Casting Mold Filling Port Oblique Angle
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Solution Overview
Problem
In the die casting method, the high-speed injection of molten metal into a casting mold can cause deformation of structures like pipes and heaters due to perpendicular impact, leading to potential damage and quality issues in the cast part.
Innovation Solution
The casting mold is designed with filling ports that intersect the surface of the structure at a non-perpendicular contact angle, allowing the molten metal to flow along the surface and minimizing the load on the structure, thereby preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molten metal is injected at high speed into the casting mold, then filling efficiency is improved, but the structure such as pipe may be deformed due to perpendicular impact
Solution Approach 1:
The filling port is designed to approach the internal space from a direction that is not perpendicular to the structure surface, but at an oblique angle. This dimensional change in the filling approach prevents direct perpendicular impact on the structure while maintaining efficient molten metal flow into the casting mold cavity.
Solution Approach 2:
The filling port is specifically positioned and angled relative to the structure location within the mold. By optimizing the local filling direction at the specific location where the structure exists, the design allows high-speed injection overall while creating a localized flow path that avoids perpendicular impact on the structure.
2Speed
If molten metal flows perpendicular to the structure surface, then filling speed is improved, but the load on the structure increases causing deformation
Solution Approach 1:
The filling port is oriented at an oblique angle rather than perpendicular to the structure surface. This changes the direction of the molten metal flow from a straight perpendicular path to an angled path that flows along the structure surface, reducing the normal force component while maintaining flow speed.
Solution Approach 2:
The oblique filling angle converts what would be a harmful perpendicular impact force into a beneficial flow pattern where the molten metal flows along the structure surface. The force that would otherwise deform the structure is redirected to follow the contour of the structure, reducing stress while maintaining filling efficiency.
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 ensures that the molten metal flows smoothly into the internal space without causing deformation to the structures, ensuring complete filling and preventing the formation of cavities, which enhances the quality of the cast part and reduces waste material.
Implementation Method 1
the molten metal flow flowing into the internal space from the filling port flows along the surface of the structure
Data Source
AI summary
The casting mold is provided with: the molding wall portion forming the internal space; and the filling ports that open to the molding wall portion and that allow the molten metal to flow into the internal space. In this configuration the channel center lines of the filling ports intersect the surface of the heater at the non-perpendicular contact angle.