Casting Core Geometry for Complex Connecting Fluid Passages
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Solution Overview
Problem
The manufacturing of cast engine components with complex connecting fluid passages is challenging due to the difficulty in creating the required complex geometry, leading to unpredictable success in achieving desired flow characteristics and material properties, and the iterative process is time-consuming and costly.
Innovation Solution
The use of a casting core with a flexible geometry factor (FGF) to ensure the creation of a connecting fluid passage that meets flow requirements, allowing for the production of cast engine components with complex geometries through a casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting methods are used to create complex connecting fluid passages, then the manufacturing process can be performed with conventional techniques, but the success in achieving desired flow characteristics and material properties is unpredictable and requires time-consuming iterative processes
Solution Approach 1:
The patent applies parameter changes by introducing the Flexible Geometry Factor (FGF) as a new design parameter that directly controls the geometry of connecting fluid passages. By varying FGF values, designers can systematically adjust passage dimensions, curvature, and connectivity to achieve target flow characteristics without iterative trial-and-error. This transforms the unpredictable traditional process into a parameter-driven deterministic approach.
Solution Approach 2:
The patent replaces the mechanical iterative design process with a computational model that uses the FGF parameter to predict flow characteristics. Instead of physically prototyping and testing multiple iterations, the system substitutes mechanical experimentation with mathematical calculations and simulations that directly compute the relationship between FGF values and flow properties, dramatically reducing development time.
2Manufacturing precision
If complex geometries are created in cast engine components, then the fluid passages can achieve desired flow characteristics, but the manufacturing difficulty and cost increase significantly
Solution Approach 1:
The patent transforms complex geometric design into a parameter optimization problem by using FGF as a control variable. Instead of directly designing complex 3D geometries which are difficult to manufacture, the system adjusts the FGF parameter within a defined range (0.1 to 10.0) to achieve desired flow characteristics. This simplifies the manufacturing process by reducing geometric complexity while maintaining flow performance through parameter tuning rather than geometric complexity.
Solution Approach 2:
The patent applies local quality by allowing different regions of the casting to have different geometric characteristics controlled by the FGF parameter. The connecting fluid passages can have varying curvature, diameter, and connectivity in different locations based on local flow requirements, while the overall geometry remains within manufacturable limits. This enables optimized flow characteristics without requiring uniformly complex geometry throughout the component.
3Reliability
If iterative design processes are used to achieve desired material properties and flow characteristics, then the final product can meet specifications, but the development time and cost increase
Solution Approach 1:
The patent applies preliminary action by establishing the FGF parameter range (0.1 to 10.0) and the relationship between FGF values and flow characteristics before actual manufacturing begins. The computational model predicts material properties and flow characteristics in advance, allowing designers to select appropriate FGF values prior to casting. This eliminates the need for post-manufacturing iterations and ensures specifications are met from the first production run.
Solution Approach 2:
The patent implements feedback through the computational model that calculates the relationship between FGF parameters and flow characteristics. The system provides immediate feedback on how changes in FGF affect material properties and flow performance, allowing real-time optimization of design parameters without physical prototyping. This closed-loop approach ensures specifications are achieved while minimizing development time.
Data Source
AI summary
A casting core is used in manufacture of a cast engine component. The cast engine component has a first area, a second area, a fluid passage wall separating the first area and the second area, and a connecting fluid passage extending through the fluid passage wall and interconnecting the first area and the second area. The casting core has a first core and a second core. The second core defines a first leg and a second leg of the connecting fluid passage. The second core defines a turn of the connecting fluid passage. At least a portion of the first core and an entirety of the second core is provided within a geometric boundary defined by a set of geometric characteristics of the first core and the second core within the geometric boundary.