Side Feeder Net Fabric Frame Casting Mold
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Solution Overview
Problem
Side feeder systems in casting molds face challenges with solidified casting material residues that require costly and labor-intensive removal processes due to the need for large connections to the mold cavity, which are difficult to break away under thermal conditions.
Innovation Solution
A side feeder system incorporating a net-like fabric with a through hole, stretched and fixed within a heat-resistant frame, positioned close to the casting model or mold cavity, ensuring low flow resistance for liquid metal and facilitating easier removal of residues by creating predetermined breaking points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connecting channel between the feeder and mold cavity is made large to accommodate side feeder positioning, then the feeder can be properly positioned laterally to the casting model, but the liquid metal flow resistance decreases and cleaning costs increase due to larger feeder residues
Solution Approach 1:
The connecting channel is segmented into two sections: an upper section with larger cross-section for proper side feeder positioning and access, and a lower section with restricted cross-section that creates predetermined breaking points. This segmentation allows the feeder to be positioned laterally while limiting the amount of residue that reaches the casting.
Solution Approach 2:
Different sections of the connecting channel have different cross-sectional dimensions tailored to their specific functions. The upper section has larger dimensions for feeder access and positioning, while the lower section has restricted dimensions to control metal flow and create breaking points for easy residue removal.
2Ease of manufacture
If a net-like fabric is arranged in the connecting channel to create predetermined breaking points for easier residue removal, then cleaning costs decrease, but the fabric may be drawn into the mold cavity due to thermal conditions and metal flow
Solution Approach 1:
A frame made of heat-resistant material is introduced as an intermediary structure to hold and secure the net-like fabric in the connecting channel. The frame acts as a mediator that prevents the fabric from being drawn into the mold cavity by metal flow or thermal conditions while still allowing the fabric to create predetermined breaking points for residue removal.
Solution Approach 2:
The mechanical strength and thermal stability parameters of the supporting structure are changed by using a frame made of heat-resistant material instead of directly relying on the net-like fabric's mechanical properties. This allows the fabric to perform its filtration and breaking point function without compromising positioning stability under thermal conditions.
3Difficulty of detecting and measuring
If the net-like fabric extends over the entire surface of the connecting duct to ensure filtration, then metal flow filtration improves, but the flow resistance for liquid metal increases significantly
Solution Approach 1:
The net-like fabric is selectively positioned only in the lower section of the connecting channel where restricted cross-section already provides flow control. This local placement maintains filtration functionality while minimizing the area where fabric resistance acts on the metal flow, thereby reducing overall flow resistance compared to full-surface coverage.
Solution Approach 2:
The connecting channel is divided into sections with the net-like fabric placed only in the lower restricted section rather than covering the entire surface. This segmentation allows filtration to occur in a controlled zone without creating excessive flow resistance throughout the entire connecting channel.
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 solution allows for reliable positioning and tensioning of the net-like fabric, preventing it from being drawn into the mold cavity and ensuring it remains effective during casting, reducing cleaning costs and improving residue removal efficiency.
Implementation Method 1
a net-like fabric made of a refractory material is arranged in the connecting channel
Implementation Method 2
stretched and fixed within a heat-resistant frame, positioned close to the casting model or mold cavity
Data Source
Figure 1
Figure 2~4
AI summary
The invention relates to a method for producing casting molds with a casting pattern (10) representing the mold cavity of the casting mold and at least one side feeder system (11) positioned on the casting pattern (10) or mold cavity, wherein the side feeder system (11) has a feeder (12) forming an inner feeder cavity (13) and a feeder cap (14) having a connecting channel (15) to the casting pattern (10) or the mold cavity, and the main axis of the connecting channel (15) runs at an angle to the main axis of the feeder (12), wherein a frame (16) made of a heat-resistant material with a net-like fabric made of a refractory material and having a through-hole stretched therein is inserted and fixed in the casting mold between the casting pattern-side end of the connecting channel (15) and the casting pattern (10) or the mold cavity.