CA2592792C - A system for providing consistent flow through multiple permeable perimeter walls in a casting mold - Google Patents
A system for providing consistent flow through multiple permeable perimeter walls in a casting mold Download PDFInfo
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- CA2592792C CA2592792C CA002592792A CA2592792A CA2592792C CA 2592792 C CA2592792 C CA 2592792C CA 002592792 A CA002592792 A CA 002592792A CA 2592792 A CA2592792 A CA 2592792A CA 2592792 C CA2592792 C CA 2592792C
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Abstract
Disclosed is a system for providing consistent lubricant and/or gas flow through multiple permeable perimeter walls (30) in a casting mold table (10). One or more of the properties of the perimeter walls indicative of the lubricant flow or gas flow rates through the perimeter walls are predetermined and the sizing of the surface area of the delivery conduits providing the lubricant or the gas are determined based on a correlation to the properties related to the measured or estimated lubricant flow rate and/or measured or estimated gas flow rates through the perimeter walls.
Description
A SYSTEM FOR PROVIDING CONSISTENT FLOW THROUGH MULTIPLE
PERMEABLE PERIMETER WALLS IN A CASTING MOLD
This is a divisional application of Canadian Patent Application No.
PERMEABLE PERIMETER WALLS IN A CASTING MOLD
This is a divisional application of Canadian Patent Application No.
2,295,839 filed July 9, 1998.
Technical Field s This invention pertains to a system for providing consistent lubricant and/or gas flow through multiple permeable perimeter walls in a metal casting mold table.
Backeround Art Metal ingots and billets are typically formed by a casting process, which io utilizes a vertically oriented mold situated above a large casting pit beneath the floor level of the metal casting facility. The lower component of the vertical casting mold is a starting block mounted on starting block pedestals.
When the casting process begins, the starting blocks are in their upward-most position and in the molds. As molten non-ferrous metal is poured into the 15 mold and cooled, the starting block is slowly lowered at a pre-determined rate by a hydraulic cylinder or other device. As the starting block is lowered, solidified non-ferrous metal or aluminum emerges from the bottom of the mold and ingots or billets are formed.
While the invention applies to casting of metals in general, including 20 without limitations aluminum, brass, lead, zinc, magnesium, copper, steel, etc., the examples given and preferred embodiment disclosed are for aluminum, and therefore the term aluminum will be used throughout for consistency even though the invention applies more generally to metals.
There are numerous mold and pour technologies that fit into these 25 mold tables. Some are generally referred to as "hot top" technology, while others are more conventional casting technologies that use floats and downspouts, both of which are known to those of ordinary skill in the art.
The hot top technology generally includes a refractory system and molten metal trough system located on top of the mold table, whereas the 3o conventional pour technology involves suspending or supporting the source of molten metal above the mold table and the utilization of down spouts or tubes and floats to maintain the level of molten metal in the molds while also providing molten metal to the molds.
These different casting technologies have different advantages and disadvantages and produce various billet qualities, but no one of which is required to practice this invention.
The metal distribution system is also an important part of the casting system. In the two technology examples given, the hot top distribution trough sits atop the mold table while the conventional pouring trough is suspended above the mold table to distribute the molten metal to the molds.
Mold tables come in all sizes and configurations because there are numerous and differently sized and configured casting pits over which mold table are placed. The needs and requirements for a mold table to fit a particular application therefore depends on numerous factors, some of which include the dimensions of the casting pit, the location(s) of the sources of !s water and the practices of the entity operating the pit.
The upper side of the typical mold table operatively connects to, or interacts with, the metal distribution system. The typical mold table also operatively connects to the molds which it houses.
The use of a permeable or porous perimeter wall has proven to be an 2o effective and efficient way to distribute lubricant and gas to the inside surface of a continuous casting mold, such as is described in U.S. Patent No.
4,598,763 to Wagstaff.
In the typical use of a permeable perimeter wall, lubricant and gas are delivered to the perimeter wall under pressure through grooves or delivery 25 conduits around the perimeter wall, typically using one delivery conduit (if grooves are used for the delivery of lubricant) and one or two delivery conduits (grooves) for the delivery of gas. The preferred lubricants are synthetic oils, whereas the current preferred gas is air. The lubricant and gas then permeate through the perimeter wall and are delivered to the interior 30 of the mold as part of the casting process.
The perimeter walls on existing mold tables each have delivery conduits to deliver the lubricant and/or gas, and the delivery conduits may be circumferential groove-shaped delivery conduits with the same depth and width, or they may be holes partially drilled through the perimeter walls, or any other delivery means for that matter. The typical perimeter wall has a separate lubricant delivery conduit and a gas conduit.
s Graphite has proven to be the preferred permeable material for use as the perimeter wall material or media. However, graphite has proven to be expensive in consistently producing high quality individual products which have very similar permeability to other graphite perimeter walls.
One of the significant factors causing the high cost incurred in jo providing consistent permeability or lubricant/gas flow rates through the perimeter walls is the variability in the relevant properties of the perimeter wall material. The properties related to the lubricant and gas flow rates can vary significantly from batch to batch of graphite for instance, and even within the same batch and within a given perimeter wall. Variations in is properties such as porosity, permeability and density, impact the rate of delivery of lubricant and or gas through the perimeter wall. Furthermore, the viscosity of a particular lubricant or gas as well as the pressure at which the lubricant or gas is supplied to the perimeter wall, are factors affecting the respective flow rates through the permeable perimeter walls.
20 Experience has taught that graphite from a particular supplier or source will tend to have more similar properties than graphite from two different sources or suppliers, however, there may still be unacceptable variations in the properties of the graphite from a single source and even from a single batch. This is the case even though a particular density is 25 typically specified when ordering.
In a typical application, one perimeter wall is used for each mold, and there are typically numerous molds on a single mold table, each mold having a perimeter wall. It is preferred to supply gas from one source line at one pressure and to supply lubricant from one source line at one pressure, to all 30 perimeter walls in molds of a particular mold table.
The variations of most concern in the lubricant and/or gas flow rates through the graphite are therefore based on the variability in the properties of the graphite related to the respective flow rates, which becomes the critical factor in accomplishing the goal of the equal or predictable flow rates of lubricant and gas through the perimeter walls in each of the molds on the same mold table, or even in the same manufacturing facility.
s Prior to this invention, achieving the same flow rate or delivery rate of lubricant and/or gas flow through multiple perimeter walls on the same mold table, was very time consuming and expensive, and resulted in significant waste. Each individual perimeter wall was extensively tested to determine its properties relevant to flow rate and an unnecessarily large ro percentage were rejected due to the flow rate variations.
With numerous molds on the same table simultaneously casting metal, it becomes critical to achieving a reliable process for producing high quality molded products (billet, ingot or special shapes) that the lubricant and/or gas delivered to the perimeter walls during casting is very closely the same from 15 perimeter wall to perimeter wall in the same mold table.
In order to achieve consistent lubricant and/or gas flow rates through the perimeter walls in each of the molds in a given mold table, a high rate of rejection of graphite rings has been experienced. Typically, graphite perimeter walls with similar properties may be grouped together to achieve zo closely similar lubricant and/or gas flow rates. However, while grouping perimeter walls together may work for new construction, managing the selective replacement of perimeter walls in place in a facility can be very difficult.
From a practical and expense perspective, lubricant and/or gas are 25 supplied at a constant pressure, and the perimeter walls are manufactured at a constant or fixed thickness and general size to fit within the molds. The inner and outer diameters of the perimeter walls, as well as their overall height also is generally fixed.
It is an objective of this invention to achieve a sufficiently consistent 3o lubricant and/or gas flow rate through multiple perimeter walls on a mold table or in a casting facility, even though the perimeter walls generally have variations in their individual properties related to the flow rate of lubricant and/or gas through the perimeter wall body.
It is also an objective of this invention to reduce the significant expense of a high rejection rate for perimeter walls to achieve the sufficiently s consistent lubricant and/or gas flow rate.
This invention accomplishes these objectives by providing a system for providing consistent lubricant and/or gas flow through multiple permeable perimeter walls. The system involves ascertaining one or more of the relevant properties, or the actual flow rate, of the perimeter walls, and then lo determining and creating the appropriate surface area of the delivery conduit which provides the lubricant and/or gas to the exterior of the perimeter wall, and/or the appropriate delivery distance.
The system provided by this invention has the significant advantage of allowing the use of multiple perimeter walls with different flow related rs properties, or with different lubricant and/or gas flow rates, to be used in the same mold table, while achieving consistent flow rates through each perimeter wall.
The system provided by this invention has the significant advantage of providing a significantly similar flow rate of lubricant or gas in a plurality of 2o perimeter walls in molds on the same mold table.
In accomplishing these objectives, this invention provides a system which is simpler and less expensive than all prior systems.
Brief Description of the Drawioes Preferred embodiments of the invention are described below with 21 reference to the accompanying drawings, which are briefly described below.
Figure 1 is an elevation view of a typical casting pit, caisson and aluminum casting apparatus;
Figure 2 is a cross sectional elevation view of a typical mold casting assembly, illustrating the perimeter wall in place;
3o Figure 3 is a cross sectional view of a perimeter wall seated in a mold housing, illustrating the flow of lubricant or gas through its body;
Figure 4 is a cross sectional view of a perimeter wall seated in a mold housing, illustrating the flow of lubricant or gas through its body, only wherein the delivery conduits are in the mold housing;
s Figure 5 is a perspective of one embodiment of a perimeter wall which is contemplated for use by this invention;
Figure 6 is a top view of the perimeter wall illustrated in Figure 5;
Figure 7 is an elevation view of the perimeter wall illustrated in Figure 5;
io Figure 8 is Section 8 - 8 from the perimeter wall illustrated in Figure 6;
Figure 9 is a top view of an alternative embodiment of a perimeter wall contemplated by this invention, wherein lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall;
Is Figure 10 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall, and wherein the holes through which lubricant and/or gas are delivered are not equally spaced;
2o Figure 11 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall, and wherein shape of the perimeter wall is not circular; and Figure 12 is a top partial view of a perimeter wall which illustrates the 25 movement of the location of the delivery holes to affect the flow rates.
Best Modes for Carrying Out the Invention and Disclosure of Invention While there are numerous ways to achieve and configure a vertical casting arrangement, Figure 1 illustrates one example. In Figure 1, the 3o vertical casting of aluminum generally occurs beneath the elevation level of the factory floor in a casting pit. Directly beneath the casting pit floor la is a caisson 3, in which the hydraulic cylinder barrel 2 for the hydraulic cylinder is placed.
As shown in Figure 1, the components of the lower portion of a typical vertical aluminum casting apparatus, shown within a casting pit 1 and s a caisson 3, are a hydraulic cylinder barrel 2, a ram 6, a mounting base housing 5, a platen 7 and a starting block base 8, all shown at elevations below the casting facility floor 4.
The mounting base housing 5 is mounted to the floor la of the casting pit 1, below which is the caisson 3. The caisson 3 is defined by its side walls io 3b and its floor 3a.
A typical mold table assembly 10 is also shown in Figure 1, which can be tilted as shown by hydraulic cylinder 11 pushing mold table tilt arm l0a such that it pivots about point 12 and thereby raises and rotates the main casting frame assembly, as shown in Figure 1. There are also mold table is carriages which allow the mold table assemblies to be moved to and from the casting position above the casting pit.
Figure 1 further shows the platen 7 and starting block base 8 partially descended into the casting pit 1 with billet 13 being partially formed. Billet 13 is on starting block 14, which is mounted on pedestal 15. While the term 20 starting block is used for item 14, it should be noted that the terms bottom block and starting head are also used in the industry to refer to item 14, bottom block typically used when an ingot is being cast and starting head when a billet is being cast.
While the starting block base 8 in Figure 1 only shows one starting 21 block 14 and pedestal 15, there are typically several of each mounted on each starting block base, which simultaneously cast billets or ingots as the starting block is lowered during the casting process.
When hydraulic fluid is introduced into the hydraulic cylinder at sufficient pressure, the ram 6, and consequently the starting block base 8, are 3o raised to the desired elevation start level for the casting process, which is when the starting blocks are within the mold table assembly 10.
The lowering of the starting block base 8 is accomplished by metering the hydraulic fluid from the cylinder at a pre-determined rate, thereby lowering the ram 6 and consequently the starting blocks at a pre-determined and controlled rate. The mold is controllably cooled during the process to assist in the solidification of the emerging ingots or billets, typically using water cooling means.
As noted earlier, Fig. 2 is a cross-sectional elevation view of a typical mold casting assembly, illustrating the perimeter wall 30 in place in mold housing 31. The entrance of the mold is indicated by reference numeral 34.
Fig. 3 shows a perimeter wall 30 contemplated by this invention seated in a mold housing 31. A gas inlet line 45 and a lubricant inlet line 44 are also shown, and illustrate how lubricant and gas may be provided to a lubricant delivery conduit 40 and gas delivery conduits 41.
Fig. 4 is also a cross sectional view of an embodiment of a perimeter wall 30 contemplated by this invention, seated in a mold housing 31, and further illustrating an embodiment wherein a lubricant delivery conduit 42 and gas delivery conduits 43 are within the mold housing 31. A gas inlet line 45 and a lubricant inlet line 44 are also shown, and illustrate how lubricant and gas may be provided to the lubricant delivery conduit 42 and the gas delivery conduits 43.
Fig. 5 is a perspective of one embodiment of a perimeter wall 30 which is contemplated for use by this invention, and illustrates an inner surface 50, an outer surface 51, gas delivery conduits 52 and a lubricant delivery conduit 53. The two gas delivery conduits 52 are shown in operative connection to one another.
Fig. 6 is a top view of the perimeter wall 30 illustrated in Fig. 5, also illustrating the inner surface 50 and the outer surface 51.
Fig. 7 is an elevation view of the perimeter wall 30 illustrated in Fig. 5, and illustrates the outer surface 51, gas delivery conduits 52 and lubricant delivery conduit 53.
FIG. 8 is section 8-8 of the perimeter wall illustrated in Fig. 6, and shows a cross section of one embodiment of the invention. Fig. 8 illustrates perimeter wall 30, perimeter wall body 56, lubricant delivery conduit 53, lubricant delivery conduit height 61, lubricant delivery conduit depth 60, gas delivery conduits 52, gas delivery conduit height 62, and gas delivery conduit depth 63. Fig. 8 further illustrates a delivery distance 66 from the termination of a delivery conduit to the inner surface 50 of the perimeter wa1130.
Fig. 9 shows an alternative embodiment of the invention wherein the gas and/or lubricant are delivered to a perimeter wall 70 through delivery holes 71 drilled from the top of the perimeter wall 70. An outer surface 73 and an inner surface 72 of the perimeter wa1170 are also shown.
Fig. 10 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through delivery holes 71 drilled from the top of the perimeter wall 70, only wherein the delivery holes 71 through which lubricant and/or gas are delivered are not equally spaced. The holes in region 74 are spaced closer together to achieve a higher flow of gas and/or lubricant in that region.
Fig. 11 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to a perimeter wall 80 through delivery holes 81 drilled from the top of the perimeter wall 80, and wherein the shape of the perimeter wa1180 is not circular.
Fig. 12 shows a section of a perimeter wall 90 within the contemplation of this invention, with an inner surface 93, an outer surface 94 and delivery holes 91. Delivery holes 91 are shown a distance 95 from the inner surface 93 of the perimeter wall 90. The distance 95 would be the delivery distance for those particular delivery holes 91. The dotted lines comprising a circle illustrate a second possible location for relocated delivery holes 92, which are a lesser second distance 96 from the outer surface of the perimeter wall 90. The second distance 96 would be the delivery distance for the relocated delivery holes 92.
Technical Field s This invention pertains to a system for providing consistent lubricant and/or gas flow through multiple permeable perimeter walls in a metal casting mold table.
Backeround Art Metal ingots and billets are typically formed by a casting process, which io utilizes a vertically oriented mold situated above a large casting pit beneath the floor level of the metal casting facility. The lower component of the vertical casting mold is a starting block mounted on starting block pedestals.
When the casting process begins, the starting blocks are in their upward-most position and in the molds. As molten non-ferrous metal is poured into the 15 mold and cooled, the starting block is slowly lowered at a pre-determined rate by a hydraulic cylinder or other device. As the starting block is lowered, solidified non-ferrous metal or aluminum emerges from the bottom of the mold and ingots or billets are formed.
While the invention applies to casting of metals in general, including 20 without limitations aluminum, brass, lead, zinc, magnesium, copper, steel, etc., the examples given and preferred embodiment disclosed are for aluminum, and therefore the term aluminum will be used throughout for consistency even though the invention applies more generally to metals.
There are numerous mold and pour technologies that fit into these 25 mold tables. Some are generally referred to as "hot top" technology, while others are more conventional casting technologies that use floats and downspouts, both of which are known to those of ordinary skill in the art.
The hot top technology generally includes a refractory system and molten metal trough system located on top of the mold table, whereas the 3o conventional pour technology involves suspending or supporting the source of molten metal above the mold table and the utilization of down spouts or tubes and floats to maintain the level of molten metal in the molds while also providing molten metal to the molds.
These different casting technologies have different advantages and disadvantages and produce various billet qualities, but no one of which is required to practice this invention.
The metal distribution system is also an important part of the casting system. In the two technology examples given, the hot top distribution trough sits atop the mold table while the conventional pouring trough is suspended above the mold table to distribute the molten metal to the molds.
Mold tables come in all sizes and configurations because there are numerous and differently sized and configured casting pits over which mold table are placed. The needs and requirements for a mold table to fit a particular application therefore depends on numerous factors, some of which include the dimensions of the casting pit, the location(s) of the sources of !s water and the practices of the entity operating the pit.
The upper side of the typical mold table operatively connects to, or interacts with, the metal distribution system. The typical mold table also operatively connects to the molds which it houses.
The use of a permeable or porous perimeter wall has proven to be an 2o effective and efficient way to distribute lubricant and gas to the inside surface of a continuous casting mold, such as is described in U.S. Patent No.
4,598,763 to Wagstaff.
In the typical use of a permeable perimeter wall, lubricant and gas are delivered to the perimeter wall under pressure through grooves or delivery 25 conduits around the perimeter wall, typically using one delivery conduit (if grooves are used for the delivery of lubricant) and one or two delivery conduits (grooves) for the delivery of gas. The preferred lubricants are synthetic oils, whereas the current preferred gas is air. The lubricant and gas then permeate through the perimeter wall and are delivered to the interior 30 of the mold as part of the casting process.
The perimeter walls on existing mold tables each have delivery conduits to deliver the lubricant and/or gas, and the delivery conduits may be circumferential groove-shaped delivery conduits with the same depth and width, or they may be holes partially drilled through the perimeter walls, or any other delivery means for that matter. The typical perimeter wall has a separate lubricant delivery conduit and a gas conduit.
s Graphite has proven to be the preferred permeable material for use as the perimeter wall material or media. However, graphite has proven to be expensive in consistently producing high quality individual products which have very similar permeability to other graphite perimeter walls.
One of the significant factors causing the high cost incurred in jo providing consistent permeability or lubricant/gas flow rates through the perimeter walls is the variability in the relevant properties of the perimeter wall material. The properties related to the lubricant and gas flow rates can vary significantly from batch to batch of graphite for instance, and even within the same batch and within a given perimeter wall. Variations in is properties such as porosity, permeability and density, impact the rate of delivery of lubricant and or gas through the perimeter wall. Furthermore, the viscosity of a particular lubricant or gas as well as the pressure at which the lubricant or gas is supplied to the perimeter wall, are factors affecting the respective flow rates through the permeable perimeter walls.
20 Experience has taught that graphite from a particular supplier or source will tend to have more similar properties than graphite from two different sources or suppliers, however, there may still be unacceptable variations in the properties of the graphite from a single source and even from a single batch. This is the case even though a particular density is 25 typically specified when ordering.
In a typical application, one perimeter wall is used for each mold, and there are typically numerous molds on a single mold table, each mold having a perimeter wall. It is preferred to supply gas from one source line at one pressure and to supply lubricant from one source line at one pressure, to all 30 perimeter walls in molds of a particular mold table.
The variations of most concern in the lubricant and/or gas flow rates through the graphite are therefore based on the variability in the properties of the graphite related to the respective flow rates, which becomes the critical factor in accomplishing the goal of the equal or predictable flow rates of lubricant and gas through the perimeter walls in each of the molds on the same mold table, or even in the same manufacturing facility.
s Prior to this invention, achieving the same flow rate or delivery rate of lubricant and/or gas flow through multiple perimeter walls on the same mold table, was very time consuming and expensive, and resulted in significant waste. Each individual perimeter wall was extensively tested to determine its properties relevant to flow rate and an unnecessarily large ro percentage were rejected due to the flow rate variations.
With numerous molds on the same table simultaneously casting metal, it becomes critical to achieving a reliable process for producing high quality molded products (billet, ingot or special shapes) that the lubricant and/or gas delivered to the perimeter walls during casting is very closely the same from 15 perimeter wall to perimeter wall in the same mold table.
In order to achieve consistent lubricant and/or gas flow rates through the perimeter walls in each of the molds in a given mold table, a high rate of rejection of graphite rings has been experienced. Typically, graphite perimeter walls with similar properties may be grouped together to achieve zo closely similar lubricant and/or gas flow rates. However, while grouping perimeter walls together may work for new construction, managing the selective replacement of perimeter walls in place in a facility can be very difficult.
From a practical and expense perspective, lubricant and/or gas are 25 supplied at a constant pressure, and the perimeter walls are manufactured at a constant or fixed thickness and general size to fit within the molds. The inner and outer diameters of the perimeter walls, as well as their overall height also is generally fixed.
It is an objective of this invention to achieve a sufficiently consistent 3o lubricant and/or gas flow rate through multiple perimeter walls on a mold table or in a casting facility, even though the perimeter walls generally have variations in their individual properties related to the flow rate of lubricant and/or gas through the perimeter wall body.
It is also an objective of this invention to reduce the significant expense of a high rejection rate for perimeter walls to achieve the sufficiently s consistent lubricant and/or gas flow rate.
This invention accomplishes these objectives by providing a system for providing consistent lubricant and/or gas flow through multiple permeable perimeter walls. The system involves ascertaining one or more of the relevant properties, or the actual flow rate, of the perimeter walls, and then lo determining and creating the appropriate surface area of the delivery conduit which provides the lubricant and/or gas to the exterior of the perimeter wall, and/or the appropriate delivery distance.
The system provided by this invention has the significant advantage of allowing the use of multiple perimeter walls with different flow related rs properties, or with different lubricant and/or gas flow rates, to be used in the same mold table, while achieving consistent flow rates through each perimeter wall.
The system provided by this invention has the significant advantage of providing a significantly similar flow rate of lubricant or gas in a plurality of 2o perimeter walls in molds on the same mold table.
In accomplishing these objectives, this invention provides a system which is simpler and less expensive than all prior systems.
Brief Description of the Drawioes Preferred embodiments of the invention are described below with 21 reference to the accompanying drawings, which are briefly described below.
Figure 1 is an elevation view of a typical casting pit, caisson and aluminum casting apparatus;
Figure 2 is a cross sectional elevation view of a typical mold casting assembly, illustrating the perimeter wall in place;
3o Figure 3 is a cross sectional view of a perimeter wall seated in a mold housing, illustrating the flow of lubricant or gas through its body;
Figure 4 is a cross sectional view of a perimeter wall seated in a mold housing, illustrating the flow of lubricant or gas through its body, only wherein the delivery conduits are in the mold housing;
s Figure 5 is a perspective of one embodiment of a perimeter wall which is contemplated for use by this invention;
Figure 6 is a top view of the perimeter wall illustrated in Figure 5;
Figure 7 is an elevation view of the perimeter wall illustrated in Figure 5;
io Figure 8 is Section 8 - 8 from the perimeter wall illustrated in Figure 6;
Figure 9 is a top view of an alternative embodiment of a perimeter wall contemplated by this invention, wherein lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall;
Is Figure 10 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall, and wherein the holes through which lubricant and/or gas are delivered are not equally spaced;
2o Figure 11 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through holes drilled from the top of the perimeter wall, and wherein shape of the perimeter wall is not circular; and Figure 12 is a top partial view of a perimeter wall which illustrates the 25 movement of the location of the delivery holes to affect the flow rates.
Best Modes for Carrying Out the Invention and Disclosure of Invention While there are numerous ways to achieve and configure a vertical casting arrangement, Figure 1 illustrates one example. In Figure 1, the 3o vertical casting of aluminum generally occurs beneath the elevation level of the factory floor in a casting pit. Directly beneath the casting pit floor la is a caisson 3, in which the hydraulic cylinder barrel 2 for the hydraulic cylinder is placed.
As shown in Figure 1, the components of the lower portion of a typical vertical aluminum casting apparatus, shown within a casting pit 1 and s a caisson 3, are a hydraulic cylinder barrel 2, a ram 6, a mounting base housing 5, a platen 7 and a starting block base 8, all shown at elevations below the casting facility floor 4.
The mounting base housing 5 is mounted to the floor la of the casting pit 1, below which is the caisson 3. The caisson 3 is defined by its side walls io 3b and its floor 3a.
A typical mold table assembly 10 is also shown in Figure 1, which can be tilted as shown by hydraulic cylinder 11 pushing mold table tilt arm l0a such that it pivots about point 12 and thereby raises and rotates the main casting frame assembly, as shown in Figure 1. There are also mold table is carriages which allow the mold table assemblies to be moved to and from the casting position above the casting pit.
Figure 1 further shows the platen 7 and starting block base 8 partially descended into the casting pit 1 with billet 13 being partially formed. Billet 13 is on starting block 14, which is mounted on pedestal 15. While the term 20 starting block is used for item 14, it should be noted that the terms bottom block and starting head are also used in the industry to refer to item 14, bottom block typically used when an ingot is being cast and starting head when a billet is being cast.
While the starting block base 8 in Figure 1 only shows one starting 21 block 14 and pedestal 15, there are typically several of each mounted on each starting block base, which simultaneously cast billets or ingots as the starting block is lowered during the casting process.
When hydraulic fluid is introduced into the hydraulic cylinder at sufficient pressure, the ram 6, and consequently the starting block base 8, are 3o raised to the desired elevation start level for the casting process, which is when the starting blocks are within the mold table assembly 10.
The lowering of the starting block base 8 is accomplished by metering the hydraulic fluid from the cylinder at a pre-determined rate, thereby lowering the ram 6 and consequently the starting blocks at a pre-determined and controlled rate. The mold is controllably cooled during the process to assist in the solidification of the emerging ingots or billets, typically using water cooling means.
As noted earlier, Fig. 2 is a cross-sectional elevation view of a typical mold casting assembly, illustrating the perimeter wall 30 in place in mold housing 31. The entrance of the mold is indicated by reference numeral 34.
Fig. 3 shows a perimeter wall 30 contemplated by this invention seated in a mold housing 31. A gas inlet line 45 and a lubricant inlet line 44 are also shown, and illustrate how lubricant and gas may be provided to a lubricant delivery conduit 40 and gas delivery conduits 41.
Fig. 4 is also a cross sectional view of an embodiment of a perimeter wall 30 contemplated by this invention, seated in a mold housing 31, and further illustrating an embodiment wherein a lubricant delivery conduit 42 and gas delivery conduits 43 are within the mold housing 31. A gas inlet line 45 and a lubricant inlet line 44 are also shown, and illustrate how lubricant and gas may be provided to the lubricant delivery conduit 42 and the gas delivery conduits 43.
Fig. 5 is a perspective of one embodiment of a perimeter wall 30 which is contemplated for use by this invention, and illustrates an inner surface 50, an outer surface 51, gas delivery conduits 52 and a lubricant delivery conduit 53. The two gas delivery conduits 52 are shown in operative connection to one another.
Fig. 6 is a top view of the perimeter wall 30 illustrated in Fig. 5, also illustrating the inner surface 50 and the outer surface 51.
Fig. 7 is an elevation view of the perimeter wall 30 illustrated in Fig. 5, and illustrates the outer surface 51, gas delivery conduits 52 and lubricant delivery conduit 53.
FIG. 8 is section 8-8 of the perimeter wall illustrated in Fig. 6, and shows a cross section of one embodiment of the invention. Fig. 8 illustrates perimeter wall 30, perimeter wall body 56, lubricant delivery conduit 53, lubricant delivery conduit height 61, lubricant delivery conduit depth 60, gas delivery conduits 52, gas delivery conduit height 62, and gas delivery conduit depth 63. Fig. 8 further illustrates a delivery distance 66 from the termination of a delivery conduit to the inner surface 50 of the perimeter wa1130.
Fig. 9 shows an alternative embodiment of the invention wherein the gas and/or lubricant are delivered to a perimeter wall 70 through delivery holes 71 drilled from the top of the perimeter wall 70. An outer surface 73 and an inner surface 72 of the perimeter wa1170 are also shown.
Fig. 10 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to the perimeter wall through delivery holes 71 drilled from the top of the perimeter wall 70, only wherein the delivery holes 71 through which lubricant and/or gas are delivered are not equally spaced. The holes in region 74 are spaced closer together to achieve a higher flow of gas and/or lubricant in that region.
Fig. 11 is a top view of an alternative embodiment in which lubricant and/or gas are delivered to a perimeter wall 80 through delivery holes 81 drilled from the top of the perimeter wall 80, and wherein the shape of the perimeter wa1180 is not circular.
Fig. 12 shows a section of a perimeter wall 90 within the contemplation of this invention, with an inner surface 93, an outer surface 94 and delivery holes 91. Delivery holes 91 are shown a distance 95 from the inner surface 93 of the perimeter wall 90. The distance 95 would be the delivery distance for those particular delivery holes 91. The dotted lines comprising a circle illustrate a second possible location for relocated delivery holes 92, which are a lesser second distance 96 from the outer surface of the perimeter wall 90. The second distance 96 would be the delivery distance for the relocated delivery holes 92.
Claims (16)
1. A permeable perimeter wall for a metal mold, comprising:
a. a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface; and b. at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
a. a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface; and b. at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
2. The perimeter wall according to claim 1, wherein said unequal flow is created by varying a surface area of said at least one delivery conduit in different regions of said perimeter wall body.
3. The perimeter wall according to claim 1, wherein said unequal flow is created by varying a delivery distance of said at least one delivery conduit from said inner surface in different regions of said perimeter wall body.
4. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a plurality of delivery holes extending through said perimeter wall body, and wherein said delivery holes are not equally spaced around said perimeter wall, thereby creating said unequal flow of said lubricant or gas into said mold cavity from said different regions of said inner surface.
5. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a plurality of delivery holes extending through said perimeter wall body, each delivery hole being spaced from said inner surface by a delivery distance, and wherein said delivery distance is greater in one region of said perimeter wall than another region thereof, thereby creating said unequal flow of said lubricant or gas into said mold cavity from said different regions of said inner surface.
6. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a plurality of delivery holes extending through said perimeter wall body, each delivery hole having an internal surface area, and wherein said delivery holes in one region of said body have internal surface areas that differ from internal surface areas of said delivery holes in another region of said body, thereby creating said unequal flow of said lubricant or gas into said mold cavity from said different regions of said inner surface.
7. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a plurality of delivery holes extending through said perimeter wall body, each delivery hole having a length within said body, and wherein said delivery holes in one region of said body have lengths that differ from lengths of said delivery holes in another region of said body, thereby creating said unequal flow of said lubricant or gas into said mold cavity from said different regions of said inner surface.
8. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a delivery hole within said perimeter wall body spaced both from said inner and outer surfaces of said body.
9. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a circumferential groove in said outer surface of said perimeter wall body.
10. The perimeter wall of claim 1, wherein the permeability of said permeable material varies in different regions of said perimeter wall body, and wherein said flow of lubricant or gas from said inner surface in said different regions is pre-determined by correlating a property of said at least one delivery conduit to the estimated flow rate of lubricant or gas through said perimeter wall in said different regions, wherein said property of said at least one delivery conduit is selected from the group consisting of surface area of said at least one delivery conduit and distance of separation of said at least one delivery conduit from said inner surface of said perimeter wall body.
11. The perimeter wall of claim 1, wherein said at least one delivery conduit comprises a delivery conduit for lubricant and a delivery conduit for gas.
12. An assembly of a mold housing and a permeable perimeter wall of a metal mold cavity, comprising:
a. a perimeter wall body of permeable material extending around and defining said mold cavity, said body including an inner surface and an outer surface;
b. a mold housing having a wall abutting said outer surface of said perimeter wall body; and c. at least one delivery conduit in said abutting wall of said mold housing adapted to supply a lubricant or gas under pressure to said outer surface of said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
a. a perimeter wall body of permeable material extending around and defining said mold cavity, said body including an inner surface and an outer surface;
b. a mold housing having a wall abutting said outer surface of said perimeter wall body; and c. at least one delivery conduit in said abutting wall of said mold housing adapted to supply a lubricant or gas under pressure to said outer surface of said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
13. The assembly of claim 12, wherein said at least one delivery conduit comprises a delivery conduit for lubricant and a delivery conduit for gas.
14. A mold table assembly for the continuous casting of metal, comprising:
a plurality of casting molds attached to a casting mold table, each casting mold including:
i. a perimeter wall comprising a perimeter wall body of permeable material extending around and defining a mold cavity and having an inner surface and an outer surface;
ii. a mold housing having a wall abutting said outer surface of said perimeter wall body; and iii. at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
a plurality of casting molds attached to a casting mold table, each casting mold including:
i. a perimeter wall comprising a perimeter wall body of permeable material extending around and defining a mold cavity and having an inner surface and an outer surface;
ii. a mold housing having a wall abutting said outer surface of said perimeter wall body; and iii. at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material;
wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
15. A process of providing a permeable perimeter wall for a metal mold, comprising:
a. providing a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface;
b. providing at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material; and c. adapting said at least one delivery conduit to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
a. providing a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface;
b. providing at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material; and c. adapting said at least one delivery conduit to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface.
16. A process of continuously casting a molten metal, comprising:
a. providing a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface;
b. providing at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material, wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface; and c. casting metal in the mold cavity while supplying said unequal flow of lubricant or gas to said inner surface.
a. providing a perimeter wall body of permeable material extending around and defining a mold cavity, said body including an inner surface and an outer surface;
b. providing at least one delivery conduit adapted to supply a lubricant or gas under pressure to said perimeter wall body for diffusion into said mold cavity through said permeable material, wherein said at least one delivery conduit is adapted to cause an unequal flow of said lubricant or gas into said mold cavity from different regions of said inner surface; and c. casting metal in the mold cavity while supplying said unequal flow of lubricant or gas to said inner surface.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US89101997A | 1997-07-10 | 1997-07-10 | |
| US08/891,019 | 1997-07-10 | ||
| CA002295839A CA2295839C (en) | 1997-07-10 | 1998-07-09 | A system for providing consistent flow through multiple permeable perimeter walls in a casting mold |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002295839A Division CA2295839C (en) | 1997-07-10 | 1998-07-09 | A system for providing consistent flow through multiple permeable perimeter walls in a casting mold |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2592792A1 CA2592792A1 (en) | 1999-01-21 |
| CA2592792C true CA2592792C (en) | 2009-05-26 |
Family
ID=38445946
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002592792A Expired - Fee Related CA2592792C (en) | 1997-07-10 | 1998-07-09 | A system for providing consistent flow through multiple permeable perimeter walls in a casting mold |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2592792C (en) |
-
1998
- 1998-07-09 CA CA002592792A patent/CA2592792C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2592792A1 (en) | 1999-01-21 |
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