Compressible Feeder Element for Metal Casting Shrinkage
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Solution Overview
Problem
In metal casting, vertically parted moulding systems face challenges in providing sufficient ferrostatic pressure and volume of liquid metal to the casting, leading to shrinkage defects due to the limitations of standard feeder sleeves and collapsible feeder elements, especially under high pressure and space restrictions.
Innovation Solution
An elongate feeder element with a compressible portion and a non-planar second sidewall region is designed, featuring a stepped collapsible portion with concentric rings and annuli, offset bore axis, and a mounting surface inclined relative to the bore axis, to enhance sand compaction and maintain the feeder sleeve position during moulding, ensuring efficient metal flow and reducing buckling under high pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a standard feeder sleeve is used in vertically parted moulding systems, then the mould structure is simple, but insufficient ferrostatic pressure and volume of liquid metal are provided to the casting
Solution Approach 1:
The feeder element is divided into multiple functional segments: a compressible portion with stepped sidewalls that compact during moulding, a rigid portion that maintains structural integrity, and a mounting surface for the feeder sleeve. This segmentation allows each part to perform its specific function optimally while working together to provide sufficient ferrostatic pressure.
Solution Approach 2:
The invention introduces a non-planar second sidewall region that extends in a direction perpendicular to the bore axis, creating a three-dimensional structure that increases the volume of metal above the bore axis without significantly increasing the footprint on the pattern plate. This dimensional enhancement provides greater ferrostatic pressure head.
2Productivity
If high pressure is applied during moulding to ensure sufficient metal flow, then casting quality improves, but the feeder sleeve may buckle or deform
Solution Approach 1:
The feeder element is segmented into a compressible portion that is intended to deform under pressure and a rigid portion that maintains structural support. This segmentation allows the structure to accommodate high moulding pressures without buckling, as the rigid portion provides a stable framework.
Solution Approach 2:
Different portions of the feeder element have different mechanical properties: the compressible portion with stepped sidewalls is designed to deform locally under pressure to compact sand, while the rigid portion maintains its shape to support the feeder sleeve. This local differentiation of material properties allows the structure to withstand high pressures reliably.
3Reliability
If the volume of metal above the bore axis is increased to improve ferrostatic pressure, then shrinkage defects are reduced, but the space requirements and yield are compromised
Solution Approach 1:
The non-planar second sidewall region extends perpendicular to the bore axis, utilizing vertical space rather than horizontal space. This allows the volume of metal above the bore axis to be increased without significantly increasing the overall footprint of the feeder element on the pattern plate, thereby maintaining yield while improving casting quality.
Solution Approach 2:
The stepped sidewalls and non-planar regions create a compact, multi-faceted geometry that efficiently encloses volume. This curved and angular geometry maximizes the volume of metal above the bore axis within the available space, providing sufficient ferrostatic pressure without excessive overall volume.
4Strength
If a collapsible feeder element is used to ensure good sand compaction, then mould strength improves, but the feeder element may break or deform under high pressure
Solution Approach 1:
The feeder element is segmented into a compressible portion designed to collapse and compact sand, and a rigid portion designed to maintain structural integrity. This segmentation allows the element to provide good sand compaction through controlled collapse while the rigid portion prevents complete breakdown or deformation under high pressure.
Solution Approach 2:
Different regions of the feeder element have different collapse characteristics: the compressible portion with stepped sidewalls is designed to collapse locally to compact sand, while the rigid portion maintains its shape. This local differentiation ensures that compaction occurs where needed without compromising the overall durability of the feeder element.
Data Source
AI summary
An elongate collapsible feeder element for use in metal casting and a feeder system with attached feeder element and feeder sleeve. The feeder element has an A end and an opposite B end measured along the height, and a C end and an opposite D end measured along the length. The A end is for mounting on a mold pattern or swing plate and the opposite B end is for receiving a feeder sleeve. A bore is between the A and B ends defined by a sidewall having a stepped collapsible portion. The feeder element is compressible in use to reduce the distance between the A and B ends. The bore is offset from the centre of the feeder element along the length towards the C end and a second sidewall region is non-planar, contiguous with a third sidewall region and located between the bore axis and the D end.