Cast Vehicle Support Structure With Rib Lightening Portions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vehicle support structures made of aluminum require thickening to achieve the same rigidity as those made of iron, leading to increased machining allowances and processing steps, particularly in areas with high loads like arm support portions, which also thickens external component mounting portions.
Innovation Solution
A vehicle support structure with rib portions that include a lightening portion formed by casting, where the external component mounting portion is created within this lightening portion, reducing machining allowances and unnecessary material, and using a method of gravity casting with a mold and strain relief to minimize processing steps and prevent blowholes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the arm support portion is cast thick to ensure rigidity, then the rigidity is improved, but the external component mounting portion becomes thick similarly, increasing the machining allowance and the number of processing steps
Solution Approach 1:
The patent applies local quality by forming a lightening portion specifically in the rib portion that does not require high strength, while maintaining the necessary thickness in the arm support portion for rigidity. This localized thickness variation allows the external component mounting portion to have reduced machining allowance without compromising the overall structural rigidity.
Solution Approach 2:
The patent segments the support structure into different functional zones: the arm support portion requiring high rigidity maintains sufficient thickness, while the rib portion containing the external component mounting portion is thinned by forming a lightening portion. This segmentation allows different parts to have optimized thickness according to their specific functional requirements.
2Strength
If the external component mounting portion is made thick to ensure rigidity, then the rigidity is improved, but the weight increases
Solution Approach 1:
The lightening portion is formed locally in the rib portion where high strength is not critically required, reducing the material volume and weight in that specific area while maintaining the necessary rigidity in the arm support portion through appropriate thickness.
Solution Approach 2:
The structure is divided into load-critical areas (arm support portion) and non-critical areas (rib portion with external component mounting portion), allowing weight reduction in the non-critical areas through the lightening portion while preserving rigidity in the load-critical areas.
3Productivity
If the casting speed is increased to improve productivity, then the productivity is improved, but blowholes may occur, degrading casting quality
Solution Approach 1:
The lightening portion is designed in advance in the rib portion, positioned away from the sprue. This preliminary structural arrangement facilitates smoother metal flow during casting, allowing higher casting speeds without causing blowholes, as the reduced material volume in the rib portion reduces flow resistance and turbulence.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration minimizes machining allowances while ensuring required rigidity, achieves weight reduction, and improves casting quality by reducing unnecessary portions and preventing blowholes, thus enhancing the manufacturing efficiency and quality of the vehicle support structure.
Implementation Method 1
a method of manufacturing a vehicle support structure, the vehicle support structure being formed by gravity casting using a mold with a sprue and a strain relief above the sprue
Data Source
AI summary
A vehicle support structure formed by casting, the vehicle support structure includes a main body part attached to a vehicle side, a plurality of support portions extending from the main body part to support vehicle components, and a plurality of rib portions configured to connect the support portions and the main body part, respectively. A lightening portion is formed by casting at least in one of the rib portions. An external component mounting portion is formed in the lightening portion.