EP1721688A1 - Noyaux de fonderie et procédé pour leur fabrication - Google Patents

Noyaux de fonderie et procédé pour leur fabrication Download PDF

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Publication number
EP1721688A1
EP1721688A1 EP05425320A EP05425320A EP1721688A1 EP 1721688 A1 EP1721688 A1 EP 1721688A1 EP 05425320 A EP05425320 A EP 05425320A EP 05425320 A EP05425320 A EP 05425320A EP 1721688 A1 EP1721688 A1 EP 1721688A1
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EP
European Patent Office
Prior art keywords
core
cores
foundry
binder
sand
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Withdrawn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
EP05425320A
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German (de)
English (en)
Inventor
Mario Borsato
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.)
Processi Innovativi Tecnologici Srl
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Processi Innovativi Tecnologici Srl
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.)
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Publication date
Application filed by Processi Innovativi Tecnologici Srl filed Critical Processi Innovativi Tecnologici Srl
Priority to EP05425320A priority Critical patent/EP1721688A1/fr
Publication of EP1721688A1 publication Critical patent/EP1721688A1/fr
Withdrawn legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • B22C9/106Vented or reinforced cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/06Core boxes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • B22C9/103Multipart cores

Definitions

  • the present invention relates to foundry cores and a method for manufacturing the same.
  • foundry sand The technology for casting weld metals in sand moulds (the so-called “foundry sand”) is widely known and used for manufacturing articles of various types and sizes, such as either motor or car transmission system components, hydraulic componentry, parts of machines of different types, etc. Many of these articles have either undercut elements or inside cavities requiring the use, inside the sand mould, of cores reproducing the voids of the piece to be manufactured.
  • cores are generally manufactured from sand and suitable binders, such as amino resins.
  • the cores generally comprise either projecting or oversized parts at the ends thereof providing the so-called "core prints", which allow the core to be supported in the proper position for casting, by resting on the sand mould in some points in which there is no interference with the piece mould.
  • both the sand mould and the sand core are eliminated by the mechanical action (vibrations, etc.), thus leaving the piece substantially clean.
  • the parts deriving from the process such as fins and casting gates, will have to be removed from the piece.
  • the fins are particularly a problem in complex-shape pieces, in which two or more half-cores require to be coupled with one another which reproduce the complexity of the piece voids, once assembled.
  • the assembly of these half-cores for providing a so-called core assembly is difficult and does not usually cause a snug fit, such that, during the casting step, the fin formation in the junction points is practically unavoidable.
  • the removal of the fins from the solidified piece requires expensive mechanical processing.
  • the first technique provides the formation of solid cores by pressing a mixture of sand and amino resins as binders.
  • the thus formed solid core is very heavy, especially with large size pieces, thus requiring large and bulky core prints to be manufactured, with a subsequent waste of material.
  • the amount of sand used further causes the costs to increase, particularly in terms of material handling. Since the mixture contains a certain amount of amino resins, a problem also exists which is connected with the release of the toxic gases in the environment which are emitted by these resins both during the formation of the core and the casting of the metal, and throughout the following cooling step.
  • a further disadvantage of the solid sand cores is the relative core rigidity, which does not allow to second the casting shrinkage during the cooling, with the possible formation of cracks in the metallic piece.
  • a further problem is connected with the difficulties in flogging, an operation that requires a considerable energy in order to crumble the core solid body.
  • This technique provides the manufacturing of a metal mould reproducing the impression either of a half-core or the whole core.
  • the metal mould is placed inside a core box either made of steel or cast iron and then brought at a high temperature (about 300-350°C, for example either by means of resistances or naked-flame heating).
  • a mixture of sand and amino resins which crosslink and embed the sand by binding the latter due to the high temperature of the metal mould surface, is blown against the metal mould surface.
  • the exceeding sand-resin mixture is drawn away (and thus recovered) and the core is extracted.
  • hollow cores are obtained characterized by a thin shell having a low weight but a non-uniform thickness, which is capable in any case of providing high-accuracy castings.
  • the thus manufactured core has a relatively high brittleness, which prevents the use thereof for large-sized pieces.
  • the problem at the heart of the present invention is to provide a foundry core which overcomes the above-mentioned drawbacks.
  • the foundry core according to the present invention which has been generally indicated with numeral 1, is hollow and consists of two half-cores 1a and 1b being coupled with each other.
  • the metallic casting the cavity of which is formed due to the core 1 has been indicated with 2.
  • the shape of the foundry core 1 is, in the drawing, merely exemplary and obviously depends on the cavity shape of the piece 13 which is intended to be manufactured.
  • the core 1 is provided with connecting portions 3a, 3b at the ends thereof, having a double-step profile. These connecting portions 3a, 3b are assembled by means of sealing elements 4a, 4b wrapping the latter. Both the half-cores 1a, 1b and the sealing elements 4a, 4b are provided in a mixture of sand and a suitable binder.
  • said binder will be an ammino resin of the type employed as a binder in foundry cores.
  • the amounts of binder will generally range between 2% and 10% by dry weight.
  • the coupling between the first half-core 1a and the second half-core 1b is carried out by means of a shape-coupling between two complementary step profiles.
  • an efficient seam seal is obtained, which minimizes the infiltration of the weld metal, while casting.
  • the weld metal infiltration would cause irreparable defects in casting.
  • the core 1 comprises a vent hole 5 located in at least one end, either for the leakage of steam or gas being generated by the binding resin while casting.
  • this vent hole 5 can be also omitted if the amount of binder is low.
  • the coupling between the first half-core 1a and the second half-core 1b can be conventionally carried out by bonding, by arranging a suitable adhesive layer either along the faying surface between the two half-cores or in suitable recesses situated on some contact points between the half-cores.
  • the adhesive will be of the type usually employed in these applications, such as a vinyl glue.
  • the sealing element 4a, 4b will be omitted.
  • connecting portions 3a, 3b being assembled with the sealing element 4a, 4b also function as core prints.
  • the cores 1 according to the invention can be prepared according to conventional methods which provide the use of core boxes consisting of two half-boxes into which the impression of the half-core 1a, 1b to be manufactured is inserted.
  • the mixture of sand and binder is blown under pressure in the boxes in the presence of suitable gaseous substances which trigger the resin crosslinking.
  • the half-core is thus removed from the core box and then coupled with a second half-core obtained in the same manner.
  • the assembly of the half-cores 1a, 1b is thus introduced into the same core box in which the sand will be blown for manufacturing the sealing element 4a, 4b.
  • this core box will comprise an impression reproducing the shape of the assembly of the half-cores 1a, 1b and sealing element 4a, 4b; therefore, in substance, the shape either of the whole core 1 or the core portion which is intended to be manufactured.
  • the cores 1 according to the invention may be manufactured by a method which provides the use of a core box as shown in Fig. 4.
  • the core box 8 consisting of two half-core boxes 8a, 8b, comprises both the impressions 9, 10 for the half-cores 1a, 1b (in the example from Fig. 1, 2, and 4, two half-cores) and the impression 11 for the final core 1, resulting from the coupling of the half-cores with the sealing element 4a, 4b (the sectional view only shows a sealing element 4a being located at one of the two ends of the core 1).
  • Suitable ducts 12', 12" , 12''' allow the introduction of the sand-binder mixture under pressure (the so-called "blowing"). Obviously, the duct or ducts for blowing the sealing element 4a, 4b will be set at the cavities being left empty after the half-cores 1a, 1b have been placed in the impression 11.
  • a preferred embodiment of the invention provides that said ducts 12', 12", 12"' end with suitable nozzles (not shown). Particularly, it is advantageous that the duct 12''' for blowing the sealing element ends with a nozzle.
  • a plurality of ducts 12 being provided with nozzles (not shown) along the profile of the cavity inside which the core is formed can be provided for complex pieces (see Fig. 8).
  • a suitable housing which can be seen from the drawing as a blind hole in the half-core 1a and a through hole in the half-core 1b) for a stiffening rod 14 in the half-cores 1a, 1b. Said stiffening rod 14 will be set upon introducing the half-cores 1a, 1b into the impression 11, before the blowing forming the finished core 1 has been carried out.
  • the method of the invention starts with the formation of the first two (or more, according to the cases) half-cores 1a, 1b by introducing the sand-binder mixture from their respective nozzles 12; 12', 12" . Then, the core box is open, the half-cores 1a, 1b are arranged in the proper position inside the impression 11 for the core 1, thus obviously leaving the space which will be taken by the sealing element 4a, 4b empty; the core box is then closed again.
  • the blowing of the sand-binder mixture will be carried out either simultaneously through all the nozzles 12, 12', 12" , 12"', or even only through one of them according to the cases, thus allowing the final core 1 and the half-cores 1a, 1b for the next core to be formed at the same time.
  • the thus obtained core 1 will be removed and the half-cores manufactured will be arranged inside the impression 11. The method will be thus repeated, and so on.
  • the processing time can be optimised, thus manufacturing with a single simultaneous blowing both the hollow core being assembled with the sealing element and the half-cores for the next manufacturing.
  • the two half-cores 1a, 1b (by way of example, they relate to the manufacturing of a pipeline cavity) comprise their respective connecting portions 3a, 3b being obtained with a step in the core thickness from the outer surface and with a raking riser, such that, after being coupled with each other, they make a groove running along the whole seam between the two half-cores 1a, 1b.
  • the mixture of sand and binder forming the sealing element 4a, 4b is blown in these grooves.
  • sealing element 4a, 4b besides providing a substantially monolithic hollow core, seals the junction and avoids the casting infiltration while casting.
  • the final metallic piece will further have a better finishing, because no seam will be left on the surface:
  • the embodiment from Fig. 6 is substantially similar to the one from Fig. 5, apart from the fact that it comprises a toothed profile ribbing 6 along the joining surface between the connecting portions 3a, 3b of the half-cores 1a, 1b, on a first connecting portion 3a engaging with a groove 7 of a complementary shape, being provided in the second connecting portion 3b.
  • the coupling between the two half-cores 1a, 1b is more accurate and stable.
  • FIG. 7 a further embodiment of the core 1 of the invention is shown.
  • the core 1, for manufacturing the cavity for a T-shaped hydraulic pipe fitting 13, consists of three half-cores 1a, 1b, 1c being assembled by means of sealing elements 4a, 4b, 4c wrapping the connecting portions 3a, 3b, 3c of the half-cores.
  • core assemblies of highly complex moulds for example, the crankcases
  • core assemblies of highly complex moulds can be manufactured by assembling several hollow cores by the method of the invention so as to provide a monolithic core assembly.
  • the hollow cores of the invention have several advantages compared to the ones of the background art of the invention.
  • the foundry cores of the invention have a low weight, compared to the solid cores, thus allowing smaller core prints to be used.
  • the amount of sand-binder mixture is reduced by 50%, with a consequent reduction in costs and, in the case of use of resins as binders, less environmental impact.
  • the hollow cores of the invention further are characterized by a higher flexibility which aids in the casting shrinkages, thus minimizing the formation of cracks.
  • the casting quality is improved even compared to the cores obtained by the "shell moulding" method.
  • hollow cores can be obtained with a uniform wall thickness by the method of the invention, because the shape of the cores solely depends on the shape of the impression used in the core box.
  • a non-homogeneous thickness in which the parts being thicker or less thick are randomly arranged, are obtained by the "shell moulding" method.
  • a uniform wall thickness is important in order to have a uniform shrinkage of the casting.
  • the cores of the invention can be also used for large-sized hollow pieces.
  • the hollow core can be provided with inside stiffening ribs in order to avoid that it may collapse.
  • the minimum diameter which the hollow core may have according to the invention will be about 30 mm, which thing means that these cores can be used for a really wide range of casting products.
  • the core assembly assembled by the method of the invention providing a second blowing in order to provide the sealing element, brings to a higher accuracy and quality of the casting, thus eliminating the fin formation.
  • the core flogging which is carried out after the casting has been solidified as said above, is made simpler, due to the lower strength of the hollow core compared to the solid core.
  • a flogging method comprising the following steps:
  • the core impregnation with water and the subsequent freezing cause the formation of flaws and cracks which can make the core more capable of being disgregated, after having increased the temperature again.
  • the hollow cores 1 are provided in a mixture of sand and cement.
  • the cement is present in the mixture in amounts ranging between 3% and 35% by dry weight.
  • the cement acts as a binder, the action of which is generated by adding either water or other additives.
  • the water will be added in amounts ranging between 2% and 15% by weight.
  • clay can be employed as a binder, preferably bentonite.
  • the amount of clay will preferably range between 3% and 40% by dry weight. Even in this case, the binding action will be generated by adding water in the amounts mentioned above.
  • a mixture of sand, cement and clay will be used, in which the sand is 60-95% by dry weight.
  • the latter will be subjected to the drying process.
  • the core strength increases, which can suffer much higher pressures. Therefore, the core drying process is particularly recommended for casting either large-sized or complex-shaped pieces.
  • the drying process will reduce the emission of vapours, particularly steam, in the metal casting step and therefore it will allow pieces with less porosities and thus a high quality to be obtained.
  • the core can be further painted, in order to increase the shelf life thereof.
  • the slag inclusion problem is also solved, i.e. the weld metal inclusions in the core surface which, after the casting has been solidified, cause a surface contaminated by the sand to form on the piece and which reduce the strength thereof and, by increasing the porosity, cause defects which will become evident in the following steps of the mechanical processing.
  • solid foundry cores with the sand-concrete mixture of the invention can be also manufactured.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP05425320A 2005-05-13 2005-05-13 Noyaux de fonderie et procédé pour leur fabrication Withdrawn EP1721688A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP05425320A EP1721688A1 (fr) 2005-05-13 2005-05-13 Noyaux de fonderie et procédé pour leur fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP05425320A EP1721688A1 (fr) 2005-05-13 2005-05-13 Noyaux de fonderie et procédé pour leur fabrication

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EP1721688A1 true EP1721688A1 (fr) 2006-11-15

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2087954A1 (fr) * 2007-12-14 2009-08-12 Rolls-Royce plc Noyau de coulée
EP2216112A1 (fr) * 2009-02-10 2010-08-11 Siemens Aktiengesellschaft Pièce coulée à base de nickel doté d'un corps de compensation et procédé de fabrication d'une pièce coulée à base de nickel
CN101417304B (zh) * 2008-11-06 2011-06-08 四川集成天元模具制造有限公司 利用水泥制作样件模具的方法
CN102205398A (zh) * 2011-04-21 2011-10-05 安徽应流铸业有限公司 呋喃树脂砂无箱造型壳型的制备方法
CN102310164A (zh) * 2011-09-14 2012-01-11 西峡县内燃机进排气管有限责任公司 覆膜砂砂芯不装砂工艺
CN102814459A (zh) * 2012-08-20 2012-12-12 合肥江淮铸造有限责任公司 一种环保型铸造型砂
CN102847877A (zh) * 2012-08-15 2013-01-02 浙江恒成硬质合金有限公司 一种合金辊环型芯
CN103182474A (zh) * 2011-12-29 2013-07-03 广西玉柴机器股份有限公司 铸件砂芯制造方法
CN103286276A (zh) * 2013-05-21 2013-09-11 佛山市南海区巨子电机配件有限公司 一种电机外壳的铸造工艺
CN104190872A (zh) * 2014-09-12 2014-12-10 苏州明志科技有限公司 一种省料砂芯及其制芯方法
CN105817584A (zh) * 2015-01-09 2016-08-03 中国第汽车股份有限公司 利用激光选区烧结工艺制造壳芯的方法
CN106180577A (zh) * 2016-09-28 2016-12-07 江苏华培动力科技有限公司 双涡流涡壳砂芯无缝组合工艺
CN106424577A (zh) * 2016-08-16 2017-02-22 浙江省机电设计研究院有限公司 一种铸钢件铁型覆砂铸造生产中防止热裂的砂芯装置和方法
CN108405809A (zh) * 2018-04-13 2018-08-17 洛阳鹏起实业有限公司 筒形铸件型芯及使用该筒形铸件型芯的铸造模具
CN110039010A (zh) * 2019-05-30 2019-07-23 大连金河铸造有限公司 复杂薄壁芯造芯方法
WO2020240342A1 (fr) * 2019-05-29 2020-12-03 Nemak. S.A.B. De C.V. Procédé de fabrication d'un noyau de coulée perdu
CN112893784A (zh) * 2021-01-22 2021-06-04 侯马市晋烽机械铸造有限公司 一种采用壳型铸造160km机车蠕墨铸铁盘体的铸造工艺
CN114309483A (zh) * 2020-09-28 2022-04-12 通用汽车环球科技运作有限责任公司 用于制造铸件的混合型芯
CN117047031A (zh) * 2023-09-08 2023-11-14 大连金河铸造有限公司 防跑火铸造工艺

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FR2187459A2 (en) * 1972-06-13 1974-01-18 Peugeot Assembling foundry moulds or cores - using a liq or pasty plastic material introduced under press into the sealing hole
US4252175A (en) * 1979-05-25 1981-02-24 Outboard Marine Corporation Cylinder block having a cast-in core unit and process for manufacturing same
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US5222544A (en) * 1991-08-12 1993-06-29 Ford Motor Company Bonding casting cores
EP0715913A1 (fr) * 1992-02-05 1996-06-12 Howmet Corporation Noyaux en plusieurs parties pour la coulée à la cire perdue
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EP1144141A1 (fr) * 1998-12-01 2001-10-17 Howmet Research Corporation Ensemble noyau a pieces multiples

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US5222544A (en) * 1991-08-12 1993-06-29 Ford Motor Company Bonding casting cores
EP0715913A1 (fr) * 1992-02-05 1996-06-12 Howmet Corporation Noyaux en plusieurs parties pour la coulée à la cire perdue
JPH09225581A (ja) * 1996-02-23 1997-09-02 Sintokogio Ltd 完成中子の製造方法およびその部分中子
JPH09225582A (ja) * 1996-02-23 1997-09-02 Sintokogio Ltd 接合中子の接合砂充填方法
WO2000013819A1 (fr) * 1998-09-03 2000-03-16 Foundry Automation S.A.S. Noyaux composites pour produits moules de fonderie
EP1144141A1 (fr) * 1998-12-01 2001-10-17 Howmet Research Corporation Ensemble noyau a pieces multiples

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Cited By (30)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8056609B2 (en) 2007-12-14 2011-11-15 Rolls-Royce Plc Core for casting
EP2087954A1 (fr) * 2007-12-14 2009-08-12 Rolls-Royce plc Noyau de coulée
CN101417304B (zh) * 2008-11-06 2011-06-08 四川集成天元模具制造有限公司 利用水泥制作样件模具的方法
CN102317008B (zh) * 2009-02-10 2013-11-20 西门子公司 具有补偿体的镍基铸造构件和用于制造镍基铸造构件的方法
EP2216112A1 (fr) * 2009-02-10 2010-08-11 Siemens Aktiengesellschaft Pièce coulée à base de nickel doté d'un corps de compensation et procédé de fabrication d'une pièce coulée à base de nickel
WO2010091931A1 (fr) * 2009-02-10 2010-08-19 Siemens Aktiengesellschaft Pièce coulée à base de nickel comprenant un corps de compensation et procédé pour la production d'une pièce de coulée à base de nickel
CN102205398A (zh) * 2011-04-21 2011-10-05 安徽应流铸业有限公司 呋喃树脂砂无箱造型壳型的制备方法
CN102205398B (zh) * 2011-04-21 2013-06-05 安徽应流铸业有限公司 呋喃树脂砂无箱造型壳型的制备方法
CN102310164A (zh) * 2011-09-14 2012-01-11 西峡县内燃机进排气管有限责任公司 覆膜砂砂芯不装砂工艺
CN103182474A (zh) * 2011-12-29 2013-07-03 广西玉柴机器股份有限公司 铸件砂芯制造方法
CN102847877A (zh) * 2012-08-15 2013-01-02 浙江恒成硬质合金有限公司 一种合金辊环型芯
CN102814459A (zh) * 2012-08-20 2012-12-12 合肥江淮铸造有限责任公司 一种环保型铸造型砂
CN103286276B (zh) * 2013-05-21 2015-01-21 佛山市南海区巨子电机配件有限公司 一种电机外壳的铸造工艺
CN103286276A (zh) * 2013-05-21 2013-09-11 佛山市南海区巨子电机配件有限公司 一种电机外壳的铸造工艺
CN104190872A (zh) * 2014-09-12 2014-12-10 苏州明志科技有限公司 一种省料砂芯及其制芯方法
CN105817584A (zh) * 2015-01-09 2016-08-03 中国第汽车股份有限公司 利用激光选区烧结工艺制造壳芯的方法
CN106424577A (zh) * 2016-08-16 2017-02-22 浙江省机电设计研究院有限公司 一种铸钢件铁型覆砂铸造生产中防止热裂的砂芯装置和方法
CN106180577B (zh) * 2016-09-28 2018-11-27 江苏华培动力科技有限公司 双涡流涡壳砂芯无缝组合工艺
CN106180577A (zh) * 2016-09-28 2016-12-07 江苏华培动力科技有限公司 双涡流涡壳砂芯无缝组合工艺
CN108405809B (zh) * 2018-04-13 2020-07-24 洛阳鹏起实业有限公司 筒形铸件型芯及使用该筒形铸件型芯的铸造模具
CN108405809A (zh) * 2018-04-13 2018-08-17 洛阳鹏起实业有限公司 筒形铸件型芯及使用该筒形铸件型芯的铸造模具
WO2020240342A1 (fr) * 2019-05-29 2020-12-03 Nemak. S.A.B. De C.V. Procédé de fabrication d'un noyau de coulée perdu
CN114126781A (zh) * 2019-05-29 2022-03-01 尼玛克股份有限公司 用于生产消失的铸造型芯的方法
US11890669B2 (en) 2019-05-29 2024-02-06 Nemak, S.A.B. De C.V. Method for producing a lost casting core
CN114126781B (zh) * 2019-05-29 2024-03-29 尼玛克股份有限公司 用于生产消失的铸造型芯的方法
CN110039010A (zh) * 2019-05-30 2019-07-23 大连金河铸造有限公司 复杂薄壁芯造芯方法
CN110039010B (zh) * 2019-05-30 2021-04-20 大连金河铸造有限公司 复杂薄壁芯造芯方法
CN114309483A (zh) * 2020-09-28 2022-04-12 通用汽车环球科技运作有限责任公司 用于制造铸件的混合型芯
CN112893784A (zh) * 2021-01-22 2021-06-04 侯马市晋烽机械铸造有限公司 一种采用壳型铸造160km机车蠕墨铸铁盘体的铸造工艺
CN117047031A (zh) * 2023-09-08 2023-11-14 大连金河铸造有限公司 防跑火铸造工艺

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