Piston Eco-Mold Apparatus for Inclined Box Casting
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Solution Overview
Problem
The existing piston mold apparatus faces challenges in efficiently casting obliquely shaped boss and box parts of the piston, particularly in forming deep grooves at the connection region between the box and boss parts, leading to increased manufacturing costs and reduced productivity due to complex assembly and disassembly requirements.
Innovation Solution
An eco-mold apparatus with a first eco-mold part that moves forward or backward to mold the eco-part, a second eco-mold part that engages with the first eco-mold part to form another portion of the eco-part, and a piston pickup part that uses a clamping or vacuum/magnetic member to separate the piston, allowing for inclined forming of the box part and easy creation of deep grooves at the connection region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional piston mold apparatus is used with straight line assembly and disassembly, then manufacturing process is simple, but it cannot efficiently cast obliquely shaped boss and box parts with deep grooves
Solution Approach 1:
The mold apparatus is divided into multiple independent mold parts including a first mold part for forming the box part, a second mold part for forming the boss part, and a core part for forming the deep groove. Each part can move independently in different directions, enabling complex oblique shapes and deep grooves to be formed through coordinated movement rather than requiring a single complex mold structure.
Solution Approach 2:
The mold parts are designed with dynamic movement capabilities where the first mold part moves in a first direction, the second mold part moves in a second direction, and the core part moves in a third direction. This dynamic configuration allows the mold to adapt to complex geometries during the casting process while maintaining relative simplicity in the static structure.
2Manufacturing precision
If multiple divided mold parts are used to cast oblique boss and box parts, then forming capability is improved, but manufacturing cost and processing time increase
Solution Approach 1:
The mold apparatus combines multiple mold parts and the core part into a single integrated system that operates cooperatively. The first mold part, second mold part, and core part are positioned and moved in coordination to form the complete piston geometry in one casting cycle, eliminating the need for multiple separate casting operations or complex assembly/disassembly steps.
Solution Approach 2:
The mold apparatus is designed as a multi-functional system where the same set of mold parts performs multiple functions: forming the box part, forming the boss part, and creating the deep groove through the core part. This universal design allows complex piston geometries to be produced in a single operation rather than requiring specialized molds for each feature.
3Manufacturing precision
If traditional mold apparatus is used, then assembly is straightforward, but it is difficult to form deep grooves of undercut shape at connection region
Solution Approach 1:
The core part is introduced as a separate element that moves in a third direction different from the first and second mold parts. This dimensional separation allows the core part to create deep grooves of undercut shape at the connection region between the box part and boss part, as the core part can be positioned and removed independently without interfering with the assembly of the main mold parts.
Data Source
AI summary
The present invention relates to an eco-mold apparatus for manufacturing a piston, a mold apparatus for manufacturing a piston, and a piston manufacturing method, which mold each part of a piston while decreasing the weight of the piston, and the apparatus may comprise: a first eco-mold part which may move forward or backward in a first direction to shape a portion of an eco-part of a piston; a second eco-mold part which may shape-match with the first eco-mold part to mold another portion of the eco-part of the piston; and a piston pickup part which picks up the piston over the second eco-mold part, so that the piston pickup part can separate the piston from the second eco-mold part.