3D Printed Sand Core Reinforcement for Hydraulic Valves
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Solution Overview
Problem
The existing 3D printing process for sand cores of integral hydraulic multi-way valves results in low compactness and strength, leading to deformation and cracking under thermal stress and buoyancy of molten iron, limiting their application to simple parts due to weak cantilever and elongated parts, and requiring costly traditional moulding methods for complex inner passages.
Innovation Solution
A process of strengthening 3D printed sand cores by analyzing weak parts in a three-dimensional model, designing pore channels for reinforcing core bars with specific diameters and lengths, and integrating these bars during the hardening process to enhance the sand core's strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 3D printing process is used for sand core, then manufacturing cycle is shortened and cost is reduced, but compactness and strength of the printed sand core are lower
Solution Approach 1:
The patent applies composite materials by combining 3D printed sand core with reinforcing core bars (metal or ceramic) to create a hybrid structure. The core bar provides structural strength while the sand core provides the necessary geometry and porosity for casting. This composite approach resolves the contradiction by maintaining the 3D printing advantages (short cycle, low cost) while compensating for the strength deficiency through the reinforcing core bar.
Solution Approach 2:
The patent applies local quality by strategically placing reinforcing core bars only in specific locations where the sand core is weakest (such as cantilever parts, elongated parts, and areas with thin walls). Instead of uniformly strengthening the entire sand core, the reinforcement is localized to critical areas, maintaining the overall 3D printed structure's simplicity while providing targeted strength enhancement where needed.
2Device complexity
If 3D printed sand core is used for complex inner passages, then manufacturing complexity is reduced, but the sand core is prone to deformation and cracking under thermal stress and buoyancy
Solution Approach 1:
The patent applies preliminary action by designing and incorporating reinforcing core bars into the sand core structure before the casting process. The core bars are pre-positioned in the 3D printed sand core at critical locations to prevent deformation and cracking during the subsequent casting process. This preliminary reinforcement ensures that when the molten iron is poured, the sand core can withstand the thermal stress and buoyancy forces without deforming or cracking.
Solution Approach 2:
The patent applies the intermediary principle by introducing the reinforcing core bar as a mediator between the 3D printed sand core and the molten iron. The core bar acts as a structural support that transfers and distributes the thermal stress and buoyancy forces from the molten iron, preventing direct stress concentration on the weak 3D printed sand core material. This intermediary element enables the use of complex inner passages while maintaining reliability.
3Strength
If traditional sand shooting process is used, then strength and compactness of sand core are improved, but manufacturing cycle is lengthened and cost increases
Solution Approach 1:
The patent applies composite materials to create a hybrid sand core structure that combines the advantages of both 3D printing and traditional sand shooting processes. The 3D printed sand core provides the necessary geometry and porosity for complex inner passages, while the reinforcing core bar (metal or ceramic) provides the structural strength and compactness typically achieved only through traditional sand shooting. This composite approach resolves the contradiction by achieving high strength without the long manufacturing cycle and high cost of traditional methods.
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 integration of reinforcing core bars significantly improves the strength and resistance of 3D printed sand cores, reducing the risk of deformation and cracking, and increasing the success rate of casting complex hydraulic multi-way valves by distributing thermal stress effectively.
Implementation Method 1
achieving tight connection of the reinforcing core bar and the sand core in the hardening or curing process of the sand core
Implementation Method 2
under the actions of long-term baking and surrounding of molten iron, the buoyancy of the molten iron and their own thermal stress
Data Source
AI summary
A process of strengthening 3D printed sand core for the casting of integral hydraulic multi-way valve and a sand core for integral hydraulic multi-way valve are provided. The process includes: creating a sand core model of a sand core for an integral hydraulic multi-way valve in three-dimensional software, analyzing parts of the sand core to determine a weak part of the sand core; designing a pore channel with a pore diameter and a length in the sand core model according to a ratio L/D of a length to a diameter of the weak part, and forming a reinforcing core bar according to the pore channel; and 3D printing the sand core according to the sand core model, placing the reinforcing core bar in the pore channel, and achieving tight connection of the reinforcing core bar and the sand core in the hardening or curing process of the sand core.