Separable Variable Mold Portions for Investment Casting
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Solution Overview
Problem
Investment casting is a time-consuming and expensive process, particularly when precise dimensions are required, and current mold systems are not adequately thermally adjustable to accommodate variations in cores, leading to issues like core cracking and imprecise casting articles, with no proactive mechanism to address these challenges.
Innovation Solution
A mold system comprising separable mold portions that can be coupled together to accommodate different cores, with interchangeable versions and thermal conduits for precise temperature control, allowing for customizable and modular mold formation to handle varied cores and improve casting article quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single mold is used for a specific core, then manufacturing precision is improved, but adaptability deteriorates when core variations occur
Solution Approach 1:
The mold is divided into multiple separable mold portions that can be independently selected and assembled. Each mold portion can be interchanged to accommodate different core variations, allowing the system to maintain precision for each core type while providing overall adaptability across multiple core designs.
Solution Approach 2:
The separable mold portions are designed with universal coupling mechanisms that allow the same portions to be used across different mold configurations. This enables a single mold portion to serve multiple functions with different cores, improving adaptability without sacrificing the precision needed for each specific core-mold pairing.
2Manufacturing precision
If traditional mold manufacturing is used, then manufacturing precision is achieved, but productivity deteriorates due to extensive manufacturing time
Solution Approach 1:
By segmenting the mold into separate portions that can be manufactured independently, the system enables parallel processing of multiple mold components. This significantly reduces total manufacturing time while maintaining the precision requirements for each individual portion through controlled manufacturing processes.
Solution Approach 2:
Mold portions are pre-manufactured and stored in a standardized format, allowing for rapid assembly when needed. This preliminary preparation eliminates the need for time-consuming on-demand mold fabrication, improving productivity while preserving precision through standardized manufacturing protocols.
3Productivity
If high pressure sacrificial fluid is injected to fill the mold, then productivity is improved, but reliability deteriorates due to core cracking or breaking
Solution Approach 1:
The separable mold portions allow for distributed fluid injection points and controlled filling patterns. By dividing the mold into multiple sections, the system can inject sacrificial fluid more gradually and controllably, preventing excessive pressure buildup that would cause core cracking, while still maintaining efficient filling speeds.
Solution Approach 2:
The system enables controlled adjustment of injection pressure parameters and fluid flow rates to each mold portion. By optimizing these parameters for each specific core-mold configuration, the system achieves reliable core integrity while maintaining high productivity through efficient filling.
4Reliability
If mold adjustments are made to address core cracking, then reliability is improved, but productivity deteriorates due to time-consuming adjustments
Solution Approach 1:
When core cracking issues arise, only the specific mold portions needing adjustment need to be replaced or modified, rather than adjusting the entire mold. This segmented approach allows for targeted repairs and adjustments that minimize production downtime and maintain overall productivity while improving reliability.
Solution Approach 2:
If a mold portion is damaged or needs adjustment, it can be quickly replaced with a备用 portion while the damaged one is repaired or recovered. This enables rapid maintenance operations that minimize impact on production schedules, maintaining both reliability and productivity.
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 mold system reduces the time and cost associated with adjusting cores and molds, enhances the ability to handle varied core structures, and prevents core damage by providing precise thermal control, resulting in improved casting article quality and reduced production costs.
Implementation Method 1
Each of the plurality of separable mold portions includes a mold thermal conducting conduit therein configured to pass a temperature controlled thermal fluid therethrough to control a temperature of at least the sacrificial material fluid within the respective separable mold portion
Data Source
AI summary
A mold system and method for forming a casting article for investment casting is disclosed. The mold system includes a mold for receiving therein a selected core chosen from a plurality of varied cores. The mold includes a plurality of separable mold portions that are coupleable together to create the mold and configured to form a sacrificial material from a sacrificial material fluid about the selected core. At least one selected separable mold portion of the plurality of separable mold portions includes a set of varied interchangeable versions of the at least one selected separable mold portion. Each varied interchangeable version of the selected separable mold portion is configured to accommodate a different core of the plurality of varied cores. A number of systems for controlling a temperature of the mold are also disclosed.