Vehicle Sub-Frame Bulging Sections for Core Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Die-cast vehicle sub-frames with hollow bodies face challenges in maintaining constant thickness to suppress weight increase while ensuring core strength, as acute angle parts in the core are fragile and difficult to form without compromising weight.
Innovation Solution
The sub-frame design incorporates bulging sections on the front and rear walls, avoiding the top and bottom parts, allowing the core to be formed without acute angles, thus securing strength and maintaining constant thickness, and the parting line is optimized to prevent molten metal backflow and impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the core is formed in a substantially trapezoidal shape in vertical cross section to match the sub-frame shape, then the sub-frame can have constant thickness and suppressed weight increase, but the core has acute angle parts that are fragile and difficult to secure strength
Solution Approach 1:
The invention applies curvature by forming bulging sections on the front wall and rear wall of the hollow body. These bulging sections replace the acute angle parts of the trapezoidal core with curved surfaces that bulge outward, eliminating the fragile corners while maintaining the overall trapezoidal shape. The curved surfaces provide better stress distribution and core strength without increasing sub-frame weight.
2Strength
If the core is formed in a substantially hexagonal shape in vertical cross section with acute angle parts removed to secure core strength, then the core strength is improved, but the sub-frame has parts thicker than other parts and it becomes difficult to suppress weight increase
Solution Approach 1:
The invention applies local quality by making only the necessary local modifications to the core shape. Instead of changing the entire core to a hexagonal shape, only the acute angle parts are replaced with bulging sections that curve outward. This localized modification provides the needed strength improvement without globally thickening the sub-frame structure.
3Shape
If the front wall and rear wall are inclined upwardly to form a trapezoidal shape, then the sub-frame achieves the desired geometric shape, but the parting line position creates challenges for core strength and manufacturing
Solution Approach 1:
The invention applies curvature at the critical locations where the parting line intersects the core. The bulging sections with outward-curving surfaces eliminate the acute angles that would otherwise be created by the trapezoidal geometry, making the core easier to manufacture and stronger, while preserving the overall trapezoidal shape of the sub-frame.
Data Source
AI summary
A vehicle sub-frame includes a hollow body having a hollow part thereinside formed by casting using a core. The hollow body includes a front wall and a rear wall. The front wall has a front bulging section formed to bulge outward at a position corresponding to a parting line. The front bulging section is formed on a part avoiding a top wall and a bottom wall of the hollow body. The rear wall has a rear bulging section formed to bulge outward at a position corresponding to the parting line. The rear wall is formed on a part avoiding the top wall and the bottom wall.