Multiple Component Core Assembly for Casting
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Solution Overview
Problem
Existing casting methods face challenges in producing components with intricately-shaped voids and internal passages, as they require precise formation and handling of fragile ceramic cores, which are costly and time-consuming, and traditional machining processes are inefficient for achieving the required features and shapes.
Innovation Solution
A mold assembly and method using a multiple component core assembly with separate core components and a core connection component that is absorbable by the component material, allowing for precise formation of internal voids and passages without the fragility issues of single ceramic cores, and reducing the complexity and time of the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a single ceramic core is used to form intricately-shaped voids and internal passages, then the component can achieve complex geometries, but the core becomes fragile and difficult to handle without damage
Solution Approach 1:
The core is divided into multiple separate ceramic core components instead of using a single monolithic core. Each core component can be independently formed, handled, and positioned, reducing the risk of damage while collectively defining the intricate internal geometry when assembled together in the mold cavity.
2Manufacturing precision
If a single ceramic core is used to precisely define cavity space, then manufacturing precision is improved, but the complexity and cost of core formation and handling increases
Solution Approach 1:
Dividing the core into multiple components allows each segment to be formed using standard molding techniques with simpler tooling, reducing the complexity of core formation. The components are designed to assemble together with precise positioning features, maintaining the required manufacturing precision for defining the cavity space.
Solution Approach 2:
A positioning component acts as an intermediary element that facilitates the precise assembly and positioning of multiple core components relative to each other and to the mold cavity. This mediator ensures accurate spatial relationships without requiring complex individual core components.
3Manufacturing precision
If traditional machining processes are used to drill and machine internal passages, then the component can achieve required features, but the process becomes time-consuming and expensive
Solution Approach 1:
The internal passages and voids are extracted and formed as positive ceramic core components before casting, rather than creating them through subtractive machining after casting. This allows the internal geometry to be formed simultaneously with the external geometry during the casting process, dramatically improving productivity.
Solution Approach 2:
The core components defining internal passages are prepared and positioned in advance before the casting process begins. This preliminary action allows the molten metal to directly form around the pre-positioned cores, eliminating the need for time-consuming post-casting machining operations to create internal passages.
4Adaptability or versatility
If a single ceramic core is used to form complex geometries, then the component design flexibility is improved, but the cost and time of the casting process increases
Solution Approach 1:
Segmenting the core into multiple components enables greater design flexibility as each component can be independently optimized and formed using efficient molding techniques. The reduced handling complexity and faster processing times of multiple simpler components offset the increased assembly steps, ultimately reducing total process time compared to forming and handling a single complex core.
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 the precise and efficient formation of components with intricate internal structures, reducing the risk of core damage and simplifying the casting process, while improving the speed and cost-effectiveness of producing components with complex geometries.
Implementation Method 1
the core connection component is formed from a connection component material that is configured to be absorbable by the component material
Data Source
AI summary
A component is formed from a component material introduced into a mold assembly. The mold assembly includes a mold that has a cavity defined therein by an interior wall. The cavity receives the component material in a molten state to form the component. A multiple component core assembly is positioned with respect to the mold and has a first core component attached to a second core component at a core split line. A core connection component is attached to each of the first and second core components at the core split line, such that the first core component is held adjacent the second core component at the core split line. The core connection component is formed from a connection component material that is at least partially absorbable by the component material.