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 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.    
   
   
       2 . The method of  claim 1 , wherein forming said metal blank includes cold forming a central portion of said metal blank.  
   
   
       3 . The method of  claim 1 , further comprising forming a cup in said projection.  
   
   
       4 . The method of  claim 1 , further comprising radially aligning a valve lever to said tubular portion.  
   
   
       5 . The method of  claim 1 , further comprising welding a valve lever to said tubular portion.  
   
   
       6 . The method of  claim 5 , wherein said welding comprises laser welding.  
   
   
       7 . 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.    
   
   
       8 . The method of  claim 7 , 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.    
   
   
       9 . The method of  claim 7 , further comprising forming a cup in said projection.  
   
   
       10 . The method of  claim 7 , further comprising welding a valve lever to said tubular portion.  
   
   
       11 . The method of  claim 10 , wherein said welding comprises laser welding