Vehicle Support Structure Rib Core Recess for Weight Reduction
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Solution Overview
Problem
The existing steering knuckle support structures for vehicles, formed using mold split casting, require a draft angle that results in unnecessary thickness and weight, hindering weight reduction while maintaining structural strength.
Innovation Solution
A support structure for vehicles with a rib continuously formed on the support portion, featuring a core portion recessed in a direction different from the mold split direction, allowing for reduced weight and streamlined manufacturing by eliminating unnecessary thickness and facilitating mold removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a draft angle is applied to the rib in mold split casting, then the rib can be removed by mold split, but unnecessary thickness is created on the rib
Solution Approach 1:
The core portion is recessed in a direction different from the mold split direction (perpendicular dimension), allowing the rib to be formed without draft angle restrictions while enabling punching mold removal through a different dimensional approach
Solution Approach 2:
The manufacturing process is segmented into two stages: first forming the rib structure without draft angle constraints, then separately removing the punching mold through the core portion recess, avoiding the need to compromise rib thickness for mold removal
2Ease of manufacture
If the base portion of the rib is made thick to accommodate mold split, then the rib can be removed by mold split, but weight reduction is hindered
Solution Approach 1:
The core portion is locally recessed only where needed for punching mold removal, while the rest of the rib maintains optimal thickness for strength and weight, avoiding unnecessary material throughout the entire rib structure
3Ease of manufacture
If the core portion is formed with an inclined wall surface, then the punching mold can be easily removed, but the appearance may become conspicuous
Solution Approach 1:
The inclined wall surface of the core portion is formed with a rounded surface that smoothly connects the bottom surface and outer surface of the rib, making the core portion less conspicuous while maintaining ease of punching mold removal
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 achieves weight reduction and maintains structural strength without unnecessary thickness, enabling efficient manufacturing and a more inconspicuous design.
Implementation Method 1
a punching mold that slides in a direction different from the mold split direction of the casting mold
Implementation Method 2
The support structure for the vehicle is molded by a casting mold
Data Source
AI summary
A support structure for a vehicle molded by a casting mold, provided between a vehicle body and a vehicle component, and including a support portion which supports the vehicle component and a rib which is continuously formed on the support portion. The support structure for a vehicle includes a core portion recessed in a direction different from a mold split direction of the casting mold on a side surface portion of the rib.