An exemplary forming assembly includes a mold having a cavity to form a component, and an insert having first, second, and third regions. The first region provides a first passageway opening in the component. The second region provides a second passageway opening in the component. The third region provides a passageway in the component. The insert is rotatable from a first position within the passageway to a second position outside the passageway. An exemplary component forming method includes positioning a material around an insert, curing the material to provide a component, and rotating the insert relative to the component from a first position where at least some of the insert is received within a passageway of the component to a second position where the entire insert is outside the passageway.

Provided is a molding device for manufacturing a molded product having an arc-shaped bent inner space, wherein the molding device includes: a pair of molds which is joinable to each other and separable from each other, and is capable of forming a cavity C which has a shape corresponding to an outer shape of the molded product in a joined state during molding; a core which has a shape corresponding to an inner shape of the molded product, and is disposed in the inside of the cavity C which the pair of molds forms during molding; and a rotation member which is joined to a terminal end of the core, and is rotatable together with the core after molding. Compared to a conventional molding device, the molding device of the present invention becomes a molding device capable of suppressing the occurrence of a defect on a molded product having an arc-shaped bent inner space at the time of taking out the molded product.

The present invention relates to an eco-mold apparatus for manufacturing a piston, a mold apparatus for manufacturing a piston, and a piston manufacturing method, which mold each part of a piston while decreasing the weight of the piston, and the apparatus may comprise: a first eco-mold part which may move forward or backward in a first direction to shape a portion of an eco-part of a piston; a second eco-mold part which may shape-match with the first eco-mold part to mold another portion of the eco-part of the piston; and a piston pickup part which picks up the piston over the second eco-mold part, so that the piston pickup part can separate the piston from the second eco-mold part.

A pendulum crankshaft for an internal combustion engine includes a pendulum crankshaft having pendulum crank rolling path inserts that are cast into the component during the casting process. The rolling path inserts are positioned in a mold prior to casting. By including the rolling path inserts in the component during the molding process, the need to press the rolling path insert into the component after the component is cast is thus avoided, thereby eliminating the resulting stresses that would otherwise result. Machining and subsequent heat treatment are unnecessary. The component can be one or both of the crankshaft pendulum and the pendulum carrier. The rolling path may be formed from a metal such as sintered powdered metal. The flowable material may be a metal such as iron. The resulting component is free of stress regions, such as on the carrier strap, that normally result from methods that involve press-fitting the rolling path insert into the component.

A method of forming a component having an internal passage defined therein includes selectively positioning a lattice structure at least partially within a cavity of a mold. The lattice structure is formed from a first material, and a core is positioned in a channel defined through the lattice structure, such that at least a portion of the core extends within the cavity. The method also includes introducing a component material in a molten state into the cavity, such that the component material in the molten state at least partially absorbs the first material from the lattice structure. The method further includes cooling the component material in the cavity to form the component, wherein at least the portion of the core defines the internal passage within the component.

An exemplary forming assembly includes a mold having a cavity to form a component, and an insert having first, second, and third regions. The first region provides a first passageway opening in the component. The second region provides a second passageway opening in the component. The third region provides a passageway in the component. The insert is rotatable from a first position within the passageway to a second position outside the passageway. An exemplary component forming method includes positioning a material around an insert, curing the material to provide a component, and rotating the insert relative to the component from a first position where at least some of the insert is received within a passageway of the component to a second position where the entire insert is outside the passageway.

A technique is provided capable of favorably preventing generation of a shrinkage cavity in solidification of molten metal poured into a casting mold, and increasing accuracy of an assembling position of a core to a mold, in casting a caliper. A caliper casting device for casting a caliper for a disc brake including a cylinder into which a piston is fitted, and a rotor housing surface that defines a space for housing a disc rotor, includes: a mold; and a core placed in the mold, the mold having a rotor housing surface forming portion that forms a part of the rotor housing surface after casting, and the core being positioned and held in the rotor housing surface forming portion during casting, and forming a part of the rotor housing surface together with the rotor housing surface forming portion after casting.

An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

A method of forming a component having an internal passage defined therein includes selectively positioning a lattice structure at least partially within a cavity of a mold. The lattice structure is formed from a first material, and a core is positioned in a channel defined through the lattice structure, such that at least a portion of the core extends within the cavity. The method also includes introducing a component material in a molten state into the cavity, such that the component material in the molten state at least partially absorbs the first material from the lattice structure. The method further includes cooling the component material in the cavity to form the component, wherein at least the portion of the core defines the internal passage within the component.

A mold assembly for use in forming a component having an internal passage defined therein includes a mold defining a mold cavity therein, and a jacketed core positioned with respect to the mold. The jacketed core includes a hollow structure, and an inner core disposed within the hollow structure and positioned to define the internal passage within the component when a component material in a molten state is introduced into the mold cavity and cooled to form the component. The jacketed core also includes a first coating layer disposed between the hollow structure and the inner core.