Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level.

Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level. A horizontal support rail slidably supports the vessel to provide a horizontal movement perpendicular to the tilt axis.

Abstract: A cutting tool having a crystalline tip is pressed with a uniform pressure against the outboard surface of a vehicle wheel as the wheel is rotated. The smoothed wheel surface is then chrome plated to provide a cosmetic finish to the wheel face.

Abstract: A mounting system for the air intake manifold assembly for attaching portions of an intake manifold. The system has an upper body part and a lower body part and is used for an internal combustion engine. The system includes a notch. The notch includes a lower surface and the notch is formed in the upper body part of the intake manifold. The system includes a mounting tab. The mounting tab includes a bottom wall. The mounting tab is formed in the lower body part of the intake manifold. A substantial portion of the lower surface of the notch and a substantial portion of the bottom wall of the mounting tab contact one another to couple the upper body part of the intake manifold and the lower body part of the intake manifold together.

Abstract: A multiple layered finish for a vehicle wheel surface that includes a first base layer formed from an organic material disposed upon a portion of the wheel surface. The finish also includes a second layer formed form a first inorganic material that covers the base layer and a third layer formed from a second inorganic material disposed over the second layer.

Abstract: This invention relates to an improved method for forming a full face fabricated vehicle wheel and includes the steps of: (a) providing a disc blank formed from a metal material; (b) subjecting the disc blank to a metal stamping operation to produce a partially formed non-bowl shaped full face wheel disc having at least one stamped pocket formed therein; (c) forming at least one decorative window in the partially formed full face wheel disc; (d) coining a back side of the window in the partially formed full face wheel disc; (e) trimming an outer edge of the partially formed full face wheel disc to a predetermined diameter; (f) forming a center hub hole in the partially formed full face wheel disc; (g) subjecting the partially formed full face wheel disc to one or more final metal forming operations to form at least one of an outer flange and a plurality of lug bolt mounting holes in the partially formed wheel disc so as to produce a finished full face wheel disc; and (h) securing the full face wheel disc to a

Abstract: An EDM apparatus for reducing wheel runout includes a support structure. The support structure is adapted to support and rotate a vehicle wheel. An electrode is also included for electric discharge machining at least one surface of the vehicle wheel.

Abstract: A mold of a casting machine is filled to make a cast article. The method includes providing a molten metal to a casting chamber in fluid communication with the mold, the casting chamber having a supply conduit for introducing a gas into the casting chamber, and the casting chamber having an evacuation conduit for delivering the molten metal from the casting chamber to the mold. The method also includes controlling the filling of the mold during a first time interval by delivering the molten metal from the casting chamber to the mold at a first rate. The method further includes controlling the filling of the mold during a second time interval by delivering the molten metal from the casting chamber to the mold at a second rate. The filling of the mold decelerates from the first rate to the second rate and the second rate does not exceed the first rate.

Abstract: An improved intake manifold valve system for use in a vehicle engine and method of assembly therein. The intake manifold valve system includes a valve housing defining an axis. The valve housing includes a first end and an opposite second end. The first end has an opening formed therein. The opening defines a first axial length. The intake manifold valve system includes a valve shaft assembly disposed in the valve housing. The valve shaft assembly includes a shaft having at least one valve provided thereon. The shaft includes a first end and an opposite second end. The second end has with an extended portion. The extended portion defines a second axial length that is greater than the first axial length of the opening. When the extended portion of the shaft is positioned in the opening, the extended portion is movable axially within the opening. At the same time, the extended portion is operative to operatively support the shaft relative to the valve housing.

Abstract: A mold temperature control system comprises a mold section having a cavity, a fluid circuit to distribute a flow of a conditioning fluid, the fluid circuit being positioned spaced apart from the cavity, a temperature sensor positioned in the mold to generate a signal representative of a temperature in the mold, a controllable supply of the conditioning fluid, and a controller for automatically initiating flow of the conditioning fluid through the fluid circuit in response to an initiation temperature and for automatically terminating flow of the conditioning fluid through the fluid circuit in response to a termination temperature.

Abstract: This invention relates to an improved fabricated vehicle wheel and method for producing the same.

Abstract: A quick-change lock assembly is adapted to releasably attach a fill tube to a mold in a casting machine, the fill tube connecting a furnace of the casting machine to the mold. The casting machine preferably utilizes a Vacuum Riserless Casting/Pressure Riserless Casting (VRC/PRC) process. The lock assembly includes an upper ring that is adapted to be attached adjacent an aperture in a surface of the mold of the casting machine. The outer ring has inner and outer concentric surfaces. The lock assembly also includes a lower ring that also has inner and outer concentric surfaces. The inner surface of the lower ring is operable to receive a fill tube. The outer surface of the lower ring is operable to be releasably attached to the inner surface of the upper ring.

Abstract: A flexible manufacturing line and manufacturing process employs an overhead gantry system to transfer fixtured workpieces between machining stations served by the gantry system. The machining stations include CNC machines, turret cells, and/or dedicated machines which receive the fixtured workpieces through top-entry openings. The invention provides flexibility and adaptability to variation, improved maintenance of reference position on the fixture during manufacture, improved accessibility to machining stations during operation, and increased safety.

Abstract: An integrally cast aluminum subframe for a vehicle suspension system has increased stiffness for an overall vehicle frame while minimizing the thickness of the main aluminum casting by using tension/compression struts to resist flexing. Various strut attachments are shown that simplify manufacturing and lower the cost. The invention results in further improvement of weight reduction while simultaneously achieving a desired amount of stiffness.

Abstract: A composite air intake manifold assembly adapted for use with an internal combustion engine includes an upper half shell formed from a polymer, a lower half shell formed from a polymer and joined to the upper half shell to define a housing having an internal cavity, and a one piece inner shell formed from a polymer and disposed within the cavity. The one piece inner shell in combination with the upper half shell and the lower half shell cooperate to define at least a pair of spaced apart air intake runners. Each of the runners includes an opened air intake end adapted to receive atmospheric air, and an opened air inlet end adapted to be connected to an associated air inlet side of a cylinder head of the internal combustion engine.

Abstract: A vehicle wheel has an outboard face which includes a smoothed portion to provide a cosmetic finish to the wheel face. The smoothed portion is formed by pressing a cutting tool having a non-symmetrical tip against the wheel surface as the wheel is rotated.

Abstract: A workpiece support device includes a body having a base portion adapted for mounting on a surface. The workpiece support device also includes a support member mounted on the body so as to be extendable outward relative to the body and away from the base portion, and retractable inward relative to the body and toward the base portion. The support member has an outer end adapted for supporting a workpiece, and it has an inner end. The workpiece support device also includes a cam member having a camming surface. The cam member is mounted on the body so as to be movable in first and second directions. The movement of the cam member in the first direction causes the camming surface to drivingly engage the inner end of the support member and force the support member to extend outward relative to the body. The movement of the cam member in the second direction allows the support member to retract inward relative to the body.

Abstract: This invention relates to an improved vehicle wheel idle station tooling apparatus. The vehicle wheel idle station tooling apparatus includes a center pilot and at least one rim block. The center pilot is adapted to be secured to a component of the vehicle wheel idle station tooling apparatus and defines an outer diameter which is slightly less than an inner diameter defined by a pilot hole of a vehicle wheel so as to pilot the vehicle wheel on the center pilot. The rim block is adapted to be secured to a component of the vehicle wheel idle station tooling apparatus and includes a surface which is operative to engage an outer surface of a flange of the vehicle wheel so as to support the vehicle wheel thereon.

Abstract: An apparatus adapted to condition the outer flanges of a vehicle wheel includes a main base assembly secured to a fixed surface, a lower tool assembly operatively supported by the main base assembly, at least one upper drive assembly operatively supported by the main base assembly, and an upper rim guide assembly. The upper drive assembly of the apparatus includes an electric servo drive unit operatively connected to drive a conditioner roll having an outer surface provided with a predetermined profile adapted to engage and condition at least one of the outer flanges of the vehicle wheel.

Abstract: A sensor for measuring the distance between two surfaces injects pressurized fluid (e.g., air) between the surfaces. The pressurized fluid passes through two flow restrictors prior to reaching the surfaces to be measured. The fluid pressures between the flow restrictors and between the downstream flow restrictor and the surfaces are compared to yield the distance between the two surfaces. An accurate distance measurement can be obtained even where the surfaces to be measured are located in a hostile environment which would destroy many other types of sensors.