The manufacturing process as recited in claim 1, wherein said lower mold has a slidable punch bar in center engageable with the bowl shaped depression in said upper mold. 4. The manufacturing process as recited in claim 1, further has a semi-circular mold in corporation with an upward shaped punching bar in step c to punch the circular bottom of each of said bowl shaped pieces into a circular opening and a semi-circular shaped configuration of the valve. 5. The manufacturing process as recited in claim 1, wherein said polishing machine in step f is of conventional. US10/852,564 -05-25 -05-25 Manufacturing process to make a valve ball Expired - Fee Related USB1 (en)

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Cited By (14)

* Cited by examiner, † Cited by third party Publication number Priority date Publication date Assignee Title EPA1 (en) * -04-10 -10-14 Viega GmbH & Co. KG Installation stopcock CNA (en) * -09-30 -01-12 郏正秋 Ball valve body processing machine tool CNA (en) * -11-01 -05-25 金云康 Making method of ABS (Antilock Braking System) shell USA1 (en) * -08-02 -03-08 Russell Kingston Methods to fabricate fully enclosed hollow structures using friction stir welding CNA (en) * -01-14 -04-24 嘉士凯（苏州）阀门配件有限公司 Manufacturing tool for grinding sphere of ball of ball valve CNA (en) * -06-17 -09-04 沈阳飞机工业（集团）有限公司 Processing method of pillar bowl-type spherical measuring head CNB (en) * -12-31 -02-01 洛阳轴研科技股份有限公司 Machining method for high-precision hemispherical part with hole CNA (en) * -11-27 -06-15 江苏远方动力科技有限公司 A kind of processing method of the path lengths such as high-precision away from interruption hole CNA (en) * -09-28 -12-14 北京铂阳顶荣光伏科技有限公司 A kind of manufacturing process of vacuum chamber CNA (en) * -01-17 -03-26 江阴中南重工有限公司 Integral type ball-type multi-way pipe fitting and preparation method thereof CNA (en) * -02-28 -06-23 苏州工业园区博斯塔机械有限公司 Machining method for hard-seal double-eccentric ball valve ball body CNA (en) * -10-14 -03-19 江门市亿高电器有限公司 Manufacturing method of cylindrical straight seam workpiece CNA (en) * -07-14 -01-14 台湾控制阀股份有限公司 Machining method of ball plug for diverter valve and ball plug CNA (en) * -10-15 -01-14 国工控股集团有限公司 A fully welded ball valve auxiliary valve body mold

Citations (2)

* Cited by examiner, † Cited by third party Publication number Priority date Publication date Assignee Title USA (en) * -06-04 -01-10 Von Holdt, Sr.; John W. Injection mold having a rotatable sprue member USA (en) * -11-16 -11-09 Wu; Lei-Jui Method of making ball valves

• • -05-25 US US10/852,564 patent/USB1/en not_active Expired - Fee Related

Patent Citations (2)

* Cited by examiner, † Cited by third party Publication number Priority date Publication date Assignee Title USA (en) * -06-04 -01-10 Von Holdt, Sr.; John W. Injection mold having a rotatable sprue member USA (en) * -11-16 -11-09 Wu; Lei-Jui Method of making ball valves

Cited By (24)

* Cited by examiner, † Cited by third party Publication number Priority date Publication date Assignee Title EPA1 (en) * -04-10 -10-14 Viega GmbH & Co. KG Installation stopcock USA1 (en) * -04-10 -10-15 Viega Gmbh & Co. Kg Shut-off valve for plumbing applications USB2 (en) -04-10 -01-14 Viega Gmbh & Co. Kg Shut-off valve for plumbing applications USA1 (en) * -08-02 -03-08 Russell Kingston Methods to fabricate fully enclosed hollow structures using friction stir welding USB2 (en) * -08-02 -11-27 Megastir Technologies Llc Methods to fabricate fully enclosed hollow structures using friction stir welding USB2 (en) -08-02 -07-23 Megastir Technologies Llc Methods to fabricate fully enclosed hollow structures using friction stir welding CNA (en) * -09-30 -01-12 郏正秋 Ball valve body processing machine tool CNA (en) * -11-01 -05-25 金云康 Making method of ABS (Antilock Braking System) shell CNA (en) * -01-14 -04-24 嘉士凯（苏州）阀门配件有限公司 Manufacturing tool for grinding sphere of ball of ball valve CNB (en) * -01-14 -06-01 嘉士凯（苏州）阀门配件有限公司 The sphere grinding fixture of ball valve spheroid CNA (en) * -06-17 -09-04 沈阳飞机工业（集团）有限公司 Processing method of pillar bowl-type spherical measuring head CNB (en) * -12-31 -02-01 洛阳轴研科技股份有限公司 Machining method for high-precision hemispherical part with hole CNA (en) * -11-27 -06-15 江苏远方动力科技有限公司 A kind of processing method of the path lengths such as high-precision away from interruption hole CNB (en) * -11-27 -10-01 江苏远方动力科技有限公司 A kind of processing method of the path lengths such as high-precision away from interruption hole CNA (en) * -09-28 -12-14 北京铂阳顶荣光伏科技有限公司 A kind of manufacturing process of vacuum chamber CNB (en) * -09-28 -10-29 北京铂阳顶荣光伏科技有限公司 A kind of manufacturing process of vacuum chamber CNA (en) * -01-17 -03-26 江阴中南重工有限公司 Integral type ball-type multi-way pipe fitting and preparation method thereof CNB (en) * -01-17 -05-12 江阴中南重工有限公司 Integrated spherical multi-way pipe fitting and preparation method thereof CNA (en) * -02-28 -06-23 苏州工业园区博斯塔机械有限公司 Machining method for hard-seal double-eccentric ball valve ball body CNB (en) * -02-28 -07-16 苏州工业园区博斯塔机械有限公司 Machining method for hard-seal double-eccentric ball valve ball body CNA (en) * -07-14 -01-14 台湾控制阀股份有限公司 Machining method of ball plug for diverter valve and ball plug CNA (en) * -10-14 -03-19 江门市亿高电器有限公司 Manufacturing method of cylindrical straight seam workpiece CNA (en) * -10-15 -01-14 国工控股集团有限公司 A fully welded ball valve auxiliary valve body mold CNB (en) * -10-15 -06-06 国工控股集团有限公司 All-welded ball valve auxiliary valve body die

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