Sand Mold Digital Flexible Extrusion Optimization
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Solution Overview
Problem
The digital die-free casting precision forming technology reduces sand mold batching production efficiency due to large molding sand removal amounts in the sand block cutting process, limiting its application in large-batch production.
Innovation Solution
A sand mold digital flexible extrusion near-net forming optimization method based on a search algorithm, which divides the CAD 3D model into sub-regions, constructs an optimization objective function, and performs a global search to optimize the position and shape of the flexible extrusion arrays, reducing waste and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If digital die-free casting precision forming technology is used, then manufacturing precision and material utilization are improved, but productivity deteriorates due to large molding sand removal amounts in sand block cutting process
Solution Approach 1:
The patent applies preliminary action by pre-dividing the sand mold cavity into multiple sub-regions and pre-calculating the optimal extrusion path and parameters before actual forming. This preparation work includes generating the digital model, segmenting the cavity, and planning the extrusion sequence, which enables the forming process to proceed efficiently without excessive sand removal during production.
Solution Approach 2:
The patent segments the sand mold cavity into multiple sub-regions that can be formed separately through digital flexible extrusion. By dividing the cavity into manageable sections, the system can optimize each segment's forming process independently, reducing the overall sand removal requirement while maintaining high forming precision and enabling batch production efficiency.
2Productivity
If traditional sand block cutting process is used, then productivity is maintained, but loss of substance increases due to large molding sand removal amounts
Solution Approach 1:
The patent replaces the traditional mechanical sand block cutting process with a digital flexible extrusion system. Instead of cutting and removing excess sand mechanically, the system uses digital modeling and controlled extrusion to build the sand mold cavity layer by layer, significantly reducing molding sand waste while maintaining production efficiency.
Solution Approach 2:
The patent changes the fundamental parameters of the forming process by transitioning from a subtractive cutting method to an additive extrusion method. This parameter change includes modifying the material deposition pattern, extrusion pressure, and layer thickness, which collectively reduce molding sand removal amounts while preserving productivity.
3Loss of substance
If digital flexible extrusion near-net forming is implemented, then loss of substance is reduced, but device complexity increases due to optimization algorithm requirements
Solution Approach 1:
The patent uses digital copying by creating an accurate digital model of the sand mold cavity before physical forming. This digital replica allows for virtual optimization of the extrusion process, including path planning and parameter adjustment, without requiring complex physical trial-and-error. The optimized digital model is then used to guide the actual extrusion process, reducing molding sand waste while managing system complexity.
Data Source
AI summary
Provided is a sand mold digital flexible extrusion near-net forming optimization method based on a search algorithm. The method includes: dividing a sand mold Computer Aided Design (CAD) 3D model near-net forming region; acquiring a curved surface function of a near-net forming sand mold CAD 3D model cavity; constructing a flexible extrusion array envelope volume optimization objective function; determining a valid optimization interval R; translating the position of a sand mold CAD 3D model cavity to a search initial position; performing a global search in the valid optimization interval R, comparing flexible extrusion array envelope volume values, and saving the larger value as V(x,y)max and the corresponding position as (x,y)max; and completing the search, translating the position of the near-net forming sand mold CAD 3D model cavity to (x,y)max, and executing a flexible extrusion array shape adjusting procedure.