Hybrid Axle Casting via Sand Core Coupling
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Solution Overview
Problem
Existing methods for producing hybrid components, particularly in the motor vehicle sector, lack sufficient freedom of shaping and efficient connection methods for hollow cast components, especially when combining different materials like light metals and conventional steel.
Innovation Solution
A method involving a sand core as a carrier for the coupling component, which is cast around with a casting material, allowing for precise positioning and form-fitting coupling, followed by removal of the sand core after solidification, enabling the production of hybrid components like axle subframes with enhanced geometric accuracy and material combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional casting methods are used for hollow components, then manufacturing simplicity is maintained, but freedom of shaping and connection quality are limited
Solution Approach 1:
The casting process is segmented into two distinct phases: first forming the hollow component shell, then separately introducing and positioning the coupling component within the hollow space. This segmentation allows each part to be optimized independently while achieving complex final geometries that would be impossible with traditional single-step casting.
Solution Approach 2:
The coupling component is preliminarily positioned and secured within the hollow component before the final casting material is introduced. This preliminary action ensures precise positioning and proper orientation of the coupling component, enabling complex shapes and improved connection quality while maintaining manufacturing feasibility.
2Adaptability or versatility
If different materials are combined in hybrid components, then functional versatility is improved, but connection reliability and joining difficulty worsen
Solution Approach 1:
A coupling component serves as an intermediary element between different materials (e.g., aluminum hollow component and steel reinforcement). This coupling component is specifically designed to interface with both materials, providing reliable mechanical connections while accommodating their different properties. The coupling component may include threaded portions, flanges, or other connection features that bridge the dissimilar materials effectively.
Solution Approach 2:
The hybrid component combines different materials (such as aluminum alloy for the hollow component and steel for the coupling component or reinforcement elements) to achieve functional versatility. The casting process integrates these different materials into a unified structure, leveraging the advantages of each material while ensuring reliable connections through the specially designed coupling component.
3Adaptability or versatility
If coupling components are positioned after casting, then flexibility is improved, but positioning precision and connection quality worsen
Solution Approach 1:
The coupling component is preliminarily positioned and secured within the hollow component before the final casting material is introduced. This preliminary positioning action ensures high positioning precision, as the coupling component can be accurately located and fixed in the desired position. The subsequent casting process then locks this position in place, maintaining both precision and flexibility.
Solution Approach 2:
The coupling component is nested within the hollow component during the casting process. This nesting arrangement allows the coupling component to be precisely positioned within the hollow space, with the casting material surrounding and securing it in place. The nested structure ensures accurate positioning while maintaining the flexibility to use different coupling component designs.
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 method provides greater freedom of shaping and improved connection quality for hybrid components, allowing for precise positioning and efficient production of hollow cast components with enhanced geometric accuracy and the ability to combine different materials effectively.
Implementation Method 1
after the casting material has solidified the sand core is shaken out
Data Source
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AI summary
The present invention relates to a method for producing a hybrid component, in particular an axle component for a motor vehicle, formed from a cast component and a coupling component, wherein the hybrid component is produced by a casting process with a sand core 7, which is characterized in that the coupling component is positioned on the sand core 7 as a support and is overmolded with a casting material, wherein after solidification of the casting material the sand core 7 is shaken out.