Chaplet, cast molding system, and method

Abstract

A chaplet includes a first portion configured to engage one of a core and a mold, a second portion configured to engage the other of the core and the mold, and an elongated rod extending between the first portion and the second portion. The rod has a plurality of breakaway sites for allowing the length thereof to be selectively reduced in predetermined increments.

What is claimed is: 
     
         1 . A chaplet comprising:
 a first portion configured to engage one of a core and a mold;   a second portion configured to engage the other of said core and said mold;   an elongated rod extending between said first portion and said second portion and having a plurality of breakaway sites for allowing the length of said rod to be selectively reduced in predetermined increments.   
     
     
         2 . The chaplet of  claim 1 , wherein said rod is threaded and in threaded engagement with at least one nut, each said at least one nut associated with one of said first portion and said second portion. 
     
     
         3 . The chaplet of  claim 2 , wherein each said breakaway site includes a groove in said rod. 
     
     
         4 . The chaplet of  claim 3 , wherein each said groove includes a groove floor extending through said rod. 
     
     
         5 . The chaplet of  claim 4 , wherein each said groove floor is approximately equal in length to a diameter of said rod. 
     
     
         6 . The chaplet of  claim 5 , wherein adjacent groove floors are non-parallel. 
     
     
         7 . The chaplet of  claim 6 , wherein adjacent groove floors are perpendicular. 
     
     
         8 . The chaplet of  claim 7 , wherein each said groove defines a plane normal to a longitudinal axis of said rod. 
     
     
         9 . The chaplet of  claim 1 , wherein said first portion is a plate fixed to a first end of said rod and said second portion is a plate having an integral nut portion in threaded engagement with said threaded rod. 
     
     
         10 . The chaplet of  claim 9 , wherein said integral nut portion includes a first tab and a second tab. 
     
     
         11 . A system for casting a component of a machine, the system comprising:
 a mold having a surface that mirrors an external surface of the component;   a core to be placed in the mold and to provide a cavity in the component;   at least one chaplet to be placed between said mold and said core, said chaplet including a first portion configured to engage one of said core and said mold, a second portion configured to engage the other of said core and said mold, and an elongated rod extending between said first portion and said second portion, said rod having a plurality of breakaway sites distributed along the longitudinal axis thereof for allowing the length of said rod to be selectively reduced in predetermined increments.   
     
     
         12 . The system of  claim 11 , wherein said rod is threaded and in threaded engagement with at least one nut, each at least one nut associated with one of said first portion and said second portion. 
     
     
         13 . The system of  claim 12 , wherein each said break away site is a groove in said rod. 
     
     
         14 . The system of  claim 13 , wherein each said groove includes a groove floor extending through said rod. 
     
     
         15 . The system of  claim 14 , wherein each said groove floor is approximately equal in length to a diameter of said rod. 
     
     
         16 . The system of  claim 15 , wherein adjacent groove floors are non-parallel. 
     
     
         17 . The system of  claim 16 , wherein adjacent groove floors are perpendicular. 
     
     
         18 . The system of  claim 17 , wherein each said groove defines a plane normal to a longitudinal axis of said rod. 
     
     
         19 . A method of positioning a core in a casting mold with a chaplet having a first portion, a second portion and a rod extending between said first portion and said second portion, the method comprising:
 measuring a distance between a surface of said casting mold and a surface of said core;   reducing said length of said rod according to said measurement by cleaving said rod along one of a plurality of grooves in said rod; and   inserting said chaplet between said surface of said casting mold and said surface of said core such that said first portion engages one of said surface of said casting mold and said surface of said core and said second portion engages said other of said surface of said casting mold and said surface of said core.   
     
     
         20 . The method of  claim 19 , wherein said rod is threaded, at least one of said first portion and said second portion includes an integral nut having a first tab and a second tab, said nut is threaded to said rod, and said inserting further includes rotating one of said first portion, said second portion and said rod to adjust a distance between said first portion and said second portion according to said measurement.