Segmented Foundry Core with Positive-Locking Sub-Segments
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Solution Overview
Problem
The complex structure of foundry cores with finely broken-down walls and multiple undercuts makes their removal from core shooting machines difficult, leading to high manufacturing costs and inefficiencies in series production.
Innovation Solution
Dividing the foundry core into sub-segments with positive-locking forming elements allows for simpler manufacturing and assembly, enabling easy positioning and secure fixing during casting, without the need for complex slider arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the foundry core is manufactured as a complete hollow body with finely broken-down walls and multiple undercuts, then the cavities and channels in the cast part are precisely formed, but the removal of the core from the core shooting machine becomes extremely difficult and costly
Solution Approach 1:
The foundry core is divided into multiple individual core pieces instead of manufacturing it as a complete hollow body. Each core piece has a simpler geometry without multiple undercuts, allowing for easier removal from the core shooting machine. The core pieces are then assembled together using connecting elements to form the complete core structure, thereby maintaining manufacturing precision while reducing device complexity.
2Ease of operation
If complex slider arrangements are provided to remove finely broken-down cores, then the cores can be separated from the core shooting machine, but the manufacturing costs increase and series production efficiency decreases
Solution Approach 1:
By segmenting the core into multiple simpler core pieces, the removal operation becomes straightforward without requiring complex slider arrangements. This enables faster ejection and handling of core pieces, significantly improving productivity in series production while maintaining ease of operation.
Solution Approach 2:
The core pieces are pre-formed as separate components with simpler geometries before assembly. This preliminary segmentation allows for rapid ejection from the core shooting machine without complex removal mechanisms, thereby enhancing both ease of operation and production efficiency.
3Ease of manufacture
If the foundry core is divided into sub-segments, then the manufacturing process is simplified and costs are reduced, but additional forming elements are needed to fix the sub-segments together
Solution Approach 1:
The core is divided into sub-segments that can be manufactured separately using simpler processes. The forming elements used to join these sub-segments are designed to be minimal and integrated into the core pieces themselves, adding negligible complexity while enabling manufacturing simplification and cost reduction.
Solution Approach 2:
The forming elements are merged with the core pieces during the same manufacturing process, rather than being added as separate components. This integration minimizes the additional complexity introduced by the forming elements while maintaining the manufacturing advantages of segmentation.
Data Source
AI summary
The present invention relates to a foundry core, which has the base form of a hollow body, with the foundry core being formed from a moulding material consisting of a mixture which is formed from a moulding sand and a binder and optionally from additives added to set its properties and a method for its manufacture. The foundry core according to the invention can be easily manufactured. This is achieved as a result of the foundry core being divided into at least two sub-segments and forming elements interacting with one another in a positive-locking manner being provided on the edge sides, with which sub-segments arranged adjacent to one another abut on one another, or in proximity to these edge sides, via which forming elements the sub-segments arranged adjacent to one another are fixed by positive locking immovably against one another at least in one direction.