V-Design Cylinder Crankcase Casting with Feeder Core Inversion

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Solution Overview

Problem

Existing methods for producing V-shaped cylinder crankcases using light metal alloys face challenges such as uneven solidification leading to reduced strength, long solidification paths, and difficulties in completely cutting off the supply path during casting, which result in coarser structures and increased tool temperatures.

Innovation Solution

A device with a feeder core arranged between opposite sleeves of the cylinder banks, allowing for a maximum of one feeder core per cylinder pair, which can be fixed in the casting mold, ensuring rapid solidification and minimizing the number of feeder cores, with multiple feeder cores providing refilling capabilities along the crankcase length to prevent blowholes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If molten metal is introduced from the cylinder head side, then the crankcase solidifies first, but the bearing seats solidify more slowly resulting in coarser microstructure and reduced strength

Engineering Contradiction:

Improvestrength in bearing seat areaVSAvoidmicrostructure uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional gating approach by introducing molten metal from the crankcase area rather than the cylinder head side. This reversal ensures that the bearing seats and cylinder webs solidify first (achieving fine microstructure and high strength), while the crankcase solidifies later, eliminating the microstructure problems associated with conventional gating.

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If molten metal is introduced from the crankcase side, then bearing seats solidify rapidly with fine microstructure, but long solidification paths require high mold temperatures causing blowholes

Engineering Contradiction:

Improvestrength in bearing seat areaVSAvoidblowholes

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces feeder cores as intermediary elements that serve dual functions: they provide localized feeding to prevent shrinkage cavities in thick-walled areas, and they act as thermal regulators to maintain appropriate temperatures in critical zones during solidification, thereby preventing blowholes while enabling rapid solidification in bearing seats.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If multiple feeder cores are arranged inside the mold, then refilling is possible throughout the crankcase, but the number of feeder cores increases making placement and demolding difficult

Engineering Contradiction:

Improveprevention of blowholesVSAvoidnumber of feeder cores

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple feeder core functions into a single strategically positioned feeder core located between opposing quills. This single feeder core provides refilling along the entire crankcase length through its positioning and dimensions, eliminating the need for multiple separate feeder cores and simplifying both placement and demolding operations.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If risers are positioned outside the cavity, then shrinkage cavities are prevented, but rapid solidification in bearing seat area and cylinder head is not achievable

Engineering Contradiction:

Improveprevention of shrinkage cavitiesVSAvoidstrength in bearing seat area

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses feeder cores that are inserted into the mold cavity and positioned to directly contact or closely approach the bearing seats and cylinder webs. These feeder cores create localized feeding zones that enable rapid solidification in critical areas while still preventing shrinkage cavities, effectively copying the beneficial effects of external risers but achieving them within the cavity structure.

Inventive Principle:

Principle #26Copying

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 achieves optimal structural properties in bearing seat and cylinder web areas with rapid cooling, reducing cycle times and avoiding structural defects, while minimizing tool temperatures and energy consumption.

Implementation Method 1

refilling can take place centrally in the cylinder crankcase

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

The mold components forming the main bearing points and the quills are designed to be actively cooled. This results in high strength values in this critical area.

Methodology Applied

Scientific EffectRapid cooling: Cooling

Implementation Method 3

the molten metal initially remains liquid after the gates are closed and solidify rapidly. The molten metal in the remaining cavities begins to solidify from the outside inwards.

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentEP2636467B1Device for manufacturing a cylinder crank case in V design

Publication Date: 2019.10.02 KS HUAYU ALUTECH GMBH

Figure 1~2

AI summary

The device has an outer casting mold (10) that is provided with molded portions (12,14,16,18) for forming a cylinder crankcase (24). Several guides (20) are retracted into the casting mold to form cylinders. Several inner cores (32) are arranged in the mold to form a portion of a crank chamber (30). Several feeder cores (44) are arranged in the interior of the mold, after removing casting. The feeder cores are positioned between the guides at the side facing the crank chamber.