DE2028855A1 - Method and apparatus for the production of castings of uniform density - Google Patents

Description

Method and device for the production of cast parts uniform density.

The invention is concerned with a method and a Apparatus for casting various types of metals and alloys, including ferrous metals, to improve quality to improve the cast product. In particular, however, the invention relates to methods for the forming ~ casting, permanent molds and vacuum casting as well as devices for their implementation and, above all, a method and an apparatus for producing cast bodies of substantially homogeneous density.

009351/1536

2023355

It is known that the casting of many types of metals and alloys, hereinafter referred to collectively as metals, in which a change of state from liquid to solid occurs, is generally accompanied by a considerable volume contraction of the metal The temperature of the casting liquid decreases before solidification begins, but also due to the shrinkage that results from the contraction or solidification of the metal during the casting process as it changes from liquid to solid. In fact, the shrinkage or contraction of the metal when changing from the liquid to the solid state to form a cast body can amount to about 2 % to about 10% of the total metal volume castings produced are often somewhat porous and contain bubbles within the actual cast body. The shrinkage and contraction can, as is often the case, create a number of voids, not just small but rather large voids, and such bubbles can then be dispersed into various zones of the finished casting, some of which draw the surface of the casting The number and size of the pores and bubbles in the finished casting naturally adversely affect the quality, uniformity and strength of the cast product and possibly also its usability and sales _value

About the emergence of such popular spots and To avoid bubbles, so-called runner and riser arrangements are currently used in and in connection with d @ n conventional casting machines and casting processes are used, which serve to ensure a good supply of liquid metal to the Maintain the cast body and the cast body for the full length of time that is required until the Cast body has solidified completely, quickly with liquid

ooot'ti / iiäi

supply etall. The metal in the runners and risers, which is fed to the Uieühohlraum as excess, is intended to compensate for and overcome the resulting, unavoidable volume changes of the metal during its transition from the liquid to the solid state and also to remove porous areas and bubbles and thereby to one lead to higher and more uniform density in the finished cast body. The excess metal fed to the runners and risers can in many cases be around 50-60 % of the total volume of metal poured into the mold. In spite of these auxiliary measures, however, the usual casting processes do not completely avoid the aspiration of internal bubbles in the cast body, especially in the areas of the outer body which are somewhat remote from the runners and risers. In any case, a large amount of material is in the manufacture of the molded product, is carried out at the very many runners and increasing _/ wasted. In addition, there is a loss of time _; and, of course, this procedure considerably increases the production costs in casting. It should also not be overlooked that these working conditions can be improved, for example, through the use of particularly thick sections, which are systematically arranged so that they the supply of the shrinkage compensating, liquid metal to these remote areas ads that in the risers and runners promote existing excess material. These thicknesses, which are usually called "plugs" in the industry, namely contribute to a substantial increase in the final weight of the cast body and thus also to an increase in costs.

According to the invention, the casting space of a fora about the correct amount of metal that is not fed only to fill the »Gieflraums» but also to form a point or a protrusion alongside and above the critical casting room, which are used to compensate

0098S1 / 1S9I

the volume changes and to equalize the casting material serves when it changes from its liquid state to the solid state. In addition, the outer Tip or the outer projection of such a nature that it can either partially or completely solidify can harden and is then driven into the grit space, thereby the inner casting material in the rest Areas in which the cast metal is in the liquid state or in the semi-liquid state, added to become and to mix intimately with this material »Thus the metal of the outer protrusion becomes the casting space either before or immediately after all the metal in this space has completely solidified, admitted, with the protruding metal in the porous and cavities Containing zones is pressed in at the place of application to a relatively large in the whole neighboring Gießrama to achieve high density »When performing this process necessarily results in an increase in the amount obtained from the manufactured product, usable cast body mass and a minimum © waste or minimal loss of material due to being more efficient and timely Use of a certain amount of additional 'casting metal to compensate for shrinkage and as precisely as possible other voids or oily spots that would otherwise be found in the product arise “Thus the product with practically the lowest possible Excess metal is produced, which is left to after complete solidification of the cast Form to be removed from the cast body and remelted.

Thus, the object of the invention is to produce a cast body of substantially uniform density and substantially free of talason or the like resulting from unhealthy contractions of the molten material that has been poured into the mold

009851/1536

For the production of a single cast body of essentially uniform density should be added some material so that a point or on the surface of the cast body a projection is formed, the additional, the mold includes supplied metal and then into the casting room is pushed in, around the in the casting or molding space to redistribute the material present and thereby bubbles and other irregularities in the material to eliminate,.

According to the invention, this task is now yellow, that the casting space within the mold is provided with at least two openings or holes, of which the an opening or a hole allows the inlet of the molten metal from which the desired casting in the Form is to be produced, while the other opening or the other hole above the casting space is sufficient To absorb the amount of metal so that a point or protrusion of a certain fora and certain volume is created, which, after it has solidified sufficiently, is driven or pressed into the casting room,

Material '

to dasxin to rearrange the casting space and re-shape and to improve the Gleiohmässigkeit or homogeneity of the density of the cast material daduroh that reduced so far available BEEN within the solidified ingot bubbles or cavities are ₀ or completely eliminated ·

In summary, the invention thus relates to a metal casting method and an associated device which minimizes the formation of bubbles to improve the quality of the finished cast product. The casting mold, which is preferably arranged next to the other parts of the casting device, is provided with an opening. which is preferably located next to a "hot spot" of the casting room where it can be expected that

009861/1538

the poured metal solidifies at a relatively slow rate so that some of the molten Metal reaches the opening and passes through it and forms a metallic tip or protrusion Rod is provided, is operated so that the rod is driven against the tip or the projection to him through the opening surface and into the casting material in order to remove bubbles or cavities that would otherwise appear in the poured product would eliminate.

AusfUhrungsbeispiele the cooked stand of the invention are in the drawing, to which the following description relates, as shown in the drawing demonstrate:

Fig. La a® Quersohnittsaiasiütit of the "basic Elements of part of the device for carrying out the casting method according to the invention,

Fig, Ib is a cross-sectional view of part of a Machine for compacting mold bodies according to the invention,

Fig. Io is a plan view of a shape of a casting pattern, -. from which certain compression points can be seen,

Fig. 2 is a cross-sectional view of another embodiment the machine according to the invention, with several / sealing cylinder and several ejection cylinders used be, and

3 shows a cross-sectional view of a further embodiment of the machine according to the invention, wherein a double-acting cylinder arrangement is used.

009,851 / 1β3β

In Figure la, the basic parts of a system for a casting device are shown with which a simple cast body, for example a brass hanger bracket can be produced. The part 10 may be a typical any, commercial casting which, if it were made with one of the conventional processes, probably a number of internal voids in F _o rm of holes, cavities, etc. would contain, which are hereinafter called blowholes and occur due to shrinkage, and usually been difficult to avoid in metallic permanent molds in the casting of brass and other metal objects were _c shrinkage in such materials, which can easily amount to more than $ 5>, has its origin from the contraction in the transition the liquid state to the solid state when the temperature falls, and manifests itself mainly in volume changes. For example, the article 10 could have substantially parallel walls 12 and 14 and would necessarily include one or more such voids which are of various shapes and sizes. This would be the case in particular if no inflow metal were present together with the device described here, which, as proposed here, is used during the casting process to introduce this material into the mold cavity in order to compensate for shrinkage caused by Volume changes occur, which occur when the metal changes from its liquid to its solid state.

0098 * 171.631

In FIG. 1 a, the outer shape for producing the product 10 is not shown, which in the preferred embodiment would have the compressor device to be described here. The shape would have a compression hole or opening 16. The hole 16 in the mold is an opening to a bore 20 of the device. The device is equipped with a rod 22 which can be moved in an aligned cylinder bore 21 in the desired manner . When the casting material enters the cavity gate or cavity opening shown in Figure 1a and partially solidifies in the mold, some of the casting material is rapidly forced through the hole 16 and into the bore 20 so that a Point or protrusion 24 is created “The metal entering into the hole 20 from the formhohlratite normally solidifies faster than the metal in the cavity, due to the forced length of the air over the condenser block and the large ratio of Fo ruf lache aia GieBaassey 'so that the tip or the protrusion Sohm-ell as an appendage aum "casting · =» material within this GieBraaiis aiHsgoToiIntet is ₀ Di © compressor device is above & mn caused ia οχειθβ carefully timed atigestiiamten relation to Yerfestigwngsgeechwindigkeit animal tip 24 from <ä®m gl © icta © m Mattrial like the product iO exists to come into action, so that the Stango Sg in direct and immediate operation stirring with the Spi ^ sa 2% is brought to thereby drive the material of the tip 2% asürlick into the casting 10,

The main task is to drive the tip material 2k into the measuring chamber 11, specifically in the area or in the vicinity thereof where the metal of the cast body has the most liquid jet. This is usually the range of the highest temperature. The material driven back into the Giessrauia is expected to be that in the casting room

00g $$ 1 / 1S3 @

Rearranges material such that the one or more cavities to be filled in the vicinity of this Materialbereiohe, resulting in a cast body of substantially throughout gleiohmässiger density results, which is thus free of voids "It is understood that the Verdichtervorriohtung, any number of rods 22 or may contain similar elements which simultaneously push a series of tips or protrusions, such as tip 2k, back into the mold to simultaneously eliminate shrinkage and other leakage defects due to shrinkage in several so-called "hot spots" within the mold cavity. The solution to the stated problem has the particular economic advantage that, if desired, a high density cast can be achieved in areas which are remote from the usual filler neck and riser systems which are part of normal commercial practice. It is found that a density equivalent to that achieved by the method described herein can only be achieved in conventional gate and riser systems by enlargements and cast body design changes that promote consolidation towards the gates and risers. These conventional methods, however, require significantly more metal either in the castings themselves or in the gates and risers, reduce the overall production speeds of the device, and result in a corresponding increase in the cost of the end product.

It is therefore also suggested here in conjunction to use a compacting device with a casting mold to as accurately as possible the existing and unavoidable To compensate for changes in the casting material caused by the contraction, welohe im Form system occur in the production of a cast body «,

009051/1538

In Figure Ib, the cross-section of a part of a machine is shown senematically, which works with a single working cylinder for compression and pouring purposes. The machine is capable of compressing the cast body simultaneously at several remote locations in the manner outlined above. The machine has a single working cylinder 41, but if desired it can also be equipped with two or more compression cylinders similar to the cylinder% 1 are constructed and work either independently or in conjunction with one another to produce a single casting. Six cylinders are required to produce the cast body construction shown in Figure Ic. In figure Ib, however, four so-called compressor rods 42, 42a, 42b and shown 42c that are respectively aligned with the cylinders 43 ₉ 45 _s 43 b 43 c, however, "Two other compression points 42d and 42e are shown in FIG ic to Seisen ₈ for the sake of Simplification not shown in Figure Ib "The part of the machine shown in cross-section in Figure Ib shows only the four compression cylinder points, which are arranged along the center line AA of Figure Ic"

Figure Ib shows schematically a portion of the permanent mold and casting apparatus which can be used to produce a single casting similar to that shown in Figure Ie. A casting of any shape can be produced with a machine showing the above structure. Molten metal, supplied from a suitable furnace (not shown) and transported in through a pipe or conduit, can be poured into the cavity 45 through an opening or a gate 47 located at the dividing line 49 between adjacent mold segments or blocks 52 and 54 is located. The molten metal flows freely öiareli the Foraliohlraum 45, until this cavity is filled _a boron pressure & r melt-

however, liquid is sufficient to allow the Mold cavity 45 to cause moving metal into the four compression ports 60, 60a, 60b and 60c in one to form the tips or projections 72, 72a, 72b and 72c in the bores 61, 6la, 6lb and 6lc Volume to enter. The molten metal in the mold cavity 45 then partially solidifies so that a coating or skin of solid metal can form, such as it is shown for example at 62 in Figure la. The skin 62 generally surrounds the liquid metal in the Measures how it solidifies in place. The inner region of the metal is denoted by 11 in FIG. in the Generally there is a temperature gradient which is approximately proportional to the cross-sectional thickness of the solidifying Molding is "

Once the Metali has sufficiently solidified, supported by the Ktihlwirkung the various Verdichtungsblöclce 55, 55a, .55b, 55c, ionn .'die * einzelen rods 42, 42a, 42b and 42c, the "it to the cylinders 41 are connected, by a separate, not shown Hydraulikeyβ tea set in motion "This hydraulic system performs each cylinder 41 hydraulic fluid to so that each rod drive? O, the piston head 71 and the corresponding rod 42 are driven downwards" each rod 42 moves in the corresponding opening 61 and Exerts an appropriate mechanical pressure on the tip or the projection 72, which drives the material located in the tip 72 through the opening 60 and into the foam cavity 45, as described above in connection with FIG. 1 a, FIG. 1 a shows the whole generally on a larger scale part of the Ueßhohlraues shown in Figure Ib.

009851/1536

The movement of the rod 42, which is aligned with the cylinder, is timed so that it with the Requirements of the solidifying metal in the area 45 coincides, so that the metal in the tip 72 in the relatively "hot spot" of the previously cast metal in the casting cavity 45 can be driven into all to fill any voids in the potted material in the vicinity before the material solidifies completely and thereby compensate for the shrinkage that takes place under the changing thermal conditions that the transition from the molten to the solid state accompany the casting. If allowed, the shrinkage, as already indicated, between two percent and ten percent of the total volume of the metal in the casting cavity «The amount of cast metal and the amount of metal designated for the tip or protrusion 72 is so dimensioned or calculated or adjusted that it is sufficient under the prevailing conditions to the blowholes or to compensate for porous areas that may possibly occur in the cavity 45.

The volume of metal required for the novel compaction process, i.e. the metal that goes into the Tip 72 has been cast or pressed in to be returned to the casting cavity 45, can to the desired or predetermined value and adjust the to the particular mold cavity and its Itoriß is adapted and also to the used Metals or other materials is matched, furthermore on the thermal conditions and other parameters of the construction «A nit threaded locking nut assembly 76 serves as a convenient adjustment device for this purpose « Thus, the amount of metal that can enter the compression bore 6l can be varied, for example by trying out during preproduction evaluations and planning «The setting of the backup

009851/1636

Nut mechanism 76 controls the distance between the end of cylinder rod 42 and parting line 49 that separates mold blocks 52 and $ k . With careful adjustment, the amount of material fed to the tip should be made just enough to achieve the desired reintroduction of the metal to remove the voids which would otherwise occur in the casting. If any excess should occur, it can be removed in any known manner after the casting has been ejected from the mold. If, during the preproduction attempts, there is an inadequate amount of material in the compaction tips 72, then the lock nut mechanism 76 can be rotated back so that the distance between the end of the rod 42 and the parting line 49 increases, thereby allowing more metal into the bore 61 is filled for the compaction process. The diameter of the compression opening 60 through which the metal is fed to form the tip 72 is dimensioned to account for the expected shrinkage of the cast material during solidification. In this manner, essentially the correct amount of material will reach the device and the tip 72 need not be driven in the mold cavity 45 beyond the dividing line 49 during compaction.

The form block 5 ^ lies on a so-called support block 78. The form block that works with him is also on a block ÖO, which, if desired , May be part of a casting ejection mechanism, not shown, of known type separate from the block 54 so that the hardened casting in the mold cavity 45 from this cavity and the compression device can be removed after completion of the compaction process.

009851/1538

Although the construction shown in Figure 1b has four lined up compression cylinders, as shown at kl , nooh additional cylinders of the same construction can be arranged on both sides of the dividing line k9 , so that any number of compression cylinders is achieved. In addition, cooperating cylinders can be used to feed material to the same location or area so that tips, such as tip 72, are fitted from the two opposite sides of a casting cavity so that opposing pressures remove voids in the same casting zone In other words, the compaction proposed here can take place in the respective device at two or more coinciding points in order to achieve any desired degree of compaction at one point or in a region within the cast body.

The various parts of the compression mechanism shown in FIG. 1b can be arranged and coordinated in such a way that differences in thermal expansion that are caused by different temperatures are compensated for, as is the case with the respective mold or the respective molding system, as it is, for example, in connection with FIG Ib has been described, and the molten metals given this form usually occur. Thus, 54 reach a © temperature of about 204 ⁰ C, for example, the shape of block and retained, while the adjacent nozzle block 78 reaches a temperature of about 149 ° C. The higher temperature arises in the mold block 5k because it is adjacent to the mold cavity 45 in which the very high temperature molten metal is located, but the device proposed here compensates so that misalignment of the device is avoided will and

Deformations and incorrect or inaccurate operations of the device can be prevented. Because of the temperature differences between, for example, the Stlitzblock? Ö and the mold block 54, which is warmer with respect to this, there is a greater thermal expansion in the lilock 54 than in the .Stlitzblock 78. Such different thermal expansion could lead to undesirable misalignments, whereby the rod 42 warps and the cylinder 43 aligned with it gets quite far out of alignment with respect to the tip 72. Any such misalignment, if it never happened, would cause friction and seizure between the moving piston and rod parts due to the thermal changes. This disadvantageous effect is now reduced, if not completely eliminated, with the aid of the method and device proposed here for implementation, namely with the aid of a ball 82 and an associated mechanism arranged between the body 70 and the rod head 8% are. The rod head controls the movement of the holder body 86, which holds the spring 88 in the cylinder 41 in the retracted position. The rod 42 is now caused by this mechanism to move substantially in a straight line direction, always correctly aligned and centered, and this straight line movement is not caused by the above-mentioned temperature fluctuations of the heated parts, for example parts 5% and 78 influenced. By maintaining linearity and thereby preventing misalignment of the moving parts of the compacting device, the device is enabled to apply constant pressure to the tip and direct it upright in its correct path of travel as it passes through opening 60 into the To drive cavity 45 into it.

009851/1538 _BAD

The stroke and movement of the rod 42 in its alignment cylinder 43 can be controlled and set in motion by the hydraulic pressure applied through an opening 90. The hydraulic medium can either be a gas or a liquid, for example oil. The action of the hydraulic medium through orifice 90 is substantially on the entire planar surface of piston 71 and therefore moves rod drive 70 and its rod 42 downward to exert a force on tip or protrusion 72 which pushes the tip into mold cavity 45 drifts in. The stroke of rod 42 is timed and controlled to complete the compression work by an external "valve mechanism, not shown, of any known construction." After completion of the compression stroke of rod 42, the hydraulic pressure previously applied through opening 90 is released. Shortly after the hydraulic pressure on the head 71 has been released, the rod drive 70 returns to its starting position. The spring 88, held within the mounts 85 and 86, compresses when the rod 42 moves towards the tip 72, but then serves to move the piston structure to the right and thus back to its normal position. However, it is pointed out that this return stroke can also be brought about by other known devices, for example a pneumatic or hydraulic device. In this way, the compaction rod k2 and the remaining part of the arrangement are prepared for the next casting cycle, which can then be run as soon as the solidified casting has been removed from the casting cavity 45.

Thus, molten liquid is initially in the casting cavity 45 filled through the inlet opening 47 to the

009851/1536

To fill the mold cavity 45, and a certain amount of this Metal is then caused to exit the mold cavity 45, in order to produce the tip 72 in the cylinder bore 6i. The metal forming the tip 72 can solidify or may harden to exert a counterforce on rod 42 in the compression cycle once the piston 70 is put into operation, whereupon the tip 72 is driven back into the mold cavity to remove the semi-set To add metal and thereby the desired elimination to reach the blowholes in the casting cavity 45. The cyclic operation can be controlled by the hydraulic mechanism, which is attached to the inlet opening 9o, and the valve device can be set to automatic operation, if required, to repeat the operation at regular intervals.

The blocks 52 and 54, which are in the assembled state Forming the slide cavity 45 can be made of any suitable molding materials. The block 55 can from be made similar materials or preferably made of a very good thermally conductive material, for example Copper, molybdenum or tungsten or their alloys. Block 55 also contains a number of machined ones Buffers or openings 94 forming air gaps which are constructed to allow heat transfer from the interior of the mold in the compressor block 55. However, other insulation options can also be used. Air for cooling purposes can into the rooms of the compressor block 55 through a Opening 95 are blown. The flow of cooling air is controlled or metered with the help of any needle valve The air thus supplied enters the block 55 through a pipe a and forms a coolant, which not only the block 55

009851/1536

cools, but also the tip 72 within the opening 60, before the metal in the mold cavity 45 also cooled M. The cooling effect of the air supplied helps with the material the tip 72 to solidify partially, so that it is under the action of force can be driven into the cavity 45 by means of the rod 42 and a ridge formation between the side walls of the opening and the rod 42 are minimized which interferes with the repeated operation of the device would. The cooling air can be blown out through an air duct 98 which kasua lead to the atmosphere. If if desired, any other cooling medium can be used for this purpose, for example water, which in many cases was a completely adequate remedy, but would require minor modifications to the device in order to obtain a seal To allow entry and exit of the coolant.

The rod 42 is sized to be fairly accurate into the hole 6l and the aligned © !! Cylinder 43 fits so that it is ensured that the material of the tip 72 can be pressed into the cavity 45 nineing © within a fairly wide range of the plastic state.

The compression blocks 55 are shaped and sized to comfortably fit into the designated spaces of the mold insert block 54 and can be held in place using support block 78.

Fig. 2 schematically shows an arrangement in which each Rod 142 fulfills two specific, chronologically sequential tasks, namely, first, it drives the tip or protrusion 172 into the mold cavity to effect the desired compaction. The tip 172 is open

ÖÖ9851 / 1

the outer surface of the mold cavity 145 as in FIG Trap of Pig. Ib formed, which was explained above. The second task of the rods 142 is then to eject the finished casting from the casting cavity 145 after the casting has solidified in the cavity 145.

In Fig. 2, only the essential items are the Solidifying device shown schematically. the other operating elements are known to the person skilled in the art or result from this description without supplementary Note.

In Fig. 2, two compression cylinders 140 and 140a and two ejection cylinders 141 and 141a are shown. The compression cylinder 140 controls a piston 100 which is connected through a coupling 101 connected to the compression rod 142. As has already been explained, the rod 142, which is in the position shown in its normal position in which it is ready to carry out the compaction, moved down from its compression position to the tip or protrusion 172 through the opening through and into the mold cavity 145, whereby the material of the tip 172 with the in the Mold cavity 145 mixed material and thereby the density of the casting material in the mold cavity changes. This additional material eliminates the voids present in the adjacent region of the mold space 145. The compression rod 142 is provided with a head 103 which is arranged and between the body 104 of the Coupling 101 and an internally threaded mounting piece 105 is held that the compression rod

009851/1536

142 and the coupling 101 at the same time and in the same direction can be operated. The mounting cavity 106 of the coupling 101 is threaded that fits onto a externally threaded rod 10o of the cylinder 140 can be screwed on so that the coupling 101 is moves simultaneously with the piston 100 and the compression rod 142. In this way, every movement of the Cylinder 140 a corresponding movement of the compression rod 142, which is then with the material of the tip 172 in direct contact occurs to drive this material into the mold cavity 145. Any coupling arrangement for example the coupling 101, serves to ensure the correct misalignment of the rod 142 within the opening 161 when temperature changes occur, so that the rod 142 with the material of the tip 172 in direct and immediate contact occurs as soon as the rod 142 is driven in for compaction purposes.

The compression cylinder 140a and its piston 100a similarly control the two clutch mechanisms 101a. In this case there are two coupling mechanisms 101a is used in place of just one, and its functions are substantially the same as those of the clutch mechanism 101 of the cylinder 140 described above.

Fig. 2 shows a relatively large H-beam block 110, which has a bottom part 111, a head part 112 and a transverse part 113. Both compression cylinders 140 and 140a as well as both ejection cylinders 141 and 141a stand with the H-shaped support block 110 in connection and are of worn him. The support block 110 holds and supports a plurality of compression and ejection cylinders. As can be seen from FIG. 2, the H-shaped support block 110 is in one

0Q9851 / 1S38

relatively large U-shaped block 115 stored. This U-shaped block 115 forms a base support so that the movements of the compression and ejection cylinders in the mechanism in their relative positions being held.

As can be seen from FIG. 2, the adjacent blocks 152 and 154 form several mold elements of the mold system, internally the mold cavity 145 is located the two blocks 152 and 154 have their dividing line 149 for example where the blocks can be separated from each other. Block 152 must be from the adjacent block be pushed away as soon as the finished castings are to be ejected, and it must be in the one in the drawing position shown when another casting cycle is performed with a different series of castings shall be.

In the so-called filling position of the mechanism. the compression rod 142 and the ejection cylinders 141 are in their retracted positions, as can be seen in FIG. This filling position is indicated schematically by block 123. During this filling cycle of the casting process, molten material can be conveyed from the reservoir of a furnace, for example an electric furnace, through a conduit (not shown) to the incision or inlet 147 under any desired pressure.The molten material then fills the mold cavity 145 _t it through the opening 14 leading to it? achieved. The pressure acting on the molten material should be so great that some of the molten metal also fills the opening 160 of the mold cavity 145, so that each of the

003851/15 3 6

Tips or protrusions 172, as discussed above, is formed. The Meobaniemus is then ready for the Compaction cycle.

During the compression cycle, compression cylinders 140 and 140a are caused to move downward. This lower position is symbolic by the Compression position 124 shown in FIG Position, each compression rod 142 touches the corresponding tip 172, the material of which has hardened or is partially has solidified wisely, and the one on the compaction rod Applied pressure then moves the tip material through opening 160 into mold cavity 145 into where it reaches the so-called "hot spot". This removes the voids present in this area of the hot spot and thus the material in the mold cavity 145 rearranged so that the density of the material in the entire area is After that, the compression cycle is over.

In order to eject the finished casting from the Fο nahohohar 145 after the cast material has solidified sufficiently, the block 152 must be separated from the block 154. Shortly thereafter, the H-shaped support block 110 is caused to descend under the pressure applied to the ejection cylinders 141 and 141a. The output division symbolically corresponds to block 125 in FIG. 2. The end of the rod 142 extends through the opening 16Ο so that the casting is ejected from the mold cavity 145. Thus, the exhaust cycle is terminated and the cylinder 141, 141a, 140 and 140a return to their initial position in which they are ready for "inen new cycle is _o Block 152

Q098S1 / 1538

then returned to its position shown in Fig. 2, whereupon the mechanism is ready for the next Is the operating cycle in the production of another casting or other series of castings.

Among other things, air or another coolant can be used to cool the compressor block 155 during the operating cyclone are supplied through the opening 130, then through their channels 131 and 132 and through the channel 133. The Coolant is then discharged into a suitable exit chamber or into the atmosphere. The effect of the Coolant in the area of the bore 161 accelerates the formation of a partially solidified tip 172 for compressing the casting material.

The movements of the compression cylinders 140 and the discharge cylinder 141 is operated by hydraulic pressure controlled, which can be generated with the mechanism in any way. The hydraulic pressure is not used only to move the cylinder forward in one direction, i.e. in the downward direction, as well as to Compression and subsequent ejection, but also the reverse movement of the cylinders to the cylinders returned to their filling position for the start of the next operating cycle.

In Fig. 3 a further embodiment is schematically form of the cast compression system, in which a single, double-acting cylinder mechanism the Functions of the compressor cylinder mechanisms 140 and 141a of FIG. 2 jointly fulfilled. Also here are again only the absolutely necessary individual parts of the overall mechanism are shown, while the other parts stand for

009851/1536

will be apparent to those skilled in the art from the above description.

In Fig. 3, a single double acting cylinder mechanism 236 is shown in an assembled view. The mechanism works the same way the mechanism shown in Figure 2, i.e., it processes the molten metal in the mold cavity 245 of the mold system. The cylinder mechanism 236 is operated so that it the relatively solid tip 272 drives into the mold cavity 245 to thereby increase the density of the in improve the cavity of the material being conveyed, and then eject the casting after it has solidified.

The mechanism of Fig. 3 is in its initial or Filling stage shown in the molten material the Forming system can be fed. The molten metal enters through an opening 247 leading to the mold cavity 245 of the mold system and after the melt the cavity 245 is filled and inserted into the opening 260 of the Has penetrated the cavity, a tip or protrusion 272 of the type described above is formed. The filling process is then completed.

Initially, before the rod 242 can move to the right, over the tip 272 into the mold cavity 245 Hydraulic fluid under pressure is supplied to port 227 from a source of fluid. This hydraulic medium pressure acts on the walls 23O and 232 of the cylinder rod 200 to move between them both walls maintain a relatively wide, constant gap, and thereby the cylinder in its Hold filling position 223. While this pressure is applied to the opening 227, the same thing acts

0098S1 / 1S36

- 25 - 2Ö28855

Apply pressure to another port 228 that urges the wall to start the compression cycle permit. Because of this through the second opening 228 acting pressure is the cylinder rod 200 over moved downward a certain distance to compression position 224. In this respect the cylinder rod 200 is coupled by the coupling 201 to which the compression rod 242 is attached, the rod 242 becomes advanced through opening 26i to reach opening 260 in cavity 245. The movement of the compaction rod 242 through this distance causes the tip 272 to enter the adjacent mold cavity is driven into it, in the direction of the hot spots present in it, so that the material of the Tip 272 mixes with the other material in this area and thereby essentially all of it Removed voids in this area. The blocks 223 and 224 figuratively represent the forward movement of the rod used to compact the material of the tip 272 242 into the casting material of the cavity 245. The one moving forward under the acting pressure Cylinder 200 comes to a standstill as soon as surface 237 contacts surface 229. When the finishes and 229 touch each other, then a not shown causes Control mechanism that vent 231 to atmosphere or a suitable drainage container to relieve the pressure previously acting in port 228.

The mold parts 252 and 254 are then separated from one another in a known manner, so that the solidified cast body can be ejected. The ejection of the cast body occurs only when the rod 242 continues through

009851/1536

the bore 26l advances "In order to perform the ejection of the finished Gußstüoks, the initial, holding pressure acting through the opening 227 is lowered, and then the cylinder 200 further moves downward to advance in the same hub, the rod 242 and to cause it, through the opening 260 drive through and eject the casting located in the casting cavity 245. The movement of the rod 242 stops as soon as the wall 232 hits the wall 230. The ejection position is then identified quite generally by the reference number 225.

To return the lifting mechanism to its starting or filling position and thus to prepare for another process of filling the molten metal into the casting cavity 245 at the beginning of the next cycle, the pressure previously exerted through the opening 228 must be released and at the same time the pressure must be pushed back into the opening 227 be to separate DI® surface of the surface 230th At this point the port 231 is vented either to the atmosphere or to a suitable hydraulic reservoir. The rod 242 is returned to its normal or fill pitch in preparation for the next cycle. Block 225 shows the point of greatest advance of the rod and the associated mechanism for ejecting the finished casting. The cylinder 200 is completely returned to its starting or filling position by re-pressurizing the opening 231 in order to separate the wall 237 from the wall 229. When this is done, the next cycle can be performed you operation sequence.

009351/1538

Figs. Ib, 2 and 3 indicate common O-rings Places where it is important that flow nipples are prevented from leaking. For example, in Fig. Ib there are two O-rings shown. It seems superfluous on the location and the purpose of the other O-rings in the other figures To refer to.

Although the novel procedure and the device for carrying it out are generally related to the Manufacture of metal castings have been described, which could be made of any metal, for example made of ferrous metal, aluminum, etc., the method and its device can be used in the same way for the Use in the manufacture of non-metallic castings such as plastic parts and plastic products.

The parts of the overall mechanism are dimensioned and arranged in such a way that the desired temperatures are maintained at critical points in the structure, for example where the compression is to take place. It is important that the molten material which is fed into the inlet openings kl of FIG. 1b reaches the mold cavity 45 and completely fills it before the solidification cycle is initiated. It is also important that another or second opening 60 be provided adjacent one or more hot spots within the mold cavity 45 and that the pressure applied to the molten material be sufficient to force some of the molten material through the opening 60 . Finally, it is equally important that the material conveyed through the opening forms a point or projection which is driven back through the second opening 60

009851/1536

or can be returned to with the material im Feasible area of the casting cavity 45 in intimate contact to come and thereby produce the desired uniformity of the density of the cast material.

It is also important that the movement the rod 42 controlling mechanism in relation to temperature and other parameters which could affect the direction of movement of the rod 42 and thus could also cause poor compaction as well as Boglich is balanced.

These are some essential factors to consider when carrying out the novel method of manufacture should be strictly adhered to by good castings.

009851/1536

Claims (1)

PATENT CLAIMS 1. Method of making castings more uniform Density in a casting cavity, characterized in that the casting cavity is filled with molten material is filled that an additional amount of molten material is forced into the casting space to one to form attached material additive to this space, which is arranged outside this space, and that the additional material is pushed back into the casting cavity, to remove existing voids in the room * 2. The method according to claim 1, characterized in that the additional material by one in addition to one hot spot within the mold cavity movable opening is pushed out of the mold cavity. 3. The method according to claim 2, characterized in that the additional material is oriented so that its axis substantially coincides with the axis of the hot spot. k. A method according to claim 3, characterized in that the material is expelled from the casting cavity after it has completely solidified. 5. The method according to any one of claims i to k, characterized in that molten material from which the product is to be made is poured into the casting cavity of a molding system, that then the molten material is pressurized to a part of it 009851/1536 out of the casting cavity so that it becomes a Appendix to the mold cavity forms, and that the appendix or additional material thereafter is pushed back into the mold cavity. 6. The method according to claim 5, characterized in that that the additional material is pushed back into the mold cavity after it has partially solidified, and in that the pressure for the return movement of the material is transmitted by a rod which is essentially is aligned and moved along the axis of the additional material. 7. The method according to claim 6, characterized in that the rod is moved along the same axis, after the material has completely solidified to expel the molded product. 8. The method according to any one of claims 1 to 7, characterized characterized in that material is poured under pressure through a first opening into the casting cavity of a molding system is that the pressure is maintained to allow some of the material from the second opening of the mold cavity to form a material attachment next to the second opening is pushed out, and that the attached Material through the second opening into the mold cavity is pushed back to locate in the mold cavity To essentially eliminate voids. 9 · The method according to claim 8, characterized in that the material continues in the direction of the material attachment is pushed through the second opening in order to expel the material located in the casting cavity after the material has completely solidified. 009851/1538 10. Pouring device for carrying out the process according to claims 1 to 9, characterized by a casting cavity (45) and two different openings (47> 60) extending from different parts of the casting cavity to two corresponding segments (52, 54) of the outer wall of the molding system, means for feeding molten material through the one opening (4?) Into the casting cavity (45) until a certain amount of molten material through the second opening (60) has passed through in order to create a material attachment (? the mold cavity can be pushed back after it has been calibrated has partially solidified. 11. The device according to claim 10, characterized in that the device (42, 55) for driving back a machine is equipped with a reciprocating element (42) with which the material attachment (72) in the Casting cavity (45) can be returned. 12. The device according to claim 10, characterized by duroh a third opening which extends from another part of the casting cavity (45) to the outer wall of the mold system streokt and through which also a certain amount of molten material to create a second Material attachment on the casting cavity can be moved through, wherein the device (42, 45, 70) for driving back of the material can drive both material attachments back into the casting cavity. 13. The device according to claim 12, characterized in that that the device for driving back both material attachments drives back into the mold cavity substantially simultaneously. 009851/1536 14. Casting device, characterized by a mold (52, 54) »with a cavity (45), the molten Receives metal, a first opening (47) leading into the mold through which the molten metal is poured into the mold cavity (45), a second in the mold Located opening (6O) for receiving a certain amount of metal after the metal through the mold cavity has passed through to form a projection (72) arranged on the mold cavity, and through means (41, 42, 45 »70) by which this projection (72) can be pressed into the mold cavity in order to reduce any voids located in it. 15. Device according to claim 14, characterized in that the space around the projection (72) can be cooled, see above that the material in the protrusion was partially cooled before it was pressed into the mold cavity. 16. The apparatus according to claim 14, characterized in that the device for pressing in the material • having tangle-like element (42). Device according to Claim 15 _f, characterized in that the device for pressing in has a rod-like element (42) which is movable in one direction in order to drive the projection (72) into the mold cavity (45) in this way. 16. The device according to claim 16, characterized by Means for further advancing the rod-like element (42) to eject the casting from the mold cavity (45) after it has solidified. 009851/1536 19. Device for producing a metallic cast body which is essentially free of voids, characterized by a molten metal pourable mold (52,54), one in the mold existing opening (60) through which some of the molten metal in the mold cavity can be pressed is to form a protrusion (7 <0) on the outside of the mold, a rod-like element (42) which is movable a first predetermined distance to driving the projection (72) into the mold cavity (45), and by means (22, 41, 140) with which the rod-like element over a further distance jjj is movable to eject the cast bodies from the cavity of the mold after it has solidified, 20 · Device according to claim 19, characterized in that that the space around the projection (72) on a considerable lower temperature than the mold (52, 54) can be maintained. 21. The device according to claim 19, characterized in that the opening (6o) located in the mold is arranged is that the material protrusion (72) next to the opening arises, in the direction of one existing in the form showing hot spot. 22. The device according to claim 19, characterized in that a rod-like element (42) is movable in one direction which substantially coincides with a hot spot present in the mold cavity (45). 23. Casting device for metal, characterized by a mold consisting of several elements, which forms a mold cavity { 45), a device for pouring 0 0 9851/1536 -34- 2023855 of molten metal in the mold cavity, of des part of the opening (60) of the fora (52, 54) can be delivered is, in addition to the Formliolilraum an existing from the metal Projection (72) and means (41, 42, 45, 140) for driving the projection (72) into the mold in order to reduce the cavities in it. 24. The device according to claim 23 »characterized in that the driving device is a reciprocating Element (42) which is in contact with the projection (72) and passes it through the opening (60) and drives into the mold cavity (45) to thereby the to shrink in this cavity. 25. The device according to claim 24, gekennzeichß © t toroh einrichtimg,) with the back and forth movable © Element (42) can be moved further through the opening (6 ©) is after the parts (52 »54) of the F @ na from each other have been separated to the solidified © © oussbody from eject the mold cavity (45). 009851/1536 original snspected