Radial Pattern Assembly for Investment Casting Yield
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Solution Overview
Problem
Existing pattern assemblies for investment casting, particularly countergravity investment casting, are limited by the size of the central sprue, which restricts the number of patterns that can be attached and the casting yield due to the sprue diameter and length, limiting the amount of molten material that can be supplied.
Innovation Solution
A radial pattern assembly is formed using a hollow sprue with a sprue wall that allows for the attachment of multiple patterns and gates radially outward and inward, increasing the surface area for pattern attachment and molten metal flow, enabling higher casting yields by optimizing the sprue wall thickness, length, and periphery to enhance metallodynamic flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a centralized sprue is used to attach patterns, then the pattern assembly can be formed, but the number of patterns that can be attached is limited by the sprue diameter and length
Solution Approach 1:
The pattern assembly is divided into multiple pattern segments (first pattern segment, second pattern segment, etc.), each attached to different portions of the sprue wall. This segmentation allows multiple patterns to be distributed around the sprue perimeter rather than being limited by a single centralized attachment point, thereby increasing the overall casting yield without requiring an excessively large sprue diameter.
Solution Approach 2:
The invention transitions from a single-dimensional (centralized) sprue attachment to a multi-dimensional arrangement where patterns are attached radially around the sprue wall. By utilizing the circumferential dimension of the sprue wall, multiple patterns can be attached at different angular positions, effectively increasing the number of patterns that can be accommodated within the same sprue size constraints.
2Quantity of substance
If the sprue diameter is increased to attach more patterns, then more patterns can be attached, but the amount of molten material that can be supplied is limited by the sprue cross-sectional area
Solution Approach 1:
The sprue wall thickness is varied locally to optimize material distribution. The sprue wall has a first thickness at a first location and a second thickness at a second location, allowing different regions of the sprue to supply appropriate amounts of molten material to different pattern segments. This local variation in thickness enables adequate material supply to multiple patterns without requiring a uniformly large sprue cross-section, thus maintaining sufficient material flow capacity while accommodating more patterns.
3Productivity
If multiple patterns are attached to the sprue, then casting yield increases, but the sprue wall thickness must be optimized to ensure complete filling of pattern cavities
Solution Approach 1:
The sprue wall thickness is changed as a critical parameter to optimize both material distribution and pattern cavity filling. By adjusting the sprue wall thickness at different locations, the invention ensures that sufficient molten material is supplied to all attached pattern segments while maintaining the structural integrity of the sprue. This parameter optimization enables high casting yield with complete pattern cavity filling.
Data Source
Figure 1
Figure 2A~2H
Figure 3A~4B
AI summary
A method of making a radial pattern assembly is disclosed. The method includes forming a hollow sprue comprising a sprue wall disposed about a longitudinal axis, the sprue wall having a thickness, a length and a periphery; a pattern disposed outwardly of the sprue wall; and an outwardly extending gate attached to and extending between an outer surface of the sprue wall and the pattern, the hollow sprue, pattern and gate each formed from a fugitive material.