Ford Global Technolgoies, LLC

Ford Motor Company Limited

Paul Christopher Susalla

Varinder Singh Saini

Ronald H Hassenbusch

David Michael Boren

Richard Raymond Urban

Scott Gafken

Lixing Ma

John Phillips

Yuan-Ping Hu

A method for forming a product having cast-in components provides an insulating barrier of solidified sand formed next to the insider diameter of the cast-in component. The center of the solidified sand is hollow. Before pouring the molten metal into the primary runner/riser system that feeds the portion of the mold that will create the actual part, the molten material is poured into the hollow portion of the solidified sand through a separate runner/riser system. This molten metal provides the energy necessary to heat the cast-in part to an acceptable temperature. The temperature can be controlled by the shape, thickness and material of the insulating member. This controlled time/temperature profile enables the creation of a final cast product that demonstrates good quality properties at the cast/insert interface. The method of the disclosed inventive concept has the added benefit of not altering the resulting part itself.

Method for thermal control of cast-in components during manufacturing

The present invention provides methods to create a pattern part, and a subsequent mold core package, that can be used in the casting process to cast one or more die components having a near net-shape of the finished part. In this way, the present invention provides a cast part which greatly reduces the amount of finishing work that needs to be performed on the part after casting. Further, the present invention provides a method which involves less upfront stock material to cast the near net-shape of the desired die component part. The present invention accomplishes this by providing an efficient and effective automated method to determine where and how to add appropriate mechanical features to a design model part to produce a manufacturing model part in a CAD software program.

Automated cad process for creating mold packages

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South Lyon, MI, United States of America

Paul Christopher Susalla