Lost Pattern Casting Cooling Element Isolation
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Solution Overview
Problem
The existing lost mold casting process faces limitations in cooling efficiency, mechanical stress on coolers, sand infiltration, and maintenance challenges due to direct contact with vibrating tanks, which affects the precision and longevity of equipment and the quality of cast parts.
Innovation Solution
A lost mold casting process where the cooling element is used as a support for the model without direct contact with the tank, allowing vibrations to distribute sand evenly while isolating the cooler from mechanical stress, and utilizing a suspension system to maintain the cooler's independence from the tank's vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If coolers are fixed inside the molding vessel to cool faces of the model, then mechanical properties of the material are improved on cooled faces, but the coolers constitute masses of inertia which oppose the vibrations of the vessel causing significant mechanical stresses on their fixings leading to fatigue cracks
Solution Approach 1:
The cooling function is segmented from the tank structure. Instead of fixed coolers integrated into the tank, the invention uses detachable cooler assemblies that can be independently positioned and removed. This segmentation allows the coolers to perform their cooling function without being part of the vibrating tank structure, eliminating the mechanical stress and fatigue crack issues while maintaining the ability to cool specific faces of the model for improved mechanical properties
Solution Approach 2:
The cooler assembly is made dynamic rather than static. The cooler can be positioned, fixed during operation, and removed as needed. This dynamic approach allows the system to adapt between different operational states (fixed during casting, removable for maintenance and cleaning) resolving the contradiction between needing stable cooling contact and avoiding vibration-induced mechanical stress
2Temperature
If coolers are fixed inside the molding vessel, then cooling of model faces is achieved, but the vibration imposed on the coolers causes friction between them and the coated cluster causing abrasion of the coating and the risk of sand infiltration at the interface which can cause defects in the part
Solution Approach 1:
The cooler assembly is segmented as a separate, detachable unit rather than being fixed to the tank. This allows the cooler to be positioned in contact with the model for cooling while being independently supportable, reducing friction and preventing coating abrasion and sand infiltration during the casting process
Solution Approach 2:
The cooler assembly acts as an intermediary between the model and the operator. It provides the necessary cooling contact with the model while being designed to minimize harmful interactions (friction, abrasion) through its specific structural design and support mechanism
3Temperature
If coolers are fixed inside the molding vessel, then cooling function is provided, but the tanks are specific and a change of tank is necessary to pour without a cooler, and the conditioning of the tanks is difficult due to cleaning and warming up of the coolers
Solution Approach 1:
The cooling system is segmented into a detachable cooler assembly rather than being integrated into the tank. This allows the cooler to be easily removed for cleaning and maintenance without requiring tank disassembly or specialized cleaning procedures, significantly improving ease of manufacture and operational efficiency
Solution Approach 2:
The cooler assembly transitions from a fixed, permanent installation to a dynamic, removable component. This dynamic design enables easy removal for cleaning and warming up between casts, eliminating the complex conditioning procedures previously required and allowing flexible adaptation to different casting requirements
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 enhances cooling efficiency, reduces mechanical stress and maintenance, minimizes sand infiltration and wear, and improves the dimensional precision and mechanical properties of the cast parts, while allowing for easier cooler handling and reduced equipment requirements.
Implementation Method 1
at least one element capable of cooling one or more faces of the model
Implementation Method 2
a lost mold casting process consists of placing one or more models in a sublimable material in a container, then drowning the assembly in sand, leaving a casting orifice in which liquid metal is poured. The model is sublimated and metal comes to replace it
Implementation Method 3
The vibration of the tank allows the sand to occupy all the interstices and cavities of the polystyrene model, as if it were a liquid
Implementation Method 4
The cluster alloy solidifies and cools then naturally slowly in the sand with very insulating properties
Data Source
Figure 1~2b
Figure 3~4
Figure 5~6
AI summary
The invention relates to a lost-wax casting process in which one or more patterns (1) made of a sublimable material are placed in a container, the pattern(s) are embedded in sand, leaving a pouring orifice, and liquid metal is poured into this orifice. The process is characterized in that the pattern(s) (1) are first placed in an enclosure (2) having at least one element adapted to cool one or more faces of the pattern (1), the enclosure/pattern(s) assembly (2, 1) being positioned in the container without contacting it. Application to the manufacture of cylinder heads.