Optimized recursive foundry tooling fabrication method

Abstract

A method for producing a pattern for making a cast part is described which comprises the steps of defining the structure of the part in terms of computer aided design system data, selecting a parting surface for the part to be cast; defining core requirements for the part by sweeping each positive feature of the part to the parting surface, subtracting the part from the projection, adding any remaining volume to the core, sweeping negative features away from the parting surface to the top or bottom of the mold and subtracting the negative features from the projection and intersecting the remainder of the part and adding any remaining volume to the core; repetitively generating alternative parting surfaces for the part and defining the corresponding core requirements whereby an optimum parting surface is defined for which the quantity and complexity of the corresponding core requirements are minimized, constructing core prints for each core requirement; constructing a pattern by adding the core prints to the part; and defining draft for the pattern surfaces perpendicular to the optimum parting surface.