DE102016123491B4 - Casting device, press and method for casting a component - Google Patents

Abstract

Casting device (103) for press casting a component by means of a tool (105), which has a shape (113) for shaping the component, the casting device having a tool holder (111, 119) for holding the tool, and the tool holder (111, 119 ) a drive for applying a pressing force is assigned, the casting device having at least two metering cavities (121), each of which is assigned a fluid connection, so that melts located in the metering cavities can be transferred into the mold, and at least a first punch (123) and one has a second stamp, the tool having a first tool part (107) and a second tool part (109), which form the shape when closed, characterized in that the dosing cavities on and / or in the first tool part and the stamps on and / or are arranged in the second tool part or vice versa, so that the melts in the respective dosing cavities be displaced into the mold by immersing the respective stamp via the respective fluid connection.

Description

The invention relates to a casting device for casting a component by means of a tool, which has a shape for shaping the component and the casting device has a tool holder for receiving the tool. Furthermore, the invention relates to a press and a method for casting a component and a component.

In conventional die casting processes, the mold is filled with melt from a central casting unit by moving a driven casting piston. Here, the casting unit is usually arranged outside the casting tool, so that there is a long flow path of the melt to the mold to be filled.

The disadvantage is that the casting time is limited due to the temperature loss of the melt along the flow path, since the melt already begins to solidify on the flow path. This requires a high flow rate of the melt, which in turn leads to abrasive wear on the tool and / or the mold. In addition, the flow resistance on the flow path leads to a high required drive energy and / or a high required casting pressure in the mold.

The above-mentioned disadvantages also exist if the melt is not fed centrally to the mold at one point, but is divided into partial flows via a sprue system with branches and enters the mold at several points.

Consequently, the known casting devices and casting methods are limited for the reasons mentioned above with regard to the wall thickness, strength and the production of large-area parts.

In the DE 10 2013 101 962 B3 describes a method for producing cast components with a casting device, in which the filling chamber, operated by a casting piston, is connected to the mold cavity via a plurality of casting runs, and the speed of the melt in the casting runs is set by means of electromagnetic fields.

The DE 39 31 194 Al discloses a hot chamber die casting machine with a pouring system and with a plurality of casting units, each casting unit consisting of an oven, crucible, casting container and an injection cylinder with pressure pistons and the respective pressure pistons of the plurality of casting units being jointly controlled for the production of large-area castings.

The DE 102 56 834 Al claims a method and a device for producing large-area workpieces in the die-casting method with a plurality of casting systems, each having a casting cylinder and a driving hydraulic cylinder, each casting cylinder being connected to the casting mold via a plurality of casting runs / gates.

In the DE 196 06 806 A1 has a device for thixoforming two mold halves and at least two casting runs, each casting run being fed by a separate filling chamber and the two casting runs being arranged on the lower and the upper mold halves.

The EP 1 588 823 A1 relates to a device for producing injection molded parts with a mutually braced core part and shell part, which form the mold, wherein a high-pressure feed for the injection molding material opens into the cavity of the mold.

In the US 8 210 233 B2 describes a device for producing metal objects, in which the melt overflows from a melting furnace under pressure through a feed channel into hollow recesses in the cavity in the lower part of the mold. Subsequently, stamps arranged in the upper part of the mold are pressed into the liquid metal in the hollow depressions by means of hydraulic cylinders in each case, in order to directly shape the respective metal object in the form of a bowl.

The US 3 951 200 A discloses a device for steam casting, in which a central filling chamber arranged in the lower mold is filled with melt and after closing and locking the mold, deionized water is injected into the center of the molten metal in the filling chamber via an injection nose, as a result of which is formed Water vapor pressure pushes the metal into the mold through the sprue.

The object of the invention is to improve the prior art.

The object is achieved by a casting device for press casting a component by means of a tool, which has a shape for shaping the component, the casting device having a tool holder for receiving the tool, and the tool holder being assigned a drive for applying a pressing force, the casting device has at least two dosing cavities, each of which is associated with a fluid connection, so that melts located in the dosing cavities can be transferred into the mold, and has at least a first stamp and a second stamp, the tool having a first tool part and a second Has tool part, which form the shape when closed, and the dosing cavities are arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa, so that the melts in the respective dosing cavity by immersing the respective punch the respective fluid connection are displaced into the mold.

Thus, a central casting unit and / or a sprue system with branches is omitted.

Because each dosing cavity is directly connected to the mold via a fluid connection, there is a shorter flow path to the mold. As a result, the casting process can be carried out significantly more slowly and / or with a lower casting pressure than when using a central casting unit. As a result, mold and / or tool wear is reduced.

Since no complex branched sprue system is used, but rather a fluid connection, which directly connects a dosing cavity as a local melt supply with the mold to be filled, the proportion of solidified melt that remains in the fluid connection after the casting process has been carried out is reduced in weight. As a result, the waste to be disposed of and / or the recycling material are reduced.

With regard to the projected tool area, the locally arranged dosing cavity with the short fluid connection leads to a smaller closing area of the tool and thus to a lower required closing force of the casting device and / or press.

Furthermore, the casting tool can be designed and manufactured more easily because of the omitted sprue node and the omitted branched sprue system. In particular, the dosing cavities can be manufactured in the tool together with the construction of the mold.

An essential idea of the invention is based on the fact that a plurality of local dosing cavities are arranged close to and / or within the mold cavity, so that the mold cavity is filled by these several local dosing cavities each via a very short fluid connection.

The following terms are explained

A “casting device” is in particular a device for casting a component. A casting device has in particular at least two dosing cavities as a dosing container, at least two fluid connections and a shaping tool. A central melt container with a liquid melt can be assigned to the casting device.

"Casting" is in particular a manufacturing process in which a solid body of a certain shape is created from a liquid material (melt) after solidification. In particular, a tool is used as a permanent mold for casting. Casting includes, in particular, die casting, permanent mold casting and / or continuous casting.

A “component” is in particular an individual part of a technical complex, such as a machine or an apparatus, made from a workpiece. The component is created especially plastically due to a change in shape through targeted casting and / or forming. A component thus has, in particular, almost finished or finished shapes or geometries.

A “tool” is in particular an object in which a workpiece is machined and / or cast to produce a component, the tool being guided by a person and / or a machine. A tool is in particular a molding tool. The tool is used in particular in a shaping manufacturing process, such as preforming, shaping and / or primary shaping, such as casting. The tool is used in particular in a casting device and / or a press. The tool can consist of a single tool part which has the shape directly, of at least two tool parts, for example a lower and an upper tool, or a plurality of tool parts which form the shape when the tool is closed. Furthermore, the tool can also have further tool parts that do not form. The tool can have an inner contour, which is applied as an outer contour to the component to be cast.

A “mold” is understood to mean, in particular, a cavity of the tool, the inner contour of which is impressed on the workpiece as the outer contour and / or in which the cavity of the mold is poured out with melt to produce the component. A shape is also referred to as a “shape cavity”.

A "tool holder" is a component that holds and / or holds the tool during casting and / or machining. The tool holder in particular allows a quick change of the tool and / or represents an interface between the tool and the drive.

A “dosing cavity” is in particular a dosing container for the melt, which is located locally in the Proximity, to and / or in the form is arranged. The dosing cavity in particular only takes up a part of the melt which is necessary to fill the mold. The various partial melts of the individual locally arranged dosing cavities together in particular result in at least the melt volume which is necessary for completely filling the mold. The dosing cavity can be a recess on three sides which is closed in the tool and / or in the mold for receiving the melt. Likewise, the dosing cavity can be an open-topped container which is inserted into the tool and / or the mold.

A “fluid connection” is, for example, a cavity that enables a connection between a dosing cavity and the mold, so that the melt can flow out of the dosing cavity into the mold. The fluid connection can be a pipe or a channel. However, a fluid connection can also be a direct opening between the dosing cavity and the mold, so that the fluid connection here has only a very short elongated extension of a few millimeters. The melt flows through the fluid connection, in particular due to gravitation and / or an applied casting pressure.

A “melt” is in particular molten metal and / or metal alloys.

In a further embodiment, the casting device has the first dosing cavity, the first fluid connection, the second dosing cavity and the second fluid connection and / or a third dosing cavity and a third fluid connection, a fourth dosing cavity and a fourth fluid connection, a fifth dosing cavity and a fifth fluid connection and / or a further dosing cavity and a further fluid connection.

Thus, several dosing cavities, each with a fluid connection, can be arranged locally according to the shape of the component to be cast and / or further requirements on the component. The position, number and / or size of the dosing cavities depend on the mass distribution of the component to be manufactured. Above all, this enables or enables the production of large-area components and / or a minimization of the wall thickness and / or an increase in the strength of the component.

The third, fourth, fifth and / or further dosing cavity corresponds in its design and function to the dosing cavity defined above.

A third, fourth, fifth and / or further fluid connection corresponds in its design and function to the fluid connection defined above.

In order to cast complex and / or large-area components, the tool has a first tool part and a second tool part, which form the shape when closed.

Of course, the tool can also have a third, fourth, fifth and / or further tool part, especially if special geometries and / or very large components are to be cast.

In a further embodiment, the first tool part and the second tool part are aligned horizontally or vertically by means of the tool holder.

Compared to the usual vertical alignment of the tool parts and mold in conventional casting, a horizontal arrangement of the tool parts and mold is also possible.

In order to transfer the melt from each dosing cavity through the respective fluid connection into the respective mold with a corresponding casting pressure and / or a corresponding flow rate, the casting device has a first stamp, a second stamp, a third stamp, a fourth stamp, a fifth stamp and / or a further punch, so that the melt in the respective dosing cavity is displaced into the mold by immersing the respective punch via the respective fluid connection.

When the tool parts are aligned horizontally, a plunger preferably dips into the dosing cavity from above. When the tool parts are aligned vertically, the punch is moved laterally into the dosing cavity and must therefore seal the dosing cavity before the filling of the dosing cavity with melt. In this case, the dosing cavity is filled, for example, through an additional filling opening arranged at the top in the dosing cavity.

A “stamp” (also called “dosing bolt”) is in particular a component that, due to its movement, displaces the melt in a dosing cavity and thereby presses it into the mold through the associated fluid connection. A stamp can be, for example, a cylinder made of solid material with or without ventilation. The shape of the stamp is matched in particular to the inner shape of the dosing cavity, so that the stamp can plunge flush into the associated dosing cavity.

According to the invention, the dosing cavity is arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa.

Thus, the punches do not need their own drive for immersion in the respective dosing cavity, but the immersion of the punches can be achieved by moving the first tool part and / or the second tool part. For this purpose, the length of each punch is matched to the corresponding end position of the movable first tool part and / or the second tool part. The stamp and / or the dosing cavities can be arranged flush, protruding and / or recessed on the first tool part and / or on the second tool part.

In order to keep the amount of solidified melt after casting and thus the accumulation of waste and / or circuit material and the explosive surface small, the dosing cavities are arranged directly on and / or in the mold, so that the fluid connection or the fluid connections have a length of less than 50 mm , in particular less than 20mm, preferably less than 5mm.

A dosing cavity can therefore also be part of the mold.

It is particularly advantageous if the fluid connection is only designed as a direct opening between the dosing cavity and the mold.

In addition, a very short fluid connection reduces the volume of air in the fluid connection that is present before casting, so that less air is introduced into the mold during casting. This casts a more homogeneous component.

In a further embodiment, the casting device has at least one casting robot and / or a melt container.

As a result, the dosing cavities can each be filled with melt from a melt container by means of at least one casting robot. Each dosing cavity is preferably filled by its own casting robot, so that all dosing cavities can be filled at the same time.

A “casting robot” is in particular a robot with a mounted spoon for the automated scooping of melt from the melt container into a dosing cavity. When scooping by the casting robot, the amount of melt required to fill the dosing cavity in each case is precisely measured by precisely positioning the pouring spoon at an angle using a path measurement.

A “melt container” is a container in which a solid is melted into a liquid melt. In particular, the melt for the particular metering cavity to be filled is removed from the melt container by means of a casting robot or several casting robots.

In a further aspect of the invention, the object is achieved by a press for casting a component, the press having a drive for applying a pressing force with a previously described casting device.

Thus, not only a pressing force can be applied via the drive of the press, but the mold can also be filled beforehand by moving a tool part by immersing the punches in the dosing cavities. Thus, no separate drive and / or separate hydraulic cylinders are or are necessary for the stamp movement.

As a result, the press can be designed in a smaller design. In addition, the press according to the invention can also be used to manufacture large-area components, in particular with a horizontal alignment, so that the overall height of the press is reduced compared to a vertical alignment.

A “press” is, in particular, a forming machine with a straight relative movement of the tool. In a press, in particular, manufacturing processes such as master shaping, casting, forming, deep drawing, joining, coating, separating, cutting and / or changing material properties are carried out. A press is in particular a tied-up, energy-bound or force-bound press.

In a further embodiment of the press, the first tool part and / or the second tool part has or have a movable tool part and a fixed tool part, so that the stamp can be moved freely by applying the pressing force via the movable tool part.

By dividing the first and / or the second tool part into a movable tool part and a fixed tool part, first the stamp movement for filling the mold and then a movement of the fixed tool part can compress and repress the melt and press the cast part via a movement of the fixed tool part Component take place due to the application of the pressing force on the fixed tool part and the movable tool part. Thus, both the filling of the mold and the actual pressing can be realized using a single tool with a movable and a fixed part.

• - Befüllen von wenigstens zwei Dosierkavitäten mittels wenigstens eines Gießroboters mit Schmelze,
• - Schließen des ersten Werkzeugteils und des zweiten Werkzeugteils zum Ausbilden der Form,
• - Eintauchen von jeweils einem Stempel in die jeweilige Dosierkavität durch eine Bewegung des ersten Werkzeugteils oder des zweiten Werkzeugteils und Verdrängen der Schmelze aus den Dosierkavitäten durch die Fluidverbindungen in die Form,
• - Verbinden der Schmelzen in der Form zu einem homogenen Bauteil.

In an additional aspect of the invention, the object is achieved by a method for casting a component by means of a previously described one Casting device and / or a press described above with the following steps:

• Filling of at least two dosing cavities with melt by means of at least one casting robot,
• Closing the first tool part and the second tool part to form the shape,
• Immersing one stamp in each case into the respective dosing cavity by moving the first tool part or the second tool part and displacing the melt from the dosing cavities through the fluid connections into the mold,
• - Connecting the melts in the mold to a homogeneous component.

A simplified method for casting a component is thus provided, in which the mold is filled and thus the component is poured via locally arranged dosing cavities. Above all, the method enables the casting of a homogeneous and / or large-area component.

In a further aspect of the invention, the object is achieved by a component, the component being produced using a previously described method.

Due to the adjustment of the position, number and / or size of the dosing cavities to the mass distribution of the component to be manufactured, a very homogeneous component with increased strength is produced. In addition, components with smaller wall thicknesses and / or larger components can be manufactured.

• 1 eine schematische Schnittdarstellung einer Presse mit einer Druckgießvorrichtung und einem geöffneten Werkzeug mit Dosierkavitäten und Dosierbolzen,
• 2a die Presse aus 1 mit geöffnetem Werkzeug und gefüllten Dosierkavitäten,
• 2b die Presse aus 2a mit geschlossenem Werkzeug und eingetauchten Dosierbolzen,
• 2c die Presse aus 2b mit weiterem Eintauchen der Dosierbolzen und Nachverdichten, und
• 2d die Presse aus 2c bei Konstanthalten der Presskraft.

The invention is explained in more detail below on the basis of exemplary embodiments. Show it

• 1 1 shows a schematic sectional illustration of a press with a die casting device and an open tool with dosing cavities and dosing bolts,
• 2a the press out 1 with opened tool and filled dosing cavities,
• 2 B the press out 2a with closed tool and immersed dosing bolts,
• 2c the press out 2 B with further immersion of the dosing bolts and recompression, and
• 2d the press out 2c while keeping the pressing force constant.

A press 101 has a die casting device 103 and a tool 105 on. The tool 105 consists of the upper tool base plate 111 , the shaping upper tool 107 and the lower tool 109 , The top tool base 111 is on a press ram 117 attached and has two dosing bolts 123 on. The top tool base 111 is about two feathers 125 with the movable shaping upper tool 107 connected. The top tool 107 has two spacer elements at the top 128 opposite the upper tool base plate 111 on.

The lower tool 109 is at a press table 119 attached and has two dosing cavities 121 on. Both sides on the edge of the lower tool 109 are two distance cylinders 127 appropriate. Below the press table 119 is a table ejector plate 129 arranged.

In case of closing the tool 105 form the top tool 107 and the lower tool 109 the mold cavity 113 out.

The dosing bolts 123 are in their length to a lower end position of the upper tool 107 Voted. The spacer cylinders 127 of the lower tool 109 have an upper and a lower end position.

The following operations are done with the press 101 , the die casting device 103 and the tool 105 realized:

With the tool open 105 is the press ram 117 at top dead center. The movable upper tool 107 has been lowered and will spring with a spring force 125 kept in its lower position. The two dosing cavities are made by means of two casting robots, not shown 121 of the lower tool 109 filled with a required melt volume from a central melt container, not shown. The spacer cylinders 127 in the lower tool 109 are in their upper end position.

After filling the dosing cavities 121 is caused by movement of the press ram 117 down in a closing direction 131 the tool 105 closed. On the one hand, the upper tool 107 in addition to the weight due to the acting springs 125 pressed down with a preselected force and, on the other hand, now additionally upwards when closing the tool against the closing direction 131 pressed until the spacer elements 128 a path between the moving top tool 107 and the upper tool base plate 111 limit. Only when the spacer elements stop 128 to the upper tool base plate 111 is a ram force greater than the spring force on the upper tool 107 transferable.

By putting on the upper tool 107 on the spacer cylinders 127 of the lower tool 109 becomes the mold cavity 113 closed. Here, the mold cavity 113 however not yet closed to the extent that a wall thickness of a component to be manufactured has been reached. Closing in the closing direction 131 continues with the dosing bolts 123 into the dosing cavities 121 immerse and melt from the dosing cavities 121 into the directly connected mold cavity 113 displace. Here the closing force exists between the upper tool 107 and lower tool 109 only from the dead weight of the movable upper tool 107 and the feathers 125 , so in the tool 105 there is no higher casting pressure.

The filling of the mold cavity 113 will end when the spacer 128 between the fixed upper tool base plate 111 and the movable upper tool 107 sit on and transmit a force. Then the spacer cylinders 127 in the lower tool 109 relieved and the upper tool base plate 111 and the movable top tool 107 will continue in the closing direction 131 moved until the tool 105 is closed to the extent that the actual wall thickness of the component to be cast has been reached. The dosing bolts are immersed 123 further into the dosing cavities 121 and compress the cast component. With this post-compaction, an entire surface of the tool is simultaneously processed 105 the ram force is exerted on the cast component.

The ram force is maintained and after the cast component has solidified, the tool becomes 105 open. The component is then removed via the table ejector plate 129 in the press table 119 raised.

This provides a press with a die casting device and a tool with integrated dosing cavities and dosing bolts, which enable very short flow paths to the mold cavity, low mold and tool wear and low material waste. In addition, a very homogeneous component with a complex, large-area geometry is manufactured.

LIST OF REFERENCE NUMBERS

101

Press

103

die casting

105

Tool

107

upper tool

109

lower tool

111

Upper tool base

113

mold cavity

117

press ram

119

press table

121

metering cavity

123

Dosierbolzen

125

feather

127

Distance cylinder

128

spacer

129

Tischauswerferplatte

131

closing direction

Claims (8)

Casting device (103) for press casting a component by means of a tool (105), which has a mold (113) for shaping the component, the casting device having a tool holder (111, 119) for holding the tool, and the tool holder (111, 119 ) a drive for applying a pressing force is assigned, the casting device having at least two metering cavities (121), each of which is assigned a fluid connection, so that melts located in the metering cavities can be transferred into the mold, and at least a first punch (123) and one has a second stamp, the tool having a first tool part (107) and a second tool part (109), which form the shape when closed, characterized in that the dosing cavities on and / or in the first tool part and the stamps on and / or are arranged in the second tool part or vice versa, so that the melts in the respective dosing cavity ität by displacing the respective stamp on the respective fluid connection in the mold. Pouring device after Claim 1 , characterized in that the casting device, the first dosing cavity, the first fluid connection, the first stamp, the second dosing cavity, the second fluid connection, the second stamp and / or a third dosing cavity, a third fluid connection and a third stamp, a fourth dosing cavity fourth fluid connection and a fourth plunger, a fifth dosing cavity, a fifth fluid connection and a fifth plunger and / or a further dosing cavity, a further fluid connection and a further plunger. Casting device according to one of the preceding claims, characterized in that the first tool part and the second tool part are aligned horizontally or vertically by means of the tool holder. Casting device according to one of the preceding claims, characterized in that the dosing cavities are arranged directly on and / or in the mold, so that the fluid connection or the fluid connections has a length of less than 50mm, in particular less than 20mm, preferably less than 5mm. Casting device according to one of the preceding claims, characterized in that the casting device has at least one casting robot and / or a melt container. Press for casting a component, the press having a drive for applying a pressing force, characterized by a casting device according to one of the Claims 1 to 5 , Press after Claim 6 , characterized in that the first tool part and / or the second tool part has or have a movable tool part (107) and a fixed tool part (111), so that a movement of the stamps can be realized without applying the pressing force via the movable tool part. Method for casting a component by means of a casting device according to one of the Claims 1 to 5 or a press Claim 6 or 7 , characterized by the following steps: - filling at least two dosing cavities with at least one casting robot with melt, - closing the first tool part and the second tool part to form the mold, the mold being closed in such a way that a wall thickness to be produced of the component has not yet been reached - Immersion of a stamp in each case in the respective dosing cavity by moving the first tool part or the second tool part, the mold being closed in such a way that the wall thickness of the component to be produced is achieved, and displacing the melts from the dosing cavities via the fluid connections into the mold so that the melts are connected in the mold to form a homogeneous component.

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