Pin-Shaped Positioning Elements for Casting Die Stress Reduction

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Solution Overview

Problem

Existing casting methods for light-metal alloys result in high stress peaks due to fixed positioning elements, which are inefficient and prone to material weaknesses under dynamic loads, especially in the motor vehicle industry.

Innovation Solution

A casting tool employing pin-shaped positioning elements that taper towards their end, allowing for precise core part positioning and easy removal, minimizing stress peaks by leaving small openings or indentations in the workpiece, with conical and cylindrical sections for effective penetration and frictional engagement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If fixed positioning elements are arranged in the core part, then the core part can be positioned within the mold, but high stress peaks occur in the rim regions under dynamic bending and torsional stresses

Engineering Contradiction:

Improvepositioning precisionVSAvoidstress resistance

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

Instead of fixing positioning elements in the core part (traditional approach), the patent inverts the approach by fastening pin-shaped positioning elements to the casting tool and allowing them to penetrate the core part during casting. This reversal transfers the positioning function from the core part to the casting tool, eliminating stress concentration in the rim while maintaining precise positioning.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the positioning function from the core part and relocates it to the casting tool. By removing the positioning elements from the core part after casting, only small openings remain in the rim, significantly reducing stress peaks while preserving the positioning precision achieved during casting.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If positioning elements with large peripheries are used to hold core parts, then positioning is achieved, but weak material points are formed causing high stress peaks

Engineering Contradiction:

Improvepositioning accuracyVSAvoidstress peaks

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the geometric parameters of the positioning elements by using pin-shaped elements with small diameters (typically 0.5-2 mm) instead of large peripheral elements. This parameter change allows precise positioning while minimizing the size of openings in the rim, thereby reducing stress concentration factors.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies local quality by using small-diameter pin-shaped positioning elements only where needed for positioning, rather than using large peripheral elements throughout. This localized approach maintains positioning accuracy at critical points while avoiding the creation of weak material points in the rim structure.

Inventive Principle:

Principle #3Local quality

3Strength

If pin-shaped positioning elements fastened to the casting tool are used, then core part positioning is reliable and stress peaks are reduced, but the positioning elements must be removed from the workpiece

Engineering Contradiction:

Improvestress peak reductionVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The casting process itself serves to remove the positioning elements. As the light-metal alloy solidifies around the core part, the positioning elements are naturally expelled or easily removed due to the shrinkage and solidification forces, eliminating the need for separate removal operations and simplifying the manufacturing process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The positioning elements serve their function during the casting process and are then periodically removed after the workpiece solidifies. This periodic use and removal cycle allows the positioning elements to be reused multiple times, reducing overall manufacturing complexity and cost.

Inventive Principle:

Principle #19Periodic action

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

The solution significantly reduces stress peaks in light-metal workpieces, enabling the production of components with high construction freedom and resilience to dynamic bending and torsional forces, particularly suitable for motor vehicle components like wheels and suspension parts.

Implementation Method 1

the core part is held in frictional engagement by the positioning element during casting

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS7909084B2Casting die and method for producing cast workpieces consisting of light metal alloys

Publication Date: 2011.03.22 AUSTRIA ALU GUSS

AI summary

The invention relates to a casting tool for producing workpieces from light metal alloys. The system includes a positioning element, a core part, a first mold part structured to carry the positioning element and be movable toward the core part, and a core part support structured to support the core part. The system also includes at least one stop structured to limit movement of the front mold part toward the core part and to allow the positioning element to be introduced into the core part, whereby the positioning element holds the core part in a predetermined position for casting.