BG61184B1 - Method and device for the manufacture of moulded profile articles - Google Patents

Abstract

A method for producing shaped articles which comprises feeding non- a delayed flow of molten material to a shape having two opposing moving surfaces; forming means placed in a position between the opposing surfaces at desired intervals so as to separate the molten material into separate segments, wherein the molding means are retained in the molten material during its transition to a solid state, such as form molded shaped articles of the material that essentially crystallizes. Then the crystallized material is removed in the form of shaped articles. The opposing ones the moving surfaces are flat and the molding means are attached to one or both moving surfaces.

Description

The present invention relates to machines and methods for casting separate solid shaped articles of flowable, moldable or molten material, in particular continuous casting of individual shaped articles using a stationary molding machine or, preferably, a rolling mill form. In this form, for example, molded articles are formed between spaced portions of a pair of endless flexible casting belts that move along opposite surfaces of the cast metal.

Although according to the principles of the invention, any material can be cast - flowable, moldable or molten, for example plastics, the invention is described in terms of continuous casting of molten metal in the form of separate and variable shaped articles such as ingots, anodes, semi-finished wire products or casting in foundries.

The individual metal fittings are usually molded into individual molds using a continuous stream of molten metal. A large number of casting molds are fed in succession and the desired amount of metal jet for each of them is controlled either manually by an operator or automatically. Continuous castings of various shapes are used to reduce production costs and improve the quality of products in the processing of non-ferrous and ferrous metals in other industries. Two basic systems, known as fixed and rolling methods, are used in the continuous casting of shaped workpieces such as blooms or continuous strips. In fixed-casting machines, the walls of the mold are stationary while the cast products move to and crystallize in them. Rolling molding machines use bands, chains, drums, wheels or other surfaces that move at about the same speed as crystallizing metal.

Continuous casting of metal in rolling molding machines comprising at least one moving belt and a corresponding fixed or movable surface, which together form the two opposite surfaces in which the cast material crystallizes, is described in the following U.S. patents: 2 631 343 , 2 904 860, 3 036 348, 3 123 873, 3 123 874, 3 167 830, 3 533 463, 3 864 973, 3 878 883, 3 921 697, 3 937 274, 3 949 805, 3 955 615, 4 002 197 and 4 854 371.

In the case of a two-band molding machine, in which two movable strips form in operation, a continuous stream of molten metal is fed at the inlet of the machine into a cavity formed by a pair of movable flexible casting strips, usually one above the other, and from lateral supporting walls, which the metal stream exits at the other end of the cavity (outlet of the machine) as a crystallized tape or rod of metal. The strip or rod is fed sequentially to another machine for machining or cutting and / or welding, where its dimensions are altered in cross section. For example, two-band molding machines of the type described are used to convert molten copper into a roughly rectangular rod material, which is then fed continuously into a rolling machine with several rolling stages to convert the rectangular rod into a circular rod. Typically, the round rod is eventually drawn on wire of different numbers (thicknesses).

In one prior art experience in the continuous production of molded articles, a known two-band molding machine was modified by making smaller support walls at known intervals, in order to provide anode-shaped cast material, i. flat rectangular shape with supporting shoulders. However, after casting, the workpiece must be cut to produce separate anode products.

Another method of continuous casting is a casting wheel with a peripheral channel. Part of the channel is enclosed by a continuous / infinite / molding strip in which the molten metal is poured to crystallize into a mold and be removed from it. Such constructions are described in US NN 3 279 000 and 23 496 620.

Continuous casting using a fixed form is also described in US Patent Nos. 2,938,251, 2,946,100, 3,066,664, 3,089

209, 3 098 269 and 3 115 686. The main point is that molten metal is continuously fed into the mold and the solidified article is continuously removed from it. Usually the shape is in the upright position and the molten metal is poured into its upper part.

Known is AC SU No. 262 331, which describes a method and apparatus for producing molded shaped articles, in particular bushings. The known method consists in feeding into a continuous stream of molten material. The molding means, made as rings, are placed in the mold to distribute the molten material into separate segments and are retained therein until the material crystallizes and is then separated as separate bushings. The mold is formed by molding rollers and a slider that moves between the rollers. U.S. Patent No. 4,276,921 discloses a two-band casting device for producing a continuous series of individual moldings by molds formed by a pair of strips.

Although the foundry machines described are very successful and widely used in the industry, there is a need for this type of continuous casting machine that produces individual products. It is an object of the invention to provide a device and methods for continuous casting of such individual shaped articles.

According to the invention, there is provided a method of manufacturing molded articles in which a continuous stream of molten material is fed to a mold having two opposing moving surfaces and molding means placed between these surfaces at desired intervals so as to divide the molten material into separate segments. The molding means are retained in the molten material during its transition to a solid state, in which molded molded articles are formed, and the material crystallizes and is then removed in the form of these articles. The opposing moving surfaces are flat and the molding means are attached to one or both of them. The invention further provides a device for continuous casting of molded shaped articles, including a mold having two opposite movable surfaces, a means for feeding a continuous stream of molten material to the mold, one or more molding agents forming therein separate chambers for molding the molten material in cast material with configuration of individual segments, cooling unit for cooling said segments to a solid state and separating means for dividing the individual solid segments as separate forms molded molded articles. The adjoining movable surfaces are preferably flat and the molding means are attached to one or both movable surfaces.

The present invention provides a continuous casting device for casting individual shaped castings such as semi-finished products for wire, ingots, blooms, briquettes, tapes and shaped castings-profiles of molten material. Various types of continuous casting machines may be used according to the invention, but the casting of lead in blocks is conveniently described using a two-band molding machine in which a pair of moving bands form a moving / moving / molten metal form.

The apparatus and method of the invention can be used for any flowable, moldable or molten material, for example plastics and ferrous and non-ferrous metals, which include, but is not limited to, steel, cast iron, copper, lead, bismuth and aluminum. The invention is particularly useful for the continuous casting of fragile or brittle materials that cannot normally be rolled, rolled, rolled, or solid.

The method according to the invention comprises the following steps: supplying a continuous stream of molten material in a fixed or moving form; forming a continuous stream of molten material into separate segments of predetermined volume and shape; crystallizing this molten material and separating the segments into separate shaped blanks, the molding taking place before any significant crystallization of the molten metal. The molding step can be accomplished by using molding agents such as inserts, spacers, spacers and the like which will be described.

The device according to the invention includes a continuous casting machine with a first molding means, which first means a moving or stationary surface depending on the shape used, a second means for feeding a continuous stream of molten material to the mold, one or more molding agents, which form separate chambers in the form and form molten metal in the form of a cast having the configuration of separate segments and crystallization means and separating means for separating from the separate segments in separate shaped pieces from the cast material. In a two-band die-casting machine, the moving surface is flat, while in a disk-type foundry machine, the moving surface is curved. In the case of a stationary form, the latter is essentially stationary with respect to the molten and crystallized material passing through the form. In casting, fixed movements often use reciprocating or other vibrating motions.

The invention is illustrated by the accompanying figures, of which:

Figure 1 is a schematic representation of a two-band molding machine showing an advanced molding means for molding individual shaped articles;

FIG. 2 is a side sectional view taken in a plane perpendicular to the inlet rollers and representing the intermediate tank, the support wall and the molten metal; FIG.

3 is a top plan view of a lower casting bar showing a molded ingot formed using a special molding means;

FIG. 4 is a side view of a lower casting strip showing a molded ingot formed using a special molding means. FIG.

Figure 1 shows an exemplary embodiment of a continuous metal casting machine equipped with one embodiment of the present invention. In this casting machine 10, the molten metal 11 is fed from a spill or bucket / not shown / into an intermediate reservoir 12. From the reservoir 12, the metal 11 is fed into an inlet section 13 formed between the spaced parallel surfaces of the upper and lower endless coffees. the casting strip, respectively 14 and 15. The cavity formed between the strips 14 and 15 and the partition elements 16 can be defined as a casting zone 17 in which the molten metal is cast in the desired shape and solidifies. Preferably the casting strips are made of steel or other alloys that have a toughness and abrasion resistance and physical damage and resistance to thermal shocks and stresses due to the temperature difference observed during casting.

The casting belts 14 and 15 are worn and driven by the upper and lower undercarriage, typically 18 and 19. The two undercarriages are mounted to the machine body (not shown). Each chassis includes two main drums that carry, drive and guide the casting belts and consist of an upper and lower input drum 20 and 21, respectively, and an upper and lower output drum 22 and 23, respectively.

A flexible endless metal retaining barrier 16 is disposed on each side of the casting strips to form the lateral ends of the casting area to limit the molten metal. The side barriers 16 are guided at the starting end of the casting device 10 by sickle elements 24, which are mounted on the lower running gear 19.

During the casting operation, the two casting belts 14 and 15 are driven at approximately the same linear speed by the propulsion mechanism, preferably the upper and lower running gear are inclined in the direction of flow so that the casting area 17 between the casting belts is inclined. This decreasing slope facilitates the flow of molten metal inside the casting zone.

After the castings have solidified and left the device as indicated by 25, a secondary coolant 26 may be used to fully crystallize and / or cool the cast. The use of this method, called "secondary cooling", is used to obtain higher casting rates. The use of secondary cooling also facilitates the removal of the molding means 27 from the cast metal by a thermal shock mechanism caused by the existence of different coefficients of expansion between the agent and the metal, which greater differences between the coefficients will result in greater thermal shock and effect of separation. The primary coolant (not shown) is typically implemented using a high-speed moving liquid coolant passing on opposite sides of the strips 14 and 15 which form.

The advanced apparatus and method according to the invention use molding means 27 on the casting belts to provide a separate molding in the shape and area of casting 17. The molding means 27 are preferably attached to the upper casting strip 14 and can be varied in shape and distance. to determine the desired shape configuration in the casting area 17. Exemplary molding structures are described below.

In a preferred embodiment of the invention, an additional chassis 28 and a belt 29 are used to allow the molding means 27 to be separated from the belt 14, controlled by a synchronizer 30 and positioned on the belt 14, at a predetermined desired distance. Using this separation system, the weight (s) and size (s) of the individual shaped castings obtained during casting can be varied by adjusting the synchronizer 30. The chassis 28 may use, as indicated, two drums 31 and 32.

The individual shaped articles 33 are removed from the casting device and transported to the desired location.

Preferably, the machine 10 and the intermediate tank 12 are of the "open" type, the outlet / outlet / of the tank 12 being specially modified to allow the molding means 27 to enter the casting area 17. The molten metal bath at the inlet 13 of the casting machine it preferably fills it so that the molding means 27 come into contact with the molten metal 11 at the inlet 13.

Preferably, the upper part of the intermediate tank 12 is made of graphite or other soft, washable material, which also facilitates the casting and lubrication of the lower strip 15. A drawing of the proposed structure is shown in FIG. As the metal, tape, and molding agents converge at about one point, no gas or vapor after the molding means 27 can escape into the atmosphere and cannot cause bubbles (pores) to form after the metal casting agent. The barrier members 16 preferably have a very pronounced conical shape from the inner surface (the wide portion being at the bottom) to prevent or otherwise move the molding means in the shape.

As the metal passes through the foundry machine, the process will be the same as that of a standard foundry machine. However, the casting speed will usually be accelerated or slowed by the use of molding means 27, which act as heat sinks or insulators, depending on the material used for them.

In one preferred embodiment, the molding means 27 are removably attached, for example, magnetically, to the belts 14 and 29. In operation, the molding means 27 will be spaced from the strip 14, and as it rotates, the desired molded molding will be molded. After crystallization, the individual casting will be separated from the continuous casting strip (including the molding means 27) with the molding means magnetically gripped and taken to the strip 29. The means will then be brought to the synchronization device 30, where they will be stacked and fed again to the strip 14 with the desired distance between them.

A device for separating the individual castings from the casting tape made in the foundry machine may be used in heading 34. For example, a bending motion may be applied to the casting is the molding means 27 removed from the strip 29 and transferred to the casting strip 14 as described.

The designs of the molding means 27 may be quite different. As shown in FIG. 3, the U-shaped tool 27 produces a shaped ingot 33. Similarly, FIG. 4 represents an inverted T-shaped tool, which also produces a shaped ingot 33. If required, using a suitable forming tool. castings, openings, gaps, markings, factory signs or other markings can be made.

The molding means 27 may be made of a plurality of materials. The more powerful its magnetic force is, in magnetic separators, the smaller the inner cone or alignment will be required to trap the means in the shape space. In some applications, it may also be desirable to make the molding agents partly or wholly of cast sand or refractory, or metal balls as a filler for intricate or punctured holes and shapes in the casting or as separators.

Removal of the molding means 27 from the strip 14 and / or the casting may be facilitated by the use of molding agents which are combustible (such as wood) or removable. Another solution is to use a thin flexible partitioning agent containing a substance such as water that expands upon contact with molten metal (due to the formation of steam or vapors in the molding agent) and which shrinks upon cooling. As the molding agent contacts the molten metal 11, it expands and the mold is molded with the expanded tool. After crystallization and cooling, the molding agent shrinks, facilitating its removal. The thin stainless steel agent can be used to cast lead into blocks.

In the case of a casting wheel device, the molding means 27 may be affixed to the wheel or strip to set the desired individual configuration in the form formed by the peripheral groove in the casting wheel and the endless strip as indicated. In continuous casting using a stationary mold, the molding means 27 may be inserted into the cavity at the desired intervals to provide separation of the molten metal (separation of individual shaped articles). Suitably, beads which project into the cavity of the mold can be used to form the separation of the molten metal cast. The molten metal can then be easily separated into separate preforms after crystallization.

Claims (8)

1. A method of manufacturing molded articles, in which a continuous stream of molten material is fed to a mold having two opposing moving surfaces and molding means placed in a space between opposing surfaces at desired intervals so as to divide the molten material into separate segments, wherein the molding means are retained in the molten material during its transition to a solid state, forming molded molded articles from the material which crystallizes substantially, after which the crystal ized material is removed in the form of shaped articles, characterized in that the opposed moving surfaces are opposite moving flat surfaces, and the forming means are attached to one or two moving surfaces. A method according to claim 1, characterized in that the opposing moving surfaces are a two-band casting device. A device for continuous casting of molded shaped articles, including a mold having two opposing movable surfaces, a means (12) for feeding a continuous flow of molten material to the mold, one or more molding means (27) forming separate molding chambers in the form of molten material in cast material with configuration of individual segments, cooling unit for cooling the segments to a solid state and separating means (34) for dividing the individual solid segments as separate molded articles (33) from Ivan material, characterized in that the opposing movable surfaces (14, 15) are mainly flat, and forming means (27) are secured to one or both rolling surfaces (14, 15). Apparatus according to claim 3, characterized in that the shape has two and one opposite to one another, preferably flat, surfaces (14, 15) which together form the shape. A device according to claim 4, characterized in that the molding means (27) are disposed on the upper planar surface (14). The device according to claim 4 or 5, characterized in that the two substantially flat surfaces (14, 15) are strips. Device according to any one of claims 4 to 6, characterized in that the molding means (27) are fixed sideways to the movable flat surface 10 (14). Device according to claim 7, characterized in that it includes means (28, 29, 31, 32) for removing the molding means (27) from the flat surface (14), for collecting the molding means (27) and for repositioning them on the movable flat surface (14). Device according to any one of claims 3 to 8, characterized in that there are transversally restricting partitions (16) attached to at least one of the flat surfaces (14, 15) for determining the casting area between the partitions (16) ) and surfaces (14, 15).