Permanent Mold for Crankcase Casting with Segmented Insert Design

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Solution Overview

Problem

Permanent mold casting processes for internal combustion engine crankcases are limited by the need for draft angles, restricting design freedom and weight savings opportunities.

Innovation Solution

A permanent mold system comprising a metallic base plate with first mold portions and second mold portions made of a non-metallic material, allowing for the formation of a crank chamber with a bearing seat and channel, which includes protrusions and recesses for enhanced geometry and reinforcement, and can be positioned securely using form-fit elements and connecting webs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a permanent mold is used for casting crankcases, then the casting process is reusable and efficient, but the need for draft angles restricts design freedom

Engineering Contradiction:

Improvereusability of permanent moldVSAvoiddesign freedom

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The permanent mold is divided into a base plate with first mold portions and separate second mold portions made of mold material. The second mold portions can be arranged on the first mold portions to form complex geometries without draft angle restrictions, while the base plate remains reusable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the mold have different properties: the base plate provides structural support and reusability, while the second mold portions made of mold material provide the necessary geometric flexibility and complex shapes in specific local areas where draft angles would otherwise be required.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If complex geometries are achieved through mechanical machining, then design freedom is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvedesign freedomVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The complex geometries are pre-formed in the second mold portions before the casting process. This preliminary formation of bearing seats, channels, and other features eliminates the need for subsequent mechanical machining operations, reducing manufacturing complexity while maintaining design freedom.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If draft angles are used in permanent mold design, then ease of mold removal is improved, but geometric precision and weight optimization are compromised

Engineering Contradiction:

Improveease of mold removalVSAvoidgeometric precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The second mold portions are designed to be removable from the base plate after casting. This extraction of the geometric-forming elements allows for precise bearing seats and channels to be created without draft angles, while still enabling easy removal of the mold sections after the casting process is complete.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11219941B2Ingot mold and process for manufacturing a crankcase

Publication Date: 2022.01.11 BAYERISCHE MOTOREN WERKE AG

AI summary

A permanent mold has a base made of metal. The base has a plurality of first mold portions, which are mutually spaced along a longitudinal axis and which are designed to shape a bearing tunnel of a crankcase. Second mold portions are arranged on the first mold portions and consist of a mold material.