3D Printed Sand Casting Mold Runner System Design
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Solution Overview
Problem
The conventional manufacturing process of sand casting molds for complex compression components, such as those in scroll compressors, is inefficient due to the need for continuous mold modification, leading to prolonged casting cycles and difficulties in ensuring accurate molding requirements.
Innovation Solution
A sand casting mold configured for 3D printing, comprising an upper and lower portion with specific sprue and runner designs, through holes, and a feeder system, allowing for rapid modification and production of complex structures without the need for extensive mold redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional mold is used to manufacture sand casting molds, then the mold structure is fixed and requires modification for product changes, but the continuous modification of the mold lengthens the casting cycle and increases production time
Solution Approach 1:
The patent applies 3D printing technology to create sand casting molds directly from digital models, eliminating the need for physical mold modifications when product designs change. The digital model can be easily updated and reprinted, providing rapid adaptability without time-consuming mold reconstruction
Solution Approach 2:
The invention changes the manufacturing method from conventional subtractive molding to additive 3D printing, allowing for rapid parameter changes in mold geometry through digital model updates. This enables quick adaptation to product design changes without physical mold rework
2Manufacturing precision
If a conventional mold is used to manufacture sand casting molds, then the manufacturing process is established, but it is difficult to ensure molding requirements for components with complicated structures
Solution Approach 1:
3D printing creates precise digital copies of the mold cavity geometry, ensuring accurate reproduction of complex component features. The additive process maintains high dimensional accuracy for intricate structures that are difficult to achieve with conventional molding methods
Solution Approach 2:
The invention transitions from conventional 2D/3D molding to 4D printing (3D + time), enabling the mold to adapt its structure dynamically. This allows for optimized runner systems and gating that can be precisely configured for complex geometries without increasing device complexity
3Ease of manufacture
If the sand casting mold is manufactured by a conventional mold, then the production process is standardized, but the production cost increases due to continuous mold modification
Solution Approach 1:
The patent uses digital copying through 3D printing to replace physical mold copying and modification. Digital models can be stored, modified, and reproduced without the costs and time associated with physical mold rework, significantly reducing production costs for design iterations
Solution Approach 2:
The invention treats sand casting molds as disposable or short-lived components manufactured through 3D printing. Rather than investing in expensive, long-lived conventional molds that require modification, the system uses affordable, rapidly manufacturable molds that can be discarded or updated easily, reducing overall production costs
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 3D printing method reduces production costs and enhances the ability to accurately cast complex components by enabling rapid design iteration and precise mold formation.
Implementation Method 1
a method of forming the sand casting mold by 3D printing
Data Source
AI summary
A sand casting mold configured to cast a component and a method of forming the sand casting mold configured to cast the component by 3D printing are disclosed. The sand casting mold includes: an upper portion and a lower portion; a mold cavity defined by the upper portion and the lower portion; an upper sprue in the upper portion; a lower sprue which is in the lower portion and is in communication with the upper sprue; an upper runner which is in the upper portion, is separated from the upper sprue by a predetermined distance, and is in communication with the mold cavity; and a lower runner which is in the lower portion, is in communication with the lower sprue, is separated from the mold cavity in the lower portion, and has a first end in communication with the lower sprue, and a second end in communication with the upper runner. With the sand casting mold configured to cast the component according to the embodiments of the present invention, for example, a production cost can be reduced.