Split Mold Casting Device with Dual Suction for Decompression Control
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Solution Overview
Problem
The suctioning counter-pressure casting method faces challenges in stabilizing the degree of decompression and decompression rate for complex-shaped products using split molds, leading to degraded filling performance and high facility costs due to the need for a hermetic chamber.
Innovation Solution
A casting device and method utilizing a combined structure of split molds and cases with chamber and cavity suction devices to directly reduce pressure within the chamber and cavity, independent of the mold clearance and chamber volume, improving filling performance and reducing facility costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hermetic chamber covering the entire mold is used for suctioning counter-pressure casting, then the degree of decompression can be controlled, but the facility cost increases and the chamber volume becomes large
Solution Approach 1:
The invention divides the suction system into two independent parts: a chamber suction device for the hermetic chamber and a cavity suction device for the mold cavity. This segmentation allows each suction device to operate independently with optimized parameters, eliminating the need for a large hermetic chamber while maintaining decompression control stability.
Solution Approach 2:
The invention introduces a communication pathway as an intermediary between the cavity and chamber, allowing pressure equalization and controlled air flow. This intermediary structure enables precise decompression control without requiring the entire chamber to be sealed and evacuated, reducing facility complexity and cost.
2Device complexity
If indirect suction through hermetic chamber decompression is used, then the system is simpler, but the decompression rate cannot be stabilized for complex-shaped products
Solution Approach 1:
The invention segments the suction function into two independent devices: chamber suction device for overall pressure control and cavity suction device for precise cavity decompression. This segmentation enables stable decompression rate control for complex-shaped products while maintaining system simplicity through modular design.
Solution Approach 2:
The invention changes the suction parameters by providing separate control for chamber and cavity decomposition rates. The cavity suction device can be adjusted to provide higher negative pressure specifically for complex-shaped products, ensuring stable filling without requiring complex overall system redesign.
3Volume of stationary object
If the chamber volume is reduced to lower facility costs, then the equipment becomes more compact, but the decompression control becomes less stable
Solution Approach 1:
The invention segments the suction control into two independent systems, allowing the chamber volume to be minimized while the cavity suction device provides precise decompression control. This segmentation decouples the relationship between chamber volume and decompression stability.
Solution Approach 2:
The communication pathway acts as an intermediary that allows the small chamber to effectively control the larger cavity decompression. The pathway enables pressure equalization and controlled air flow, maintaining decompression stability even with reduced chamber volume.
4Reliability
If high negative pressure is applied to inhibit air on low temperature surfaces, then air entrapment is reduced, but the risk of suctioning outer air through parting lines increases
Solution Approach 1:
The invention applies preliminary anti-action by providing a communication pathway that allows controlled air flow between chamber and cavity before high negative pressure is applied. This prevents uncontrolled outer air suction through parting lines while maintaining effective air entrapment prevention.
Solution Approach 2:
The communication pathway serves as an intermediary that mediates between the cavity and outer environment, allowing controlled pressure equalization and preventing uncontrolled air suction through parting lines while still enabling effective decompression to prevent air entrapment.
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
This configuration stabilizes the decompression and compression rates, enhances the filling performance of molten metal, reduces defects, and lowers production costs by minimizing the chamber volume and energy loss, particularly suitable for complex-shaped products requiring split molds and cores.
Implementation Method 1
reduces the pressure at least in the chamber by means of a chamber suction device through a chamber pipe that is connected to the chamber and extends to the outside of the chamber
Implementation Method 2
reduces the pressure in the cavity by means of a cavity suction device through a cavity pipe that is connected to the cavity and extends to the outside of the chamber
Implementation Method 3
a compressor that increases the pressure in the holding furnace
Data Source
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AI summary
A casting device includes: a split mold for forming a cavity, including a lower mold, a middle mold that slides in a horizontal direction on the lower mold and an upper mold; a split case for forming a chamber, including a lower case to which the lower mold is attached and an upper case to which the upper mold is attached; a chamber suction device that reduces a pressure at least in the chamber through a chamber pipe that is connected to the chamber and extends to an outside of the chamber; and a cavity suction device that reduces a pressure in the cavity through a cavity pipe that is connected to the cavity and extends to the outside of the chamber. The cavity and the chamber are formed when the middle mold is closed on the lower mold and the split case is closed.