JP4195767B2 - Casting method, casting equipment, metal material manufacturing method and metal material manufacturing apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method and apparatus for casting a metal containing various alloys, and further relates to a method and apparatus for producing a metal material to be applied in a casting facility and an injection molding machine. The present invention relates to a casting method, a casting facility, a method of manufacturing a metal material, and a manufacturing apparatus that effectively use thixotropy of the above.
[0002]
[Prior art]
Conventionally, thixocasting method (semi-melting casting method) and rheocasting method (semi-solidifying casting method) are known as thixotropy of semi-molten and semi-solid metal, that is, the low viscosity and excellent fluidity. It has been. In any of these casting methods, casting is performed using a metal slurry in a semi-molten and semi-solid state in which a molten liquid phase metal and a solid phase metal are mixed.
[0003]
Among these, the thixocast method is one in which a solid metal is heated to a semi-molten metal slurry and supplied to a mold. On the other hand, in the rheocast method, after melting a solid metal once, the molten metal is cooled to a semi-solidified metal slurry having granular crystals and supplied to a mold.
[0004]
According to these casting methods, casting using a metal having a high solid phase ratio and low viscosity is possible, so that the filling property to the mold is improved, and (1) the yield is improved, and (2) a large product. (3) It is possible to improve the mechanical strength by suppressing the generation of shrinkage nests, (4) It is possible to reduce the thickness of the product, and so on. In addition, since the heat load on the mold is reduced, the service life of the mold is extended.
[0005]
[Problems to be solved by the invention]
By the way, in any of the above-described casting methods, in order to effectively use the thixotropy of the semi-molten metal and the fluidity of the semi-solid metal, the semi-molten / semi-solid metal is as fine and uniform as possible. It must have dendritic crystals (preferably spherical crystals). However, if the solid metal is simply heated to the semi-molten state or the molten metal is simply cooled to the semi-solid state, most of them will appear in the semi-molten / semi-solid metal as dendrites. The thixotropy of semi-molten metal and the fluidity of semi-solid metal cannot be obtained sufficiently.
[0006]
For this reason, in the thixomolding method, generally, a screw type extruder used in an injection molding machine is applied, and this is heated in a semi-molten state by sequentially heating while giving a shearing force to a solid metal in the barrel of the extruder. Many methods for forming metal slurry are used.
[0007]
However, the screw-type extruder has a complicated structure and is expensive, so that the cost for applying to a casting facility is extremely enormous. And since the metal slurry produced | generated within the barrel of an extruder will be supplied to a metal mold | die as it is, it cannot be confirmed whether the crystal state is a desired non-dendritic crystal. Furthermore, as the solid metal supplied to the barrel, it is necessary to apply a chip formed in a chip shape, and the raw material cost becomes extremely expensive.
[0008]
On the other hand, in the rheocast method, for example, as disclosed in Japanese Patent Application Laid-Open No. 10-34307, a solid-liquid coexistence composed of a solid phase and a liquid phase by bringing a metal melted in a holding furnace into contact with a cooling body. A method is used in which a metal slurry is produced by cooling to a state and cooling while holding it in a semi-molten temperature range in a holding container.
[0009]
According to such a method, a large number of crystal nuclei are crystallized when the molten metal comes into contact with the cooling body and further grows spherically in the holding container. A desired metal slurry can be obtained without necessity. In addition, since the metal lump may be supplied as it is to the holding furnace, an increase in raw material costs can be suppressed. Furthermore, it is possible to easily confirm whether or not the metal slurry generated in the holding container has the desired non-dendritic crystals, and effectively uses the fluidity of the semi-solid metal. Casting becomes possible.
[0010]
However, in order to actually build a mass production system in the above-mentioned rheocast method, a large number of holding containers are installed between the cooling body for cooling the molten metal and the mold to which the metal slurry is supplied, and the molten metal is melted. The process of bringing the metal into contact with the cooling body and the process of supplying the metal slurry to the mold must be linked using these holding containers, and extremely complicated control is required. Furthermore, the metal slurry in each holding container requires accurate temperature management until it is supplied to the mold, further complicating the above-described control.
[0011]
In view of the above circumstances, the present invention provides a casting method and a casting facility that can suppress casting increases in application costs and raw material costs, and enables casting effectively using thixotropy without requiring complicated control. Is a solution issue.
[0012]
[Means for Solving the Problems]
As a result of intensive research to solve the above-mentioned problems, when a metal slurry having non-dendritic crystals is rapidly cooled, even if it becomes solid and becomes a metal material, the thixotropy is potentially retained, When heated to a molten state, it was confirmed that thixotropy was exhibited again for about 1 hour. The present invention solves the above-mentioned problems by utilizing the property of exhibiting thixotropy again when heated to a semi-molten state after the metal slurry having such non-dendritic crystals once becomes a solid metal material. It is a thing.
[0013]
That is, in the casting method according to the present invention, the first generation step of generating the metal slurry containing the solid phase by cooling the molten metal, and the first generation of the solid metal material by further cooling the metal slurry. And a step of heating the metal material to a semi-molten state and supplying it to a mold, In the first generation step, the molten metal is cooled on the surface of the cooling unit disposed in the lower area of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. Have I am doing so.
In this case, it is preferable that the second generation step includes a step of continuously generating a metal material from the metal slurry and cutting the metal material into a predetermined length.
[0014]
In the casting equipment according to the present invention, the first generating means for generating the metal slurry containing the solid phase by cooling the molten metal, and the second generating the metal material solidified by cooling the metal slurry. Generating means, The first generation means has a cooling unit disposed in a lower region of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit, After the metal material is heated to a semi-molten state, it is supplied to the mold.
In this case, it is preferable that the 2nd production | generation means is provided with the cutting unit which produces | generates a metal raw material continuously from a metal slurry, and cut | disconnects this metal raw material to predetermined length.
[0015]
The method for producing a metal material according to the present invention is a method for producing a metal material to be supplied to a mold in a heated state in a semi-molten state,
A first generation step of cooling the molten metal to generate a metal slurry containing a solid phase; and a second generation step of further cooling and solidifying the metal slurry.
In the first generation step, the molten metal is cooled on the surface of the cooling unit disposed in the lower area of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. Have It is characterized by that.
[0016]
Further, the metal material manufacturing apparatus according to the present invention is an apparatus for manufacturing a metal material supplied to a mold in a state of being heated to a semi-molten state, and is a metal containing a solid phase by cooling the molten metal A first generating means for generating a slurry; and a second generating means for further cooling and solidifying the metal slurry, The first generating means has a cooling unit disposed in a lower region of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. I am doing so.
In this case, it is preferable that the 2nd production | generation means is equipped with the cutting unit which solidifies a metal slurry continuously and cut | disconnects this to predetermined length.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
FIG. 1 shows an embodiment of a casting facility according to the present invention. The casting equipment illustrated here is particularly for casting a desired product using a magnesium alloy typified by AZ91D as a raw material, and includes a melting tank 1.
[0018]
The melting tank 1 is covered with a melting heater 2, and the melting tank 1 is driven to maintain the above-described magnesium alloy in a molten state, that is, in a liquid phase temperature state. The melting tank 1 is provided with a hot water passage 3 at the bottom. The hot water passage 3 is for pouring the molten magnesium alloy stored in the melting tank 1 downward, is bent in a substantially crank shape, and includes a switching valve 4 in the middle thereof. The switching valve 4 is constituted by a valve plunger 5 which is disposed so as to be able to advance and retract to open and close the hot water passage 3 and a valve cylinder 6 which moves the valve plunger 5 forward and backward.
[0019]
A cooling unit 10 is disposed in the lower region of the melting tank 1 as a first generating means. As shown in FIGS. 2A and 2B, the cooling unit 10 has a plurality of guide grooves 11 on the surface and a cooling water circulation passage 12 inside thereof. The cooling unit 10 is inclined and disposed with the guide groove 11 facing the lower end opening of the tap water passage 3. In addition, the code | symbol 13 in FIG. 1 is the cover block arrange | positioned so that a predetermined space | interval may be ensured and covered with the lower end opening of the hot water passage 3, and the surface of the cooling unit 10. FIG.
[0020]
Further, the casting facility is provided with a storage tank 20, a pair of feed rollers 30, 31, and a cutting unit 40 as second generation means.
[0021]
The storage tank 20 is a tank opened on the upper surface, and is disposed in the lower area below the lower end of the cooling unit 10. The storage tank 20 is provided with a material forming passage 21 having a circular cross section. The material forming passage 21 extends in the horizontal direction from the lower portion of the storage tank 20 and opens to the side wall, and includes a quenching unit 22 at an opening end thereof. As shown in FIG. 3A, the rapid cooling unit 22 includes an annular jacket 23 that surrounds the entire circumference of the material forming passage 21, and an injection port that opens from the annular jacket 23 toward the axis of the material forming passage 21. 24.
[0022]
The pair of feed rollers 30 and 31 are arranged side by side in a state where their peripheral surfaces are opposed to each other. Each of the feed rollers 30 and 31 has feed grooves 30a and 31a having a radius of curvature that is substantially the same as the inner diameter of the material forming passage 21 described above, and between the feed grooves 30a and 31a. An interval is secured between each other so that the distance matches the inner diameter of the material forming passage 21. Although not clearly shown in the drawing, a rotation actuator is linked to each of the feed rollers 30 and 31, and the feed roller 30 positioned above rotates clockwise in FIG. The feed roller 31 positioned is rotated counterclockwise in FIG. 3A.
[0023]
As shown in FIG. 1, the cutting unit 40 includes a unit main body 41, a fixed clamper 42A, a movable clamper 42B, and a pair of discharge rollers 44 and 45.
[0024]
The unit main body 41 is movably supported by the guide rod 46, and can reciprocate horizontally along the axial direction of the material forming passage 21 on the extension region of the material forming passage 21 described above. . A retract cylinder 47 is interposed between the unit main body 41 and the fixed frame F. The retract cylinder 47 allows the unit main body 41 to move when an external force is applied to the unit main body 41 in a direction in which the unit main body 41 is separated from the storage tank 20, while the unit main body 41 approaches the storage tank 20 when it is extended. This is an actuator for returning to the specified position.
[0025]
As shown in FIG. 3B, the fixed clamper 42A and the movable clamper 42B are block-like members having clamp through holes 49A and 49B opened by slits 48A and 48B, respectively. Each of the clamp through holes 49A and 49B has a slightly larger inner diameter than the material forming passage 21 described above. The slits 48A and 48B are formed along a plane including the axis of the clamp through holes 49A and 49B, and have a function of expanding and reducing the inner diameters of the clamp through holes 49A and 49B by appropriately changing the widths thereof. is there. Each slit 48A, 48B is formed with tapered inclined surfaces 50A, 50B at the respective opening end portions, and a pair of rod through holes 51A, 51B are crossed at positions that are intermediate portions thereof. The tapered inclined surfaces 50A and 50B are inclined portions whose width gradually increases outward. The rod through-holes 51A and 51B are provided so as to be parallel to each other, and have hemispherical recesses 52A and 52B at the opening portions at both ends.
[0026]
These clampers 42A and 42B are provided with a pair of clamp hydraulic cylinders 53A and 53B and unclamp hydraulic cylinders 54A and 54B, respectively.
[0027]
The clamp hydraulic cylinders 53A and 53B are configured such that the piston rods 53aA and 53aB are inserted into the rod through holes 51A and 51B described above via the clamp pieces 55, respectively, and further clamped at the protruding ends of the piston rods 53aA and 53aB. 56 is attached to each of the clampers 42A and 42B. The clamp pieces 55 and 56 are piece members having a spherical shape with a radius that matches the concave portions 52A and 52B at the portions facing the concave portions 52A and 52B of the rod through holes 51A and 51B, and are clamped to the clamp hydraulic cylinders 53A and 53B. When hydraulic pressure is applied, the slits 48A and 48B of the clampers 42A and 42B are narrowed via the recesses 52A and 52B, that is, the clamp through holes 49A and 49B function.
[0028]
The unclamping hydraulic cylinders 54A and 54B are held by the clampers 42A and 42B via the holding brackets 57 with the tip ends of the piston rods 54aA and 54aB facing the opening ends of the slits 48A and 48B. An expansion rod 58 is interposed between the piston rods 54aA and 54aB of the unclamping hydraulic cylinders 54A and 54B and the tapered inclined surfaces 50A and 50B of the slits 48A and 48B, respectively. The expansion rod 58 is a cylindrical member that is in contact with the tapered inclined surfaces 50A and 50B. When the unclamping hydraulic pressure is applied to the unclamping hydraulic cylinders 54A and 54B, the expanding rod 58 is interposed via the tapered inclined surfaces 50A and 50B. Thus, the slits 48A and 48B of the clampers 42A and 42B are expanded, that is, the diameters of the clamp through holes 49A and 49B are increased.
[0029]
The fixed clamper 42A having the above-described configuration is fixed to the unit main body 41 with the axis of the clamp through hole 49A aligned with the axis of the material forming passage 21 and the slit 48A extending vertically upward. It is.
[0030]
On the other hand, the movable clamper 42B is held by the cutting cylinder 59 in a state where the slit 48B extends vertically downward and the end toward the storage tank 20 is in contact with the fixed clamper 42A.
[0031]
The cutting cylinder 59 is attached to the unit main body 41 via the cylinder main body 59b with the piston rod 59a directed vertically downward, and moves the movable clamper 42B along the vertical direction with respect to the fixed clamper 42A. It has a function. When the cutting cylinder 59 is most contracted, the movable clamper 42B stops at the highest position, and the axis of the clamp through hole 49B matches the axis of the material forming passage 21, that is, the clamp through hole. 49B is in a state of matching with the clamp through hole 49A of the fixed clamper 42A. On the other hand, when the cutting cylinder 59 is most extended, the movable clamper 42B is lowered most, and the clamp through hole 49B stops at a position completely displaced from the clamp through hole 49A of the fixed clamper 42A.
[0032]
The pair of discharge rollers 44 and 45 are arranged in parallel up and down on the roller bracket 60 extending from the above-described movable clamper 42 </ b> B with their peripheral surfaces facing each other. Each of the discharge rollers 44 and 45 has discharge feed grooves 44a and 45a having a radius of curvature substantially the same as the inner diameter of the material forming passage 21 described above, and the discharge feed grooves 44a and 45a. An interval is secured between each other so that the distance therebetween matches the inner diameter of the material forming passage 21. Although not clearly shown in the drawing, a rotation actuator is linked to each of the discharge rollers 44 and 45, and the discharge roller 44 positioned above rotates clockwise in FIG. The positioned discharge roller 45 rotates counterclockwise in FIG. 3A.
[0033]
In addition, the code | symbol 61 in FIG. 1 is a guide block which makes between the cover block 13 and the storage tank 20 continue.
[0034]
Furthermore, the casting equipment is provided with an injection device 70 as shown in FIG. The injection device 70 is for supplying metal heated to a semi-molten state to the mold 90 and includes a heating chamber 71. The heating chamber 71 is a substantially sealed chamber whose periphery is covered by a heater 72, and a discharge port 73 provided at the upper end portion of the heating chamber 71 is connected to a pouring port 91 of the mold 90 through an auxiliary nozzle 74.
[0035]
The heating chamber 71 is provided with a suction rod 75 and a preheating barrel 76.
[0036]
The suction rod 75 is a columnar member that is movably disposed on the upper end wall of the heating chamber 71. The suction rod 75 is connected to a suction cylinder 77, and is moved forward and backward with respect to the inside of the heating chamber 71 by the operation of the suction cylinder 77.
[0037]
The preheating barrel 76 is a cylindrical member extending from the side wall of the heating chamber 71 along the horizontal direction. The preheating barrel 76 has a tip end portion having substantially the same inner diameter as the material forming passage 21 of the storage tank 20 described above, while an inner diameter of a proximal end portion adjacent to the heating chamber 71 is larger than this. These are continuous by a taper inner diameter part. As shown in FIG. 4, the leading end of the preheating barrel 76 is provided with a throwing opening 78 in the upper part thereof, and a chute plate 79 is continuously connected to the throwing opening 78.
[0038]
The preheating barrel 76 is provided with a preheating heater 80 on the outer periphery of the base end portion thereof, and a plunger 81 is provided on the tip end portion thereof.
[0039]
The preheating heater 80 is provided so as to surround the periphery of the preheating barrel 76. The preheating heater 80 is for heating the preheating barrel 76, and is set to a slightly lower heating temperature than the heating heater 72 of the heating chamber 71 described above.
[0040]
The plunger 81 is a cylindrical member having a size that fits into the tip of the preheating barrel 76. The plunger 81 is connected to an extrusion cylinder 82 for moving the plunger 81 forward and backward within the preheating barrel 76.
[0041]
In the casting equipment configured as described above, first, a lump of magnesium alloy is put into the melting tank 1 and the melting heater 2 is driven to hold the molten magnesium alloy in the melting tank 1 and the cooling unit 10 is cooled. The state in which water is circulated and the cooling water is supplied to the rapid cooling unit 22 is a standby state. In this case, in the cutting unit 40, the retract cylinder 47 is extended and the unit main body 41 is disposed at a position close to the storage tank 20, and the cutting cylinder 59 is retracted to move the movable clamper 42B to the highest position. It has stopped. Further, the unclamping hydraulic pressure is applied to the unclamping hydraulic cylinders 54A and 54B with the clamping hydraulic cylinders 53A and 53B set to the tank pressure, and both the fixed clamper 42A and the movable clamper 42B expand the clamp through holes 49A and 49B. The diameter is maintained. Further, the pair of feed rollers 30 and 31 are rotated at a constant speed, respectively, while the discharge rollers 44 and 45 are held in a stopped state.
[0042]
When the valve cylinder 6 is retracted from the standby state and the valve plunger 5 is retracted, the hot water passage 3 is opened, and the molten magnesium alloy M1 stored in the melting tank 1 is poured into the cooling unit 10 through the hot water passage 3. (Arrow A in FIG. 1).
[0043]
The molten magnesium alloy M1 poured out to the cooling unit 10 flows down the guide groove 11 in accordance with the inclination of the cooling unit 10 and is temporarily stored in the storage tank 20 (arrow B in FIG. 1). During this time, the molten magnesium alloy M1 flowing down the cooling unit 10 is appropriately cooled by the cooling unit 10 to become a metal slurry M2 crystallizing a large number of crystal nuclei therein, and the above-mentioned crystal nuclei are spherical in the storage tank 20. To have fine and uniform spherical crystals. That is, sufficient fluidity can be obtained in the metal slurry M2 without requiring an expensive extruder, and the increase in application cost can be significantly reduced. Moreover, since the metal lump can be supplied as it is to the melting tank 1, an increase in raw material costs can be suppressed.
[0044]
The metal slurry M2 once stored in the storage tank 20 is then sequentially discharged to the outside through the material forming passage 21. During this time, the metal slurry M2 passing through the material forming passage 21 is cooled by the cooling water passing through the annular jacket 23 of the quenching unit 22 and further rapidly cooled by the cooling water supplied from the injection port 24. As a result, the cylindrical solid metal material M3 is continuously discharged to the outside of the storage tank 20. Here, the completely solidified metal material M3 is produced by rapidly cooling the metal slurry M2 having sufficient thixotropy, and potentially holds the thixotropy. This can be easily confirmed by observing the crystal structure contained in the metal material M3.
[0045]
Next, the metal material M3 discharged from the storage tank 20 is supplied to the cutting unit 40 by a pair of feed rollers 30 and 31, and sequentially passes through the clamp through hole 49A of the fixed clamper 42A and the clamp through hole 49B of the movable clamper 42B. Further, the ink is supplied between the pair of discharge rollers 44 and 45.
[0046]
In the meantime, in the casting equipment, the rotational speed of the feed rollers 30 and 31 is constantly monitored. When the rotational speed reaches a preset value, the cutting process of the metal material M3 is performed according to the following procedure.
[0047]
That is, when the rotational speed of the feed rollers 30 and 31 reaches a preset value, first, the hydraulic pressure applied to the clamp hydraulic cylinders 53A and 53B and the unclamp hydraulic cylinders 54A and 54B is appropriately switched, and the fixed clamper 42A and the movable clamper 42B are switched. Both hold the clamp through holes 49A and 49B in a reduced diameter state. As a result, as shown in FIG. 5A, the metal material M3 is clamped by the fixed clamper 42A and the movable clamper 42B, and the unit body 41 moves along the guide rod 46 together with the metal material M3 while retracting the retract cylinder 47. As a result, the relative speed between the clampers 42A and 42B and the metal material M3 becomes zero.
[0048]
Thereafter, the extension operation of the cutting cylinder 59 is immediately started, and the movable clamper 42B is sequentially moved downward with respect to the fixed clamper 42A. As a result, as shown in FIG. 5 (b), a shearing force acts between the metal material M3 after passing through the fixed clamper 42A and the metal material M3 before that, and the metal material M3 is formed with these as a boundary. Cutting progresses.
[0049]
As shown in FIG. 5 (c), when the cutting cylinder 59 is most extended and the cutting of the metal material M3 is completed, the hydraulic pressure applied to the clamping hydraulic cylinder 53B and the unclamping hydraulic cylinder 54B is switched appropriately only at the movable clamper 42B. The movable clamper 42B holds the clamp through hole 49B in an expanded state. Further, when the discharge rollers 44 and 45 are rotated at the same time, the cut metal material M3 moves with respect to the movable clamper 42B and is discharged onto a predetermined conveyor 100 (see FIG. 1).
[0050]
When the cut metal material M3 is discharged onto the conveyor 100, the rotation of the discharge rollers 44 and 45 is stopped and the cutting cylinder 59 and the fixed clamper 42A are in a standby state as shown in FIG. In this state, the retract cylinder 47 is further extended to return the unit main body 41 to the standby state.
[0051]
Thereafter, by repeatedly performing the above-described operation, the metal material M3 is sequentially discharged onto the conveyor 100 at a predetermined length.
[0052]
In the cutting process as described above, since the cutting unit 40 cuts the metal material M3 in a state where the relative speed with the metal material M3 is zero, the generation of the metal material M3 is stopped. This can be continuously cut without any problems.
[0053]
On the other hand, as shown in FIG. 4, the metal material M3 produced as described above is sequentially fed into the preheating barrel 76 through the chute plate 79 from the charging opening 78. In this case, as shown in FIG. 6A, when the metal material M3 is put into the preheating barrel 76, the preheating heater 80 and the heating heater 72 of the heating chamber 71 are sequentially driven.
[0054]
The metal material M3 charged into the preheating barrel 76 is sequentially supplied to the heating chamber 71 by the reciprocating movement of the plunger 81, and is held in a semi-molten state in the heating chamber 71 as shown in FIG. It becomes like this.
[0055]
Here, according to the above casting apparatus, since the preheating heater 80 preliminarily heats the metal material M3 in the preheating barrel 76, when the metal material M3 reaches the heating chamber 71, the preheating is performed immediately. A semi-molten state can be achieved. Further, since the inner diameter of the tip portion of the preheating barrel 76 is substantially the same as that of the metal material M3, the preheating barrel 76 is closed by the metal material M3 before being heated to a semi-molten state. There is no possibility that the inner semi-molten magnesium alloy M4 flows backward.
[0056]
When a predetermined amount of the magnesium alloy M4 that has been in a semi-molten state is stored in the heating chamber 71 as described above, the plunger 81 moves forward by the extension operation of the extrusion cylinder 82, as shown in FIG. At the same time, the suction rod 75 moves forward into the heating chamber 71 by the extension operation of the suction cylinder 77. As a result, the semi-molten magnesium alloy M2 stored in the heating chamber 71 is supplied to the mold 90 through the discharge port 73 and the auxiliary nozzle 74, and is molded into a desired shape in the mold 90. become.
[0057]
Here, the semi-molten magnesium alloy M4 supplied to the mold 90 is obtained by heating the metal material M3 that potentially holds thixotropy, and again exhibits thixotropy. Therefore, casting using this thixotropy is possible, that is, casting using a magnesium alloy having a high solid phase ratio and low viscosity is possible, and the filling property to the mold 90 is improved and the yield is improved. It is possible to mold a large product, to suppress the generation of shrinkage nests, to improve the mechanical strength, to reduce the thickness of the product, and so on. Further, since the heat load on the mold 90 is also reduced, the service life of the mold 90 is extended.
[0058]
Moreover, according to the above casting equipment, the metal slurry M2 is once solidified to produce the metal material M3, which is heated again into a semi-molten state and supplied to the mold 90. There is no need to link the cooling unit 10 that cools the injection unit 70 with the injection device 70 or to perform accurate temperature control on the metal material M3. Therefore, no complicated control is required, and casting using thixotropy can be performed very easily. Furthermore, once solidified, the metal material M3 can be handled as a single body, and further convenience can be improved.
[0059]
When the supply of the semi-molten magnesium alloy M4 to the mold 90 is completed, as shown in FIG. 6 (d), the extrusion cylinder 82 is contracted and the suction cylinder 77 is contracted, so that the molten metal surface of the heating chamber 71 is changed. It begins to decline. Therefore, a situation in which the semi-molten magnesium alloy M4 is solidified in the discharge port 73 and the auxiliary nozzle 74 does not occur.
[0060]
Thereafter, the above-described operation is repeatedly performed, and a desired product can be mass-produced in the mold 90.
[0061]
In the above-described embodiment, a casting facility for manufacturing a product using a magnesium alloy as a raw material is illustrated, but a product using other metal or alloy such as aluminum or an alloy thereof as a raw material may be manufactured. Is possible.
[0062]
In the above-described embodiment, since the cutting unit for cutting the metal material is provided, the metal material can be easily handled, but the cutting unit is not necessarily provided. In this case, the generated metal material may be heated to a semi-molten state as it is and supplied to the mold. Further, the generated metal material does not necessarily have a circular cross section.
[0063]
【The invention's effect】
As described above, according to the present invention, an expensive extruder is not required as in the conventional thixocasting method, and a metal lump can be applied as it is. An increase in cost can be suppressed. Moreover, since the generated metal slurry is once solidified, the process of generating the metal slurry and the process of supplying it to the mold are linked, and accurate temperature control is performed on the solidified metal slurry. Therefore, casting using thixotropy can be performed easily.
[Brief description of the drawings]
FIG. 1 is a sectional view conceptually showing an embodiment of a casting facility according to the present invention.
2A is a longitudinal sectional view of a first generating means for cooling a molten metal to generate a metal slurry, and FIG. 2B is a transverse sectional view thereof.
3A is a cross-sectional view of a second generating means for generating a metal material from a metal slurry, and FIG. 3B is an enlarged cross-sectional view taken along line 3-3 in FIG.
4 is an enlarged cross-sectional view taken along line 4-4 in FIG.
FIGS. 5A and 5B are conceptual diagrams sequentially illustrating a cutting process of a metal material by a cutting unit.
FIGS. 6A and 6B are conceptual diagrams sequentially illustrating a process of supplying a metal material to a mold. FIGS.
[Explanation of symbols]
1 Melting tank
2 Melting heater
3 Hot spring passage
4 Switching valve
5 Valve plunger
6 Valve cylinder
10 Cooling unit
11 Guide groove
12 Circulation passage
13 Cover block
20 Reservoir
21 Material molding passage
22 Rapid cooling unit
23 Ring jacket
24 injection port
30, 31 Feed roller
30a, 31a Feed groove
40 cutting unit
41 Unit body
42A Fixed clamper
42B Movable clamper
44, 45 discharge roller
44a, 45a Discharge feed groove
46 Guide rod
47 Retract cylinder
48A, 48B slit
49A, 49B Clamp through hole
50A, 50B tapered inclined surface
51A, 51B Rod through hole
52A, 52B recess
53A, 53B Clamp hydraulic cylinder
53aA, 53aB Piston rod
54A, 54B Unclamping hydraulic cylinder
54aA, 54aB Piston rod
55, 56 Clamp piece
57 Holding bracket
58 Expanding rod
59 Cutting cylinder
59a Piston rod
59b Cylinder body
60 Roller bracket
70 Injection device
71 Heating chamber
72 Heater
73 Discharge port
74 Auxiliary nozzle
75 Suction rod
76 Preheated barrel
77 Suction cylinder
78 Input opening
79 Chute board
80 Preheating heater
81 Plunger
82 Extrusion cylinder
90 mold
91 Pouring gate
100 Conveyor
F Fixed frame

Claims (8)

A first generation step of generating a metal slurry containing a solid phase by cooling the molten metal, a second generation step of further cooling the metal slurry to generate a solid metal material, and the metal material Heating to a semi-molten state and supplying it to the mold,
In the first generation step, the molten metal is cooled on the surface of the cooling unit disposed in the lower area of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. casting method characterized in that there.   The casting method according to claim 1, wherein the second generation step includes a step of continuously generating a metal material from the metal slurry and cutting the metal material into a predetermined length. Comprising a first generating means for generating a molten metal metal slurry containing the cooled solid-phase, and a second generating means for generating a solidified metal material by further cooling the metal slurry, said The first generating means has a cooling unit disposed in the lower region of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit,
A casting facility, wherein the metal material is heated to a semi-molten state and then supplied to a mold.   The casting equipment according to claim 3, wherein the second generating means includes a cutting unit that continuously generates a metal material from the metal slurry and cuts the metal material into a predetermined length. A method for producing a metal material to be supplied to a mold in a heated state in a semi-molten state, the first production step of cooling the molten metal to produce a metal slurry containing a solid phase, A second production step of further cooling and solidifying the metal slurry;
In the first generation step, the molten metal is cooled on the surface of the cooling unit disposed in the lower area of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. A method for producing a metal material, comprising:   The method for producing a metal material according to claim 5, wherein the second generation step includes a step of solidifying the metal slurry continuously and cutting the slurry into a predetermined length. An apparatus for producing a metal material supplied to a mold in a heated state in a semi-molten state,
A first generating means for cooling the molten metal to generate a metal slurry containing a solid phase;
A second generating means for further cooling and solidifying the metal slurry;
The first generating means has a cooling unit disposed in a lower region of the melting tank and inclined forward and downward, and a plurality of guide grooves are formed on the surface of the cooling unit. Material production equipment.   8. The apparatus for producing a metal material according to claim 7, wherein the second generation means includes a cutting unit that continuously solidifies the metal slurry and cuts the slurry into a predetermined length.

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