EP0036273B1 - Method of, and pattern for use in, forming a sand mould, and method of producing an annular casting using the mould - Google Patents

Method of, and pattern for use in, forming a sand mould, and method of producing an annular casting using the mould Download PDF

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Publication number
EP0036273B1
EP0036273B1 EP19810300927 EP81300927A EP0036273B1 EP 0036273 B1 EP0036273 B1 EP 0036273B1 EP 19810300927 EP19810300927 EP 19810300927 EP 81300927 A EP81300927 A EP 81300927A EP 0036273 B1 EP0036273 B1 EP 0036273B1
Authority
EP
European Patent Office
Prior art keywords
pattern
segments
ring
annular
radially
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.)
Expired
Application number
EP19810300927
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0036273A3 (en
EP0036273A2 (en
Inventor
Edward E. Flesburg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Caterpillar Inc
Original Assignee
Caterpillar Tractor Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Caterpillar Tractor Co filed Critical Caterpillar Tractor Co
Publication of EP0036273A2 publication Critical patent/EP0036273A2/en
Publication of EP0036273A3 publication Critical patent/EP0036273A3/en
Application granted granted Critical
Publication of EP0036273B1 publication Critical patent/EP0036273B1/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/28—Moulds for peculiarly-shaped castings for wheels, rolls, or rollers

Definitions

  • This invention relates to sand moulds for producing an annular casting, particularly a fluid flow deflector, such as the stator of a torque converter or a compressor wheel for a turbine.
  • the blade patterns were pegged into a shell ring prior to forming a sand mould thereabout.
  • a problem arose in such manufacture in that variation in spacing and profile occurred in the patterns so that the deflector was not completely uniform and this did not provide a com- pleteiy balanced flow of the fluid.
  • US-A-118,693 discloses a pattern for a sand mould for the radially outer part of a tubular casting, the pattern having some radially inwardly tapering segments so that the segments can be removed from the mould upon radially inward displacement after withdrawal of a central core. This is not relevant to a sand mould pattern for an annular casting having blades extending radially between inner and outer rings.
  • a pattern for use in forming a sand mould for a one-piece annular casting having a radially inner ring, a radially outer ring and a plurality of angled blades extending in spaced annular annular array between the rings comprises a plurality of pattern segments each having a first end portion defining a portion of the profile of one of the rings, and a second end portion defining the profile of one blade; means for supporting the pattern segments in an annular array to define cumulatively a pattern structure corresponding to the configuration of the one ring and blades, and a removable pattern ring coaxial with the array of segments to provide a pattern defining the profile for the other of the rings; the pattern segments being shaped to permit selective radially directed removal thereof from the array upon removal of the supporting means.
  • first end portion of at least one pattern segment may be tapered radially inwardly or outwardly to permit radially outward or inward respectively removal thereof from the array of segments upon removal of the supporting means.
  • the first end portions of the pattern segments may define the profile of a radially outer ring, but preferably define the profile of the radially inner ring. In the latter case radial removal of the pattern segments from the annular array will be in the radially inward direction. To facilitate this, the first end portions of adjacent ones of the segments may be tapered in opposite radial directions. Upon removal of the support for the segments, every other segment may then be removed by a radially inwardly directed movement thereof prior to removal of the other segments.
  • the removable pattern ring may comprise a split ring.
  • the ring defines a pattern selected to permit suitable subsequent machining of the portion of the casting defined by the pattern ring, to the final desired configuration.
  • the invention also includes a method of forming a sand mould for a one-piece annular casting having a radially inner ring, a radially outer ring, and a plurality of angled blades extending in a spaced annular array between the rings and utilizing a pattern as previously defined, the method comprising the steps of supporting the pattern segments in an annular array to define cumulatively a pattern structure corresponding to the configuration one of the rings and the blades; securing the removable pattern ring coaxially with the array of pattern segments; forming a sand mould about the associated parts of the pattern; discontinuing the support of the pattern segments; removing the pattern ring from the mould; and removing the pattern segments from the mould by movement thereof radially with respect to the axis of the annular array of pattern segments.
  • the segments may be mounted coaxially of an annular supporting surface during the mould- forming steps.
  • the annular supporting surface may be provided on a mandrel which urges the pattern segments radially outwards and locks them in the annular array.
  • the segments Upon removal of the mandrel at the completion of the sand mould formations, the segments may be withdrawn sequentially into the axial space previously occupied by the mandrel.
  • the faces of the adjacent segments fit closely together and my additionally be locked to one another, for example by means of a locking ring engaging in a groove in the segments.
  • this provides a positive, fixed location of the segments of the pattern during the sand mould forming step.
  • Each of the pattern segments may be readily formed by identical machining operations so as to provide uniformity in the blade configuration throughout the array.
  • the first end portion of each of the pattern segments may be machined to define selectively the inwardly and outwardly tapering configuration discussed above.
  • the resulting annular casting may thus comprise a totally uniform configuration to provide a completely balanced flow of fluid therethrough.
  • the pattern and method of forming the sand mould utilizing the pattern are extremely simple and economical while yet providing the highly improved cast structure.
  • the manufacture of a stator 10 involves the formation of a pattern 11 for producing the stator 10 as a one-piece casting.
  • the stator includes a radially inner annular shell ring 12, a coaxial radially outer blade support ring 13, and a plurality of angled blades 14 extending in a spaced annular array between the shell and the blade support rings to define a fluid flow deflector, such as for use in a torque converter stator structure.
  • the blades 14 are of complex configuration and it is desirable to arrange the blades in the array illustrated in Figure 1 in accurately positioned and spaced relationship so as to provide a completely balanced and uniform stator 10.
  • the individual blades 14 are defined by identical segments 15 of the pattern 11 which differ only in the angularity of the circumferentially opposite side faces 16 and 17 of an inner end portion 18 of the segments.
  • inner end portions 18a of segments 15a define planar side faces 16a and 17a which converge radially outwardly from the axis 19 of the segment array.
  • Inner end portions 18b of segments 156 define planar side faces 166 and 176 which converge radially inwardly in facial abutment with surfaces 16a and 17a of the adjacent segments 15a.
  • the included angle between faces 16a and 17a and, thus, between faces 16b and 17b is approximately 60°.
  • faces 16b and 176 intersect in spaced relationship to axis 19.
  • Segments 15a as shown in Figure 6, include a first inner end portion 18a defined by the planar surfaces 16a and 17a, and segments 15b include a corresponding inner end portion defined by surfaces 1 6b and 17b.
  • Each of the segments defines a similar blade portion 21 joining the respective inner end portion at 20a.
  • the side surfaces of the inner end portions of the segments are curvilinear.
  • Segment 15c includes an inner end portion 18c wherein the side surfaces 17c and 16c extend at an angle suitably to engage the counterclockwise side surface of the adjacent segment 15b and the clockwise side surface of the adjacent segment 15a.
  • the annular array 22 of the segments defines a complete annulus wherein the inner portions 18 define an inner continuous ring and the blades 21 are spaced apart uniformly at a uniform angle to define a fluid flow deflector pattern 23.
  • the annular array 22 is formed about a transversely split mandrel 25, which, as illustrated in Figure 7, has an outer arcuate configuration corresponding to the desired inside configuration of the finished stator wheel.
  • a lock ring 25a positioned in a groove 25b located in the inner portion 18 of the segments 15. They are then locked in position by the mandrel, the two parts of which urge the segments radially outwards as the parts are brought together.
  • an outer ring 26 which forms a portion of core box 28, is brought into encircling relationship to the outer tips 24 of the blades, as shown in Figure 4.
  • the mandrel 25 is omitted in Figure 4 to facilitate showing of the arrangement of the segments).
  • Outer ring 26 and core box 28 preferably comprise a split ring which includes locking means 27 for causing firm embracing of the blade tips 24 in the annular array of the segments.
  • moulding sand 29 may be packed around the pattern and subsequently cured to form the desired sand mould M in which the stator 10 is cast.
  • Sand mould M is then removed from the core box 28 and mandrel 25 and split ring 26 are removed.
  • Removal of mandrel 25 from annular array 22 permits the removal of the segments 15 sequentially from the annular array. More specifically, upon removal of mandrel 25, segments 15a may be removed by a radially inward withdrawal thereof from the annular array as permitted by the inwardly widening side surface configuration. Upon removal of segments 15a, segments 15b, and segment 15c when used, may then be removed to complete the removal of the pattern from the sand mould for subsequent casting of the stator 10 in the formed mould.
  • the sand mould correspondingly defines a continuous ring cavity for defining the shell 12 of the stator 10, seen in Figure 1.
  • the resultant cast blades 14 are similarly accurately spaced and positioned in the stator 10.
  • the configuration of the split ring 26 may not correspond exactly to the desired final configuration of the blade support 13.
  • the outer portion of the casting may comprise a rectangular section ring which may be suitably machined to the final configuration of the blade support 13, as shown in Figure 3.
  • the shell 12 may be further machined at its opposite ends 30 and 31, as desired.
  • the casting produced with the pattern of the present invention provides an improved uniform, accurately configured complex-shaped structure which is adaptdd for use in a wide range of industrial applications, such as the stator of a torque converter wherein it is desirable to provide accurate, uniform blade deflectors at low cost.
  • the pattern for the casting mould is made up of a plurality of readily repeatable machined segments, high accuracy in the configuration of the pattern and, as a result, the configuration of the casting made from the mould formed by the pattern, is obtained.
  • the pattern may provide either an even number of blades or an odd number of blades in the cast stator as desired.
  • the segment 15c is omitted and the circumferential extent of each of the segments 15a and 15b correspondingly increased to form the continuous annular array defining the shell portion of the stator.
  • the invention permits the production of sand moulds for castings in such relatively complex-shaped castings as stator 10 by numerical control machining steps in forming the individual segments.
  • the interlocking angle of the side surfaces of the segments assures that the blade portions thereof are effectively accurately retained while the moulding stand is being packed around the pattern, thereby assuring a uniform blade arrangement.
  • stator is utilized as a torque converter stator, such uniform stator configuration provides a highly desirable balanced flow of fluid through the diverter means.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
EP19810300927 1980-03-13 1981-03-05 Method of, and pattern for use in, forming a sand mould, and method of producing an annular casting using the mould Expired EP0036273B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
WOPCT/US80/00268 1980-03-13
PCT/US1980/000268 WO1981002536A1 (en) 1980-03-13 1980-03-13 Sand core pattern and method of forming a sand mold

Publications (3)

Publication Number Publication Date
EP0036273A2 EP0036273A2 (en) 1981-09-23
EP0036273A3 EP0036273A3 (en) 1981-12-09
EP0036273B1 true EP0036273B1 (en) 1983-11-09

Family

ID=22154237

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19810300927 Expired EP0036273B1 (en) 1980-03-13 1981-03-05 Method of, and pattern for use in, forming a sand mould, and method of producing an annular casting using the mould

Country Status (6)

Country Link
EP (1) EP0036273B1 (pt)
JP (1) JPH0113941B2 (pt)
BR (1) BR8009025A (pt)
CA (1) CA1154570A (pt)
DE (1) DE3161348D1 (pt)
WO (1) WO1981002536A1 (pt)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10041505A1 (de) * 1999-12-23 2001-09-06 Alstom Schweiz Ag Baden Werkzeug zur Herstellung von Gusskernen
DE10064268A1 (de) * 2000-12-22 2002-07-04 Alstom Switzerland Ltd Werkzeug und Verfahren zum Giessen eines Formteils für die Herstellung einer Turbinenschaufel
CN110434283A (zh) * 2019-07-30 2019-11-12 共享铸钢有限公司 一种水轮机上冠和外环铸件同箱铸造的方法

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0962270A1 (en) * 1998-06-01 1999-12-08 Ford Global Technologies, Inc. A method for forming turbine hubs
CN103418754B (zh) * 2013-08-30 2015-12-02 中国南方航空工业(集团)有限公司 一种用于铸造航空发动机机匣部件的铸型的制造方法
CN105290336B (zh) * 2015-11-18 2018-01-09 江苏中联铝业有限公司 具有定位和排气功能的中空型车轮砂芯

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US118693A (en) * 1871-09-05 Improvement in casting toothed cylinders
US3247548A (en) * 1962-05-28 1966-04-26 Roehr Metals & Plastics Compan Apparatus for making a molded article
US3552480A (en) * 1968-07-12 1971-01-05 Caterpillar Tractor Co Pattern for making a sand mold with a back draft
US3570585A (en) * 1969-04-25 1971-03-16 Caterpillar Tractor Co Pattern for making mold with a back draft
US3820753A (en) * 1972-12-04 1974-06-28 Tempcraft Tool & Mold Apparatus for molding ceramic cores and wax or plastic patterns
US4043385A (en) * 1976-08-23 1977-08-23 Mercury Machine Co. Molding apparatus
JPS5333091A (en) * 1976-09-09 1978-03-28 Nec Corp Electronic message device
US4231413A (en) * 1979-02-27 1980-11-04 Graham Bretzger Assembly for and method of making mold and casting of one-piece impellers

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10041505A1 (de) * 1999-12-23 2001-09-06 Alstom Schweiz Ag Baden Werkzeug zur Herstellung von Gusskernen
DE10064268A1 (de) * 2000-12-22 2002-07-04 Alstom Switzerland Ltd Werkzeug und Verfahren zum Giessen eines Formteils für die Herstellung einer Turbinenschaufel
CN110434283A (zh) * 2019-07-30 2019-11-12 共享铸钢有限公司 一种水轮机上冠和外环铸件同箱铸造的方法
CN110434283B (zh) * 2019-07-30 2020-11-13 共享铸钢有限公司 一种水轮机上冠和外环铸件同箱铸造的方法

Also Published As

Publication number Publication date
EP0036273A3 (en) 1981-12-09
JPH0113941B2 (pt) 1989-03-08
JPS57500421A (pt) 1982-03-11
DE3161348D1 (en) 1983-12-15
BR8009025A (pt) 1982-02-09
CA1154570A (en) 1983-10-04
EP0036273A2 (en) 1981-09-23
WO1981002536A1 (en) 1981-09-17

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