Casting Core Insert Prevents Parting Plane Burrs
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Solution Overview
Problem
The formation of core dividing burrs on casting cores, which can lead to stress peaks and potential failure in cast parts, especially in delicately shaped components like cylinder heads, is a challenge due to the unavoidable notch-like depression caused by the parting plane, making it difficult to design these parts to withstand practical stresses.
Innovation Solution
A method involving the pre-fabrication of a casting core insert from molding material, which is perfectly shaped to match the critical side surface section of the casting core, is positioned within the mold cavity to block the parting plane intersection, preventing the formation of burrs by creating a shape-fit and material-fit connection with the subsequent casting core molding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a multi-part core box is used to produce casting cores, then the core box can be opened to remove the finished casting core, but core dividing burrs are formed at the parting plane intersection with the mold cavity
Solution Approach 1:
A casting core insert is pre-formed in a separate mold cavity before the main casting core is produced. This insert is then positioned in the mold cavity to cover the mouth region where the parting plane intersects the mold cavity, preventing burr formation during subsequent core shooting operations
Solution Approach 2:
The casting core insert acts as an intermediary element that blocks the harmful interaction between the molding material and the parting plane intersection. By positioning the insert to cover the mouth region, it mediates between the core box structure and the molding material flow, preventing burr formation
2Device complexity
If the parting plane runs through the mold cavity, then the core box can be separated for core removal, but notch-like depressions are formed on the casting core side surface
Solution Approach 1:
The casting core insert is pre-formed with a shape that matches the critical side surface section, and is positioned in advance to cover the region where the parting plane would create a notch-like depression. This preliminary positioning prevents the depression from forming during core shooting
3Productivity
If molding material is shot into the mold cavity under pressure, then the casting core is formed efficiently, but molding material penetrates into the separating join between core box parts
Solution Approach 1:
The casting core insert serves as a barrier that intercepts the molding material flow before it can penetrate into the separating join. By positioning the insert to cover the mouth region, it prevents the high-pressure molding material from entering the gap between core box parts, eliminating burr formation while maintaining efficient core shooting
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 approach ensures a burr-free transition region on the casting core, enhancing the structural integrity and reducing the risk of crack formation, allowing for the production of cast parts with minimal wall thicknesses that can withstand operational stresses without impairment.
Implementation Method 1
solidifying the casting core molding material that was introduced into the mold cavity, thereby forming a shape-fit and/or material-fit connection between the casting core molding material that was introduced into the mold cavity and the casting core insert
Data Source
AI summary
A method for producing a casting core including: producing a casting core insert having a side surface section that is equal to a corresponding section of a side surface of the casting core from a casting core molding material; positioning the casting core insert in a mold cavity of a core box with the side surface section of the casting core insert in the place of the corresponding section of the side surface of the finished casting core, wherein a parting plane intersects the side surface section; introducing a casting core molding material into the mold cavity of the core box to form the remainder of the casting core, wherein the introduced casting core molding material comes into contact with the casting core insert; and solidifying the casting core molding material, thereby forming a shape-fit and/or material-fit connection between the introduced casting core molding material and the casting core insert.