Mold Designing Apparatus for Thermal Expansion Compensation
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Solution Overview
Problem
In casting operations, burrs often form due to uneven mold expansion caused by temperature and pressure differences, leading to increased costs and reduced productivity as they require additional processing steps for removal and can stick to molds, affecting subsequent casting processes.
Innovation Solution
Designing molds by calculating the distribution of contact surface pressure and setting machining amounts based on this distribution to prevent clearance formation between mating surfaces, ensuring uniform contact and reducing the likelihood of burr generation through reverse shaping of the mold surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molds are used in casting operations, then casting production is enabled, but uneven mold expansion causes burr generation and mold sticking
Solution Approach 1:
The patent applies preliminary action by pre-calculating the deformation amount of the mold's mating surface using finite element analysis before casting operations. The mold design is adjusted in advance to compensate for expected thermal expansion, ensuring uniform contact pressure distribution when the mold is heated during casting. This prevents burr generation and mold sticking by eliminating clearance formation at the mating surface before the casting process begins.
2Manufacturing precision
If burr removing operations are added, then burr defects are eliminated, but production cost increases and productivity decreases
Solution Approach 1:
The patent converts the harmful effect of thermal expansion into a beneficial outcome by calculating and compensating for the deformation amount in the mold design phase. Instead of allowing uneven expansion to cause burrs and requiring costly removal operations, the mold is pre-adjusted so that the expansion itself achieves uniform contact pressure distribution. This eliminates the need for burr removing operations while maintaining high casting quality and productivity.
3Manufacturing precision
If molds are fastened tightly to prevent burrs, then burr generation is reduced, but mold deformation increases under thermal stress
Solution Approach 1:
The patent applies parameter changes by modifying the mold design parameters based on calculated deformation amounts. Instead of applying uniform tight fastening that causes overall mold deformation, the mold mating surface is pre-adjusted with compensation values derived from finite element analysis. This allows the mold to maintain proper contact uniformity under thermal stress without excessive fastening force, preserving both contact quality and mold dimensional stability.
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 reduces the occurrence of burrs by maintaining uniform contact between mold surfaces during casting, minimizing additional processing steps and improving productivity by preventing burr formation and mold sticking issues.
Implementation Method 1
molds are respectively expanded due to heat which is applied from a molten bath
Data Source
AI summary
A mold is designed by calculating a distribution of a contact surface pressure of a mating surface of a mold under a casting condition, and setting a machining amount of the mating surface of the mold based on the calculated distribution of the contact surface pressure.