Manufacturing a rocker lever using cold forming and welding

Abstract

A method and system for forming a rocker assembly includes cold forming a metal blank to produce a portion of the rocker assembly. This portion has a tubular portion that rotatably engages a shaft and an arm that couples with a pushrod. This portion is welded to a valve lever to form the rocker assembly.

1 . A rocker assembly for an engine comprising: 
 a tubular member having a first axial end, a second axial end, and an integrally formed arm adjacent said first axial end; and    a valve lever coupled to said tubular member adjacent said second axial end and opposite of said arm.    
   
   
       2 . The assembly of  claim 1  further comprising:  
     a cup formed within said arm, said cup adapted to selectively couple with a push rod.  
   
   
       3 . The assembly of  claim 1  further comprising:  
     a valve contacting surface formed on said valve lever.  
   
   
       4 . The assembly of  claim 1  wherein a side of said valve lever contacts an axial end of said tubular member.  
   
   
       5 . The assembly of  claim 1  wherein said valve lever is coupled to said tubular member by welding.  
   
   
       6 . The assembly of  claim 1  wherein said valve lever is coupled to said tubular member by laser welding.  
   
   
       7 . The assembly of  claim 1  wherein said valve lever is coupled to said tubular member by electron beam welding.  
   
   
       8 . The assembly of  claim 1  wherein said valve lever is coupled to said tubular member by pulsed plasma arc welding.  
   
   
       9 . A method of manufacturing a cam-engaged rocker comprising: 
 obtaining a metal blank, said metal blank defined, at least in part, by a first surface, an opposing second surface, a peripheral surface intersecting both said first surface and said second surface, and a projection, wherein said metal blank contains a predetermined amount of a metal; and    forming at least a portion of said metal blank by exerting a force on said metal blank adjacent said first surface, wherein a tubular portion is formed by the flow of a portion of said metal.    
   
   
       10 . The method of  claim 9 , wherein forming said metal blank includes cold forming a central portion of said metal blank.  
   
   
       11 . The method of  claim 9 , further comprising forming a cup in said projection.  
   
   
       12 . The method of  claim 9 , further comprising radially aligning a valve lever to said tubular portion.  
   
   
       13 . The method of  claim 9 , further comprising welding a valve lever to said tubular portion.  
   
   
       14 . The method of  claim 13 , wherein said welding comprises laser welding.  
   
   
       15 . A method of manufacturing a cam-engaged rocker comprising: 
 obtaining an annular metal blank, said annular metal blank defined, at least in part, by an outer cylindrical surface, an inner cylindrical surface a valve end, and a cup end, wherein said annular metal blank contains a predetermined amount of a metal; and    forming a projection on said annular metal blank by exerting a force on at least a portion of said annular metal blank adjacent said cup end, wherein a projection is formed by the flow of a portion of said metal, the projection extending from a tubular portion.    
   
   
       16 . The method of  claim 15 , further comprising: 
 positioning said annular metal blank adjacent a die, wherein said die includes a cavity, wherein forming the annular metal blank includes exerting a force on said annular metal blank in a predetermined direction thereby causing a flow of the metal into said cavity.    
   
   
       17 . The method of  claim 15 , further comprising forming a cup in said projection.  
   
   
       18 . The method of  claim 15 , further comprising welding a valve lever to said tubular portion.  
   
   
       19 . The method of  claim 18 , wherein said welding comprises laser welding