Turbocharger Casing Casting with Angled Parting Plane
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Solution Overview
Problem
Existing methods for producing turbocharger housings using the casting process face challenges in achieving precision and complexity in the outer surface structures due to the division of mold parts along the longitudinal axis, leading to manufacturing tolerances that are not sufficiently precise and the presence of unsightly burrs.
Innovation Solution
The method involves using core elements with parting planes at a predetermined angle, allowing the molded part to be formed entirely in one mold half, with core elements that can be destroyed post-casting to create more complex outer surfaces and integrated cooling jackets, thereby enhancing precision and reducing manufacturing tolerances to +/- 0.5mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the molded part is divided into two mold parts along the longitudinal axis and molded in two mold halves, then the casting can be produced using conventional casting methods, but the manufacturing precision deteriorates and burrs are generated at the parting plane
Solution Approach 1:
The mold is divided into two mold halves, but the molded part is segmented differently - it is divided into a casting part formed in one mold half and a feeder system formed in the other mold half. This segmentation allows the casting to be produced with high precision in one mold half without generating burrs at the parting plane, while the other mold half accommodates the feeder system.
Solution Approach 2:
The parting plane is rotated from the conventional position (perpendicular to the longitudinal axis) to a new orientation at a predetermined angle (e.g., 45 degrees) to the longitudinal axis. This dimensional change in the parting plane orientation allows the molded part to be formed entirely in one mold half, eliminating burrs and improving precision while still using a two-mold-half structure.
2Manufacturing precision
If the molded part is formed entirely in one mold half, then manufacturing precision and surface quality improve, but the mold structure becomes more complex
Solution Approach 1:
The mold structure is segmented into two functional mold halves: one dedicated to forming the casting part with high precision, and the other dedicated to forming the feeder system. This functional segmentation simplifies the manufacturing of each individual mold half while achieving overall high precision in the casting.
Solution Approach 2:
The parting plane is oriented at a predetermined angle (e.g., 45 degrees) to the longitudinal axis instead of being perpendicular to it. This angular orientation allows the casting part to be formed entirely in one mold half, improving precision and surface quality, while the mold structure remains manufacturable through conventional techniques.
3Shape
If core elements are used to form complex outer surfaces, then surface complexity and integration of cooling jackets improve, but the core elements must be destroyed after casting
Solution Approach 1:
The core elements are designed as disposable components that are destroyed after serving their purpose of forming the outer surface and cooling jacket cavities. The destruction of core elements through mechanical shaking or thermal binder breakdown is an acceptable trade-off for achieving complex outer surfaces and integrated cooling jackets without additional post-casting processing steps.
Solution Approach 2:
The core elements are made from inexpensive materials (molding sand with binder) that can be easily destroyed after use. These short-living core elements form the complex outer surfaces and cooling jacket cavities during casting, then are discarded through simple mechanical or thermal processes, avoiding the need for expensive or time-consuming post-casting operations.
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 approach enables the production of turbocharger housings with greater precision and complex outer surface structures, eliminating burrs and improving the integration of cooling jackets, resulting in improved manufacturing accuracy and heat dissipation capabilities.
Implementation Method 1
the core element can be mechanically destroyed after casting, for example by shaking
Implementation Method 2
the binder of the molding sand of the core element is destroyed by the heat during casting, so that the core element disintegrates by itself
Data Source
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AI summary
The invention relates to a method for producing a casting, in particular a housing of a turbocharger, wherein at least one mold part for forming the casting has a respective parting plane which is arranged at a predetermined angle with respect to the longitudinal axis of the casting, and wherein at least one core element is provided.