EP1749596B1 - Process for the manufacture of a mould from a binded material for metal foundry - Google Patents

Process for the manufacture of a mould from a binded material for metal foundry Download PDF

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Publication number
EP1749596B1
EP1749596B1 EP05016479A EP05016479A EP1749596B1 EP 1749596 B1 EP1749596 B1 EP 1749596B1 EP 05016479 A EP05016479 A EP 05016479A EP 05016479 A EP05016479 A EP 05016479A EP 1749596 B1 EP1749596 B1 EP 1749596B1
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EP
European Patent Office
Prior art keywords
foundry
mould
mould material
mold
procedure according
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EP05016479A
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German (de)
French (fr)
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EP1749596A1 (en
Inventor
Rezo Dr.-Ing. Aliyev
Detlev Gantner
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ACTech GmbH
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ACTech GmbH
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Priority to DK05016479T priority Critical patent/DK1749596T3/en
Priority to EP05016479A priority patent/EP1749596B1/en
Priority to AT05016479T priority patent/ATE364462T1/en
Priority to ES05016479T priority patent/ES2287844T3/en
Priority to DE502005000878T priority patent/DE502005000878D1/en
Publication of EP1749596A1 publication Critical patent/EP1749596A1/en
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Publication of EP1749596B1 publication Critical patent/EP1749596B1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings

Definitions

  • the invention relates to a method for producing a casting mold from a composite molding material composed of various molding materials which are heat-resistant for the casting of metals and which have a different material composition or a different content of organic or inorganic binders.
  • molding materials are in particular compositions of heat-resistant molding compositions and core materials, which consist of a refractory mineral base material, usually quartz sand, and a binder system.
  • quartz sand is the predominant molding material due to its reasonable price, its frequency and its properties.
  • the largest part of the molding box or the core box is filled with a molding material of lesser value, the so-called filler or filler sand. It contains significantly less binder and allows significant cost reductions compared to filling the entire mold with high-quality molding material, as it is needed at the contact surface of the molding material to the liquid metal.
  • the disadvantage is that a model is needed for the production of a casting mold. The production of a model is associated with a further cost increase and a considerable amount of time. Besides that is limited the process to the production of molds consisting exclusively of foundry sand.
  • a method of making a lost mold from a composite molding material having a plaster mold embedded in a sand mold is known.
  • each of the production of a model is required.
  • a model is made of wax, which is placed in a container and potted with a gypsum slurry.
  • the plaster mold is subjected to primary and secondary calcination to harden the ceramic mold.
  • the plaster mold is embedded in the casting mold with foundry molding sand and subsequently the liquid metal is poured.
  • This procedure requires various time-consuming manufacturing steps for the manufacture of the sand mold and plaster mold models, which are associated with considerable expense. In particular, for the rapid production of prototypes, the proposed method is not suitable for this reason.
  • the individual molded part segments consist of one and the same foundry usual foundry sand, which is cured with a binder.
  • the individual segments with the mating surfaces are molded separately with a pattern device.
  • the mold-forming inner contour of the casting mold assigned to the respective segment is produced by direct milling of the molding material using CAD data.
  • the individual molding material segments are joined together after milling to form the mold and interconnected by means of locking elements.
  • the segments without forming inner contour can be advantageously made on stock. Due to the individual production, however, the molding segments are subject to tolerances that can adversely affect the assembly.
  • the invention aims at a rapid and inexpensive process for the production of a mold from a composite molding material for foundry, which is composed of various molding materials.
  • the invention solves the above problem by the production of a block-shaped composite molding material from different foundry mold materials and its subsequent mechanical processing.
  • a solid molded body of the foundry material A is first prepared, usually cuboid, which is enveloped by a powdery and pourable foundry mold material B, usually chemically bonded molding sand, which is connected after curing with the foundry material A and a positive fit Connection is received.
  • the positive embedding of the ceramic molding in the foundry sand can be done by means of projections or recesses or by a corresponding prismatic shape of the ceramic molding with conically extending side walls.
  • the negative contour of the casting is introduced into the area of the foundry mold material A, while in the area of the foundry mold material B only the sprue system and feeder system is introduced.
  • a separate CAD / CAM machining program for the machining of the mold cavity for the casting in the region of the foundry mold material A.
  • a second processing program for a removal process preferably a milling program for direct molding material milling, can accordingly be used.
  • the advantage of the proposed method is a mold made of a composite molding material of two different foundry mold materials, which has a different material composition corresponding to the desired casting quality.
  • the different material composition may be characterized by a different content of binders or by the composition of the foundry molding material used.
  • Particularly advantageous is a composite molding material in combination of conventional foundry sand for the foundry mold material B with ceramic materials for the foundry mold material A.
  • the ceramic material contains only the casting geometry.
  • FIG. 1 shows one of the casting mold halves which together with the counterpart, not shown, together form a casting mold for a metallic casting.
  • the mold cavity 1 of the casting is thereby imaged by a molded body 2, which is made entirely of a ceramic foundry mold material A.
  • the molded body 2 forms with a molding material block 3 of a foundry mold material B a block-shaped composite molding material.
  • a piece of the sprue system 4 and the feeder system 5 is visible.
  • the mold is a two-part mold, for example with a top and a bottom.
  • the mold may consist of several parts, e.g. still made of cores.
  • core marks 6 can be easily incorporated into the mold halves.
  • a composite molding material corresponding to the respective mold half is produced, which contains a shaped body 2 made of a ceramic foundry mold material A.
  • a prismatic molded body 2 is first produced, which substantially corresponds to the dimensions of the actual casting, except for the sprue system 4 and feeder system 5.
  • the ceramic body 2 is made in final strength using a foundry material A suitable for abrasive machining by a method such as milling, drilling, turning, grinding or erosion is suitable and meets the casting requirements in terms of heat resistance and the reaction resistance to the casting material.
  • the ceramic molded body 2 from the foundry mold material A with a powdery and pourable, chemically bound foundry mold material B is wrapped, whereby the molding material block 3 is formed.
  • the sprue system 4 and the feeder system 5 are substantially integrated.
  • the molding 2 is to be positively connected to the enveloping chemically hardening foundry molding material B.
  • the positive connection can be effected by means of projections or recesses or by a corresponding prismatic shape of the shaped body 2 with conically extending side walls 7.
  • a quartz sand foundry molding sand is used with a thermosetting binder for wrapping the ceramic molded body 2.
  • the casting mold is heated to a temperature above the melting temperature of the binder during block molding with the introduced foundry sand - binder - mixture and the molding material block 3 cured.
  • the molded body 2 of the foundry mold material A with the molding material block 3 from the foundry mold material B forms a composite molding material which can be machined in one clamping by a machining process with a corresponding machine tool by milling, drilling, turning or grinding.
  • the invention should not be limited to a foundry mold material B with a thermosetting binder. Rather, bentonites can be used in the context of the patent claims as a binder for foundry molding sand.
  • binders for example, water glass or furan resins and other products of organic chemistry are applicable.
  • cement can be successfully used as a hardening binder. It is also possible to use a foundry mold material which has an addition of gypsum as binder.
  • binders can be used which subsequently enable the machining of the casting system with erosive methods.
  • the machining of the sprue system 4 and of the feeder system 5 takes place in a further working step, which can be carried out particularly advantageously when using foundry molding sand by direct molding material milling with a CNC milling machine.
  • the production of the mold cavity 1 for the casting is also carried out with a CNC machine tool.
  • CAM systems are used which make manual programming superfluous.
  • the development work in the production of prototypes is reduced to the tailor - made design within a CAD system.
  • Such systems are independent of the complexity of the casting and allow different machining instructions for milling strategies and other abrasive methods.
  • the production of the prototypes is thus based directly on the 3D datasets of the cast raw part, from which the datasets for the mold cavity 1 are generated.
  • the construction of the cavity for the sprue system 4 and the feeder system 5 is made from the raw part data of the casting, from which the datasets for the sprue system 4 and the feeder system 5 are made.
  • the milling program is created with the NC data derived from it using the tool specifications.
  • Advantageous is the possibility of using a special milling strategy for the production of the sprue system 4 and the feeder system 5 when using a resin bonded foundry sand.
  • a foundry mold material A which is optimal for the casting can be selected, while the foundry mold material B simplifies the mechanical processing or better satisfies other boundary conditions. Accordingly, for the mold cavity 1, the sprue system 4 and for the feeder system 5, the most favorable milling strategy can be selected separately.
  • This method can also be used for castings with a complicated geometry. In this way, the invention enables the production of faster prototypes.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

Method of preparing a casting mold from composite molding material for foundries consisting of a composition containing two different molding materials and which is heat resistant to metals. A solid molding body (2) is obtained from a foundry molding material (A) which is partially or completely enveloped by a fluid powdered chemically bonded foundry molding materal (B). A molding material block (3) is produced from a block shaped composite molding material after hardening the material (B), which is subjected to a removal process, e.g. milling, boring, turning or grinding. A feedhead system (sic) (4) and storage system (5) using CAD data.

Description

Die Erfindung bezieht sich auf ein Verfahren zur Herstellung einer Gießform aus einem Verbundformstoff für Gießereizwecke, der aus verschiedenartigen Formstoffen zusammengesetzt ist, die für das Gießen von Metallen hitzebeständig sind und die eine unterschiedliche stoffliche Zusammensetzung oder einen unterschiedlichen Gehalt an organischen oder anorganischen Bindemitteln aufweisen. Derartige Formstoffe sind insbesondere Zusammensetzungen von hitzebeständigen Formmassen und Kernmassen, die aus einem feuerfesten mineralischen Grundstoff, meist Quarzsand, und einem Bindersystem bestehen. Für besondere Ansprüche an die Form und das Gussteil werden auch feuerfeste keramische Massen und Werkstoffe eingesetzt, die sich durch abtragende Fertigungsverfahren bearbeiten lassen. Quarzsand ist wegen seines angemessenen Preises, seiner Häufigkeit und seiner Eigenschaften der überwiegende Formgrundstoff.The invention relates to a method for producing a casting mold from a composite molding material composed of various molding materials which are heat-resistant for the casting of metals and which have a different material composition or a different content of organic or inorganic binders. Such molding materials are in particular compositions of heat-resistant molding compositions and core materials, which consist of a refractory mineral base material, usually quartz sand, and a binder system. For special demands on the mold and the casting refractory ceramic materials and materials are used, which can be processed by removing manufacturing processes. Quartz sand is the predominant molding material due to its reasonable price, its frequency and its properties.

Im Streben nach kostengünstigen Lösungen bei der Herstellung von Gießformen ist es seit langem in der Praxis bekannt, Formstoffe mit unterschiedlichen Eigenschaften und demzufolge verschiedener Zusammensetzung einzusetzen. Nach Ambos, Urformtechnik metallischer Werkstoffe, Verlag für Grundstoffindustrie, 2. Auflage, Leipzig 1982, Seite 51 , ist es bei manueller und mechanisierter Herstellung der Formen und Kerne üblich, sobald diese eine bestimmte Mindestgröße überschreiten, an das Modell oder die Kernkastenwand eine dünne Schicht hochwertigen Formstoffs anzulegen. Dieser Formstoff gerät beim Gießen in unmittelbaren Kontakt mit dem flüssigen Metall und muss die dem Gussteil adäquaten Eigenschaften aufweisen. Er enthält deshalb einen relativ hohen Anteil von Bindemittel und wird als Modellformstoff bezeichnet.In the pursuit of cost-effective solutions in the production of molds, it has long been known in practice to use moldings with different properties and consequently different composition. To Ambos, Urformtechnik metallic materials, publishing house for primary industry, 2nd edition, Leipzig 1982, page 51 It is customary in manual and mechanized production of the molds and cores, as soon as they exceed a certain minimum size, to apply a thin layer of high-grade molding material to the model or the core box wall. This molding material is in direct contact with the liquid metal during casting and must have the casting properties adequate properties. It therefore contains a relatively high proportion of binder and is referred to as a model molding material.

Der größte Teil des Formkasten beziehungsweise des Kernkastens wird jedoch mit einem Formstoff geringerer Wertigkeit, dem so genannten Füllformstoff oder Füllsand, ausgefüllt. Er enthält wesentlich weniger Bindemittel und gestattet maßgebliche Kostenreduzierungen gegenüber dem Füllen der gesamten Form mit hochwertigem Formstoff, wie er an der Kontaktfläche des Formstoffs an das flüssige Metall benötigt wird. Nachteilig ist, dass für die Herstellung einer Gießform ein Modell benötigt wird. Die Herstellung eines Modells ist mit einer weiteren Kostenerhöhung und einem erheblichen Zeitaufwand verbunden. Außerdem ist das Verfahren auf die Herstellung von Gießformen beschränkt, die ausschließlich aus Gießereiformsand bestehen.However, the largest part of the molding box or the core box is filled with a molding material of lesser value, the so-called filler or filler sand. It contains significantly less binder and allows significant cost reductions compared to filling the entire mold with high-quality molding material, as it is needed at the contact surface of the molding material to the liquid metal. The disadvantage is that a model is needed for the production of a casting mold. The production of a model is associated with a further cost increase and a considerable amount of time. Besides that is limited the process to the production of molds consisting exclusively of foundry sand.

Aus der JP 61 245 942 A1 ist ein Verfahren zur Herstellung einer verlorenen Gießform aus einem Verbundformstoff bekannt, die eine in eine Sandform eingebettete Gipsform aufweist. Für die Anfertigung der Gipsform und der Sandform ist jeweils die Herstellung eines Modells erforderlich. Für die Gipsform wird ein Modell aus Wachs gefertigt, das in einen Behälter eingesetzt und mit einem Gipsbrei vergossen wird. Die Gipsform wird einer Primär - und Sekundärcalcination unterworfen, damit die keramische Form gehärtet wird. Die Gipsform wird in die Gussteilform mit Gießereiformsand eingebettet und nachfolgend wird dann das flüssige Metall gegossen. Bei dieser Verfahrensweise werden verschiedene zeitaufwändige Herstellungsschritte für die Herstellung der Modelle für die Sandform und die Gipsform erforderlich, die mit einem erheblichen Kostenaufwand verbunden sind. Insbesondere für die schnelle Herstellung von Prototypen ist das vorgeschlagene Verfahren aus diesem Grunde nicht geeignet.From the JP 61 245 942 A1 For example, a method of making a lost mold from a composite molding material having a plaster mold embedded in a sand mold is known. For the preparation of the plaster mold and the sand mold each of the production of a model is required. For the plaster mold, a model is made of wax, which is placed in a container and potted with a gypsum slurry. The plaster mold is subjected to primary and secondary calcination to harden the ceramic mold. The plaster mold is embedded in the casting mold with foundry molding sand and subsequently the liquid metal is poured. This procedure requires various time-consuming manufacturing steps for the manufacture of the sand mold and plaster mold models, which are associated with considerable expense. In particular, for the rapid production of prototypes, the proposed method is not suitable for this reason.

In der DE 101 56 332 A1 wird schließlich ein Baukastensystem vorgeschlagen, mit dem aus quaderförmigen Segmenten eine große Gießform gebildet wird. Die einzelnen Formteilsegmente bestehen aus ein und demselben gießereiüblichen Formsand, der mit einem Bindemittel ausgehärtet wird. Die einzelnen Segmente mit den Passflächen werden separat mit einer Modelleinrichtung abgeformt. Nach dem Abformen und Aushärten wird die dem jeweiligen Segment zugeordnete, formbildende Innenkontur der Gießform durch das direkte Formstoff- Fräsen unter Verwendung von CAD - Daten erzeugt. Die einzelnen Formstoffsegmente werden nach dem Fräsen zu der Gießform zusammengefügt und mit Hilfe von Verriegelungselementen untereinander verbunden. Die Segmente ohne formbildende Innenkontur können vorteilhaft auf Vorrat gefertigt werden. Aufgrund der Einzelfertigung sind die Formteilsegmente dagegen mit Toleranzen behaftet, die sich beim Zusammenfügen nachteilig auswirken können.In the DE 101 56 332 A1 Finally, a modular system is proposed, with the cuboidal segments, a large mold is formed. The individual molded part segments consist of one and the same foundry usual foundry sand, which is cured with a binder. The individual segments with the mating surfaces are molded separately with a pattern device. After molding and curing, the mold-forming inner contour of the casting mold assigned to the respective segment is produced by direct milling of the molding material using CAD data. The individual molding material segments are joined together after milling to form the mold and interconnected by means of locking elements. The segments without forming inner contour can be advantageously made on stock. Due to the individual production, however, the molding segments are subject to tolerances that can adversely affect the assembly.

In der Produktentwicklung werden kostengünstige und schnelle Prototypen mit zunehmender Seriennähe zu Designstudien und Funktionszwecken benötigt, um die hohen Entwicklungskosten herabzusetzen. Durch die notwendige Anfertigung von Modellen ist die schnelle Verfügbarkeit von Prototypen nicht gewährleistet, weil die Herstellung keramischer Gießformen einen hohen zeitlichen Bedarf beansprucht. Die Erfindung bezweckt daher ein schnelles und kostengünstiges Verfahren für die Herstellung einer Gießform aus einem Verbundformstoff für Gießereizwecke, der aus verschiedenartigen Formstoffen zusammengesetzt ist.In product development, cost-effective and fast prototypes with increasing proximity to the series are needed for design studies and functional purposes in order to reduce the high development costs. Due to the necessary production of models, the rapid availability of prototypes is not guaranteed because the production of ceramic Molds claimed a high temporal demand. The invention therefore aims at a rapid and inexpensive process for the production of a mold from a composite molding material for foundry, which is composed of various molding materials.

Die Erfindung löst die voran stehende Aufgabe durch die Herstellung eines blockförmigen Verbundformstoffs aus unterschiedlichen Gießereiformstoffen und dessen anschließende mechanische Bearbeitung. Bei der Herstellung des blockförmigen Verbundformstoffs wird zunächst ein fester Formkörper aus dem Gießereiformstoff A hergestellt, meist quaderförmig, der von einem pulverförmigen und rieselfähigen Gießereiformstoff B, meist chemisch gebundener Formsand, umhüllt wird, der nach dem Aushärten mit dem Gießereiformstoff A verbunden ist und eine formschlüssige Verbindung eingeht. Das formschlüssige Einbetten des keramischen Formkörpers in den Gießereisand kann mit Hilfe von Vorsprüngen oder Ausnehmungen oder durch eine entsprechende prismatische Form des keramischen Formkörpers mit konisch verlaufenden Seitenwänden erfolgen.The invention solves the above problem by the production of a block-shaped composite molding material from different foundry mold materials and its subsequent mechanical processing. In the production of the block-shaped composite molding material, a solid molded body of the foundry material A is first prepared, usually cuboid, which is enveloped by a powdery and pourable foundry mold material B, usually chemically bonded molding sand, which is connected after curing with the foundry material A and a positive fit Connection is received. The positive embedding of the ceramic molding in the foundry sand can be done by means of projections or recesses or by a corresponding prismatic shape of the ceramic molding with conically extending side walls.

Bei der anschließenden mechanischen Bearbeitung wird in den Bereich des Gießereiformstoffes A die Negativkontur des Gussteiles eingebracht, während in den Bereich des Gießereiformstoffes B ausschließlich das Anguss-System und Speisersystem eingebracht wird. Entsprechend den unterschiedlichen Werkstoffdaten ist es zweckmäßig, für die Bearbeitung des Formhohlraumes für das Gussteil in dem Bereich des Gießereiformstoffs A ein separates CAD / CAM Bearbeitungsprogramm zu verwenden. Für die Bearbeitung des Anguss-Systems und des Speisersystems im Bereich des Gießereiformstoffs B kann dementsprechend ein zweites Bearbeitungsprogramm für ein abtragendes Verfahren, vorzugsweise ein Fräsprogramm für das direkte Formstoff- Fräsen eingesetzt werden.In the subsequent mechanical processing, the negative contour of the casting is introduced into the area of the foundry mold material A, while in the area of the foundry mold material B only the sprue system and feeder system is introduced. According to the different material data, it is expedient to use a separate CAD / CAM machining program for the machining of the mold cavity for the casting in the region of the foundry mold material A. For processing the sprue system and the feeder system in the area of the foundry mold material B, a second processing program for a removal process, preferably a milling program for direct molding material milling, can accordingly be used.

Der Vorteil des vorgeschlagenen Verfahrens ist eine Gießform aus einem Verbundformstoff von zwei unterschiedlichen Gießereiformstoffen, die eine unterschiedliche stoffliche Zusammensetzung entsprechend der gewünschten Gussteilqualität aufweist. Die unterschiedliche stoffliche Zusammensetzung kann durch einen unterschiedlichen Gehalt an Bindemitteln oder durch die die Zusammensetzung des verwendeten Gießereiformstoffs gekennzeichnet sein. Besonders vorteilhaft ist ein Verbundformstoff in Kombination von herkömmlichem Gießereisand für den Gießereiformstoff B mit keramischen Werkstoffen für den Gießereiformstoff A. Der keramische Werkstoff enthält dabei ausschließlich die Gussteilgeometrie.The advantage of the proposed method is a mold made of a composite molding material of two different foundry mold materials, which has a different material composition corresponding to the desired casting quality. The different material composition may be characterized by a different content of binders or by the composition of the foundry molding material used. Particularly advantageous is a composite molding material in combination of conventional foundry sand for the foundry mold material B with ceramic materials for the foundry mold material A. The ceramic material contains only the casting geometry.

Die Herstellung von qualitativ hochwertigen Gussteilen bezüglich Maßhaltigkeit und Oberflächengüte mit einer keramischen Gießform kann wesentlich vereinfacht und beschleunigt werden, weil der Anteil der zu bearbeitenden Keramik auf ein Minimum reduziert werden kann.The production of high-quality castings with regard to dimensional accuracy and surface quality with a ceramic casting mold can be considerably simplified and accelerated because the proportion of the ceramic to be processed can be reduced to a minimum.

Die Erfindung soll nachstehend anhand eines Ausführungsbeispiels unter Bezugnahme auf die Zeichnungen näher erläutert werden. Vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen. Im Einzelnen zeigt

Figur 1
eine halbe Gießform aus zwei Gießereiformstoffen,
Figur 2
die Herstellung eines blockförmigen Verbundformstoffs aus zwei unterschiedlichen Gießereiformstoffen und
Figur 3
das Einbringen der Formkontur durch Fräsen in schematischer Darstellung.
The invention will be explained below with reference to an embodiment with reference to the drawings. Advantageous embodiments of the invention will become apparent from the dependent claims. In detail shows
FIG. 1
a half mold made of two foundry mold materials,
FIG. 2
the production of a block-shaped composite molding material from two different foundry mold materials and
FIG. 3
the introduction of the shape contour by milling in a schematic representation.

Das nachfolgende Ausführungsbeispiel soll anhand einer keramischen Gießform für ein Gussteil, beispielsweise ein Feingussteil, beschrieben werden. In der Figur 1 ist eine der Gießfomihälften dargestellt, die mit dem nicht dargestellten Gegenstück zusammen eine Gießform für ein metallisches Gussteil ergibt. Der Formhohlraum 1 des Gussteiles wird dabei durch einen Formkörper 2 abgebildet, der vollständig aus einem keramischen Gießereiformstoff A hergestellt wird. Der Formkörper 2 bildet mit einem Formstoffblock 3 aus einem Gießereiformstoff B einen blockförmigen Verbundformstoff. Im Bereich des Formstoffblocks 3 aus dem Gießereiformstoffes B ist ein Stück des Anguss-Systems 4 und des Speisersystems 5 sichtbar. Die Gießform ist eine zweiteilige Form beispielsweise mit einem Oberteil und einem Unterteil. Bei komplexeren Gussteilen kann die Gießform aus mehreren Teilen bestehen, z.B. noch aus Kernen. Für das Einlegen von Kernen können in die Gießformhälften problemlos Kernmarken 6 eingearbeitet werden.The following embodiment will be described with reference to a ceramic casting mold for a casting, for example, a precision casting. FIG. 1 shows one of the casting mold halves which together with the counterpart, not shown, together form a casting mold for a metallic casting. The mold cavity 1 of the casting is thereby imaged by a molded body 2, which is made entirely of a ceramic foundry mold material A. The molded body 2 forms with a molding material block 3 of a foundry mold material B a block-shaped composite molding material. In the area of the molding material block 3 from the foundry mold material B, a piece of the sprue system 4 and the feeder system 5 is visible. The mold is a two-part mold, for example with a top and a bottom. For more complex castings, the mold may consist of several parts, e.g. still made of cores. For inserting cores core marks 6 can be easily incorporated into the mold halves.

In dem Ausführungsbeispiel wird gemäß Figur 2 zur schrittweisen Anfertigung einer Gießform ein der jeweiligen Gießformhälfte entsprechender Verbundformstoffhergestellt, der einen Formkörper 2 aus einem keramischen Gießereiformstoff A enthält. Aus dem keramischen Gießereiformstoff A wird zunächst ein prismatischer Formkörper 2 hergestellt, der im Wesentlichen den Abmessungen des tatsächlichen Gussteiles entspricht, ausgenommen das Anguss-System 4 und Speisersystem 5. Der keramische Formkörper 2 wird in Endfestigkeit unter Verwendung eines Gießereiformstoffs A hergestellt, der für eine abtragende Bearbeitung durch ein Verfahren wie Fräsen, Bohren, Drehen, Schleifen oder Erodieren geeignet ist und der den gießtechnischen Anforderungen in Bezug auf Hitzebeständigkeit und die Reaktionsfestigkeit gegenüber dem Gusswerkstoff genügt.In the exemplary embodiment, according to FIG. 2, for the step-by-step production of a casting mold, a composite molding material corresponding to the respective mold half is produced, which contains a shaped body 2 made of a ceramic foundry mold material A. From the ceramic foundry material A, a prismatic molded body 2 is first produced, which substantially corresponds to the dimensions of the actual casting, except for the sprue system 4 and feeder system 5. The ceramic body 2 is made in final strength using a foundry material A suitable for abrasive machining by a method such as milling, drilling, turning, grinding or erosion is suitable and meets the casting requirements in terms of heat resistance and the reaction resistance to the casting material.

Im nächsten Arbeitsschritt, vor der Herstellung des Formhohlraums 1 für das Gussteil, wird der keramische Formkörper 2 aus dem Gießereiformstoff A mit einem pulverförmigen und rieselfähigen, chemisch gebundenen Gießereiformstoff B umhüllt, womit der Formstoffblock 3 entsteht. In den Formstoffblock 3 sind im Wesentlichen das Anguss-System 4 und das Speisersystem 5 integriert. Während der Blockabformung des Formstoffblocks 3 soll der Formkörper 2 formschlüssig mit dem umhüllenden chemisch aushärtenden Gießereiformstoff B verbunden werden. Der Formschluss kann mit Hilfe von Vorsprüngen oder Ausnehmungen oder durch eine entsprechende prismatische Form des Formkörpers 2 mit konisch verlaufenden Seitenwänden 7 erfolgen. Vorzugsweise wird für das Umhüllen des keramischen Formkörpers 2 ein aus Quarzsand bestehender Gießereiformsand mit einem wärmehärtbaren Bindemittel eingesetzt. Daraufhin wird die Gießform während der Blockformung mit dem eingebrachten Gießereisand - Bindemittel - Gemisch auf eine Temperatur oberhalb der Schmelztemperatur des Binders erhitzt und der Formstoffblock 3 ausgehärtet. Nach der Aushärtung bildet der Formkörper 2 aus dem Gießereiformstoff A mit dem Formstoffblock 3 aus dem Gießereiformstoff B einen Verbundformstoff, der in einer Aufspannung durch ein abtragendes Verfahren mit einer entsprechenden Werkzeugmaschine durch Fräsen, Bohren, Drehen oder Schleifen bearbeitet werden kann.
Die Erfindung soll jedoch nicht auf einen Gießereiformstoff B mit einem warmhärtbaren Bindemittel beschränkt werden. Vielmehr können im Rahmen der Patentansprüche als Bindemittel für Gießereiformsand Bentonite eingesetzt werden. Als aushärtende Bindemittel sind beispielsweise Wasserglas oder Furanharze sowie andere Produkte der organischen Chemie anwendbar. Für größere Gussstücke kann mit gutem Erfolg Zement als aushärtendes Bindemittel verwandt werden. Es kann auch ein Giessereiformstoff eingesetzt werden, der einen Zusatz von Gips als Bindemittel aufweist. Insgesamt können Bindemittel eingesetzt werden, die nachfolgend die Bearbeitung des Gießsystems mit abtragenden Verfahren ermöglichen.In the next step, before the production of the mold cavity 1 for the casting, the ceramic molded body 2 from the foundry mold material A with a powdery and pourable, chemically bound foundry mold material B is wrapped, whereby the molding material block 3 is formed. In the molding material block 3, the sprue system 4 and the feeder system 5 are substantially integrated. During the block molding of the molding material block 3, the molding 2 is to be positively connected to the enveloping chemically hardening foundry molding material B. The positive connection can be effected by means of projections or recesses or by a corresponding prismatic shape of the shaped body 2 with conically extending side walls 7. Preferably, a quartz sand foundry molding sand is used with a thermosetting binder for wrapping the ceramic molded body 2. Then, the casting mold is heated to a temperature above the melting temperature of the binder during block molding with the introduced foundry sand - binder - mixture and the molding material block 3 cured. After curing, the molded body 2 of the foundry mold material A with the molding material block 3 from the foundry mold material B forms a composite molding material which can be machined in one clamping by a machining process with a corresponding machine tool by milling, drilling, turning or grinding.
However, the invention should not be limited to a foundry mold material B with a thermosetting binder. Rather, bentonites can be used in the context of the patent claims as a binder for foundry molding sand. As curing binders, for example, water glass or furan resins and other products of organic chemistry are applicable. For larger castings, cement can be successfully used as a hardening binder. It is also possible to use a foundry mold material which has an addition of gypsum as binder. Overall, binders can be used which subsequently enable the machining of the casting system with erosive methods.

Nach Figur 3 erfolgt in einem weiteren Arbeitsschritt die Bearbeitung des Anguss-Systems 4 und des Speisersystems 5, das besonders vorteilhaft bei Verwendung von Gießereiformsand durch direktes Formstoff - Fräsen mit einer CNC - Fräsmaschine vorgenommen werden kann. Die Erzeugung des Formhohlraums 1 für das Gussteil erfolgt ebenfalls mit einer CNC-Werkzeugmaschine.
Zur NC - Programmierung komplizierter dreidimensionale Oberflächen werden CAM Systeme eingesetzt, die eine manuelle Programmierung überflüssig machen. Die Entwicklungsarbeit bei der Herstellung von Prototypen reduziert sich auf das maßgerechte Konstruieren innerhalb eines CAD - Systems. Derartige Systeme sind unabhängig von der Komplexität des Gussstücks und ermöglichen unterschiedliche Bearbeitungsanweisungen für Frässtrategien und andere abtragende Verfahren. Die Fertigung der Prototypen basiert somit direkt auf den 3D - Datensätzen des Gussrohteiles, aus denen die Datensätze für den Formhohlraum 1 generiert werden. Durch den Einsatz des direkten Formstoff - Fräsens ist damit eine noch schnellere und kostengünstige ausschließlich computergestützte Bereitstellung von Prototypen möglich.
Die Konstruktion der Kavität für das Anguss-System 4 und das Speisersystem 5 erfolgt aus den Rohteildaten des Gussstücks, aus denen die Datensätze für das Anguss-System 4 und das Speisersystem 5 angefertigt werden. Durch einen Datentransfer wird mit daraus abgeleiteten NC - Daten das Fräsprogramm unter Verwendung der Werkzeugvorgaben erstellt. Vorteilhaft ist die Möglichkeit des Einsatzes einer besonderen Frässtrategie für die Herstellung des Anguss-Systems 4 und des Speisersystems 5 bei Einsatz eines kunstharzgebundenen Gießereiformsands.According to FIG. 3, the machining of the sprue system 4 and of the feeder system 5 takes place in a further working step, which can be carried out particularly advantageously when using foundry molding sand by direct molding material milling with a CNC milling machine. The production of the mold cavity 1 for the casting is also carried out with a CNC machine tool.
For NC programming of complicated three - dimensional surfaces, CAM systems are used which make manual programming superfluous. The development work in the production of prototypes is reduced to the tailor - made design within a CAD system. Such systems are independent of the complexity of the casting and allow different machining instructions for milling strategies and other abrasive methods. The production of the prototypes is thus based directly on the 3D datasets of the cast raw part, from which the datasets for the mold cavity 1 are generated. Through the use of direct molding material milling, an even faster and cost-effective exclusively computer-assisted provision of prototypes is possible.
The construction of the cavity for the sprue system 4 and the feeder system 5 is made from the raw part data of the casting, from which the datasets for the sprue system 4 and the feeder system 5 are made. Through a data transfer, the milling program is created with the NC data derived from it using the tool specifications. Advantageous is the possibility of using a special milling strategy for the production of the sprue system 4 and the feeder system 5 when using a resin bonded foundry sand.

Für den Formkörper 2 kann ein für das Gussteil optimaler Gießereiformstoff A ausgewählt werden, während der Gießereiformstoff B die mechanische Bearbeitung vereinfacht oder anderen Randbedingungen besser genügt. Demzufolge kann für den Formhohlraum 1, das Anguss-System 4 und für das Speisersystem 5 separat jeweils die günstigste Frässtrategie ausgewählt werden.For the molded body 2, a foundry mold material A which is optimal for the casting can be selected, while the foundry mold material B simplifies the mechanical processing or better satisfies other boundary conditions. Accordingly, for the mold cavity 1, the sprue system 4 and for the feeder system 5, the most favorable milling strategy can be selected separately.

Dieses Verfahren kann auch bei Gussteilen mit einer komplizierten Geometrie eingesetzt werden. Auf diese Weise ermöglicht die Erfindung die Herstellung schneller Prototypen.This method can also be used for castings with a complicated geometry. In this way, the invention enables the production of faster prototypes.

Claims (7)

  1. Procedure for the manufacture of a mould from a composite mould material for foundry purposes, which is made up of various types of mould materials that are heat-resistant for the casting of metals and have a varying material composition, characterized in that a solid mould body (2) is produced from a foundry mould material A and during manufacture is completely or partially enclosed with a powdered and pourable chemically bonded foundry mould material B, whereby a block - shaped mould material block (3) being formed from the composite mould material after the curing of the foundry mould material B and subsequently worked by a method of material removal such as milling, drilling, turning or grinding, the mould cavity (1) being introduced into the mould body (2) consisting of the foundry mould material A and the sprue system (4) and feeder system (5) being introduced into the mould material block (3) consisting of the foundry mould material B by using CAD data.
  2. Procedure according to Claim 1, characterized in that refractory, thermal-shock resistant ceramic foundry mould materials of their final strength are used for the foundry mould material A and are worked by a method of material removal such as milling, turning, drilling or grinding.
  3. Procedure according to Claim 1, characterized in that foundry moulding sand with a thermocurable binder or a binder based on bentonites, water glass, furan resin, cement or gypsum of its final strength is used for the foundry mould material A, the binder content being different and or the type of sand being different than in the case of foundry mould material B.
  4. Procedure according to Claim 1, characterized in that foundry moulding sand with a thermocurable binder or a binder based on bentonites, water glass, furan resin, cement or gypsum is used for the foundry mould material B.
  5. Procedure according to Claims 1 to 4, characterized in that, during the block shaping, the mould body (2) of the foundry mould material A is positively connected to the foundry mould material B by means of projections or recesses and/or by a prismatic shape with conically extending side walls (7).
  6. Procedure according to Claims 1 to 5, characterized in that the working of the mould cavity (1) for the cast part is performed with an NC program generated from the 3D data records of the cast blank and the production of the sprue system (4) and feeder system (5) is performed with a separate NC program with respectively adapted working parameters.
  7. Procedure according to one of Claims 1 to 6, characterized in that core marks (6) for cores are incorporated in the mould.
EP05016479A 2005-07-29 2005-07-29 Process for the manufacture of a mould from a binded material for metal foundry Not-in-force EP1749596B1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
DK05016479T DK1749596T3 (en) 2005-07-29 2005-07-29 Process for making a mold of composite molding material and for molding purposes
EP05016479A EP1749596B1 (en) 2005-07-29 2005-07-29 Process for the manufacture of a mould from a binded material for metal foundry
AT05016479T ATE364462T1 (en) 2005-07-29 2005-07-29 METHOD FOR PRODUCING A MOLD FROM A COMPOSITE MOLDING MATERIAL FOR FOUNDRY PURPOSES
ES05016479T ES2287844T3 (en) 2005-07-29 2005-07-29 METHOD FOR THE MANUFACTURE OF A GLASS MOLD FROM A COMPOSITE MOLDING MATERIAL FOR GLASS PURPOSES.
DE502005000878T DE502005000878D1 (en) 2005-07-29 2005-07-29 Process for producing a casting mold from a composite molding material for foundry purposes

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US8852478B2 (en) 2010-08-09 2014-10-07 DePuy Synthes Products, LLC Injection molding method including machining of both injection mold and molded product
DE102021122520A1 (en) 2020-08-31 2022-03-03 Mikromat Gmbh Process and device for the development and/or production of cast components

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US4104347A (en) * 1974-11-19 1978-08-01 Kubota, Ltd. Method of making a sand mold
JPS61172650A (en) * 1985-01-29 1986-08-04 Mitsubishi Heavy Ind Ltd Molding method of casting mold
JPS61245942A (en) 1985-04-22 1986-11-01 Honda Motor Co Ltd Production of metallic mold
GB8726967D0 (en) * 1987-11-18 1987-12-23 D Sa R Production of castings
JP3114159B2 (en) * 1995-11-29 2000-12-04 株式会社荏原製作所 Mold manufacturing method
DE19825448C2 (en) * 1998-06-06 2000-07-13 Actech Gmbh Adv Casting Tech Method and device for the direct production of a lost casting mold for metal castings
US6286581B1 (en) * 1999-07-28 2001-09-11 Ronald Gustafson Method for machining sand block into sand molding elements including sand molds and sand cores for metal casting foundry operations
DE10242191B4 (en) * 2001-09-27 2009-02-05 Actech Gmbh Process for the production of heat-resistant casting molds
DE10156332B4 (en) * 2001-11-19 2005-09-15 Actech Gmbh Advanced Casting Technologies Giessereitechnologie Method and modular system for the rapid production of molds
JP3533444B2 (en) * 2001-12-10 2004-05-31 サカキバラモデル株式会社 Casting mold manufacturing method and master mold for mold
EP1334785A1 (en) * 2002-02-07 2003-08-13 X-Tend ApS A method of machining a mould from a block of sand and use of said method
DE10247715B4 (en) * 2002-10-12 2004-09-30 Actech Gmbh Advanced Casting Technologies Giessereitechnologie Multi-bladed milling tool with inserts for direct molding milling

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ATE364462T1 (en) 2007-07-15
ES2287844T3 (en) 2007-12-16
DK1749596T3 (en) 2007-10-08
DE502005000878D1 (en) 2007-07-26

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