Lost Core Positioning in Precision Casting Molds

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Solution Overview

Problem

Existing precision casting methods face challenges in accurately positioning lost cores relative to ceramic molds, leading to positional misplacements, waste, and increased costs due to the need for expensive processing mounts that can deform under casting temperatures.

Innovation Solution

A method involving a 3D model with digital geometrical coordinates is used to position a ceramic blank on a processing mount with a fixing mechanism, allowing for precise CNC production of a lost core and model blank, utilizing zero point fixing systems and stabilizing frames to maintain core stability and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a lost core is positioned in a ceramic mold using conventional methods, then the component can be produced, but positional misplacement occurs leading to waste and increased costs

Engineering Contradiction:

Improvepositioning accuracy of lost coreVSAvoidwaste from positional misplacement

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by positioning the lost core in the ceramic mold before the casting process, using a processing mount that is pre-configured with the core in the correct position. This ensures that the core remains stationary and accurately positioned throughout the subsequent ceramic mold application and casting operations, preventing positional misplacement and associated waste.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces an intermediary processing mount that serves as a mediator between the lost core and the ceramic mold. This processing mount provides a stable platform for positioning the lost core accurately and maintains this positioning during the ceramic mold application, eliminating the need for the core to be directly positioned in the final ceramic mold with high precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If expensive processing mounts are used to maintain core position, then positioning stability is improved, but the cost and complexity of the system increases

Engineering Contradiction:

Improvepositioning stability of lost coreVSAvoidcomplexity of processing mount system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a disposable processing mount that is inexpensive and single-use. This processing mount is designed to be discarded after the ceramic mold is applied, eliminating the need for expensive, reusable mounts that would require complex heating and cooling systems. The low-cost disposable mount provides sufficient positioning stability for the required operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts the positioning function from the final ceramic mold and places it in the disposable processing mount. This separation allows the processing mount to be optimized solely for positioning stability during the critical setup phase, while the ceramic mold can be applied without requiring complex temperature-resistant positioning mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If processing mounts resistant to high temperatures are used, then the casting process can be completed, but the mount deforms under casting temperatures causing positional deviations

Engineering Contradiction:

Improveresistance to casting temperaturesVSAvoidpositional accuracy under heat

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by completing all positioning and ceramic mold application operations while the lost core is still supported by the processing mount, before the high-temperature casting process begins. This ensures that the core is already accurately positioned in the ceramic mold structure, eliminating the need for the processing mount to maintain precision under casting temperatures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the positioning function from the high-temperature casting environment and performs it during the setup phase while the processing mount is still in place. The processing mount is removed after the ceramic mold is applied, so it never needs to withstand casting temperatures, eliminating the contradiction between temperature resistance and positional accuracy.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11607721B2Method for producing a model mold core blank and a precision casting mold, and a casting method for producing a cast part having a void structure

Publication Date: 2023.03.21 JOHANNES MICHAEL OTTO GBR

AI summary

A method for producing a model mould core blank uses a ceramic blank fixed to a processing holder. During fixing, a lost core is manufactured from the ceramic blank based on a CNC manufacturing process 3D model, the processing holder being fastened in the running CNC machine. A model blank is produced by casting model material around the lost core while fixing persists. The model blank becomes part of another method for producing a model mould core, wherein an outer contour of a lost model is produced from and/or on the model blank on the basis of a second CNC manufacturing process 3D model, wherein fixing and processing holder fastening also occurs. Another method produces a precision casting mould, in which a ceramic mould is applied to the outer contour of the lost model, and a cast part having a hollow cavity structure is produced by the precision casting mould.