Diecasting Tool Bush Insert for Cooled Motor Housing
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Solution Overview
Problem
Existing diecasting tools are unable to produce cooled motor housings with thin-walled, concentrically extending walls without additional process steps, and there is no knowledge on producing cooled motor housings using diecasting.
Innovation Solution
A diecasting tool with mould halves featuring a cylindrically extending annular gap and a movable mould half, where a thin-walled bush insert is arranged to form the inner lateral surface, sealed by chamfers to prevent casting material intrusion, allowing for one-piece production of cooled motor housings with concentric cylindrical walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solid parts are cast in using existing diecasting tools, then the casting process is simple, but thin-walled concentric cylindrical walls cannot be produced without additional process steps
Solution Approach 1:
The diecasting tool is divided into multiple components including a stationary mould half, a movable mould half, and a bush insert. The bush insert is further segmented into a body portion and a base portion, allowing each component to perform its specific function independently while contributing to the overall precision of thin-walled concentric cylindrical wall production
Solution Approach 2:
The bush insert acts as an intermediary element between the mould halves and the casting material. It provides a precise geometric form for the inner lateral surface and cooling channel, enabling the production of thin-walled concentric cylindrical walls without requiring complex tooling or additional process steps
2Manufacturing precision
If a bush insert is used to form the inner lateral surface, then thin-walled concentric cylindrical walls can be produced, but the annular gap must be sealed to prevent casting material intrusion
Solution Approach 1:
The base portion of the bush insert is designed with sealing surfaces that preliminarily seal the annular gap between the bush body and the mould half before the casting process begins. This preliminary sealing action prevents casting material from intruding into the annular gap during injection, eliminating the need for complex sealing mechanisms or additional sealing steps
Solution Approach 2:
The sealing function is localized to specific regions of the bush insert, namely the base portion and its sealing surfaces. This localized sealing approach ensures that only the critical annular gap is sealed, while the rest of the bush insert maintains its function of forming the inner lateral surface and cooling channel
3Reliability
If the bush is properly centred and sealed, then casting quality is improved, but the diecasting tool requires precise positioning mechanisms
Solution Approach 1:
The bush insert is designed with an asymmetric structure where the base portion has a larger diameter than the body portion. This asymmetric geometry provides stable positioning and centring of the bush within the annular gap, ensuring reliable casting quality without requiring complex positioning mechanisms. The chamfered edges further assist in precise positioning during assembly
Solution Approach 2:
The bush insert is nested within the annular gap formed by the stationary and movable mould halves. This nested arrangement, combined with the asymmetric base portion, ensures automatic centring and stable positioning of the bush during the casting process, improving reliability while minimizing the need for additional positioning mechanisms
Data Source
AI summary
A diecasting tool has an insert for producing a cooled motor housing. The diecasting tool has mould halves including: a stationary mould half; and movable mould half. One of the mould halves has a cylindrically extending annular gap having a central axis. The moveable mould half is arranged so as to be movable parallel to the central axis. The insert is arranged in the cylindrically extending annular gap. The insert is a bush. One end of the bush projects into a mould cavity, which is formed by the stationary mould half and the movable mould half, and is at least partially surrounded in a form-fitting manner by the casting material in a state when the casting material is cast.