Die Cast Orifices with Radially Projecting Appendages
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Solution Overview
Problem
Existing die casting methods struggle to create machine threaded holes efficiently, as conventional core pins are prone to breakage and cannot pre-cast core holes for mounting threads, limiting their durability and application.
Innovation Solution
Die cast orifices with a round central portion and radially projecting portions are created using die core pins with appendages, which increase the section modulus and prevent breakage, allowing for the use of self-threading screws and extending the core pins' lifespan, enabling the creation of pre-cast threaded holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional core pins are used in die casting, then the casting process can be performed, but the core pins are prone to breakage and cannot support radially projecting slots
Solution Approach 1:
The core pin is segmented into a central portion and multiple radially projecting appendages. This segmentation allows the appendages to form the desired slot or channel shapes in the die cast orifice while the central portion provides structural support, preventing breakage during the die casting process.
Solution Approach 2:
The core pin design adds radial dimensionality by projecting appendages outward from the central portion. This dimensional change enables the formation of radially projecting slots and channels in the orifice while maintaining the structural integrity of the core pin through the central portion's support.
2Ease of manufacture
If conventional die casting methods are used, then housings can be produced, but pre-cast core holes with threaded mounting capabilities cannot be created
Solution Approach 1:
The core pin appendages are designed with predetermined geometries that directly form the desired slot or channel shapes in the die cast orifice. This preliminary action eliminates the need for subsequent machining operations to create threaded mounting capabilities, as the appendages themselves define the final orifice structure.
Solution Approach 2:
The core pin serves multiple functions: it forms the central portion of the orifice, creates radially projecting slots or channels through its appendages, and enables subsequent threaded mounting operations. This multi-functionality integrates what would traditionally require separate operations into a single die casting process.
3Ease of manufacture
If radially projecting appendages are added to core pins, then self-threading apertures can be created, but stress concentrations may increase
Solution Approach 1:
The core pin central portion is designed with a rounded or spheroidal geometry, and the appendages are smoothly connected to it. This curvature eliminates sharp corners and stress concentration points, allowing the core pin to withstand the high stresses of the die casting process while maintaining the ability to form self-threading apertures.
Solution Approach 2:
The dimensions, shapes, and distributions of the radially projecting appendages are optimized to balance two competing requirements: creating effective self-threading apertures while minimizing stress concentrations. By adjusting parameters such as appendage thickness, length, and radial distance from the center, the design achieves both manufacturing capability and structural integrity.
Data Source
AI summary
The disclosure relates to an industrial die cast component comprising a first side, a second side, said second side having a second side surface, an aperture opening at said second side and through said second side surface, said aperture having a respective first arcuate surface bounding a central portion of the aperture and said aperture having a respective second surface bounding a projecting portion of the aperture, said projecting portion having a closed end and an open end, said open end forming a gap in said first arcuate surface and said projecting portion closed end extending radially beyond said first arcuate surface, wherein said first arcuate surface is constructed to be engaged by a fastener.