Ground Engaging Tool Throat Profile for Riser-Free Casting
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Solution Overview
Problem
The existing manufacturing process for ground engaging tools, such as shrouds, is limited by low productivity, high rework and scrap rates due to the use of side risers, which also increases the risk of porosity and cracking.
Innovation Solution
A new geometric profile for shrouds with a throat portion thickness ratio of 1.1 to 1.2 compared to the leg thickness, and beveled portions to alleviate flow hesitation, allowing for a mold design with increased cavities and a single rear gate, reducing porosity risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If side risers are used in the casting process, then the risk of porosity is reduced, but productivity decreases and manufacturing complexity increases
Solution Approach 1:
The patent removes side risers from the casting process entirely, replacing them with a modified geometric profile that inherently prevents porosity without requiring additional riser structures. This extraction of the problematic component directly increases productivity while maintaining reliability through the optimized throat portion geometry.
Solution Approach 2:
The patent changes the geometric parameters of the throat portion, specifically setting the thickness ratio between the throat portion and leg to 1.1-1.2. This parameter modification alters the casting flow dynamics to eliminate porosity formation, replacing the need for side risers and thereby improving productivity.
2Productivity
If side risers are eliminated to increase productivity, then manufacturing complexity decreases, but porosity risk increases
Solution Approach 1:
The patent modifies the throat portion thickness parameter to create a ratio of 1.1-1.2 relative to the leg thickness. This specific geometric parameter change optimizes metal flow during casting, preventing porosity formation without requiring side risers, thus achieving both high productivity and reliability.
Solution Approach 2:
The patent applies a localized geometric modification specifically to the throat portion area where porosity is most likely to form. By concentrating the thickness increase in this critical zone rather than uniformly throughout the component, the design prevents porosity locally while maintaining overall manufacturing efficiency.
3Reliability
If the throat portion thickness ratio is increased to 1.1-1.2, then porosity is reduced, but material usage increases
Solution Approach 1:
The patent concentrates the increased material thickness specifically in the throat portion where it is most needed to prevent porosity, rather than uniformly increasing thickness throughout the entire component. This localized approach minimizes overall material usage while achieving the porosity reduction goal.
Data Source
AI summary
A wear member includes a first leg, a second leg, and a throat portion connecting the first leg to the second leg. The first leg defines a first leg thickness, and the throat portion defines a throat portion thickness disposed adjacent to the first leg thickness. A ratio of the throat portion thickness to the first leg thickness ranges from 1.1 to 1.2.