Casting Assembly Core Body Hollow Cavity Parameter
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Solution Overview
Problem
Casting processes face challenges with thermal property mismatches and internal stresses due to varying thicknesses in casting assemblies, leading to irregularities and defects in cast parts, especially when forming parts with large internal cavities and cooling channels.
Innovation Solution
A casting assembly design featuring a core body with a hollow cavity and a shell body, where the core body and shell body have specific thickness ratios and geometric profiles to match thermal properties, reducing internal stresses and improving casting accuracy through the use of a hollow cavity parameter (HCP) that balances body area, hollow area, minimum core thickness, and minimum shell thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core body and shell body have uniform thickness, then the manufacturing process is simpler, but thermal property mismatches cause internal stresses and deformations
Solution Approach 1:
The patent applies local quality by varying the thickness of the core body and shell body at different locations. The core body has a first thickness in a first region and a second thickness in a second region, with the second thickness being greater than the first. This non-uniform thickness distribution is designed to match thermal properties and reduce internal stresses and deformations during the casting process, particularly when forming parts with large internal cavities and cooling channels.
2Reliability
If the core body thickness is increased to reduce internal stresses, then thermal property matching improves, but the core removal becomes more difficult
Solution Approach 1:
The patent implements local quality through spatially varying thickness in the core body. The core body has different thicknesses in different regions (first thickness in first region, second thickness in second region). This allows the core to have sufficient thickness in certain areas for thermal property matching and stress reduction, while maintaining easier removal characteristics in other regions where the thickness is reduced.
Solution Approach 2:
The core body is segmented into different thickness zones rather than being uniformly thick. This segmentation allows different portions of the core to serve different functions: some regions provide thermal stability and stress reduction, while other regions facilitate easier removal after casting.
3Adaptability or versatility
If the casting assembly forms parts with large internal cavities, then the part functionality improves, but thermal property mismatches and internal stresses increase
Solution Approach 1:
The patent applies local quality by designing the core body with non-uniform thickness distribution specifically tailored for forming parts with large internal cavities. The first and second thicknesses of the core body are optimized for different regions to match thermal properties and reduce internal stresses, enabling the casting of complex geometries with large cavities and cooling channels while maintaining reliability.
Data Source
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AI summary
A casting assembly (10, 110, 210) includes a core body (20, 120A, 120B, 120C, 220) extending along an axial direction (A) between a first end and a second end, the core body having a core interior surface (22, 122A, 122B, 122C, 222A, 222B) and a core exterior surface (24, 124A, 124B, 124C, 224), with the core exterior surface shaping a part surface of a cast part. The core interior surface at least partially bounds a hollow cavity (25, 125A, 125B, 225A, 225B). The casting assembly also includes a shell body (30, 130, 230) extending along the axial direction and having a first shell surface (34, 134, 234) and a second shell surface (32, 132, 232), with at least a portion of the second shell surface facing the exterior surface of the core body.