Integrated Chill Mold Body for 3D Sand Casting

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Solution Overview

Problem

Incorporating traditional chills into 3D sand printed mold bodies is challenging due to machinery constraints, leading to issues with dimensional tolerances and securing the chill during the casting process, as the chill must be produced separately and inserted into the mold body.

Innovation Solution

The mold body design includes integrated chill cavities with fill channels and vent channels, allowing for the direct 3D printing of chill materials like metallic beads or specialty sands with higher thermal conductivity, eliminating the need for a separate near-net shape chill and improving alignment and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional chills are produced separately and inserted into 3D sand printed mold bodies, then the mold body can be created using 3D printing technology, but the chill cannot be properly positioned and secured during the casting process

Engineering Contradiction:

Improvemold body productionVSAvoidchill positioning and alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent combines the chill and mold body into a single integrated structure, eliminating the separate production and insertion steps. The chill is formed as an integral part of the mold body during the 3D printing process, ensuring precise positioning and alignment without requiring separate handling or securing mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chill is nested within the mold body structure, with the chill material contained within a chill cavity that is formed as part of the mold body. This nesting approach ensures the chill remains properly positioned and secured throughout the casting process while maintaining the benefits of 3D printed mold production.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If chills are produced separately from the mold body, then the chill can be made from materials with high thermal conductivity, but dimensional tolerances between the chill and mold body cavity become difficult to maintain

Engineering Contradiction:

Improvethermal conductivityVSAvoiddimensional tolerances

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

By merging the chill and mold body production into a single 3D printing process, the patent eliminates the interface between separately manufactured components. The chill cavity and mold body are printed together as one structure, ensuring perfect dimensional compatibility and eliminating tolerance accumulation issues that arise from separate manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes the ability of 3D printing to precisely control material properties and geometric parameters. By adjusting printing parameters such as layer thickness, infill density, and material composition, the chill can be optimized for thermal conductivity while maintaining exact dimensional tolerances with the mold body cavity.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the chill is inserted into the mold body after 3D printing, then the mold body can be fully formed, but the chill may move or become dislodged during casting

Engineering Contradiction:

Improvemold production efficiencyVSAvoidchill stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent merges the chill and mold body into a single printed structure, eliminating the need for separate insertion and securing operations. The chill becomes an integral part of the mold body, ensuring it cannot move or become dislodged during the casting process while maintaining production efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The chill is pre-positioned and secured within the mold body structure during the 3D printing process itself, before the casting operation begins. This preliminary positioning ensures the chill is firmly in place and cannot move during casting, eliminating the need for additional securing measures.

Inventive Principle:

Principle #10Preliminary action

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 efficient and cost-effective production of mold bodies with integrated chills, reducing inventory needs and personnel costs while maintaining precise thermal control and alignment during the casting process.

Implementation Method 1

a first chill material (130) disposed within the first chill cavity (110) and having a thermal conductivity that is greater than the thermal conductivity of the mold body

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3576895B1Mold body with integrated chill

Publication Date: 2020.11.18 FISHER CONTROLS INT LLC

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AI summary

A mold body for use in a mold includes a mold cavity, a chill cavity, a fill channel, and a chill material having a thermal conductivity that is greater than the thermal conductivity of the mold body disposed within the chill cavity. The chill cavity is formed adjacent the mold cavity and is separated from the mold cavity by a chill wall. The fill channel is in communication with the chill cavity and with an exterior surface of the mold body.