Casting Mold Base with Pressure Boosting Unit
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Solution Overview
Problem
Casting die assemblies with flat attachment surfaces are prone to deformation, leading to gaps and metal spits during the casting process, resulting in burrs on the cast product, and are costly and heavy due to the need for precise recesses in traditional designs.
Innovation Solution
A casting die assembly with a plate-shaped base and a pressure boosting unit that increases pressure on the cavity die, minimizing deformation and eliminating gaps, while reducing manufacturing costs and weight by eliminating the need for recesses in the dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the base is formed into a plate shape to reduce weight, then the weight is reduced, but the rigidity is reduced and deformation occurs easily
Solution Approach 1:
The base is segmented into a plate-shaped base and a separate support structure. The support is positioned to contact the rear surface of the cavity die, providing localized reinforcement exactly where needed to prevent deformation during die closure, while the rest of the base remains lightweight plate structure.
Solution Approach 2:
The invention creates a composite structure combining the plate-shaped base with a support element. This composite arrangement allows the base to maintain low weight while the support provides the necessary rigidity and strength to prevent cavity die deformation when the dies are combined.
2Ease of manufacture
If the base is formed into a plate shape to reduce manufacturing cost, then the manufacturing cost is reduced, but the rigidity is reduced and deformation occurs easily
Solution Approach 1:
The base structure is segmented into a simple plate-shaped base and a separate support component. This segmentation allows the base to be manufactured easily as a simple plate, reducing manufacturing cost, while the support is added specifically to provide the necessary rigidity without complicating the base manufacturing process.
3Reliability
If pressure is increased on the cavity die to prevent deformation, then deformation is prevented, but the complexity of the device increases
Solution Approach 1:
The support structure is designed to automatically provide the necessary pressure to the cavity die when the first die and second die are combined. The support acts as a self-regulating element that increases pressure precisely when and where needed, without requiring external control systems or complex mechanisms.
Solution Approach 2:
The support serves as an intermediary element between the plate-shaped base and the cavity die. It mediates the force transmission, concentrating and directing pressure to the cavity die to prevent deformation, while isolating the complexity from the overall system design.
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
The solution effectively minimizes burrs on the cast product, reduces manufacturing costs, and enhances the versatility of the casting die assembly by maintaining intimate contact between the cavity dies and preventing metal spits, while maintaining high dimensional accuracy.
Implementation Method 1
the deformable portion is configured to be elastically deformed to become convex away from the cavity die when the first die and the second die are combined with each other
Data Source
AI summary
Provided is a highly versatile casting mold in which weight and manufacturing cost can be reduced, and whereby flash can be suppressed. A plate-shaped base part having a flat attachment face to which a back face of a fixed-cavity mold is attached is provided to a fixed mold constituting a casting mold. A portion of the base part in contact with the back face of the fixed-cavity mold has an attachment part body for supporting the fixed-cavity mold, and a pressure increasing means for increasing the pressure imparted to the fixed-cavity mold via the attachment part body in a state in which the mold is closed.