EP0535421A1 - Procédé et dispositif pour la fabrication de pièces de construction - Google Patents

Procédé et dispositif pour la fabrication de pièces de construction Download PDF

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Publication number
EP0535421A1
EP0535421A1 EP92115545A EP92115545A EP0535421A1 EP 0535421 A1 EP0535421 A1 EP 0535421A1 EP 92115545 A EP92115545 A EP 92115545A EP 92115545 A EP92115545 A EP 92115545A EP 0535421 A1 EP0535421 A1 EP 0535421A1
Authority
EP
European Patent Office
Prior art keywords
mold
filling
filling chamber
plunger
melt
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.)
Granted
Application number
EP92115545A
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German (de)
English (en)
Other versions
EP0535421B1 (fr
Inventor
Friedhelm Prof. Dr.-Ing. Kahn
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Individual
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Individual
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Publication date
Application filed by Individual filed Critical Individual
Publication of EP0535421A1 publication Critical patent/EP0535421A1/fr
Application granted granted Critical
Publication of EP0535421B1 publication Critical patent/EP0535421B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/30—Accessories for supplying molten metal, e.g. in rations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • B22D17/12—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled with vertical press motion

Definitions

  • the invention relates to a method and devices for producing components in which liquid or partially liquid material is introduced into a mold cavity formed at least from two mold halves.
  • the causes of defects lie mainly in the large number of production parameters, which usually come into effect at the same time in the shortest possible time, often with mutual influence, and thus largely elude both detection and regulation.
  • the manufacturing process essentially consists of only two steps.
  • the first step is the preparation of the shaping tool and the melting of the material batch.
  • the melt is then transported from the separate furnace via distributor systems into the mold cavity, where it should solidify to the desired component under controlled thermal conditions and under sufficiently high supply pressure.
  • the component quality is determined by the additional occurrence of structural porosity, which is caused by the separation of gases dissolved in the melt, e.g. Hydrogen, or the inclusion of gases in the mold cavity during solidification is reduced.
  • the batch of alloy to be processed is melted in a separate premelting furnace and then transferred to the holding furnace on the die casting machine by means of transport pans. From there, the melt quantity required for a cast is passed with a ladle or other metering device via a freely falling pouring jet into the mostly horizontal shot chamber, where the melt first forms a pool with a large surface area and cools down rapidly.
  • the shot piston pushes the melt together in the shot chamber in accelerated movement, preferably avoiding splashes and air pockets, until it reaches the gate leading upwards into the mold cavity. From that point onwards the melt is sprayed at high speed into the mold cavity, which it fills in a fraction of a second.
  • the inclusion of gas residues from the mold cavity in the structure of the very rapidly solidifying casting is practically unavoidable, which leads to the known disadvantages of the die-cast product, such as a lack of elongation, lack of weldability and curability.
  • melts e.g. magnesium alloys
  • alloy additives due to a higher vapor pressure can cause problems.
  • the melt is pressed from below into the casting mold from the holding furnace by means of gas pressure via a riser pipe and is held in the mold under a slight excess pressure of maximum 1 bar until the solidification is complete.
  • This process enables a small amount of circulation in the cast production, but requires special measures against oxide formation in the riser pipe and, due to its convection-related long cycle times, proves to be disadvantageous compared to other casting processes.
  • the melt is poured from above with a freely falling pouring jet into an initially open die, the lower one Part or all of it.
  • a stamp moves into the die from above and displaces the melt to completely fill all the shape contours.
  • the solidification proceeds under the further pressure of the punch, so that a workpiece with a dense structure can be obtained, provided sufficient ventilation of the mold cavity has been achieved. This process could not prevail in production technology because it is cumbersome and time-consuming and only supplies simple, thick-walled workpieces.
  • the melt is conveyed from a swiveling casting unit from below into a die.
  • Disadvantages also appear here: the necessary filling of the casting chamber swung out together with the piston and drive via the free-falling pouring jet by means of dosing from a separate holding oven, the additional steps of swiveling back and coupling the casting unit to the mold, and the complex and expensive overall construction.
  • the object of the present invention is to create a novel method and novel devices which Enable the production of heavy-duty components, particularly those with large dimensions, complex shapes and multiple functions, in a compact system with the tightest coupling and control of the manufacturing steps while simultaneously reducing the cycle time in a particularly efficient manner.
  • the conditions for the processes during melting, mold filling and solidification are to be optimized so that components with a particularly fine-grained and dense structure with a high degree of uniformity are obtained.
  • the material is brought into a consistency suitable for the mold filling in at least one filling chamber directly adjacent to the mold cavity, then conveyed into the mold cavity which is not yet completely closed for ventilation and there after the mold cavity is closed while the consolidation is kept under pressure.
  • the method according to the invention is distinguished by a number of considerable advantages.
  • the charging bodies can be optimally matched to the component weight, so that the considerable amount of material required in the conventional mode of operation is avoided. So there is the possibility that the plunger end face can be used as a molded wall part.
  • the filling chamber is formed directly adjacent to the mold cavity, there are minimal transport or conveying paths for the melt, so that the disadvantages known from the prior art are avoided.
  • First of all there are no disadvantageous temperature fluctuations, uncontrollable oxide formation and loss of burn-off.
  • Due to the possibility of suitable Setting mold filling temperatures in the filling chamber with appropriate heating can also process supercooled or partially solidified material.
  • Due to the large filling cross-sections and short flow paths, a strongly calmed mold filling with a compact melt volume is achieved without spraying and swirling. Since there is no atomization of the melt during mold filling due to the low filling pressure and the possible large cross-sections compared to the die-casting process, lost cores can also be used in a similar way to gravity die casting.
  • the present invention is furthermore suitable for introducing prefabricated solid bodies into the mold cavity which are to be connected to the melt material or to be integrated into the component.
  • the solids can consist, for example, of semi-finished profiles, which are then connected during the filling process by the melt, which then solidifies to form nodes.
  • the possible melting of the profile ends to be connected ensures an optimal bond.
  • This enables the production of larger frame structures, for example for chassis or body construction.
  • prefabricated reinforcements made of high-strength materials can be fixed in a suitable manner in the mold cavity and integrated into a heavy-duty component by the melt after solidification. In a similar way, it is possible to include packing elements remaining in the component for the production of box-shaped structures with high structural strength.
  • metallic coatings or layers, and fire-resistant reinforcement of combustion chamber walls are further examples of the various problem-solving options offered by composite materials using the new process and in particular the simultaneous filling of a mold cavity with melts from different materials.
  • the latter also offers particular advantages in the production of components with particular local stress.
  • the distribution of several filling chambers over larger areas allows the production of particularly large shapes for correspondingly larger components or for the production of several parts at the same time.
  • the subdivision of the filling chamber into the melting and pressing chamber enables the use of different materials for these different functional areas, for example ceramics or cermets for the melting chamber and hot-work steel for the pressing chamber.
  • ceramics or cermets for the melting chamber and hot-work steel for the pressing chamber.
  • highly refractory, electrically non-conductive materials for the melting chamber wall when using induction heating advantages.
  • the proposed complete closing of the mold immediately before the build-up of a higher pressure, as proposed at the end of the mold filling, also allows a free extraction for the gases which are present in the mold cavity or in contact with the melt with the mold wall size during the mold filling. These can escape before the melt flowing in compactly, so that the extremely disadvantageous gas inclusions in the component structure which occur in known, similar processes are prevented.
  • the required enlargement of the mold space can be achieved, for example, by an elastic bulge which can be regulated via the mold wall thickness, caused by pressure increase in the filling material and limited by pressure elements which then also provide the provision.
  • the pressure elements can also take on a cooling function and implement a solidification control by suitable timing of the activation.
  • the melt located in the narrowing feed channels is moved. This can also be achieved with the help of the pressure elements in cooperation with the plunger by using pulsating pressure at a suitable frequency.
  • the charging bodies with the aid of a feed device and the plunger - in the case of multiple melting chambers also directly - transported into the melting chambers, which had previously been flushed with protective gas together with the press chambers and the mold cavity.
  • the plungers push the melt through the press chambers to fill the mold into the mold cavity. This is initially opened to the outside in the sense of an optimized mold filling without spraying and gas interlacing with sufficiently large ventilation channels or, depending on the particular component geometry, is not yet completely closed at the beginning and during the mold filling.
  • the gases located in the mold cavity or which additionally arise due to the melt coming into contact with the mold release agent can completely escape upward before the melt, which essentially flows in compactly from below, or can be suctioned off by applying negative pressure.
  • the mold can only be fully closed during mold filling, for example by lowering a bale part or completely retracting core slides, then these measures also improve mold ventilation and further increase the filling speed due to the additional displacement effect with short flow paths . Both increase the mold filling capacity of the melt in a special way, so that the feared cold running risk is eliminated.
  • the mold is then completely closed, which in the case of use of ventilation channels by covering them, for example with the aid of slides, which can also stop any melt emerging.
  • the plunger and other pressure elements installed in a suitable place in the mold walls, such as, for example, movable mold inserts, ejector pins or mold components a local elastic mold wall deformation to exert pressure, the cooling and solidifying component to compensate for the volume deficit caused by the solidification shrinkage under a corresponding pressing pressure.
  • the melt volume required for the compensation is kept ready at the respective points of contact of the melt with the pressure elements by the enlargement of the mold space set there at the end of the mold filling.
  • the pressure can be simultaneously from all pressure elements, for. B. jerky, exercised and maintained until the component completely solidifies.
  • a pressing pressure pulsating with a suitable frequency can also prove to be particularly advantageous for the sealing supply of the structure in complex-shaped components with larger wall thickness differences and material accumulations.
  • two pressure transmitters can correspond to one another over a suitable distance in such a way that melt is reversibly displaced within a feed channel connecting them during solidification, which significantly improves the feed conditions.
  • pressure transmitters can be used in conjunction with mold cooling, for example the swell sequence cooling according to DE-PS 26 46 060, which has been successfully used in the mold casting process, a significant reduction in cycle times being achievable.
  • the mold cavity is formed by an upper mold part 3 and a lower mold part 4.
  • the upper mold part 3 is fastened to a clamping plate 15 and is arranged such that it can be displaced in height by means of a locking device 10 in the form of a toggle lever.
  • the toggle lever is actuated via a hydraulic drive 16 which is attached to the machine frame 9b.
  • the lower mold part 4 is carried by the machine frame 9a and has 3 openings 5 on its underside, via which the liquefied material is pressed into the mold cavity 1.
  • Filling chambers 2 are connected to the openings 5, which pass through the machine frame 9 and form two regions, namely an upper pressing chamber 23 and a lower melting chamber 24.
  • a feed table 12 for feeding blanks 11 into the filling chambers 2.
  • the blanks 11 are introduced into the melting chamber 24 with the aid of plungers 7, each plunger 2 being assigned a plunger 7.
  • the plungers 7 are arranged on a plunger plate 18 which is displaced via a hydraulic drive 17 which is attached to the machine frame 9c.
  • the blanks 11 are, as shown in Fig. 1, pushed over the downward moving plunger and inserted into the melting chamber 24 via this. After the blanks have melted, the melt is moved upward into the press chamber 23 by means of the plunger 7, whereupon the latter can exit into the mold cavity 1. Because of the large cross sections of the openings 5, this insertion can take place without great turbulence and with a relatively low pressure.
  • the upper part of the mold is slightly lifted off from the lower part of the mold, so that the air in the mold cavity can escape through the gap between upper part 3 and lower part 4 of the mold.
  • the upper part 3 is sealingly lowered onto the lower part 4, whereupon the melt solidifies with the application of the high pressure, for example by the plunger 7.
  • the melting chamber 24 is advantageously heated by means of an induction heater 8, the hollow cylinder consisting of high-strength steel having to pass through both areas when the filling chamber 2 is formed as a pressing chamber and melting chamber.
  • the blank 11 or the charging bolt is melted in a low-pressure melting furnace 13, with the blanks 11 being a Feed pipe 21 are introduced into the furnace 13.
  • the feed pipe 21 is sealed by means of a seal 26 which is arranged between the blank 11 and the inner wall of the feed pipe 21.
  • the melt is pressed into the filling chamber 6 via an opening 20 via a riser pipe 14 which is provided with a level sensor 22.
  • the plunger 7 is moved upward, the opening 20 being closed, so that no further material can flow into the filling chamber 6.
  • the melt material 19 is then pressed through the openings 5 according to FIG. 1 into the mold cavity.
  • the melting and dosing device according to FIG. 2 is also particularly suitable for the production of particularly large components with increased material requirements.
  • the melt can be pressed out of the melting furnace 13 through the metering gap 20 and the filling chamber 6 into the mold cavity, in which case the plunger 7 merely ends the mold filling and takes over the make-up - if necessary in conjunction with further pressure elements in the mold wall. If several filling chambers 6 are used, these can be supplied with melt via branches or multiple arrangement of the filling tube 14.
  • This embodiment differs from that of FIG. 1 essentially in that the filling chamber 2 is formed in two parts and is divided into a separate press chamber 23 and melting chamber 24.
  • the melting chamber 24 can be moved relative to the pressing chamber 23, so that the blank 11 can be melted elsewhere, and the individual melting chambers can also be arranged in a carousel, for example. This is advantageous because this can significantly increase the performance of the casting device, because the melting time no longer extends the mold filling and solidification time for the production of the component.
  • the inner sleeve of the melting chamber 24 can also be produced from an insulating material which then does not necessarily have to withstand high compressive forces. This sleeve made of insulating material 27 is then surrounded by the induction heater 8.
  • the plunger 7 Since the plunger 7 is inserted into the movable melting chamber from below, either a displaceable base 28 must be inserted into the melting chamber, which prevents the melting material from escaping, or the heating device is arranged so that the lower region of the blank does not melt, so that the blank itself forms the bottom closure.
  • An insulating ring 29 is arranged to hinder the flow of heat from the melting chamber 24 into the plate 9a.
  • the upper mold part 3 is supported by a spring 33 with respect to the platen 15.
  • This spring has the effect that, on the one hand, the upper mold part rests with sufficient pressure on the lower mold part 4 during mold filling, but on the other hand the openings 31 are not yet closed by the slide 32. After the openings 31 have been closed and during solidification under high pressure, the clamping plate 15 lies with the slide plate 41 frictionally on the upper mold part 3, so that the upper mold part and lower mold part are then pressed against one another with the desired pressure.
  • the pressure maintained during the solidification process can be applied either by the plunger 7 or by a further plunger 30, whereby a reversible flow of the melt in the mold cavity 1 can also be obtained by the interaction of both pistons during the solidification process.
  • This embodiment differs from that according to FIG. 3 in that the charging material is introduced into the melting chamber 24 in a cup 35 made of refractory material and is melted therein. Following this, the cup, including all or part of the melted material, is pushed into the press chamber 23 by means of the press piston 7. The actual introduction of the melt material into the mold cavity 1 then takes place by means of a plunger 34 which dips into the cup from above, the melt being displaced from this and reaching the mold cavity 1 between the piston wall and the cup inner wall.
  • the exemplary embodiment according to FIG. 5 shows a wall section 36, for example of the upper or lower mold part, this wall section 36 being formed from a relatively thin material, so that it deforms during the filling process of the mold cavity 1.
  • a plunger 37 Arranged behind this flexible wall section 36 is a plunger 37 which, for example, can be provided with bores 38 for a coolant or heating medium. During the solidification process the plunger 37 is pressed against the flexible wall section 36, so that the pressure in the material can be maintained even during the solidification process.
  • the embodiment according to FIG. 6 likewise shows a flexible wall section 36, behind which a pressure chamber 39 is arranged.
  • This wall section can likewise be deformed away from the mold space - to enlarge it - during the mold filling, this deformation then being reversed again during the solidification process due to a pressure medium introduced through a pipe 40, whereby a deformation of the wall section 36 towards the molding space is likewise obtained can.
  • This enlargement of the mold space at the component areas suitable for this at the end of the mold filling and the corresponding reductions during solidification by the device examples according to FIGS. 3, 5 and 6 compensate for the volume deficit in the component caused by the solidification shrinkage.
  • the pressure medium can also be used for cooling or heating the corresponding wall section 36.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • Forging (AREA)
  • Nonmetallic Welding Materials (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
EP92115545A 1991-10-01 1992-09-11 Procédé et dispositif pour la fabrication de pièces de construction Expired - Lifetime EP0535421B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4132732A DE4132732A1 (de) 1991-10-01 1991-10-01 Verfahren und vorrichtung zur erzeugung von bauteilen
DE4132732 1991-10-01

Publications (2)

Publication Number Publication Date
EP0535421A1 true EP0535421A1 (fr) 1993-04-07
EP0535421B1 EP0535421B1 (fr) 1997-03-12

Family

ID=6441939

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92115545A Expired - Lifetime EP0535421B1 (fr) 1991-10-01 1992-09-11 Procédé et dispositif pour la fabrication de pièces de construction

Country Status (4)

Country Link
EP (1) EP0535421B1 (fr)
AT (1) ATE149894T1 (fr)
DE (2) DE4132732A1 (fr)
ES (1) ES2099777T3 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1275451A2 (fr) * 2001-07-02 2003-01-15 Tetsuichi Motegi Machine pour la coulée de métaux
DE102004008157A1 (de) * 2004-02-12 2005-09-01 Klein, Friedrich, Prof. Dr. Dr. h.c. Gießmaschine zur Herstellung von Gussteilen
DE102007062436A1 (de) 2007-12-20 2009-07-02 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines Gussteils
WO2017070723A1 (fr) * 2015-10-27 2017-05-04 Platzer Christian Procédé et dispositif de production d'au moins une pièce moulée

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19950037C2 (de) * 1999-10-16 2001-12-13 Drm Druckgus Gmbh Verfahren und Vorrichtung zum Urformen eines Werkstoffes
DE10012787B4 (de) * 2000-03-16 2008-04-10 Volkswagen Ag Verfahren zur Herstellung von Leichtmetallgussteilen mit eingegossenen Buchsen
DE10043717A1 (de) * 2000-09-04 2002-03-14 Buehler Druckguss Ag Uzwil Verfahren und Vorrichtung zum Druckumformen von metallischen Werkstoffen
DE10047735A1 (de) * 2000-09-27 2002-04-11 Rauch Fertigungstech Gmbh Verfahren zum Druckgiessen und Füllbüchse hierfür sowie Druckgiessmaschine
DE10256834A1 (de) * 2002-12-04 2004-07-08 Drm Druckguss Gmbh Verfahren und Vorrichtung zur Herstellung großflächiger Werkstücke im Druckgießverfahren
DE102016107572B3 (de) 2016-04-22 2017-05-18 Stefan Argirov Vorrichtung zur Herstellung von Gussteilen, wie Alumiumguss, im Niederdruckgießverfahren

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2128425A1 (de) * 1970-08-21 1973-01-04 Friedhelm Dipl Ing Kahn Giessverfahren mit druckanwendung und einrichtung zur durchfuehrung des verfahrens
DE2646060A1 (de) * 1976-10-13 1978-04-20 Friedhelm Prof Dr Ing Kahn Verfahren und vorrichtungen zur steuerung des waermehaushalts von giessformen
DE3023917C2 (de) * 1979-07-26 1984-02-23 Ube Industries, Ltd., Ube, Yamaguchi Vorrichtung zum Zuführen der Schmelze von unten in eine Vertikal-Kaltkammer-Druckgießmaschine
US4436140A (en) * 1979-01-26 1984-03-13 Honda Giken Kogyo Kabushiki Kaisha Method of charging molten metal into a vertical die casting machine

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2128425A1 (de) * 1970-08-21 1973-01-04 Friedhelm Dipl Ing Kahn Giessverfahren mit druckanwendung und einrichtung zur durchfuehrung des verfahrens
DE2646060A1 (de) * 1976-10-13 1978-04-20 Friedhelm Prof Dr Ing Kahn Verfahren und vorrichtungen zur steuerung des waermehaushalts von giessformen
US4436140A (en) * 1979-01-26 1984-03-13 Honda Giken Kogyo Kabushiki Kaisha Method of charging molten metal into a vertical die casting machine
DE3023917C2 (de) * 1979-07-26 1984-02-23 Ube Industries, Ltd., Ube, Yamaguchi Vorrichtung zum Zuführen der Schmelze von unten in eine Vertikal-Kaltkammer-Druckgießmaschine

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1275451A2 (fr) * 2001-07-02 2003-01-15 Tetsuichi Motegi Machine pour la coulée de métaux
EP1275451A3 (fr) * 2001-07-02 2003-12-03 Tetsuichi Motegi Machine pour la coulée de métaux
US6923244B2 (en) 2001-07-02 2005-08-02 Tetsuichi Motegi Pouring apparatus for castings
AU784737B2 (en) * 2001-07-02 2006-06-08 Kiichi Miyazaki Pouring apparatus for castings
DE102004008157A1 (de) * 2004-02-12 2005-09-01 Klein, Friedrich, Prof. Dr. Dr. h.c. Gießmaschine zur Herstellung von Gussteilen
DE102007062436A1 (de) 2007-12-20 2009-07-02 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines Gussteils
DE102007062436B4 (de) * 2007-12-20 2010-11-11 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines Gussteils
WO2017070723A1 (fr) * 2015-10-27 2017-05-04 Platzer Christian Procédé et dispositif de production d'au moins une pièce moulée

Also Published As

Publication number Publication date
ATE149894T1 (de) 1997-03-15
DE4132732A1 (de) 1993-04-08
ES2099777T3 (es) 1997-06-01
DE59208164D1 (de) 1997-04-17
EP0535421B1 (fr) 1997-03-12

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