Crusher Core Netlike Fabric Frame for Casting Residue Removal
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Solution Overview
Problem
The existing crusher cores in foundry technology often leave metal residues on cast pieces, requiring additional cleaning efforts after casting, and existing solutions do not effectively manage the tension and stability of net-like fabrics during the casting process.
Innovation Solution
A disc-shaped crusher core with a net-like fabric held by an annular frame made of heat-resistant material, featuring a stepped offset and secure anchoring, which positions the breaking point on the cast surface and ensures reliable tension and stability of the fabric, preventing residue entrapment and minimizing cleaning efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional crusher core with a simple opening is used, then the structure is simple and easy to manufacture, but metal residues remain on the casting surface requiring additional cleaning
Solution Approach 1:
The crusher core is segmented into multiple functional zones: a net-like fabric layer for breaking metal residues, a frame structure for support, and a stepped offset configuration. This segmentation allows each component to perform its specific function effectively, resulting in cleaner casting surfaces.
Solution Approach 2:
The net-like fabric acts as an intermediary element between the molten metal flow and the casting surface. It intercepts and breaks metal residues before they can adhere to the casting, thereby improving surface quality without requiring direct contact between the crusher core and the casting surface.
2Reliability
If the net-like fabric is positioned at the upper end of the side wall, then the structure is simpler, but the fabric lacks sufficient tension and stability during casting
Solution Approach 1:
The frame structure introduces a vertical dimension through the stepped offset, creating two distinct levels: an upper level for anchoring the frame to the crusher core body and a lower level for positioning the net-like fabric at the breaking point. This dimensional arrangement provides both tension and stability to the fabric.
Solution Approach 2:
The stepped offset changes the positional parameter of the net-like fabric from the upper end to the lower end of the side wall. This parameter change ensures the fabric is positioned at the optimal location for breaking metal residues while maintaining sufficient tension through the frame structure.
3Manufacturing precision
If the net-like fabric is not properly tensioned, then the structure is simpler, but metal residues become entrapped and require additional cleaning
Solution Approach 1:
The frame structure with stepped offset preliminarily tensions the net-like fabric before the casting process begins. This preliminary action ensures the fabric is properly positioned and tensioned to effectively break metal residues, preventing entrapment and reducing the need for additional cleaning operations.
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 significantly reduces metal residues on cast pieces, simplifies cleaning, and ensures the fabric's stability and tension, preventing residue entrapment and maintaining the integrity of the casting process without producing harmful combustion gases.
Implementation Method 1
a breaker core with a netlike tissue which penetrates its opening... the net-like fabric is located in the area of the underside of the crushing core facing the casting pattern, and when the feeder with crushing core is formed in the casting mold, is positioned directly on the surface of the casting formed by the pouring process
Implementation Method 2
a ring-shaped frame made of a heat-resistant material with the net-like fabric stretched therein is fixed in the crushing core
Data Source
Figure 1~5
Figure 6
AI summary
A crusher core (10) for use in a foundry, wherein the disc-shaped crusher core (12) having a passage opening (11) for the liquid metal can be fixed to the underside of a feeder to be attached to the casting pattern, with a net-like fabric (15) penetrating its passage opening (11), is characterized in that an annular frame (12) made of a heat-resistant material is fixed in the crusher core (10), with a net-like fabric (15) made of a refractory material stretched therein, which spans the passage opening (11) of the crusher core (10), wherein the frame (12) is fixed to the body of the disc-shaped crusher core (10) with an outer side wall (17), and the plane of the net-like fabric (15) stretched in the frame (12) is fixed with a step-like offset to the upper end of the side wall (17) facing the feeder. is,so that the net-like fabric (15) is located in the area of the underside of the crushing core (10) facing the casting pattern and, when the riser with crushing core (10) is molded into the casting mold, is positioned directly on the surface of the casting formed by the pouring process.