Ribbed Extrusion Profile for Filigree Casting Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing casting processes for producing components with cavities face issues such as deformation during cooling, geometric restrictions, and limitations in achieving complex structures, making them unsuitable for filigree designs and requiring significant effort.
Innovation Solution
A method involving the production of a profile with ribs by extrusion, which is then used in a core casting tool to create a core, allowing for the casting of a component with cavities that can be complex and filigree in design, with the core being removable to leave chambers that form the cavities, enabling cost-effective production of complex components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting processes are used to produce cores from salt or inorganic molding materials, then cores can be produced with simple geometries, but the cores undergo deformation during cooling leading to deviation from target geometry and are limited in achieving complex filigree structures
Solution Approach 1:
The invention applies preliminary action by pre-forming a profile with ribs through extrusion before the casting process. This profile serves as a precise geometric template that guides the formation of the core and casting jacket, ensuring that complex filigree structures are created with high geometric accuracy from the beginning, eliminating deformation issues during cooling.
Solution Approach 2:
The invention segments the casting process into distinct components: a profile with ribs, a core formed in the space between the profile and core casting tool, and a casting jacket. This segmentation allows each component to be optimized independently - the profile for geometric precision, the core for structural support, and the jacket for final shaping - thereby achieving complex geometries with high accuracy.
2Ease of manufacture
If traditional casting methods are used, then production processes are simple, but complex hollow structures cannot be produced cost-effectively and require significant effort
Solution Approach 1:
The invention merges multiple functions into a single integrated process. The profile with ribs simultaneously serves as a support structure, a geometric template for the core, and a form-maker for the casting jacket. This consolidation allows complex hollow structures to be produced in one casting operation without requiring multiple separate manufacturing steps, making complex structures cost-effective.
Solution Approach 2:
The profile with ribs acts as an intermediary element between the core casting tool and the final component. It mediates the formation of the core and casting jacket, enabling complex geometries to be achieved through a controlled intermediate step rather than requiring direct complex tooling or post-processing operations.
3Strength
If cores are produced with limited cross section to length ratios in the prior art, then mechanical properties are maintained, but filigree structures with higher aspect ratios cannot be achieved
Solution Approach 1:
The invention applies local quality by providing enhanced structural support specifically at critical locations through the ribs of the profile. The ribs are strategically positioned to reinforce areas where high aspect ratios would otherwise compromise mechanical strength, allowing filigree structures with elevated cross-section-to-length ratios to achieve the necessary mechanical properties locally where needed.
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 method allows for the production of components with advantageous mechanical properties, enabling the creation of filigree structures without costly post-processing, and facilitates the manufacture of complex components in a cost-effective manner.
Implementation Method 1
the profile together with the ribs being produced by extrusion
Implementation Method 2
producing a core in the space between the profile and the core casting tool
Implementation Method 3
casting a casting jacket, the Cast jacket has contact with the core and at least partially contact with at least a part of the ribs
Data Source
Figure 1a~2
Figure 3~4b
Figure 5a~6c
AI summary
The invention relates to a method for manufacturing a component with a cavity, comprising at least the following steps: - providing a profile with ribs, - arranging the profile in a core casting tool such that the ribs extend in a space between the profile and the core casting tool, - producing a core in the space between the profile and the core casting tool, - removing the profile with the core arranged thereon from the core casting tool, - arranging the profile with the core in a casting tool, - casting a casting shell, wherein the casting shell has contact with the core and at least partial contact with at least a part of the ribs, - removing the core.