Dual-Axis Tilting Casting Mold for Complex Geometry Filling
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Solution Overview
Problem
Existing casting machines face challenges in producing high-quality cast products with complex geometries due to issues like porosity, contamination with oxides, and air pockets, particularly when dealing with complex shapes, as they are limited by the radial arrangement of the sprue and lack of flexibility in mold positioning.
Innovation Solution
A casting machine and method that allows the casting mold to be tilted about two axes, enabling movement in three dimensions, which adapts to the shape of the product, prevents air pockets and oxide contamination, and allows for more flexible sprue positioning, using a pivoting device controlled by a sensor and control system to regulate the tilting and melt flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the casting mold is arranged with the sprue positioned radially relative to the filling axis, then the casting machine structure is simple, but the product design is limited and complex shapes cannot be cast with high quality
Solution Approach 1:
The casting mold is made dynamically tiltable about two transverse axes during the filling process, allowing the mold orientation to change dynamically to adapt to complex product geometries while maintaining a relatively simple radial sprue arrangement
Solution Approach 2:
The system adds rotational degrees of freedom by enabling tilting about two transverse axes, transforming the mold positioning from a single fixed orientation to multi-dimensional adjustable orientation, thereby achieving complex shape casting capability without complicating the fundamental radial sprue structure
2Device complexity
If the melt is poured into the casting mold without tilting about two axes, then the filling process is simple, but air pockets, cold running, and oxide contamination occur
Solution Approach 1:
The casting mold is dynamically tilted about two transverse axes during melt filling, creating dynamic motion that directs the melt flow to completely fill complex cavities while preventing air pockets, cold running, and oxide contamination
Solution Approach 2:
The system changes the motion parameters of the casting mold by introducing dual-axis tilting, which modifies the melt flow characteristics and filling pattern to achieve complete cavity filling and eliminate casting defects
3Device complexity
If the casting mold is tilted about one axis only, then the mold can be moved in one plane, but complex product shapes cannot be filled completely and evenly
Solution Approach 1:
The system adds a second transverse axis for tilting, expanding the mold movement from one plane to three-dimensional space, enabling complete and even filling of complex product geometries while keeping the pivoting device structure manageable
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
This approach enables the production of high-quality cast products with complex geometries by ensuring complete and even filling of the mold, reducing waste, and allowing for more efficient use of mold space, while preventing defects like air pockets and oxide contamination.
Implementation Method 1
the casting mold is moved by means of a pivoting device of the casting machine during filling of a melt into the casting mold and is tilted about a first axis, wherein the casting mold is tilted about a second axis by means of the pivoting device during filling
Data Source
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AI summary
The invention relates to a method for pouring a melt into a mold and a casting machine, wherein at least one mold (21) is mounted on a frame (24) of a casting machine (20), wherein the mold is moved by means of a swiveling device (25) of the casting machine during the filling of a melt into the mold and is tilted about a first axis (26), wherein the mold is tilted about a second axis (27) by means of the swiveling device during the filling, wherein the first axis is designed to extend transversely relative to the second axis.