Mold Parting Plane Clearance Design for Leakage Prevention
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Solution Overview
Problem
The existing casting methods often result in molten metal leaking onto the parting plane during the pressurizing process, leading to fins on the castings and reduced productivity due to the need for additional removal processes and potential defects from excess molten metal forming extraneous objects.
Innovation Solution
A mold design with clearances between the press-fit portions of the upper and lower molds, along with a flow-off cavity, to prevent molten metal from leaking onto the parting plane and reduce kinetic energy, thereby minimizing leaks and fins on the castings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gating system is provided to control molten metal flow, then casting quality is improved, but productivity and cost efficiency deteriorate due to the need to remove the gating system after crashing the mold
Solution Approach 1:
The invention extracts and eliminates the gating system from the mold structure. Instead of providing a separate gating system that needs to be removed, the mold is designed with a cavity that directly receives molten metal, and the parting plane is positioned to naturally contain any excess metal without requiring additional gating components that would need post-processing removal.
2Shape
If the upper mold is pressed onto the lower mold to form the casting cavity, then the casting shape is formed, but molten metal leaks onto the parting plane forming fins that require additional removal processes
Solution Approach 1:
The invention applies preliminary action by designing the mold cavity and parting plane configuration before pouring to prevent metal leakage. The cavity is formed with proper dimensions and the parting plane is positioned and dimensioned in advance to contain molten metal, preventing fin formation before the casting process even begins.
Solution Approach 2:
The invention changes critical parameters including the positioning of the parting plane, the dimensions of the cavity, and the clearance between mold surfaces. These parameter changes ensure that molten metal is contained within the cavity during pressing, preventing leakage onto the parting plane that would create fins requiring removal.
3Adaptability or versatility
If excess molten metal is poured into the lower mold, then tolerance in metal amount is achieved, but metal leaks onto the parting plane forming extraneous objects that prevent complete pressurizing
Solution Approach 1:
The parting plane acts as an intermediary element that mediates between the cavity and the external environment. It is designed with appropriate dimensions and positioning to serve as a barrier that contains molten metal within the cavity, preventing it from leaking onto surfaces where it would form extraneous objects that interfere with complete pressurizing.
Data Source
AI summary
A mold that can prevent molten metal from leaking out of it as well as from leaking onto a parting plane of the mold. The mold includes a lower mold having a concave portion that has the shape of a product, into which the amount of molten metal required to produce a casting is poured and an upper mold comprising a convex portion that has the shape of the casting, and forming a cavity that molds the casting, when the upper mold overlaps the lower mold. A structure is formed so as to have certain clearances between the lower mold and the upper mold such that molten metal is prevented from leaking onto the parting plane that is formed where the upper mold and the lower mold overlap, when the casting is produced.