David A Caulk

US Patent:

7225049, May 29, 2007

Filed:

Jun 21, 2005

Appl. No.:

11/158283

Inventors:

David A. Caulk - Troy MI, US

Assignee:

GM Global Technology Operations, Inc. - Detroit MI

International Classification:

G06F 19/00
B22C 9/04

US Classification:

700146, 436 55, 164 41, 164 34, 164457

Abstract:

Parameters specifying properties of the materials used in the lost foam casting process are input at an input step. Numerical methods may be used to simultaneously solve a set of coupled equations relating thermal properties, flow properties, and other physical properties of the metal and foam. A profile number Ω and an engulf number E may be evaluated using the values of physical quantities determined during the numerical solution step. Once values for the profile number Ω and engulf number E have been determined, these values may be checked to see if they lie within appropriate ranges.

US Patent:

7618823, Nov 17, 2009

Filed:

Jun 21, 2005

Appl. No.:

11/158299

Inventors:

Martin R. Barone - Skovde, SE
David A. Caulk - Troy MI, US

Assignee:

GM Global Technology Operations, Inc. - Detroit MI

International Classification:

G01N 35/08
G06F 19/00
B22D 46/00
B22C 9/02

US Classification:

436 55, 164457, 164 34, 164 41, 700146

Abstract:

Disclosed are a method, system and apparatus for analyzing foam decomposition in contact mode during mold filling in lost foam casting, the foam decomposition having a foam material vapor fraction and the mold filling having a mold filling speed. The method includes providing a plurality of parameter values for casting process parameters as variables of a plurality of predetermined equations, simultaneously solving the plurality of predetermined equations including the parameter values, calculating a vapor value for the fraction of the foam material that decomposes to vapor, an undercut length value designating the amount of coating exposed to gas diffusion, and a speed value for the mold filling speed, and determining whether to adjust at least one of the parameter values based on the results for the vapor value, the undercut length value, or the speed value.

US Patent:

20060000576, Jan 5, 2006

Filed:

Jun 21, 2005

Appl. No.:

11/158279

Inventors:

David Caulk - Troy MI, US

International Classification:

B22C 9/04
B22D 46/00

US Classification:

164457000, 164004100, 164034000

Abstract:

Disclosed are a method, system and apparatus for analyzing foam decomposition in gap mode during mold filling in lost foam casting, the casting process in gap mode characterized by a bubble flux and the mold filling having a mold filling speed. The method includes providing a plurality of values for casting process parameters as variables in a plurality of predetermined equations, simultaneously solving the plurality of predetermined equations including the parameter values, calculating a flux value for the bubble flux, a gap value for the gap width, and a speed value for the mold filling speed, and determining whether to adjust at least one of the parameter values based on at least one result for the bubble flux, mold filling speed, or gap width.