Titanium Golf Club Casting Cluster for Centrifugal Thin-Wall Filling
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Solution Overview
Problem
Casting golf club heads with thin walls using conventional techniques is challenging due to the need for a narrower mold cavity, which requires excessive force to fill and results in low yield and high material waste.
Innovation Solution
A casting cluster with a receptor, runners, and multiple molds configured to receive molten metal, allowing for the production of golf club heads with thin walls by rotating the cluster at high speed to ensure complete filling without voids, achieving a yield of at least 80%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional casting techniques are used to produce golf club heads with thin walls, then the wall thickness can be reduced, but the mold cavity becomes narrower requiring excessive force to fill and resulting in low yield and high material waste
Solution Approach 1:
The invention divides a single large mold cavity into multiple smaller mold cavities arranged in an array. Each cavity is filled independently through its own gate system, eliminating the need to force molten metal through a narrow single cavity. This segmentation allows thin-walled club heads to be produced without excessive filling forces while maintaining high yield through simultaneous multi-cavity casting.
2Length of moving object
If conventional casting techniques are used to produce golf club heads with thin walls, then the wall thickness can be reduced, but material waste increases due to low yield
Solution Approach 1:
The invention merges multiple mold cavities into a single casting cluster that is filled from a common molten metal source. The cluster includes multiple gates distributed across the cavity array, allowing simultaneous filling of multiple thin-walled club heads in one casting operation. This merging approach increases overall yield by producing multiple parts per cycle while maintaining the thin wall geometry through optimized gate distribution.
3Length of moving object
If a narrower mold cavity is used to accommodate thin walls, then the wall thickness can be reduced, but the force required to fill the cavity increases excessively
Solution Approach 1:
The casting system segments the filling process by providing multiple independent filling paths through distributed gates across the mold cavity array. Instead of forcing molten metal through a single narrow cavity requiring excessive force, the system distributes the filling action across multiple cavities, each receiving molten metal through its own gate. This segmentation reduces the force requirement per cavity while enabling production of thin-walled club heads.
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 enables efficient production of golf club heads with thin walls, reducing material waste and increasing yield, while maintaining structural integrity and durability.
Implementation Method 1
rotating the cluster at high speed to ensure complete filling without voids
Data Source
AI summary
Disclosed herein is a casting cluster for casting a body of a golf club head made of titanium or a titanium alloy. The casting cluster comprises a receptor and a plurality of runners coupled to the receptor and configured to receive molten metal from the receptor. The casting cluster also includes at least twenty-eight main gates. At least two of the main gates are coupled to each of the runners and each main gate is configured to receive molten metal from a corresponding one of the plurality of runners. The casting cluster further comprises at least twenty-eight molds. Each mold of the at least twenty-eight molds is configured to receive molten metal from a corresponding one of the main gates and to cast a body of a golf club head that has a volume of at least 100 cm3.