Casting Method Using Dynamic Mold Speed Control
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Solution Overview
Problem
Conventional casting methods with gating systems reduce yield rates and increase production costs due to the need for post-mold removal processes, which hinder productivity and efficiency.
Innovation Solution
A casting method and press system that control the speed of the upper mold's overlap with the lower mold, using a detection system to stop the pressing process when predetermined conditions are met, ensuring uniform temperature distribution and preventing excessive pressure, thus producing high-quality castings without a gating system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gating system is provided to control molten metal flow, then casting quality is improved, but yield rate decreases and production cost increases
Solution Approach 1:
The invention removes the gating system entirely from the mold structure. The upper and lower molds directly form the casting cavity without any additional gating passages, eliminating the need for post-mold gating system removal and improving yield rate while maintaining casting quality through direct cavity formation.
Solution Approach 2:
The gating system is eliminated by preliminarily forming the complete casting cavity shape through the upper and lower mold design itself, rather than requiring separate gating passages to transport and distribute molten metal. This preliminary cavity formation eliminates subsequent gating removal steps.
2Manufacturing precision
If a gating system is provided to control molten metal flow, then casting quality is improved, but production cost increases
Solution Approach 1:
The gating system is completely removed from the mold structure, eliminating the additional manufacturing steps and costs associated with creating, assembling, and subsequently removing gating components. The mold design directly forms the final casting cavity without requiring separate gating system fabrication.
3Productivity
If the upper mold overlaps the lower mold quickly to improve productivity, then production time is reduced, but temperature distribution uniformity and pressing control deteriorate
Solution Approach 1:
The pressing process uses dynamic speed control with multiple stages: an initial fast pressing stage to quickly close the mold and improve productivity, followed by a slower pressing stage to ensure uniform temperature distribution and proper density. This dynamic adjustment of pressing speed resolves the contradiction between production time and quality.
Solution Approach 2:
The pressing operation is divided into periodic stages with different speeds - a first pressing period at high speed for efficiency, followed by a second pressing period at lower speed for quality control. This periodic variation in pressing speed achieves both productivity and uniformity requirements.
4Productivity
If the upper mold overlaps the lower mold quickly to improve productivity, then production time is reduced, but pressing control and penetration prevention deteriorate
Solution Approach 1:
The pressing system dynamically adjusts speed based on the process stage - high speed initially for productivity, then transitions to controlled slower pressing for reliable density control and penetration prevention. This dynamic adaptation ensures both efficiency and process reliability.
Solution Approach 2:
The pressing process incorporates feedback control where pressing speed and load are adjusted based on real-time monitoring of mold closure progress and material response. This feedback mechanism prevents excessive pressing and penetration while maintaining efficient production timing.
Data Source
AI summary
A casting method to produce a casting and a press used for the casting method, using a mold which forms a cavity in a shape of a casting, so as to produce a casting by overlapping a lower mold with an upper mold, which molds are molded by a molding method, the casting method comprises the steps of:pouring into the lower mold a quantity of molten metal required to produce a casting;lowering the upper mold at a predetermined first speed until the upper mold reaches a predetermined position just before the upper mold starts contacting a surface of the molten metal;lowering the upper mold at a predetermined second speed after the upper mold is further lowered beyond the predetermined position;detecting and obtaining information on the status of the upper mold which overlaps the lower mold; andstopping the lowering of the upper mold when detecting the information on the status of the upper mold that shows that the predetermined conditions are met.