Patent ID: 8784081

Claim:
A method of manufacturing a plunger pump fluid end housing to redistribute stress, the method comprising: providing a plunger pump fluid end housing comprising a first bore having a first bore longitudinal axis and a first bore transition area, a second bore having a second bore longitudinal axis and a second bore transition area, a third bore having a third bore longitudinal axis and a third bore transition area, and a fourth bore having a fourth bore longitudinal axis and a fourth bore transition area, said first and second bore longitudinal axes being substantially collinear to form a common axis, and all bore longitudinal axes being coplanar; machining a barrel-profile central cavity into the housing in fluid communication with said first, second, third and fourth bores, said barrel-profile central cavity having a central cavity wall and connecting said first and second bore transition areas, said central cavity being formed substantially symmetrically about said common axis and having a maximum transverse diameter between relatively smaller transverse diameters of first and second end chamfers adjacent to said first and second bore transition areas respectively; said first end chamfer intersecting said first bore transition area, said third bore transition area, and said fourth bore transition area; and said second end chamfer intersecting said second bore transition area, said third bore transition area, and said fourth bore transition area; each said bore transition area having a plurality of bore intersection angles with said barrel-profile central cavity, and each said bore intersection angle being obtuse; estimating a first local maximum peak cyclic stress near a stress concentration in said central cavity wall and a second local maximum peak cyclic stress in said central cavity wall more distant from said stress concentration, said first local maximum peak cyclic stress being greater than said second local maximum peak cyclic stress; estimating a ratio of said first local maximum peak cyclic stress to said second local maximum peak cyclic stress; and adjusting said central cavity maximum transverse diameter in said machining step to alter said ratio by a predetermined amount to redistribute stress in said plunger pump fluid end housing.