EP1303373B1 - Procede et appareil destines a faciliter le retrait de moules en sable a partir de pieces coulees - Google Patents

Procede et appareil destines a faciliter le retrait de moules en sable a partir de pieces coulees Download PDF

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Publication number
EP1303373B1
EP1303373B1 EP01939335A EP01939335A EP1303373B1 EP 1303373 B1 EP1303373 B1 EP 1303373B1 EP 01939335 A EP01939335 A EP 01939335A EP 01939335 A EP01939335 A EP 01939335A EP 1303373 B1 EP1303373 B1 EP 1303373B1
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EP
European Patent Office
Prior art keywords
mold
casting
sand
energy
castings
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 - Lifetime
Application number
EP01939335A
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German (de)
English (en)
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EP1303373A1 (fr
Inventor
Scott P. Crafton
Paul M. Crafton
Volker R. Knobloch
James L. Lewis, Jr.
Ian French
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Consolidated Engineering Co Inc
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Consolidated Engineering Co Inc
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Filing date
Publication date
Priority claimed from US09/852,256 external-priority patent/US6622775B2/en
Application filed by Consolidated Engineering Co Inc filed Critical Consolidated Engineering Co Inc
Priority to EP05008776A priority Critical patent/EP1563930A1/fr
Publication of EP1303373A1 publication Critical patent/EP1303373A1/fr
Application granted granted Critical
Publication of EP1303373B1 publication Critical patent/EP1303373B1/fr
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    • 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
    • B22D29/003—Removing cores using heat
    • 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
    • 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
    • B22D29/006—Removing cores by abrasive, water or air blasting
    • 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
    • B22D29/007—Removing cores by using explosive shock waves

Definitions

  • the present invention relates generally to the manufacturing of metal castings and more particularly to manufacturing castings within sand mold packs.
  • a traditional casting process for forming metal castings generally employs a mold or die, such as a permanent, metal die or a sand mold, having the exterior features of a desired casting, such as a cylinder head, formed on its interior surfaces.
  • a sand core comprised of sand and a suitable binder material and defining the interior features of the casting is typically placed within the die to further define the features of the casting.
  • Sand cores generally are used to produce contours and interior features within the metal castings, and the removal and reclaiming of the sand materials of the cores from the castings after the casting process is completed is a necessity.
  • the binder for the sand core and/or sand mold may comprise a phenolic resin binder, a phenolic urethane "cold box” binder, or other suitable organic binder material.
  • the die or mold is then filled with a molten metallic alloy, which is allowed to cool to a certain, desired degree to cause the alloy to solidify.
  • the casting is then moved to a treatment furnace or furnaces for further processing, including heat-treating, reclamation of the sand from the sand cores, and aging.
  • Heat treating and aging are processes that condition metallic alloys so that they will be provided with different physical characteristics suited for different applications. Heat treating may include processing and/or thermal processing.
  • Sand molds and/or cores generally are removed from the casting prior to completion of heat treatment.
  • the sand molds and/or cores are typically separated from their castings by one or a combination of means. For example, sand may be chiseled away from the casting or the casting may be physically shaken or vibrated to break-up the sand molds and internal sand cores within the castings and remove the sand.
  • the organic or thermally degradable binder for the sand molds and cores generally is broken down or combusted by exposure to the high temperatures for heat treating the castings to a desired metal properties so that the sand from the molds and cores can be removed from the castings and reclaimed, leaving the finished, heat-treated castings.
  • Such furnace systems and methods of heat treating castings are found in U.S. Patent Nos. 5,957,188, 5,829,509, and 5,439,045.
  • the present invention comprises a method and system for enhancing the removal of sand molds from castings formed within sand molds.
  • the sand molds may be removed from the castings by scoring the molds and applying a force sufficient to cause the mold to fracture and break into pieces.
  • the molds may be fractured by thermal expansion of the castings being heated therein by the application of radiant energy or inductive energy to the molds, or by other applications of force and/or energy.
  • a high-pressure fluid may be directed at the exterior walls of the mold to further aid in breaking down the mold.
  • the castings may be heat treated while the pieces of the sand molds are heated to a temperature sufficient to cause the binder materials thereof to combust for breakdown and reclamation of sand from the molds and cores.
  • the present invention generally comprises a method for enhancing the breakdown and removal of a sand mold from a casting formed within the mold to speed up the exposure of the casting to heat treatment temperatures and enhance the breakdown and reclamation of sand from the sand molds.
  • the mold may be removed from around its casting either prior to the introduction of the sand mold and casting into a heat treatment furnace or unit, or within the heat treatment furnace or unit itself for heat treatment and sand reclamation within the unit.
  • An example heat treatment furnace system for heat treatment of castings and at least partial breakdown and removal of sand molds and sand cores and reclamation of sand is shown in U.S. Patent Nos. 5,294,994, 5,565,046, 5,738,162, and 5,957,188 and U.S. Patent Application Serial No. 09/313,111, filed July 27,2000.
  • the method of dislodging a mold from a casting can include scoring the sand mold.
  • the scored mold is typically a "precision sand mold" generally comprised of a foundry sand material and a phenolic resin, phenolic urethane, or other suitable organic binder that generally decompose and/or combust when exposed to heat treatment temperatures for treating most castings, as is conventionally known.
  • the sand molds can also include semi-permanent type molds formed from a combination of standard binder materials and a metal such as steel. The mold typically fractures and breaks along the score lines set into the mold as the binder material combusts to facilitate the dislodging and removal of the mod from the casting contained therein.
  • the score lines generally are placed at predetermined locations along or about the sides and/or top and bottom of each mold, with these locations generally selected to be optimal for breaking down the mold. The placing of the score lines in such predetermined locations is dependent upon the shape of the mold and the casting formed within the mold.
  • scoring can include any type of cut, line, scratch, indentation, groove or other such markings made into the top, bottom and/or side walls of the mold by any mechanism including cutting blades, milling devices and other, similar automatically and/or manually operated cutting or grooving devices.
  • the scoring generally may take place on the exterior of the mold, but is not limited only to the exterior surfaces of the mold, and it will be understood that the interior surfaces of the mold also can be scored or grooved, in addition to or alternatively of the scoring of the exterior surfaces.
  • Each mold may be scored by any conventional means such as by molded or scratched lines placed or formed on the exterior and/or interior surfaces of the mold during formation of the mold, or at some point thereafter, up to the introduction of the mold, with a casting therein, into a heat treatment furnace.
  • a force may further be applied to the mold to enhance the fracture and breaking of the mold into various pieces, which can then be easily dislodged or dropped away from the casting.
  • a force may be applied to the inner walls of the mold, to the outer walls of the mold or a combination of the two.
  • the force applied to the inner walls of the mold typically results from the thermal expansion of the casting within the mold, with the expansion of the casting further being enhanced or accelerated by heating the casting using radiant energy, inductive energy or a combination thereof.
  • the energy sources used to heat the casting may include electromagnetic energy, lasers, radio waves, microwaves and combinations thereof.
  • the energy sources used to heat the mold and/or casting may also include lasers, radio waves, microwaves, or other forms of electromagnetic energy and/or combinations thereof. In general, these and other energy sources are radiated toward the exterior or directed to specific areas of the mold or casting for the purpose of heating the mold and casting to cause thermal expansion leading to mold and/or core sand fracture or breakdown.
  • inductive energy involves enveloping the casting and mold in a field of electromagnetic energy which induces a current within the casting leading to the heating of the metal, and to a lesser degree, the mold.
  • inductive energy generally offers some limited heating effect directly within the mold, but not to the degree of the heat generated within the casting.
  • score lines can be added to the mold or by the mold itself to aid in the dislodging of the mold from the casting or mold in conjunction with the application of force thereto.
  • Pulsations of energy also may be applied within specially designed process chambers such as for example a furnace.
  • Design features may include the capability of withstanding pulsations and resultant effects, provide for the transportation of mold/casting into and out of the chamber to provide precise control of the pulsation.
  • the energy pulsations generally enhance to some degree heat transfer to the mold cores and castings.
  • the pulsations also promote mass transport of decomposed binder gases out of the mold and cores, oxygen bearing process gas to the mold and cores, and loosens sand out of the casting.
  • the pulsations may occur at both low or high frequencies, where low frequency pulsations would generally be utilized to generate a force for fracturing the mold or cores and the higher frequencies would be employed to enhance the transfer, mass transport and some fracturing on a smaller scale. Higher frequency pulsations induce vibration effects to some degree within the casting to promote the mechanical effects of the above process.
  • the mold and/or cores may be broken down by the application of any or all of these energy sources to the mold and/or cores to promote the decomposition of the organic or thermally chemical binder of the sand mold and/or core, which binder breaks down in the presence of heat thus facilitating the degradation of the mold.
  • the mold may be broken down by the application of a high pressure fluid(s) such as air, products of combustion, oxygen enriched gases or other fluid materials to the exterior walls of the mold.
  • a direct application of force in the form of shock waves, pressure waves, acoustical waves, or a combination thereof can be applied to the mold, cores, or casting to aid in fracturing and breaking the mold into pieces.
  • the present invention envisions several alternative embodiments and/or methods for performing this function of dislodging or breaking up the sand molds prior to or during heat treatment of the castings. It will also be understood that any of the described methods can be used in conjunction with or separately from one another. These various methods are illustrated in Figs. 1A through 3B.
  • a sand mold 10 with a casting 11 therein is shown with at least one, and typically multiple, score lines 12 or relief lines formed in the exterior side walls 13 of the mold 10.
  • the score/relief lines 12 typically will be cut or otherwise formed as grooves or notches in the exterior side walls of the mold and act as break lines for the exterior walls of the mold pack. It is also possible to cut or form the score/relief lines 12A in the interior walls 14 of the mold as shown in Fig. 1A and/or in the top and bottom walls 16 and 17 of the mold 10.
  • these score/relief lines weaken the mold walls so as to predetermine the locations and positions of the fracture or breaking apart of the mold 10, such that as a force F is applied to the walls of the mold, walls of the mold are caused to crack and break apart along these score/relief lines as illustrated at 18 in Fig. 1B.
  • this force F includes the exertion of pressure against the interior walls 14 of the mold 10 by the castings themselves due to the thermal expansion of the metal of the castings as they are subjected to heating or elevated temperatures for heat treating the castings.
  • a series of nozzle stations 42 generally are positioned at specific locations or positions along the path of travel of the mold/core laden casting into or within a heat treatment furnace, either as a part of the heat treatment furnace, such as in an initial or prechamber, or placed in front of or prior to the heat treatment fiunaces, to aid in the removal of the sand core from the castings.
  • the number of nozzle stations can vary as needed, depending upon the core print or design of the casting being formed in the mold.
  • Each of the nozzle stations or assemblies 42 generally includes a series of nozzles 43 mounted and oriented at known or registered positions about the side walls, top or upper walls and/or lower or bottom walls of the molds 50 corresponding to known, indexed positions of the cores and castings 51.
  • the number of nozzles in each nozzle station is variable, depending upon the core prints of the castings, such that different types of castings having differing core prints can utilize an optionally different arrangement or number of nozzles per nozzle station.
  • the nozzles also may be automatically controlled through a control system for the heat treatment station or furnace that can be operated remotely to cause the nozzles to move to various desired positions about the side walls and top and bottom walls and of the mold as indicated by arrows 48 and 48' and 49 and 49' in Figs. 2A and 2B.
  • Each of the nozzles is typically supplied with a high-pressure heated media.
  • the high-pressure media may include air, thermal oils, water or other known fluid materials that are directed at the side walls, top wall and/or bottom wall of each mold/core under high pressure, typically in the range of 0,344 bar to 3,102 bar (5 psig to 45 psig), although greater or lesser pressures also can be used as required for the particular casting application.
  • These fluid pressures are converted to high fluid velocities at the nozzle exit which delivers the energy of the fluid to the mold/bore and applies forces sufficient to at least partially fracture and/or otherwise degrade the mold and/or cores.
  • High fluid velocities typically cause or promote higher heat transfer to the casting, mold, and cores which has added benefit in breaking down mold and core sands.
  • the pressurized fluid flows which are administered by the nozzles, can be applied in continuous flows or as intermittent blasts that impact or contact the mold walls to cause the mold walls to fracture or crack and can promote more rapid decomposition and/or combustion of the binder materials of the sand molds to help at least partially degrade or break down the mold.
  • Figs. 3A-3B illustrate still a further alternative embodiment of the present invention for enhancing the breakdown and removal of molds 90 from castings 91 contained therein.
  • the oxygen chamber generally is an elongated autoclave or similar pressurized heating chamber capable of operating under higher than ambient pressures.
  • the oxygen chamber 93 is provided with an enriched oxygenated environment and includes a high pressure upstream side 94 and a low pressure downstream side 96 that are positioned opposite each other to assist in drawing an oxygen flow therebetween.
  • heated oxygen gas is directed at and is forced through the molds, as indicated by arrows 97 (Fig. 3A) and 97' (Fig. 3B).
  • the oxygen gas is drawn or flows under pressure from the high atmospheric pressure side to the low atmospheric pressure side of the oxygen chamber, so that the oxygen gas is urged or forced into and possibly through the molds and/or cores.
  • a percentage of the oxygen gas is combusted with the binder materials of the sand molds/cores, so as to enhance the combustion of the binder material within the heating chamber.
  • This enhanced combustion of the binder materials of the molds and cores are further supplied with energy from the enhanced combustion of the binder material thereof and the oxygen, which helps enhance and/or speed up the breakdown and removal of the molds from their castings.
  • This breakdown of the molds can be further assisted by scoring or forming relief lines in the molds, as discussed in greater detail above, so as to pre-stress/weaken the molds so that as the binder materials are combusted, the mold walls will tend to crack or fracture so that the molds will break and fall away from their castings in sections or pieces.
  • the enhanced combustion of the binder materials further serves as an additional, generally conductive heat source to thus increase the temperature of the castings in the mold packs and facilitate combustion of the binder materials of the sand cores for ease of removal and reclamation.
  • the castings are raised to their heat treatment temperatures more rapidly, which helps reduce the residence time of the castings in the heat treatment furnace that is required to properly and completely heat treat the castings, as discussed in copending U.S. Patent Application serial No. 09/627,109, filed July 27, 2000.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)
  • Silicates, Zeolites, And Molecular Sieves (AREA)
  • Nitrogen Condensed Heterocyclic Rings (AREA)
  • Fats And Perfumes (AREA)

Claims (16)

  1. Procédé de démoulage d'un moule (10, 50, 90) d'une pièce coulée (11, 51, 91) ayant été coulée dans celui-ci, comprenant:
    rainurage du moule (10, 50, 90) pour fragiliser le moule (10, 50, 90);
    application d'une force suffisant à casser et fractionner le moule (10, 50, 90); et
    démoulage des pièces du moule (10, 50, 90) de la pièce coulée (11, 51, 91).
  2. Procédé selon la revendication 1, dans lequel le moule (10, 50, 90) est rainuré grâce à la réalisation de lignes de rainurage (12) sur les parois extérieures (13) du moule (10, 50, 90).
  3. Procédé selon la revendication 2, dans lequel les lignes de rainurage sont positionnées à des endroits prédéterminés pour casser et démouler des parties du moule (10, 50, 90) de la pièce coulée (11, 51, 91).
  4. Procédé selon la revendication 1, dans lequel la force suffisant à amenant le moule (10, 50, 90) à s'éclater inclut l'expansion thermique de la pièce coulée (11, 51, 91) contre le moule (10, 50, 90).
  5. Procédé selon la revendication 4, dans lequel la pièce coulée (11, 51, 91) se dilate par suite du réchauffement du moule (11, 51, 91).
  6. Procédé selon la revendication 5, dans lequel la pièce coulée (11, 51, 91) est réchauffée par une source d'énergie choisie dans le groupe formé par l'énergie radiante, l'énergie inductive et des combinaisons de celles-ci.
  7. Procédé selon la revendication 6, dans lequel la source d'énergie est choisie dans le groupe formé par l'énergie électromagnétique, les lasers, les ondes radioélectriques, les micro-ondes et des combinaisons de celles-ci.
  8. Procédé selon la revendication 1, dans lequel le moule (10, 50, 90) est formé par du sable et un liant dégradable qui est incinéré lors du réchauffement du moule (10, 50, 90) sous des pressions élevées dans une atmosphère d'oxygène enrichie pour faciliter la casse du moule (10, 50, 90).
  9. Procédé selon la revendication 1, dans lequel les pièces du moule (10, 50, 90) sont démoulées de la pièce coulée (11, 51, 91) avant le traitement thermique de la pièce coulée (11, 51, 91).
  10. Procédé selon la revendication 1, dans lequel la force suffisant à amener le moule (10, 50, 90) à s'éclater inclut la direction d'un fluide haute pression sur les parois extérieures du moule (10, 50, 90).
  11. Procédé selon la revendication 10, dans lequel le fluide haute pression comprend de l'air réchauffé, des huiles thermiques ou de l'eau.
  12. Procédé selon la revendication 10, dans lequel le démoulage des pièces du moule (10, 50, 90) comprend le réchauffage de la pièce moulée (11, 51, 91) pour faire dilater celle-ci (11, 51, 91) à l'intérieur du moule (10, 50, 90).
  13. Procédé selon la revendication 12, dans lequel le réchauffement de la pièce coulée (11, 51, 91) comprend la direction d'énergie à travers le moule (10, 50, 90) sur la pièce coulée (11, 51, 91) grâce à une source d'énergie choisie dans le groupe formé par l'énergie radiante, l'énergie inductive et des combinaisons de celles-ci.
  14. Procédé selon la revendication 13, dans lequel la source d'énergie est choisie dans le groupe formé par l'énergie électromagnétique, les lasers, les ondes radioélectriques, les micro-ondes et des combinaisons de celles-ci.
  15. Procédé selon la revendication 12, dans lequel le moule (10, 50, 90) est formé par du sable et un liant dégradable et le démoulage des pièces du moule (10, 50, 90) de la pièce coulée (11, 51, 91) comprend l'incinération du liant du moule (10, 50, 90) lors du réchauffement du moule (10, 50, 90) sous des pressions élevées dans une atmosphère d'oxygène enrichie pour faciliter le cassement du moule (10, 50, 90).
  16. Procédé selon la revendication 12, dans lequel les pièces du moule (10, 50, 90) sont démoulées de la pièce coulée (11, 51, 91) avant le traitement thermique de la pièce coulée (11, 51, 91).
EP01939335A 2000-07-27 2001-05-23 Procede et appareil destines a faciliter le retrait de moules en sable a partir de pieces coulees Expired - Lifetime EP1303373B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP05008776A EP1563930A1 (fr) 2000-07-27 2001-05-23 Procédé et appareil pour aider à la séparation d'un moule au sable et de la pièce de fonderie au sable qui y est coulée

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US627109 1984-07-02
US62710900A 2000-07-27 2000-07-27
US66535400A 2000-09-19 2000-09-19
US665354 2000-09-19
US852256 2001-05-09
US09/852,256 US6622775B2 (en) 2000-05-10 2001-05-09 Method and apparatus for assisting removal of sand moldings from castings
PCT/US2001/016686 WO2002094479A1 (fr) 2000-07-27 2001-05-23 Procede et appareil destines a faciliter le retrait de moules en sable a partir de pieces coulees

Related Child Applications (1)

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EP05008776A Division EP1563930A1 (fr) 2000-07-27 2001-05-23 Procédé et appareil pour aider à la séparation d'un moule au sable et de la pièce de fonderie au sable qui y est coulée

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Publication Number Publication Date
EP1303373A1 EP1303373A1 (fr) 2003-04-23
EP1303373B1 true EP1303373B1 (fr) 2005-08-03

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EP01939335A Expired - Lifetime EP1303373B1 (fr) 2000-07-27 2001-05-23 Procede et appareil destines a faciliter le retrait de moules en sable a partir de pieces coulees
EP05008776A Withdrawn EP1563930A1 (fr) 2000-07-27 2001-05-23 Procédé et appareil pour aider à la séparation d'un moule au sable et de la pièce de fonderie au sable qui y est coulée

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EP (2) EP1303373B1 (fr)
JP (1) JP4795624B2 (fr)
KR (1) KR100768604B1 (fr)
CN (2) CN1232371C (fr)
AT (1) ATE301017T1 (fr)
AU (1) AU2001264864B2 (fr)
CA (1) CA2422646C (fr)
DE (1) DE60112446T2 (fr)
HK (2) HK1057020A1 (fr)
MX (1) MXPA02007261A (fr)
WO (1) WO2002094479A1 (fr)

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CN104493143A (zh) * 2014-12-19 2015-04-08 中国南方航空工业(集团)有限公司 铸件的清砂方法
JP6863306B2 (ja) * 2018-01-31 2021-04-21 新東工業株式会社 鋳型ばらし方法及び鋳型ばらし装置
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Title
1988, ASM INTERNATIONAL *

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CN1666831A (zh) 2005-09-14
CN1437515A (zh) 2003-08-20
HK1080785A1 (en) 2006-05-04
CN1232371C (zh) 2005-12-21
AU2001264864B2 (en) 2005-10-27
KR20030036135A (ko) 2003-05-09
JP2004520174A (ja) 2004-07-08
DE60112446T2 (de) 2006-03-30
CA2422646A1 (fr) 2002-11-28
EP1563930A1 (fr) 2005-08-17
CA2422646C (fr) 2008-01-29
HK1057020A1 (en) 2004-03-12
KR100768604B1 (ko) 2007-10-18
MXPA02007261A (es) 2003-06-30
WO2002094479A1 (fr) 2002-11-28
CN1325207C (zh) 2007-07-11
EP1303373A1 (fr) 2003-04-23
ATE301017T1 (de) 2005-08-15
DE60112446D1 (de) 2005-09-08
JP4795624B2 (ja) 2011-10-19

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