Segmented Casting Mold Cores With Tunnel Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods struggle to produce stable cores for large-format casting molds, particularly for components like turbines or impellers, due to the challenges of connecting multiple elements made of printed sand that can withstand the stresses during casting.
Innovation Solution
The core is divided into a central element and edge elements with tunnel structures, allowing reinforcement structures to be arranged across interfaces, enhancing stability by connecting these elements with reinforcement elements like threaded rods or hollow profiles, and filling tunnel structures with molding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core is divided into multiple elements for additive manufacturing, then the manufacturability of large-format cores is improved, but the stability and strength of the core under casting stresses deteriorates due to connection challenges
Solution Approach 1:
The core is divided into multiple core elements that can be separately manufactured using additive manufacturing processes. This segmentation enables the production of large-format cores that exceed the build volume of available 3D printing equipment while maintaining the advantages of additive manufacturing for complex geometries.
Solution Approach 2:
Tunnel structures are pre-formed within each core element during the additive manufacturing process. These tunnels are prepared in advance to receive reinforcement elements, ensuring that the reinforcement structures can be efficiently installed after assembly without requiring complex post-processing or modification of the core elements.
2Strength
If reinforcement structures are added to connect core elements, then the strength and stability of the core are improved, but the device complexity increases due to additional components and assembly steps
Solution Approach 1:
Reinforcement elements are inserted into pre-formed tunnel structures that are nested within the core elements themselves. This nesting approach integrates the reinforcement system within the existing core geometry, avoiding the need for external connection hardware or complex assembly mechanisms while still providing robust structural reinforcement.
Solution Approach 2:
The tunnel structures serve as intermediary elements that facilitate the connection between core elements. These tunnels provide a controlled pathway for inserting reinforcement elements, enabling reliable connections while simplifying the assembly process compared to direct external fastening methods.
3Ease of operation
If tunnel structures are incorporated into core elements, then the ease of assembling and reinforcing the core is improved, but the volume and material usage of the core increase
Solution Approach 1:
The tunnel structures create a porous or hollow-space architecture within the core elements. Rather than adding solid material, these tunnels provide functional voids that facilitate reinforcement element insertion while minimizing additional material usage. The tunnels are efficiently configured to provide maximum structural benefit with minimal volume consumption.
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
The invention provides a method for producing a core (100) of a casting mold for a component (1), a method for producing a component, and a core for a casting mold. The method for producing the core comprises at least the steps of: - providing individual core elements (110, 112) of the core (100), which, when assembled, correspond to the core (100) to be produced, wherein the individual core elements (110, 112) comprise at least one central element (110), which contains a spatially central region of the core (100), and a plurality of edge elements (112), wherein the core elements (110, 112) have tunnel structures (106) which correspond to one another at interfaces (105) between two core elements (110, 112) in such a way that a respective reinforcement structure (140) comprising at least one reinforcement element (141, 142) can be arranged in the tunnel structures (106) across the respective interface (105);and connecting the edge elements (112) to the central element (110) and to one another to produce the core (100), comprising arranging and fastening a reinforcement structure (141, 142) in mutually corresponding tunnel structures (106) of at least two core elements (110, 112).;