CA2640308A1 - Method for assembling a mould for casting a part from molten metal - Google Patents
Method for assembling a mould for casting a part from molten metal Download PDFInfo
- Publication number
- CA2640308A1 CA2640308A1 CA002640308A CA2640308A CA2640308A1 CA 2640308 A1 CA2640308 A1 CA 2640308A1 CA 002640308 A CA002640308 A CA 002640308A CA 2640308 A CA2640308 A CA 2640308A CA 2640308 A1 CA2640308 A1 CA 2640308A1
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- CA
- Canada
- Prior art keywords
- mould
- chill
- chills
- magnet
- casting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
- B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
Abstract
The invention relates to a method for assembling a mould that is composed of mould sections and is used to cast a cylinder block of an internal combustion engine from molten metal. According to said method, at least one chill (14 -17), which forms at least one sub-section of the inner surfaces of a cylinder chamber, is positioned and held against a wall (11) of one of the mould sections (1). The method according to the invention permits moulds comprising chills in the mould cavity to be assembled simply and reliably. To achieve this, the chill (14 - 17) is held in position for a specific holding period by means of magnetic forces that are exerted by a magnet (12), which is positioned on the opposite side of the wall (11) of the mould (1) from the chill (14 - 17).
Description
SI/cs 050969wo 09 February 2007 METHOD FOR MOUNTING A MOULD FOR CASTING A CAST PART FROM A
METAL MELT
The invention relates to a method for mounting a mould composed of mould parts for casting a cylinder block of an internal combustion engine from a metal melt, in which at least one chill, which forms at least one part section of the inner surfaces of a cylinder space of the cylinder block, is positioned and retained at a wall of one of the mould parts.
Such methods and devices are used on a large technical scale, for example in the motor vehicle industry, in order to manufacture the cylinder blocks of internal combustion engines in large numbers. In this situation, there is a particular requirement, especially in the area of cylinder barrels, for a fine-grain, metallurgical microstructure to be constructed which will guarantee a high load-bearing capacity. As an example of another location at which a particularly fine-grain, rapidly solidifying and tough casting microstructure is required is the area of a cylinder block in which the bearings for the crankshafts are formed.
In order to obtain rapid solidification in the casting microstructure, in particular in the casting of light metal melts, metal inserts are introduced into the mould, referred to as "chills", which consist of a highly heat-conductive material and as such represent a heat sink, by means of which comparatively large volumes of heat are drawn within a short period of time from the melt coming into contact with the metal inserts. Accordingly, during the casting of cylinder blocks made of aluminium casting material, chills are arranged in such a way, for example, that they form the cylinder barrels in the block which is being cast. The casting material coming into contact with the chills arranged in this way then cools very much more rapidly than the melt present in the mould which is further away from the chills, with the result that the desired solidification, characterised by a fine-grain microstructure takes place in the area of the barrels.
One example of how metal inserts are introduced into moulds as chills is provided in DE 195 33 529 C2. In this patent publication, a method for casting an engine block made of aluminium is described, in which the engine block is cast into a sand mould and its cylinder cavities are formed by chills inserted into the sand mould, these chills consisting of a brass material, wherein the brass material has a coefficient of thermal expansion of more than 18 x 6 K-~, adjusted to suit the coefficient of thermal expansion of the aluminium melt being cast in each case.
Even if this method allows for the desired microstructure to be specifically created in the finished cast component, despite the adaptation of the behaviour of the chills when being heated to the coefficient of thermal expansion behaviour of the aluminium melt, it has in practice proved difficult, in certain application situations, for the chills to be removed from the completed casting after solidification of the casting material.
Due to its direct effect on the shape retention of the individual casting, however, the positioning of the metal inserts must in practice always be exact, even under the rough conditions of a casting plant. This has often proved to be an elaborate procedure if the mould as a core package is composed of several mould parts and metal inserts. The term "core packages" is given to casting moulds which are composed of several casting cores. Casting moulds can be easily assembled from core packages, with which even complex and filigree mould cavities and therefore castings can be formed.
A further problem in connection with the use of metal inserts is derived if, as in the example given in DE 195 33 529 C2, the mould is what is referred to as a "lost mould"
which is composed of parts manufactured from a mould material and must be destroyed after the solidification of the melt in order to release the finished casting from the mould. In order to be able to position the metal inserts used for cooling in such moulds in a reliable manner and keep them in position, it is necessary for them to be clamped to the moulds, with the mould material surrounding them, with the result that after solidification of the melts they can only be released from the casting with difficulty.
In order to render the release of the metal inserts easier, it has been usual hitherto to provide the metal inserts with a ceramic powder coating, with the intention of reducing the risk of damage to the metal inserts when they are removed from the finished casting. As well as the additional effort and expenditure involved with the application of the coating, this arrangement has the disadvantage that the heat transfer between the casting metal and the insert is impaired, and therefore also the cooling effect.
In addition to the prior art referred to heretofore, aimed directly at the assembly of moulds from mould parts and cores, a method and device are known from the German Patent Specification 719 454 for the manufacture of cores or mould parts for moulds made of a core compound or mould compound, which allow for a chill to be retained in the individual mould or core box in such a way that it stands reliably in the position intended for it in the individual core or mould part to be produced in each case. For this purpose, the individual chill is initially positioned in the empty mould or core box, wherein in this position it is in contact in each case with an outer wall of the mould or core box. By means of an electromagnet, which is located in a cut-out formed from the outside into the wall concerned of the mould box and exerts its effect through the wall section present between it and the chill, the chill is thereafter held in this position. Once the filling of the core compound or mould compound has been completed, the excitation current circuit of the electromagnet is switched off, with the result that the individual mould part or core can be removed from the box with the chill incorporated in it.
The invention is based on the object of providing a method of the type referred to in the preamble, by means of which, in a simple and nevertheless reliable manner, moulds can be mounted for casting cylinder blocks with metal inserts provided in the mould cavity.
METAL MELT
The invention relates to a method for mounting a mould composed of mould parts for casting a cylinder block of an internal combustion engine from a metal melt, in which at least one chill, which forms at least one part section of the inner surfaces of a cylinder space of the cylinder block, is positioned and retained at a wall of one of the mould parts.
Such methods and devices are used on a large technical scale, for example in the motor vehicle industry, in order to manufacture the cylinder blocks of internal combustion engines in large numbers. In this situation, there is a particular requirement, especially in the area of cylinder barrels, for a fine-grain, metallurgical microstructure to be constructed which will guarantee a high load-bearing capacity. As an example of another location at which a particularly fine-grain, rapidly solidifying and tough casting microstructure is required is the area of a cylinder block in which the bearings for the crankshafts are formed.
In order to obtain rapid solidification in the casting microstructure, in particular in the casting of light metal melts, metal inserts are introduced into the mould, referred to as "chills", which consist of a highly heat-conductive material and as such represent a heat sink, by means of which comparatively large volumes of heat are drawn within a short period of time from the melt coming into contact with the metal inserts. Accordingly, during the casting of cylinder blocks made of aluminium casting material, chills are arranged in such a way, for example, that they form the cylinder barrels in the block which is being cast. The casting material coming into contact with the chills arranged in this way then cools very much more rapidly than the melt present in the mould which is further away from the chills, with the result that the desired solidification, characterised by a fine-grain microstructure takes place in the area of the barrels.
One example of how metal inserts are introduced into moulds as chills is provided in DE 195 33 529 C2. In this patent publication, a method for casting an engine block made of aluminium is described, in which the engine block is cast into a sand mould and its cylinder cavities are formed by chills inserted into the sand mould, these chills consisting of a brass material, wherein the brass material has a coefficient of thermal expansion of more than 18 x 6 K-~, adjusted to suit the coefficient of thermal expansion of the aluminium melt being cast in each case.
Even if this method allows for the desired microstructure to be specifically created in the finished cast component, despite the adaptation of the behaviour of the chills when being heated to the coefficient of thermal expansion behaviour of the aluminium melt, it has in practice proved difficult, in certain application situations, for the chills to be removed from the completed casting after solidification of the casting material.
Due to its direct effect on the shape retention of the individual casting, however, the positioning of the metal inserts must in practice always be exact, even under the rough conditions of a casting plant. This has often proved to be an elaborate procedure if the mould as a core package is composed of several mould parts and metal inserts. The term "core packages" is given to casting moulds which are composed of several casting cores. Casting moulds can be easily assembled from core packages, with which even complex and filigree mould cavities and therefore castings can be formed.
A further problem in connection with the use of metal inserts is derived if, as in the example given in DE 195 33 529 C2, the mould is what is referred to as a "lost mould"
which is composed of parts manufactured from a mould material and must be destroyed after the solidification of the melt in order to release the finished casting from the mould. In order to be able to position the metal inserts used for cooling in such moulds in a reliable manner and keep them in position, it is necessary for them to be clamped to the moulds, with the mould material surrounding them, with the result that after solidification of the melts they can only be released from the casting with difficulty.
In order to render the release of the metal inserts easier, it has been usual hitherto to provide the metal inserts with a ceramic powder coating, with the intention of reducing the risk of damage to the metal inserts when they are removed from the finished casting. As well as the additional effort and expenditure involved with the application of the coating, this arrangement has the disadvantage that the heat transfer between the casting metal and the insert is impaired, and therefore also the cooling effect.
In addition to the prior art referred to heretofore, aimed directly at the assembly of moulds from mould parts and cores, a method and device are known from the German Patent Specification 719 454 for the manufacture of cores or mould parts for moulds made of a core compound or mould compound, which allow for a chill to be retained in the individual mould or core box in such a way that it stands reliably in the position intended for it in the individual core or mould part to be produced in each case. For this purpose, the individual chill is initially positioned in the empty mould or core box, wherein in this position it is in contact in each case with an outer wall of the mould or core box. By means of an electromagnet, which is located in a cut-out formed from the outside into the wall concerned of the mould box and exerts its effect through the wall section present between it and the chill, the chill is thereafter held in this position. Once the filling of the core compound or mould compound has been completed, the excitation current circuit of the electromagnet is switched off, with the result that the individual mould part or core can be removed from the box with the chill incorporated in it.
The invention is based on the object of providing a method of the type referred to in the preamble, by means of which, in a simple and nevertheless reliable manner, moulds can be mounted for casting cylinder blocks with metal inserts provided in the mould cavity.
This object is resolved according to the invention by the method described in Claim 1. Advantageous embodiments of the method according to the invention are described in the claims referring back to Claim 1.
The method according to the invention is suitable in particular for casting light metal melts, in particular aluminium-based melts.
According to the invention, the individual chill, which may also be designated hereinafter as a "metal insert", is held in a simple manner by magnetic forces, which are exerted by at least one magnet arranged in a suitable manner, in the position in the mould provided with regard to its mounting.
The only precondition for this is that the chills are themselves magnetically sensitive. Accordingly, as the material for the chills, consideration can be given in particular to ferromagnetic materials, such as iron and its alloys. In particular, chills used according to the invention can be manufactured from economical and wear-resistant materials such as cast iron.
With the method according to the invention, the magnet body exerting the retaining forces on the individual chill during the mounting procedure is arranged in such a way that it does not interfere with the casting of the metal melt or other mounting procedures. This is achieved according to the invention in that the magnet is arranged behind the wall at which the metal insert is positioned in such a way that its magnetic forces penetrate through the wall and hold the insert without a direct contact between the insert and the magnet.
The method according to the invention is suitable in particular for casting light metal melts, in particular aluminium-based melts.
According to the invention, the individual chill, which may also be designated hereinafter as a "metal insert", is held in a simple manner by magnetic forces, which are exerted by at least one magnet arranged in a suitable manner, in the position in the mould provided with regard to its mounting.
The only precondition for this is that the chills are themselves magnetically sensitive. Accordingly, as the material for the chills, consideration can be given in particular to ferromagnetic materials, such as iron and its alloys. In particular, chills used according to the invention can be manufactured from economical and wear-resistant materials such as cast iron.
With the method according to the invention, the magnet body exerting the retaining forces on the individual chill during the mounting procedure is arranged in such a way that it does not interfere with the casting of the metal melt or other mounting procedures. This is achieved according to the invention in that the magnet is arranged behind the wall at which the metal insert is positioned in such a way that its magnetic forces penetrate through the wall and hold the insert without a direct contact between the insert and the magnet.
In the method of operation according to the invention it is no longer necessary to embed the chills in a mould part in order to hold them. In fact, the chills can be handled separately from the mould parts so that when mounting the mould they can be handled like a mould part. This leads to a distinct simplification of the whole production process.
Since the chills in the method according to the invention do not have to be firmly embedded into a mould part or into the respective cast part any more, when removing a mould produced according to the invention there is also no longer the problem of damage caused to the chills or the cast part when demoulding. Therefore, the chills do not have to be coated and the amount of preparation can be reduced.
Instead, chills according to the invention held by magnetic forces can be removed easily from the cast part and the mould parts of the mould after casting. This advantage is evident particularly when casting cylinder blocks of internal combustion engines, in the technical language also referred to as "engine blocks", in which the chills represent the contact surfaces of the cylinders.
Embedding the chills required according to the prior art as early as during production of the mould parts by surrounding them with mould material in a mould is not required with the method according to the invention. Due to the fact that the chills are handled separately when the mould is assembled and are held in their position by magnetic forces exerted by an individual retaining device, it is possible, in the case of the use of moulds mounted from mould parts formed from mould material, to dispense with the need to coat the chills with a finish, as is required with the conventional procedure in order to guarantee optimum separation of the individual chill from the cast part produced in each case.
A further advantage of the invention lies in the fact that it can be easily integrated into already existing systems.
The method according to the invention therefore makes possible the manufacture of cast components in a simpler and more economical manner than with the prior art. The invention is particularly well-suited for casting light metal melts, in particular aluminium melts.
The mould parts from which a mould is composed according to the invention are preferably manufactured from a mould material which is mixed from a mould basic material and a binder. As basic materials in this situation, consideration can be given, for example, to sands containing quartz or free of quartz, while as binders use can be made of both inorganic as well as organic binders. The invention proves to be particularly advantageous if the mould is formed in a known manner as a core package.
The positioning and retaining of a chill in the mould can be carried out with the method according to the invention independently of any specific preparation of the particular location at which it the metal part is to be arranged.
Accordingly, the positioning of the metal part can in each case be carried out at a time which is determined solely by the optimum operational sequence in each case on mounting the individual mould. The only decisive factor in this situation is that the magnet required for the retention can be arranged in such a way in the area of the chill which is to be retained that the forces exerted by it will reliably secure the chill.
In order to guarantee a particularly reliable effect of the magnet provided to retain the magnetic insert, an opening may be formed in the mould part at the wall of which the chill is positioned, into which the magnet is introduced.
With this arrangement of the wall of the individual mould part, the magnet used to retain the chill can be moved into close proximity to the chill in order to facilitate the mounting process. In particular, when casting engine blocks of which the barrels are represented by chills, it can be of advantage for this reason if the mould part is designed in a mandrel shape with a blind hole aperture, into which the magnet is introduced. With this formation of the mould part concerned, a plurality of chills can be arranged next to one another on the outer surface of the mould part, so that they form in common the inner shape of the individual cylinder and are held jointly by a magnet arranged in the central blind hole aperture.
Another variant of the invention of importance for practical application is characterised in that the chill is held in its position by means of the magnet until a further mould part is arranged which then holds the chill in its position, by positive and/or non-positive fit. With this embodiment of the invention, the chill is held in its position by mould parts mounted after its positioning without magnetic forces being required for this. A further advantage of this method is that the position of the chill in the mould can be exactly defined by the other parts of the mould which come into contact with it either in positive and/or non-positive fit. The retention of the chill according to the invention by magnetic forces therefore serves, in this embodiment of the invention, only for as long as needed to bridge a situation, undefined with regard to the retaining of the chill in the mould, until the individual chill is held in its position by a further mould part, without the need for any further retention forces to be exerted by a separate retaining device.
In principle, all magnets are suitable for the application of the magnetic forces used for the retaining of the chill according to the invention which can produce a sufficiently strong magnetic field. Thus, for example, for a particularly simple, economical, and practical embodiment of the invention, permanent magnets can be provided in order to apply the retaining forces in the manner according to the invention onto the individual chills.
However, if particularly powerful forces are to be applied, and at the same time a particularly precise control of the magnetic retaining forces achieved, then an electromagnet is particularly well-suited. Electromagnets not only allow for an exact adjustment of the strength of the magnetic field generated by them in each case, but it is also possible with them, in a simple manner, by switching the electric power on and off, to determine precisely the time period within which the magnetic forces are applied on the individual chill in the manner according to the invention.
For this purpose, consideration can be given, for example, to electromagnets manufactured on the basis of coils. The magnetic field from such electromagnets can be controlled proportionally to the strength of the current conducted through the coils.
Since the chills in the method according to the invention do not have to be firmly embedded into a mould part or into the respective cast part any more, when removing a mould produced according to the invention there is also no longer the problem of damage caused to the chills or the cast part when demoulding. Therefore, the chills do not have to be coated and the amount of preparation can be reduced.
Instead, chills according to the invention held by magnetic forces can be removed easily from the cast part and the mould parts of the mould after casting. This advantage is evident particularly when casting cylinder blocks of internal combustion engines, in the technical language also referred to as "engine blocks", in which the chills represent the contact surfaces of the cylinders.
Embedding the chills required according to the prior art as early as during production of the mould parts by surrounding them with mould material in a mould is not required with the method according to the invention. Due to the fact that the chills are handled separately when the mould is assembled and are held in their position by magnetic forces exerted by an individual retaining device, it is possible, in the case of the use of moulds mounted from mould parts formed from mould material, to dispense with the need to coat the chills with a finish, as is required with the conventional procedure in order to guarantee optimum separation of the individual chill from the cast part produced in each case.
A further advantage of the invention lies in the fact that it can be easily integrated into already existing systems.
The method according to the invention therefore makes possible the manufacture of cast components in a simpler and more economical manner than with the prior art. The invention is particularly well-suited for casting light metal melts, in particular aluminium melts.
The mould parts from which a mould is composed according to the invention are preferably manufactured from a mould material which is mixed from a mould basic material and a binder. As basic materials in this situation, consideration can be given, for example, to sands containing quartz or free of quartz, while as binders use can be made of both inorganic as well as organic binders. The invention proves to be particularly advantageous if the mould is formed in a known manner as a core package.
The positioning and retaining of a chill in the mould can be carried out with the method according to the invention independently of any specific preparation of the particular location at which it the metal part is to be arranged.
Accordingly, the positioning of the metal part can in each case be carried out at a time which is determined solely by the optimum operational sequence in each case on mounting the individual mould. The only decisive factor in this situation is that the magnet required for the retention can be arranged in such a way in the area of the chill which is to be retained that the forces exerted by it will reliably secure the chill.
In order to guarantee a particularly reliable effect of the magnet provided to retain the magnetic insert, an opening may be formed in the mould part at the wall of which the chill is positioned, into which the magnet is introduced.
With this arrangement of the wall of the individual mould part, the magnet used to retain the chill can be moved into close proximity to the chill in order to facilitate the mounting process. In particular, when casting engine blocks of which the barrels are represented by chills, it can be of advantage for this reason if the mould part is designed in a mandrel shape with a blind hole aperture, into which the magnet is introduced. With this formation of the mould part concerned, a plurality of chills can be arranged next to one another on the outer surface of the mould part, so that they form in common the inner shape of the individual cylinder and are held jointly by a magnet arranged in the central blind hole aperture.
Another variant of the invention of importance for practical application is characterised in that the chill is held in its position by means of the magnet until a further mould part is arranged which then holds the chill in its position, by positive and/or non-positive fit. With this embodiment of the invention, the chill is held in its position by mould parts mounted after its positioning without magnetic forces being required for this. A further advantage of this method is that the position of the chill in the mould can be exactly defined by the other parts of the mould which come into contact with it either in positive and/or non-positive fit. The retention of the chill according to the invention by magnetic forces therefore serves, in this embodiment of the invention, only for as long as needed to bridge a situation, undefined with regard to the retaining of the chill in the mould, until the individual chill is held in its position by a further mould part, without the need for any further retention forces to be exerted by a separate retaining device.
In principle, all magnets are suitable for the application of the magnetic forces used for the retaining of the chill according to the invention which can produce a sufficiently strong magnetic field. Thus, for example, for a particularly simple, economical, and practical embodiment of the invention, permanent magnets can be provided in order to apply the retaining forces in the manner according to the invention onto the individual chills.
However, if particularly powerful forces are to be applied, and at the same time a particularly precise control of the magnetic retaining forces achieved, then an electromagnet is particularly well-suited. Electromagnets not only allow for an exact adjustment of the strength of the magnetic field generated by them in each case, but it is also possible with them, in a simple manner, by switching the electric power on and off, to determine precisely the time period within which the magnetic forces are applied on the individual chill in the manner according to the invention.
For this purpose, consideration can be given, for example, to electromagnets manufactured on the basis of coils. The magnetic field from such electromagnets can be controlled proportionally to the strength of the current conducted through the coils.
As already mentioned, the invention is particularly well-suited to the manufacture of a cylinder block of an internal combustion engine made of a light metal melt, such as an aluminium or magnesium melt, wherein at least one part section of the inner surfaces of the individual cylinder space of the cylinder block can be formed by one or more chills.
The invention is particularly well-suited for application in a fully-automatic device for assembling a mould in which devices such as robots are provided for the handling of the mould parts. With the application of the invention these devices can also position the chill with no problem at all, since the retention of this metal insert in its particular position by the magnet is assured, and no integral joining of the chill to one of the mould parts is required.
The invention is described in greater detail hereinafter on the basis of drawings representing embodiments. These show in diagrammatic form:
Fig. 1 A first mould part in a section along the section line A - A incorporated in Fig. 3, Fig. 2 The mould part represented in Figure 1 in a side view, and Fig. 3 The mould part represented in Figures 1 and 2 in a section along the section line B - B
incorporated in Figure 2.
The mould part 1 formed as a single piece is a constituent part of a mould not further represented here for casting a cylinder block for a combustion engine from a melt which is formed from an aluminium casting alloy. It is manufactured in an inherently known manner from a mould material which is mixed from a mould sand as the basic mould material and a binder and has a basic section 2, which carries a mandrel section 3 projecting upwards and essentially cylindrical in shape.
The mandrel section 3 has a casing surface 4, which is subdivided by four radially projecting ribs 5 into four part sections. In the area of the transition of the mandrel section 3 into the basic section 2 of the mould 1 is a circumferential groove 6, formed into the upper face surface 7 of the basic section running around the mandrel section 3 aligned essentially at right angles to the circumferential surface 4 of the mandrel section 3.
According to a variant not represented here, the mandrel section can also have a casing surface, which is divided by radially projecting ribs into two, three, or more part sections. In addition, the ribs can be designed, in contrast to the shape having parallel side walls represented here, conically in cross-section tapering or broadening out. According to a further conceivable embodiment, the mandrel section can also have a casing surface which is not subdivided by additional ribs. In this case, the casing surface is entirely surrounded by the chill which is to be accommodated in each case.
With the embodiment represented in the Figures, a blind hole aperture 9 is additionally formed into the casting part 1, going outwards from the lower face surface 8 of the basic section 2, opposite the upper face surface 7, this blind hole aperture 1 extending from the face surface 8 of the basic section 2 as far as the closure wall 10 of the mandrel section 3, forming the face side of the mandrel section 3. The diameter of the blind hole aperture 9 in this situation is adapted to the outer diameter of the mandrel section 3 in such a way that only one wall 11 with a low wall thickness is present between the inner faces of the blind hole aperture 9 and the casing surface 4, this wall 11 being sufficient to guarantee the required shape stability of the mandrel section 3.
Inserted into the blind hole aperture 9 is an electromagnet 12, which is secured to the free end of a rod 13. The rod 13 with the electromagnet 12 is part of a device, not further represented, for the retaining of metal parts 14, 15, 16, 17, which are put into use as chills by a device not represented here for positioning at the casing surface 4 of the mandrel section 3.
The rod 13 with the electromagnet 12 can be moved from a position of rest by means of an adjustment device likewise not represented, in which the electromagnet 12 is outside the blind hole aperture 9, into the operational position represented in Fig. 1, in which the electromagnet 12 is fully introduced into the blind hole aperture 9. The supply of the electromagnet 12 with electrical energy is effected by a control device, likewise not represented, which supplies electrical energy to the electromagnet 12 when the chills 14 - 17 are positioned, in order to retain them in their position.
The height of the chills 14 - 17 is adapted to the height of the mandrel section 3. In this context the chills in each case have on their upper and lower narrow sides a web 18, 19, projecting upwards and downwards respectively, of which the lower web 18 engages in the groove 6, so that the chills 14 - 17 are held in that location in positive fit.
At the same time, the chills 14 - 17 are cambered in such a way that they are located flush with the section of the casing surface 4 of the mandrel section 3 allocated to them in each case. At the same time, the width of the chills 14 - 17 is adjusted to the width of the sections of the casing surface 4 in such a way that the sections of the casing surface 4 are filled completely by the chills 14 - 17 located flush with them.
The chills 14 - 17 are cast as grey cast iron from a cast iron alloy, known under the designation GG20 (as per DIN
1691).
As soon as the chills 14 - 17 are positioned in the sections of the casing surface 4, the electromagnet 12 is charged with electrical energy. The magnetic field which is then generated by the electromagnet 12 acquires the chills 14 - 17, and holds them in their position at the casing surface 4 of the mandrel section 3.
Next, the other parts, not shown here, of the mould, likewise not shown, are mounted. One of the mould parts, not shown, has a groove-shaped mounting into which, after positioning of the mould part concerned, the rib 19 engages, formed at the upper end of the chills 14 - 17, such that the chills 14 - 17 are then also held in positive fit at their upper end. As soon as this state has been attained, the energy supply to the electromagnet 12 can be switched off and the rod 13 with the electromagnet 12 can be withdrawn from the blind hole aperture 9.
On casting the cylinder block in the mould, assembled by using the mould 1 and the chills 14 - 17, the chills 14 -17 form the barrels of one of the cylinders of the cylinder block. In this case, the chills 14 - 17 form a heat sink, by means of which it is ensured that the aluminium melt coming into contact with the chills 14 - 17 solidifies rapidly and forms a fine-grain microstructure.
The invention is particularly well-suited for application in a fully-automatic device for assembling a mould in which devices such as robots are provided for the handling of the mould parts. With the application of the invention these devices can also position the chill with no problem at all, since the retention of this metal insert in its particular position by the magnet is assured, and no integral joining of the chill to one of the mould parts is required.
The invention is described in greater detail hereinafter on the basis of drawings representing embodiments. These show in diagrammatic form:
Fig. 1 A first mould part in a section along the section line A - A incorporated in Fig. 3, Fig. 2 The mould part represented in Figure 1 in a side view, and Fig. 3 The mould part represented in Figures 1 and 2 in a section along the section line B - B
incorporated in Figure 2.
The mould part 1 formed as a single piece is a constituent part of a mould not further represented here for casting a cylinder block for a combustion engine from a melt which is formed from an aluminium casting alloy. It is manufactured in an inherently known manner from a mould material which is mixed from a mould sand as the basic mould material and a binder and has a basic section 2, which carries a mandrel section 3 projecting upwards and essentially cylindrical in shape.
The mandrel section 3 has a casing surface 4, which is subdivided by four radially projecting ribs 5 into four part sections. In the area of the transition of the mandrel section 3 into the basic section 2 of the mould 1 is a circumferential groove 6, formed into the upper face surface 7 of the basic section running around the mandrel section 3 aligned essentially at right angles to the circumferential surface 4 of the mandrel section 3.
According to a variant not represented here, the mandrel section can also have a casing surface, which is divided by radially projecting ribs into two, three, or more part sections. In addition, the ribs can be designed, in contrast to the shape having parallel side walls represented here, conically in cross-section tapering or broadening out. According to a further conceivable embodiment, the mandrel section can also have a casing surface which is not subdivided by additional ribs. In this case, the casing surface is entirely surrounded by the chill which is to be accommodated in each case.
With the embodiment represented in the Figures, a blind hole aperture 9 is additionally formed into the casting part 1, going outwards from the lower face surface 8 of the basic section 2, opposite the upper face surface 7, this blind hole aperture 1 extending from the face surface 8 of the basic section 2 as far as the closure wall 10 of the mandrel section 3, forming the face side of the mandrel section 3. The diameter of the blind hole aperture 9 in this situation is adapted to the outer diameter of the mandrel section 3 in such a way that only one wall 11 with a low wall thickness is present between the inner faces of the blind hole aperture 9 and the casing surface 4, this wall 11 being sufficient to guarantee the required shape stability of the mandrel section 3.
Inserted into the blind hole aperture 9 is an electromagnet 12, which is secured to the free end of a rod 13. The rod 13 with the electromagnet 12 is part of a device, not further represented, for the retaining of metal parts 14, 15, 16, 17, which are put into use as chills by a device not represented here for positioning at the casing surface 4 of the mandrel section 3.
The rod 13 with the electromagnet 12 can be moved from a position of rest by means of an adjustment device likewise not represented, in which the electromagnet 12 is outside the blind hole aperture 9, into the operational position represented in Fig. 1, in which the electromagnet 12 is fully introduced into the blind hole aperture 9. The supply of the electromagnet 12 with electrical energy is effected by a control device, likewise not represented, which supplies electrical energy to the electromagnet 12 when the chills 14 - 17 are positioned, in order to retain them in their position.
The height of the chills 14 - 17 is adapted to the height of the mandrel section 3. In this context the chills in each case have on their upper and lower narrow sides a web 18, 19, projecting upwards and downwards respectively, of which the lower web 18 engages in the groove 6, so that the chills 14 - 17 are held in that location in positive fit.
At the same time, the chills 14 - 17 are cambered in such a way that they are located flush with the section of the casing surface 4 of the mandrel section 3 allocated to them in each case. At the same time, the width of the chills 14 - 17 is adjusted to the width of the sections of the casing surface 4 in such a way that the sections of the casing surface 4 are filled completely by the chills 14 - 17 located flush with them.
The chills 14 - 17 are cast as grey cast iron from a cast iron alloy, known under the designation GG20 (as per DIN
1691).
As soon as the chills 14 - 17 are positioned in the sections of the casing surface 4, the electromagnet 12 is charged with electrical energy. The magnetic field which is then generated by the electromagnet 12 acquires the chills 14 - 17, and holds them in their position at the casing surface 4 of the mandrel section 3.
Next, the other parts, not shown here, of the mould, likewise not shown, are mounted. One of the mould parts, not shown, has a groove-shaped mounting into which, after positioning of the mould part concerned, the rib 19 engages, formed at the upper end of the chills 14 - 17, such that the chills 14 - 17 are then also held in positive fit at their upper end. As soon as this state has been attained, the energy supply to the electromagnet 12 can be switched off and the rod 13 with the electromagnet 12 can be withdrawn from the blind hole aperture 9.
On casting the cylinder block in the mould, assembled by using the mould 1 and the chills 14 - 17, the chills 14 -17 form the barrels of one of the cylinders of the cylinder block. In this case, the chills 14 - 17 form a heat sink, by means of which it is ensured that the aluminium melt coming into contact with the chills 14 - 17 solidifies rapidly and forms a fine-grain microstructure.
REFERENCE FIGURES
1 Mould part 2 Basic section 3 Mandrel section 4 Casing surface of the mandrel section 3 Ribs of the mandrel section 3 6 Groove 7 Upper face surface of the basic section 2 8 Lower face surface of the basic section 2 9 Blind hole aperture Closure wall of the mandrel section 3 11 Wall of the mandrel section 3 12 Electromagnet 13 Bar 14-17 Chills 18, 19 Webs
1 Mould part 2 Basic section 3 Mandrel section 4 Casing surface of the mandrel section 3 Ribs of the mandrel section 3 6 Groove 7 Upper face surface of the basic section 2 8 Lower face surface of the basic section 2 9 Blind hole aperture Closure wall of the mandrel section 3 11 Wall of the mandrel section 3 12 Electromagnet 13 Bar 14-17 Chills 18, 19 Webs
Claims (8)
1. Method for mounting a mould composed of mould parts for casting a cylinder block of an internal combustion engine from a metal melt, in which at least one chill (14 - 17), which forms at least one part section of the inner surfaces of a cylinder space of the cylinder block, is positioned and retained at a wall (11) of one of the mould parts (1), characterised in that the chill (14 - 17) is held in its position at least for a specific retention duration by means of magnetic forces, which are exerted by a magnet (12) which is arranged on the side of the wall (11) of the mould part (1) facing away from the chill (14 - 17).
2. Method according to Claim 1, characterised in that the mould part (1), at the wall of which the chill (14 -17) is positioned, has an aperture (9), into which the magnet (12) is introduced.
3. Method according to Claim 2, characterised in that the mould part (1) is formed in mandrel shape with a blind hole aperture (9), into which the magnet (12) is introduced.
4. Method according to any one of the preceding claims, characterised in that the chill (14 - 17) is held in its position by means of the magnet (12) until a further mould part is arranged which then holds the chill (14 - 17) in its position by positive and/or non-positive fit.
5. Method according to any one of the preceding claims, characterised in that the magnet (12) is an electromagnet.
6. Method according to any one of Claims 1 to 4, characterised in that the magnet (12) is a permanent magnet.
7. Method according to any one of the preceding claims, characterised in that the metal melt is a light metal melt.
8. Method according to Claim 7, characterised in that the metal melt is a melt based on aluminium.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102006006132.2 | 2006-02-10 | ||
| DE102006006132A DE102006006132A1 (en) | 2006-02-10 | 2006-02-10 | Method and apparatus for mounting a casting mold for casting a casting from a molten metal |
| PCT/EP2007/051294 WO2007090895A1 (en) | 2006-02-10 | 2007-02-09 | Method for assembling a mould for casting a part from molten metal |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2640308A1 true CA2640308A1 (en) | 2007-08-16 |
Family
ID=38080807
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002640308A Abandoned CA2640308A1 (en) | 2006-02-10 | 2007-02-09 | Method for assembling a mould for casting a part from molten metal |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US20090165983A1 (en) |
| EP (1) | EP1981667B1 (en) |
| JP (1) | JP2009525875A (en) |
| BR (1) | BRPI0707647A2 (en) |
| CA (1) | CA2640308A1 (en) |
| DE (2) | DE102006006132A1 (en) |
| PL (1) | PL1981667T3 (en) |
| WO (1) | WO2007090895A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102011079356A1 (en) * | 2011-07-18 | 2013-01-24 | Mahle International Gmbh | Casting core of a casting mold for producing a cylinder |
| DE102016009658A1 (en) | 2016-08-09 | 2017-02-16 | Daimler Ag | Method for casting a cast component from a molten metal |
| CN110014123B (en) * | 2019-04-19 | 2021-07-06 | 山东国创精密机械有限公司 | Casting method of hundred-ton-grade spent fuel storage and transportation integrated metal container |
| DE102019110580A1 (en) * | 2019-04-24 | 2020-10-29 | Nemak, S.A.B. De C.V. | Device and method for removing at least one cooling element from an at least partially demolded casting, method for introducing at least one cooling element into a mold core of a casting mold, cooling element and casting |
| RU2720331C1 (en) * | 2019-11-15 | 2020-04-28 | Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский Томский государственный университет" (НИ ТГУ) | Molding method into chill mold for production of flat castings from aluminum and magnesium alloys |
| CN113547081B (en) * | 2021-07-24 | 2023-03-03 | 共享装备股份有限公司 | 3D printing sand core chill fixing method |
Family Cites Families (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE719454C (en) * | 1940-06-30 | 1942-04-09 | Metallgussgesellschaft M B H | Method and device for holding the cooling irons in core or molding boxes |
| CH314713A (en) * | 1953-03-20 | 1956-06-30 | Bohn Aluminium & Brass Corp | Casting machine for the production of hollow castings |
| US2775803A (en) * | 1955-05-18 | 1957-01-01 | Victor E Zang | Chill plates |
| DD97568A1 (en) * | 1972-06-14 | 1973-05-14 | ||
| JPS54173013U (en) * | 1978-05-26 | 1979-12-06 | ||
| JPS5674349A (en) * | 1979-11-24 | 1981-06-19 | Sanwa Chuzosho:Kk | Fixing method of chill for molding |
| GB8409044D0 (en) * | 1984-04-07 | 1984-05-16 | Gkn Technology Ltd | Casting metal articles |
| JPS6149746A (en) * | 1984-08-20 | 1986-03-11 | Mazda Motor Corp | Ejecting device for molding shell casting mold |
| JPS6241439U (en) * | 1985-08-30 | 1987-03-12 | ||
| JPH03138066A (en) * | 1989-10-25 | 1991-06-12 | Mazda Motor Corp | Manufacture of cast iron-made cylinder block |
| DE4038090C2 (en) * | 1990-11-29 | 1999-12-09 | Wolfgang Huis | Magnetic kit |
| JPH08174142A (en) * | 1994-12-27 | 1996-07-09 | Nissan Motor Co Ltd | Molding method of sand mold for casting |
| DE19533529C2 (en) * | 1995-09-11 | 2001-10-11 | Vaw Alucast Gmbh | Process for casting an engine block from aluminum |
| US7409982B2 (en) * | 2005-08-19 | 2008-08-12 | Gm Global Technology Operations, Inc. | Foundry mold assembly device and method |
-
2006
- 2006-02-10 DE DE102006006132A patent/DE102006006132A1/en not_active Withdrawn
-
2007
- 2007-02-09 WO PCT/EP2007/051294 patent/WO2007090895A1/en active Application Filing
- 2007-02-09 JP JP2008553780A patent/JP2009525875A/en active Pending
- 2007-02-09 EP EP07704507A patent/EP1981667B1/en active Active
- 2007-02-09 DE DE502007002040T patent/DE502007002040D1/en active Active
- 2007-02-09 US US12/278,856 patent/US20090165983A1/en not_active Abandoned
- 2007-02-09 BR BRPI0707647-9A patent/BRPI0707647A2/en not_active IP Right Cessation
- 2007-02-09 PL PL07704507T patent/PL1981667T3/en unknown
- 2007-02-09 CA CA002640308A patent/CA2640308A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| BRPI0707647A2 (en) | 2011-05-10 |
| JP2009525875A (en) | 2009-07-16 |
| DE102006006132A1 (en) | 2007-08-16 |
| EP1981667B1 (en) | 2009-11-18 |
| EP1981667A1 (en) | 2008-10-22 |
| US20090165983A1 (en) | 2009-07-02 |
| WO2007090895A1 (en) | 2007-08-16 |
| PL1981667T3 (en) | 2010-04-30 |
| DE502007002040D1 (en) | 2009-12-31 |
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