Abstract: A method for conducting finite element analysis of a component which takes into consideration the apparent rigidity of an interface structure. The method generally includes the steps of (a) providing a standard shim bar, (b) physically measuring the natural frequencies of the standard shim bar when mounted to the interface structure in at least two orientations, (c) generating a finite element model having a shim interposed between the component and ground, (d) selecting the characteristics of the shim as a function of the measured natural frequencies of the standard test bar in both the first and second orientations, and (e) once the appropriate characteristics are selected, performing the desired finite element analysis on the finite element model.

Abstract: A mold assembly for casting or molding a multiple portion article in sequential shots without opening the mold assembly. The mold assembly includes a movable mold insert that permits the portions to be interconnected as an integral part of the casting process. The mold insert includes a first or male void for defining a male end and a second or female void for defining a female end. In operation, the mold insert is placed in a first position and molten material is introduced into a first cavity portion to form a first portion with a male end. The mold insert is then placed in a second position with the female portion surrounding the male end of the first portion. Molten material is introduced into a second cavity portion to form a second portion with a female end at least partially surrounding the male end of the first portion.

Abstract: A method for conducting finite element analysis of a component which takes into consideration the apparent rigidity of an interface structure. The method generally includes the steps of (a) providing a standard shim bar, (b) physically measuring the natural frequencies of the standard shim bar when mounted to the interface structure, (c) generating a finite element model having a shim interposed between the component and ground, (d) selecting the modulus of elasticity of the shim as a function of the measured natural frequencies of the standard test bar mounted to the interface structure, and (e) once the appropriate modulus of elasticity is selected, performing the desired finite element analysis on the finite element model.

Abstract: A stamped, steel insert for use in metal die cast articles. The insert includes first and second interconnected stamped steel insert halves spaced from one another at certain locations to define a void. Openings communicating with the void extend through each insert half to facilitate material flow and to improve interlock of the insert and die cast material. The edges of the insert lie below the surface of the casting to avoid bimetallic machining. The insert halves cooperate to define a pair of elongated passages, which are bored following die casting to form fastener holes. At least one of the passages has an elongated cross section to allow for expansion and contraction of the insert during casting.

Abstract: A mold assembly for casting or molding a multiple portion article in sequential shots without opening the mold assembly. The mold assembly includes a movable mold insert that permits the portions to be interconnected as an integral part of the casting process. The mold insert includes a first or male void for defining a male end and a second or female void for defining a female end. In operation, the mold insert is placed in a first position and molten material is introduced into a first cavity portion to form a first portion with a male end. The mold insert is then placed in a second position with the female portion surrounding the male end of the first portion. Molten material is introduced into a second cavity portion to form a second portion with a female end at least partially surrounding the male end of the first portion.

Abstract: A assembly of mated molded parts and a method for making same are disclosed in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: The stroke of the shot sleeve plunger is set at a high-volume setting corresponding to the volume of the die. Pre-production articles without an insert are cast within the die. The stroke of the shot sleeve plunger is set at a low-volume setting corresponding to the volume of the die minus the volume of the insert, and production articles each having an insert are cast within the die.

Abstract: A die casting shot sleeve having an overflow hole and an overflow valve for selectively opening and closing the overflow hole. The overflow hole extends through the shot sleeve at a level below the pour hole to allow molten material in excess of a predetermined volume to spill from the shot sleeve. When open, the overflow hole permits excess metal to spill from the shot sleeve. When closed, the metal can be expelled from the sleeve without additional material spilling through the overflow hole.

Abstract: A die casting apparatus having a die assembly with multiple die cavities that are filled with sequential shots of metal. The apparatus includes a slide that is movable to selectively define a flow path between the metal delivery system and the desired die cavity. By moving the slide between shots, the die cavities can be filled in sequence without opening the die assembly.

Abstract: A variable volume metal delivery system for a die casting machine. The system includes a shot sleeve having a plunger propelled by a shot cylinder. A stroke adjustment rod operated by a second cylinder extends into the shot cylinder to define the backward stroke limit of the shot cylinder and consequently that of the plunger. The stroke adjustment rod is movable by means of the second cylinder between a high-volume position, permitting a relatively long stroke, and a low-volume position, providing a relatively short stroke. Accordingly, the volume of the shot sleeve can be changed easily, for example, to accommodate the manufacture of articles either with or without structural inserts.

Abstract: A die casting system having an inclined shot sleeve. A pour hole is located in the upper end of the inclined sleeve. The size, shape, and position of the pour hole and the inclination of the shot sleeve are selected so that, when the sleeve is filled to capacity, the volume of air remaining in the sleeve equals the volume of material displaced by the plunger as it closes the pour hole. As the plunger is advanced, the air in the shot sleeve is expelled through the pour hole; and preferably the last air is expelled just as the pour hole is closed.

Abstract: A method for making mated molded parts in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: The vent includes a plurality of passages formed by a plurality of stacked plates. The passages are dimensioned to permit the free flow of air but to prohibit the passage of molten metal. During die casting, air is free to exit the die while molten metal is retained.

Abstract: The system includes a shot sleeve having a bore and a transverse fill hole communicating with the bore. A closure member is rotatably mounted on the shot sleeve and defines a window. The closure member rotates between a fill position in which the window is aligned with the filling hole and a casting position in which the closure member seals the filling hole. Any excess molten material from the fill is poured from the closure member as it rotates. Preferably, the closure member is mounted eccentrically with respect to, and intersects, the bore. In this case, the closure member defines an arcuate recess that aligns with the internal bore when the closure member is in the casting position, thereby allowing the plunger to reciprocate through the internal bore.

Abstract: A torque converter having an impeller, turbine, and stator each formed of interconnecting upper and lower members, and a method for producing the same. The upper and lower members each include a number of spaced apart blades disposed about a central axis. Preferably, the corresponding upper and lower members are die cast with blades spaced apart at twice the distance desired in the completed assembly. When the upper and lower members are interconnected, their blades nest such that each member provides every other blade of the assembled component.

Abstract: A structural baffle for reducing both crankshaft torsional vibration and oil aeration in an internal combustion engine. The baffle includes a baffle plate and a number of upright members. The baffle plate isolates the oil reservoir from the turbulence generated by the crankshaft, and includes openings allowing oil flowing from the engine to return to the oil reservoir. Preferably, the baffle plate includes a number of oil return towers which align with the oil return ports of the engine to channel oil to the reservoir. The upright members are mounted to the bearing caps both to bolster the bearing caps and to support the baffle plate beyond the throw of the crankshaft.

Abstract: A assembly of mated molded parts and a method for making same are disclosed in which the assembly has first and second parts with precisely mating surfaces. The first part is formed by molding, casting, or the like such that the mating surface of the first part is formed with at least one protrusion. The second part is formed in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusion. The two parts thus formed are forced apart from each other. The protrusion may be formed with a head which interlocks with the second part. When the parts are separated, the head breaks from the protrusion. In a particular embodiment, a bearing cap is disclosed having a central opening for the passage of a shaft.

Abstract: A method for making a bearing cap in which the bearing cap has first and second parts with precisely mating surfaces. The first part is cast such that the mating surfaces thereof are formed with protrusions terminating in enlarged heads. The second part is cast in place against the first part such precisely mating surfaces are formed with the second part enveloping the protrusions. The two parts thus cast are forced apart from each other such that the protrusions fracture across the narrowed neck portions by which the heads are joined.

Abstract: A method and apparatus for closed shot die casting is disclosed in which a molten metal filling cylinder is provided intersecting a shot sleeve in fluid communication with a filling hole in the shot sleeve. Molten metal is introduced into the filling cylinder. The molten metal passes from the filling cylinder through the filling hole into the shot sleeve until the shot sleeve is completely filled with molten metal. The filling cylinder includes a piston-like, reciprocating internal valve which moves into position to seal off the filling hole. As a result, the shot sleeve is completely filled with molten metal and pressure-sealed prior to the advancement of the shot plunger.

Abstract: A brake caliper for a disk-type brake is disclosed having a prefabricated, cast-in-place cylinder bore liner. The liner is made of a machinable material, preferably steel, and the caliper body is made of a lightweight material, preferably aluminum. The caliper body is cast around the cylinder liner so that no further machining of the caliper bore is required. A reinforcing arm may be provided extending from the cylinder liner through the bridge portion of the caliper. A method for making the caliper is also disclosed in which the cylinder liner is positioned within a die cavity and molten metal material is cast around the liner to incorporate the liner into the caliper body.