Impact Casting Device for Voids Elimination
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Solution Overview
Problem
Current metal casting methods, such as static casting, result in uncontrolled porosity due to trapped gases, with no known method to control the placement of voids in nonmagnetic metals.
Innovation Solution
A method and apparatus utilizing gravity to eliminate voids by repeatedly dropping a die containing molten metal onto an impact surface, leveraging high impact forces to separate gases and dross from the metal, allowing for controlled removal of voids through repeated impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If static casting is used, then the casting process is simple, but uncontrolled porosity occurs due to trapped gases
Solution Approach 1:
The patent applies dynamics by converting the static casting process into a dynamic one. The die is repeatedly raised and dropped, creating dynamic impact forces that propel molten metal upward against gravity. This dynamic action forces gases and dross to the top of the cavity where they can be removed, while maintaining relative simplicity of the casting process itself.
Solution Approach 2:
The patent changes the physical parameters of the casting process by introducing vertical motion and impact forces. The die is raised to a predetermined height and dropped repeatedly, changing the velocity, acceleration, and force parameters during metal solidification. This parameter change enables gas separation without complex additional equipment.
2Manufacturing precision
If repeated dropping of the die is performed, then voids are eliminated effectively, but the device complexity increases
Solution Approach 1:
The patent employs periodic action through repeated cycles of raising and dropping the die. This periodic impact action creates alternating forces that continuously propel molten metal upward, ensuring thorough gas and dross separation. The cyclic nature of the process achieves complete void elimination while using a relatively simple mechanical lifting and dropping mechanism.
3Productivity
If gravity-based impact method is used, then productivity increases, but energy consumption increases due to repeated lifting
Solution Approach 1:
The patent replaces complex mechanical gas removal systems with a gravity-based impact mechanism. Instead of using sophisticated gas extraction equipment or high-energy processing methods, the invention uses simple gravitational force applied through repeated die dropping. This substitution achieves effective void elimination with relatively low energy input, as gravity provides the driving force free of charge.
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 effectively eliminates voids, producing castings with densities comparable to forgings, enhancing productivity and cost-effectiveness compared to traditional methods like centrifugal casting.
Implementation Method 1
employing gravity to eliminate voids
Implementation Method 2
The average force of the impact is very high and forces the molten metal downwards while the lighter weight gases and dross are forced upwards
Implementation Method 3
the lighter weight gases and dross are forced upwards
Data Source
AI summary
A method of removing voids from a casting is disclosed including the steps of introducing molten metal into a die, providing an impact surface and dropping the die containing the molten metal at least once from a predetermined height to strike the impact surface. A device for removing voids from a casting includes a base, a drive means operably coupled to at least one cam, and a guide configured to receive a die, wherein the at least one cam is positioned on the base to contact a die placed on the guide, and wherein rotation of the at least one cam is operable to raise and subsequently release the die to strike a surface of the base, and wherein the guide maintains the die in a stable orientation relative to a horizontal axis of the base.