Aluminum Vehicle Support Structure to Prevent Casting Blowholes
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Solution Overview
Problem
Existing vehicle support structures cast in aluminum or aluminum alloys face issues with blowhole generation and weight reduction when a vehicle part is attached and fixed to boss portions at three locations, limiting further weight reduction and stiffness enhancement.
Innovation Solution
A vehicle support structure with a triangular arrangement of boss portions and tilted connection portions, cast using a method where molten metal is poured from the side of the third boss portion, reducing intermediate thickness and preventing blowholes, while maintaining stiffness through an H-shaped cross-section in the connection areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If boss portions are connected by straight-shaped connection portions in a three-location configuration, then the structure provides adequate support and attachment capability, but blowholes are generated during casting
Solution Approach 1:
The connection portions are designed with curved, tilted geometry instead of straight shapes. The first connection portion connects the first and third boss portions with a tilted configuration, and the second connection portion connects the second and third boss portions similarly. This curved design redirects molten metal flow during casting, preventing blowhole formation while maintaining structural integrity.
2Weight of moving object
If the vehicle support structure is cast in aluminum or aluminum alloy for weight reduction, then weight decreases, but blowholes are generated in the connection areas
Solution Approach 1:
The tilted, curved connection portions are specifically designed to control molten metal flow during casting. The curvature redirects the flow away from the third boss portion area, preventing blowhole formation in the aluminum alloy casting while enabling weight reduction through material selection.
3Weight of moving object
If connection portions are reduced in thickness to achieve weight reduction, then weight decreases, but stiffness may be compromised
Solution Approach 1:
The tilted, curved geometry of the connection portions provides structural efficiency. The curved shape distributes stresses more effectively than straight connections, allowing reduced thickness while maintaining or enhancing stiffness. The tilt angle optimizes both weight reduction and load-bearing capability.
Solution Approach 2:
The connection portions are designed with asymmetric tilted configurations rather than uniform thickness or symmetric shapes. This asymmetric design optimizes the distribution of material thickness to achieve the right balance between weight reduction and stiffness, with varying thickness profiles tailored to specific load requirements.
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
Prevents blowhole generation, achieves further weight reduction, and enhances stiffness by optimizing the casting process and connection geometry.
Implementation Method 1
starting pouring molten metal of aluminum or an aluminum alloy into a molding mold, with a sprue at a lateral position and the main body portion in a horizontal state
Implementation Method 2
thereafter performing casting after the pouring of the molten metal is completed while the molding mold is tilted such that the sprue is located at an upper position
Data Source
AI summary
A vehicle support structure including: a main body portion (2) for axially supporting an axle rotatably; and a vehicle part attachment portion (3) extended from the main body portion. The vehicle part attachment portion has a first boss portion (4), a second boss portion (5), and a third boss portion (6) placed in a triangular form when viewed in a direction along the axle, a first connection portion (7) connecting the first boss portion with the third boss portion, and a second connection portion (8) connecting the second boss portion with the third boss portion, and is a cast of aluminum or an aluminum alloy. The first and second connection portions are tilted in such a manner that center portions in a longitudinal direction are reduced in thickness. A sprue mark is formed on a side portion of the third boss portion on an opposite main body portion side.