EP0691165A2 - Verfahren und Vorrichtung zur Herstellung eines Gusteiles - Google Patents

Verfahren und Vorrichtung zur Herstellung eines Gusteiles Download PDF

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Publication number
EP0691165A2
EP0691165A2 EP95110408A EP95110408A EP0691165A2 EP 0691165 A2 EP0691165 A2 EP 0691165A2 EP 95110408 A EP95110408 A EP 95110408A EP 95110408 A EP95110408 A EP 95110408A EP 0691165 A2 EP0691165 A2 EP 0691165A2
Authority
EP
European Patent Office
Prior art keywords
thermoplastic resin
mold
molten metal
core
cast
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.)
Withdrawn
Application number
EP95110408A
Other languages
English (en)
French (fr)
Other versions
EP0691165A3 (de
Inventor
Masamichi Okada
Yuji Okada
Hirokazu Shirakawa
Shuichi Tomitaka
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.)
Toyota Motor Corp
Original Assignee
Toyota Motor Corp
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 Toyota Motor Corp filed Critical Toyota Motor Corp
Publication of EP0691165A2 publication Critical patent/EP0691165A2/de
Publication of EP0691165A3 publication Critical patent/EP0691165A3/de
Withdrawn legal-status Critical Current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
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores

Definitions

  • the present invention relates to a method and apparatus for producing a cast metal product using a mold or core made from a synthetic resin.
  • metal molds or cores and sand molds or cores are frequently used.
  • metal molds many products can be produced using only one set of metal molds until the molds at last cause serious abrasion or damage.
  • sand molds a set of sand molds is prepared for each product and is destroyed thereafter.
  • An object of the present invention is to provide a method and apparatus for producing a cast product wherein a mold or core cost is less than in the case of a metal mold or core, and product quality is improved compared with the case of a sand mold or core.
  • a first embodiment of the present invention relates to an apparatus for producing a cast metal product having a mold made from a synthetic resin.
  • a second embodiment of the present invention relates to a method for producing a cast metal product using a mold made from a synthetic resin.
  • a third embodiment of the present invention relates to an apparatus for producing a cast metal product, the apparatus having a core made from a synthetic resin.
  • FIG. 1 structures or methods common to all of the embodiments of the present invention will be explained with reference to FIG. 1 and, where appropriate, FIGS. 2 and 3.
  • An apparatus for producing a cast metal product 4 includes a mold 1 (or core 1') which is made from a synthetic resin.
  • the synthetic resin mold 1 (or core 1') has a molding cavity 2 therein.
  • the mold 1 (or core 1') may comprise a set of molds (or cores).
  • Molten metal for example, molten aluminum alloy
  • the molten metal is supplied to the molding cavity 2 at a pressure which may be higher than 80 MPa or lower.
  • the molten metal is then cooled and solidified to form a cast metal product 4.
  • the mold 1 (or core 1') is heated so that it melts or softens.
  • the resin constituting the mold 1 (or core 1') is thereby removed or separated from the cast metal product 4 and may be retrieved to be recycled.
  • the resin melts the resin will be automatically removed, and when the resin softens, the resin may be mechanically removed using a suitable tool.
  • the thermal characteristics of the synthetic resin used to make the mold 1 (or core 1') and its relationship with the thermal characteristics of the molten metal 3 are illustrated in FIG. 1. If the molten metal 3 is an aluminum alloy, a temperature of the molten metal 3 is at about 700°C during a molten metal feeding time period, from time t1 (initiation of feeding) to time t2 (completion of feeding). The temperature then decreases to about 550°C in about 30 seconds to 3 minutes, after which the molten metal 3 is completely solidified.
  • the temperature of the mold 1 or (core 1') increases due to heat transfer from the molten metal 3
  • the temperature of the mold 1 or (core 1') does not reach a temperature (about 200°C) at which the synthetic resin begins to soften before time t3 when the molten metal completely solidifies.
  • the molten metal 3 completes its solidification while the mold 1 (or core 1') is substantially solid.
  • the mold 1 (or core 1') does not cause deformation in the cast product 4 even if the mold 1 (or core 1') experiences a high pressure from the molten metal 3.
  • a cast metal product 4 with high dimensional accuracy can therefor be produced.
  • the mold 1 (or core 1') continues to rise in temperature, either receiving residual heat from the cast metal product or being directly heated.
  • the mold 1 (or core 1') begins to soften at an initial softening point of the synthetic resin (about 200°C).
  • the softening point means a temperature at which an elastic rate of resin of 100 - 10 ⁇ 5 GPa is obtained.
  • the temperature of mold 1 (or core 1') continues to rise to about 250°C , at which the resin of the mold 1 (or core 1') is melted or sufficiently softened.
  • the resin in the case of a crystal-type resin (for example, polypropylene), the resin will be melted at about 250°C because it has a melting point, while in the case of a non-crystal-type resin (for example, polycarbonate), the resin will soften at about 250°C because it does not have a melting point.
  • a crystal-type resin for example, polypropylene
  • a non-crystal-type resin for example, polycarbonate
  • the mold 1 (or core 1') may be heated in a furnace 8 together with the cast product 4 to a temperature above about 250°C (see FIG. 3).
  • the mold 1 (or core 1') is removed or separated from the cast metal product 4 by melting or softening the mold 1 (or core 1').
  • the removed synthetic resin may be recycled to, for example, manufacture another mold 1 (or core 1').
  • Synthetic resins which have the above-described thermal characteristics include thermoplastic resins such as polycarbonate, polypropylene, and copolymers of propylene and ethylene.
  • the apparatus for producing a cast metal product 4 includes a mold 1 made from a thermoplastic resin.
  • the mold 1 can be melted or softened by heat from molten metal 3 within the mold 1 or by the furnace 8 after the molten metal 3 solidifies so that the resin of the mold 1 (or core 1') can be removed from the cast product 4.
  • An interior surface of the mold 1 defines a molding cavity 2 and defines the cast product 4 with high dimensional accuracy when the molten metal 3 solidifies.
  • the mold 1 includes an opening 5, through which molten metal 3 is poured into the molding cavity 2.
  • the mold 1 itself can be manufactured using a metal mold (not shown) to cast the mold 1 and is manufactured per each cast product 4.
  • One mold 1 casts only one cast metal product 4.
  • a casting apparatus includes a mold 1 made from a suitable thermoplastic resin, a mold conveyor 6 for sequentially conveying a plurality of molds 1 in series, a molten metal (for example, molten aluminum alloy) supply device 7 for supplying metal to the molding cavity 2, and a furnace 8 for heating and melting or softening the mold 1.
  • the furnace 8 is located downstream of the molten metal supply device 7 on the conveyor line.
  • the casting method according to the second embodiment of the present invention conducted using the apparatus described above includes the steps of conveying a mold 1 to the molten metal supply device 7, supplying molten metal 3 to a molding cavity 2 of the mold 1 to form a cast metal product 4, and thereafter heating and melting or softening the mold 1 in the furnace 8 so that the melted or softened resin is removed or separated from the cast metal product 4 after the molten metal 3 solidifies.
  • the removed synthetic resin 3 may be retrieved and can be recycled as material to make another mold.
  • FIG. 3 shows that the molten metal supply device 7 is a pan or ladle 7A
  • the molten metal supply device 7 is not limited to a pan 7A. More particularly, the molten metal supply device 7 may be a cylinder 7B for injecting molten metal into a molding cavity 2, as shown in FIG. 4, or it may be a vacuum pump 7C for suctioning molten metal from a molten metal holding furnace 9 through a stalk 10 to a molding cavity 2, as shown in FIG. 5.
  • a casting apparatus in accordance with the third embodiment includes a set of dies 11 and at least one core 1' (for example, one set of cores 1') which is detachably mounted relative to the dies 11.
  • core 1' for example, one set of cores 1'
  • ejecting springs 12 are provided in order to easily detach the cores 1' from the metal dies 11.
  • a molding cavity 2 is not defined by the dies 11 but by the cores 1'. Due to this structure, when the type of cast products 4 to be made is changed, only cores 1' needs to be changed.
  • molten metal 3 is introduced into the molding cavity 2. After the molten metal 3 solidifies, the dies 11 are separated so that the core 1' with the cast product 4 is ejected from the dies 11 by the springs 12. Then, the core 1' with the cast metal product 4 is heated so that the core 1' is melted or softened. The melted or softened resin of the core 1' is thereby separated from the cast metal product 4. The melted synthetic resin may be retrieved to be recycled.
  • a subsequent core 1' is disposed in the main dies 11, and a casting process is conducted in the same manner as described above.
  • the product 4 being cast is changed, only the core 1' is changed without needing to change the main dies 11.
  • the following advantages are obtained: With the casting apparatus having a resin mold, production costs are reduced compared to using a metal mold and casting quality is improved compared to using a sand mold.
  • the production costs are reduced compared with a metal core and casting quality is improved compared with a sand core.
  • the resin core mold is detachable from the main dies, only the resin core needs to be changed when the kind of the cast product is changed, which facilitates casting.
  • the resinous mold (1) or core (1') is heated after the molten metal for making the cast metal product (4) solidifies so that the resin of the mold (1) or core (1') is melted or softened and is separated from the cast metal product (4).
  • the removed resin may be retrieved and recycled, for example, as material for another resinous mold or core.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)
EP95110408A 1994-07-05 1995-07-04 Verfahren und Vorrichtung zur Herstellung eines Gusteiles Withdrawn EP0691165A3 (de)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP15336694 1994-07-05
JP153366/94 1994-07-05
JP160271/95 1995-06-27
JP16027195A JPH0871690A (ja) 1994-07-05 1995-06-27 樹脂鋳型およびそれを用いた鋳造方法

Publications (2)

Publication Number Publication Date
EP0691165A2 true EP0691165A2 (de) 1996-01-10
EP0691165A3 EP0691165A3 (de) 1998-03-18

Family

ID=26482009

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95110408A Withdrawn EP0691165A3 (de) 1994-07-05 1995-07-04 Verfahren und Vorrichtung zur Herstellung eines Gusteiles

Country Status (2)

Country Link
EP (1) EP0691165A3 (de)
JP (1) JPH0871690A (de)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS522684B2 (de) * 1973-03-16 1977-01-24
GB2269771B (en) * 1992-07-30 1996-05-22 Masaru Nemoto Method of moulding articles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None

Also Published As

Publication number Publication date
EP0691165A3 (de) 1998-03-18
JPH0871690A (ja) 1996-03-19

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