EP2357049A1 - Lost pattern casting process and apparatus for the execution of this process - Google Patents

Lost pattern casting process and apparatus for the execution of this process Download PDF

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Publication number
EP2357049A1
EP2357049A1 EP10196190A EP10196190A EP2357049A1 EP 2357049 A1 EP2357049 A1 EP 2357049A1 EP 10196190 A EP10196190 A EP 10196190A EP 10196190 A EP10196190 A EP 10196190A EP 2357049 A1 EP2357049 A1 EP 2357049A1
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EP
European Patent Office
Prior art keywords
enclosure
cluster
model
container
cooler
Prior art date
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Granted
Application number
EP10196190A
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German (de)
French (fr)
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EP2357049B1 (en
Inventor
Jean-Jacques Marceau
Thierry Callais
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PSA Automobiles SA
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Peugeot Citroen Automobiles SA
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Publication of EP2357049A1 publication Critical patent/EP2357049A1/en
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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
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C13/00—Moulding machines for making moulds or cores of particular shapes
    • B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
    • B22C13/085—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores by investing a lost pattern
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • 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
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould

Definitions

  • the present invention relates to a lost mold molding process and the installation for carrying out this method.
  • a lost mold molding process (PMP process) consists of placing one or more models in a container in a sublimable material, then drowning the assembly in sand leaving a pouring orifice in which liquid metal is poured. . The model sublimates and the metal comes to replace it.
  • Such a molding process can in particular be used for molding the cylinder heads.
  • a fuse model composed of elements in a sublimable material such as expanded polystyrene (model cluster) is coated with a thin refractory layer.
  • the cluster called “coated cluster” is placed in a molding container called tank which is then filled with sand.
  • the alloy destroys the expanded polystyrene and gradually takes its place in the footprint of the thin layer of plaster and sand.
  • the alloy of the cluster solidifies and then naturally cools slowly in the sand with highly insulating properties.
  • the resulting piece of cluster can then be extracted from the tank (shakeout).
  • the cooling is limited to 1 face per piece with improved mechanical properties of the material limited to the cooled faces.
  • coolers constitute masses of inertia which oppose the vibrations of the tank causing significant mechanical stress of their fasteners may cause fatigue cracks.
  • the vibration imposed chillers causes friction between them and the coated cluster causing the abrasion of the coating and the risk of sand infiltration at the interface which can cause defects in the piece, a fouling of the coolers and, a fast wear of the coolers.
  • the tanks are specific and a change of tank is necessary to sink without cooler.
  • the conditioning of the tanks, prior to the next casting, is difficult especially because of the cleaning and heating of the coolers. A disassembly of the chillers could then be necessary which at present takes a certain time.
  • the coated cluster being very flexible, it is deformed by its contact with coolers that behave as conformers.
  • the chiller assembly must be stable and accurate to hope to obtain parts with good accuracy.
  • the present invention therefore aims to overcome these disadvantages by providing a lost mold molding process in which the vibrations of the vessel are no longer experienced by the coolers which allows in particular to improve the life of equipment.
  • the invention relates to a lost model molding process in which one or more models are placed in a container in a sublimable material, the model (s) are drowned in sand leaving a pouring orifice and poured liquid metal into this orifice, characterized in that the said model or models are introduced beforehand into an enclosure having at least an element capable of cooling one or more faces of the model, the enclosure / model (s) being introduced into the container without contact with the latter.
  • the element allowing the cooling is no longer attached to the container such as a tank but serves as a support for the model or cluster and when vibrations are applied to allow a good distribution of sand introduced into the tank , the enclosure / models do not undergo vibrations which overcomes the disadvantages mentioned above.
  • the model or cluster is placed in the enclosure at an assembly station and is transferred by appropriate means to be introduced and positioned in the vessel without contact therewith.
  • the cooler may be pre-positioned in contact with the tank to allow movement of the assembly, before filling.
  • the cooler receives the cluster and is taken up and kept separate from the tank by a suitable mechanism during the sand filling operation by vibration.
  • the present invention also relates to an installation for implementing a lost model molding process of the type comprising a container mounted on a vibrating frame, characterized in that it comprises a chamber adapted to receive one or more models and having at least one element adapted to cool one or more faces of the model, said enclosure further comprising fixing means to means for placing the enclosure / model assembly in the container without contact therewith.
  • This cooling chamber or cooler may be a one-piece assembly or may consist of several assembled elements such as four walls. It may in particular comprise movable elements to allow the establishment of the coated model or cluster while allowing the cooling of recessed shapes with respect to the main cooled faces.
  • the cooler or its elements may consist of different materials of different mechanical properties, thermal conductivity and specific heat such as steel, cast iron, aluminum, copper, sintered materials, ceramics, etc.
  • the cooler may thus consist of different shades of cast iron or steel adapted to their own functions, namely parts serving as cooling elements and other parts.
  • the cooler has at least two attachment points for attachment to means for its introduction into the tank.
  • These means may consist of suspension and transport means such as a bracket for suspending and putting it in place in the tank, to hold it suspended in and extract it from the tank during the operation of stall and also used for various handling.
  • the enclosure or cooler has four main walls. Two of these walls opposite one another and called main walls are able to absorb calories, for example made of a caloric absorbing material thus constituting two cooling elements suitable for coming into contact with the cluster introduced into the chamber while the other two walls connecting them comprise the fixing means to a suspension structure of the cooler. Additional coolers can cool other parts of the rooms.
  • the cooler is preferably in the form of an open enclosure in its upper part.
  • its main walls of contact with the coated cluster form a draft angle to allow the establishment of the coated cluster and the extraction of the solidified cluster.
  • the cluster consists of at least two parts and a filling system (down).
  • the faces to be in contact with the cooler are positioned opposite the descendant, with an angle corresponding to the draft of the cooler.
  • the chill and coated cluster assembly is positioned and maintained in the tank by means of suspension and independent transport thereof and the vibrating frame (vibrating table). This principle therefore avoids the direct transmission of vibrations to the cooler and the coated cluster.
  • the cooler absorbs the heat of the alloy during the filling, solidification and cooling phases of the cluster, until the latter is strong enough to allow the shakeout.
  • the cooler and the cluster are extracted together from the tank which is simultaneously emptied of sand (shakeout).
  • a flexible system can be used at the points of attachment of the chiller.
  • This cooling can be performed either by means of an internal circuit to the cooler, or by means of a refrigerant fluid acting at the outer walls of the cooler. This cooling may occur before, during or after the positioning of the cooler in the tank.
  • the assembly After shaking, before separation of the cooler cluster, the assembly can be directly cooled by a fluid (water, air ....), by dipping or spraying.
  • a fluid water, air ....
  • Such a molding process is particularly well suited for molding cylinder heads made of aluminum alloys, but it can be used for other parts (eg engine blocks, crankcase housing, etc.) and casting. other alloys requiring or supporting solidification and / or rapid cooling.
  • a suspended cooler according to the invention can be used with any tank filling system using or not the vibration principle (eg fluidization %), with any system or mechanism able to keep it suspended in the tank ( Robot, mechanized arm, stem, other component of the molding site (eg supendu under the tank %), with all principles of casting (gravity, low pressure %) whatever the filling material (Silica, Zircon, ....), with or without coating, with a partial coating of the model cluster polystyrene and whatever the coating used.
  • a protective film on the cooler eg poteyage
  • a coating can be permanent, semi-permanent or renewed at each cycle.
  • the cluster 1 of sublimable material such as expanded polystyrene coated is composed of at least two parts and a filling system 1 a (down) and is introduced into a chamber 2 forming the cooler.
  • This cooler 2 is in the form of an open chamber in its upper part and in its lower part and is provided with two main walls 3 opposite one of the other consist of a material absorbing calories such as cast iron, steel, aluminum alloys or cuprous .... and constituting the cooling elements of the enclosure 2.
  • These main walls 3 of contact with the coated cluster 1 form a draft angle to allow the establishment of the coated cluster 1 and the extraction of the solidified cluster.
  • the faces of the cluster 1 to be in contact with the cooler 2 are positioned opposite the descendant 1a, with an angle corresponding to the draft of the cooler 2.
  • These two main walls 3 are connected to one another by two lateral walls 4 respectively comprising fixing means 2a of the enclosure 2 to a suspension system such as an arm 5 for example to lift the assembly cooler / cluster 2, 1 to bring it to a tank 6 where the assembly is introduced without direct contact with said tank 6, suspended in said tank 6.
  • a suspension system such as an arm 5 for example to lift the assembly cooler / cluster 2, 1 to bring it to a tank 6 where the assembly is introduced without direct contact with said tank 6, suspended in said tank 6.
  • said tank 6 is filled with sand 7 during the packaging step, while subjecting the tank 6 to vibrations via a vibrating table (not shown) on which the vessel 6 rests so as to distribute the sand well.
  • the cooler / cluster 2.1 assembly being kept suspended in the tank 6, by a suspension system independent of said tank 6, thus avoiding a direct transmission of the vibrations to the cooler 2 and to the coated cluster 1.
  • casting of the alloy 7 and the cooler 2 through its main walls 3 absorbs the heat of the alloy during the filling phases, solidifying and cooling the cluster 1 until the latter is strong enough to allow the shakeout.
  • the cooler 2 and the cluster 1 are extracted together from the tank 6 which is simultaneously emptied of sand (shake).
  • the formed cluster 1 is then separated from the cooler 2 and treated according to the conventional process.
  • a lost model molding apparatus and method according to the invention accelerates solidification by improving cooling. Accelerated solidification reduces DAS (Dendritic Arm Spacing), gas porosity, micro-shrinkage and the risk of iron needles.
  • DAS Density Arm Spacing
  • gas porosity gas porosity
  • micro-shrinkage micro-shrinkage
  • the mechanical properties of the molded material are therefore improved, in particular with better elasticity (elongation A%).
  • the coolers are not directly subjected to the vibrations of the tank, it eliminates a mechanical stress of the fasteners and therefore limited maintenance interventions.
  • the tanks currently used can be kept without modification for the installations according to the invention.
  • chillers can easily be put in conditions prior to the next pour (cleaning and heating, control) in a flow independent of that of the tanks. Unit or frequency dimensional control is facilitated. Chillers being compact, their dimensional accuracy is better, which is favorable for obtaining precision dimension of the parts produced. The compactness of the cooler and a good dimensional accuracy make it possible to envisage cooling localized on other faces of the part (eg face admission of a cylinder head).
  • the compact cooler playing the role of support of the cluster, can allow to uncheck at higher temperature (the strength of the cluster is less important than in other solutions) and, therefore, reduce the outstanding cluster number of vessels, and the area occupied by the cooling zone of the molding site.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

The lost wax casting process comprises placing models made of a sublimating material in a container, spreading sand over the models, and forming a hole in the models and then pouring a liquid metal into the hole. The models are placed in an enclosure having a specific element to cool surfaces of the model. The model or cluster is placed in the enclosure to an assembly station and then transferred to a tank using an insertion unit. The enclosure is pre-positioned in contact with the container, and when the enclosure receives the cluster, the cluster is separated from the enclosure. The lost wax casting process comprises placing models made of a sublimating material in a container, spreading sand over the models, and forming a hole in the models and then pouring a liquid metal into the hole. The models are placed in an enclosure having a specific element to cool surfaces of the model. The model or cluster is placed in the enclosure to an assembly station and then transferred to a tank using an insertion unit. The enclosure is pre-positioned in contact with the container, and when the enclosure receives the cluster, the cluster is separated from the enclosure by a specific mechanism. The enclosure or model assembly is kept in suspension in the container without contact with each other. An independent claim is included for an installation for molding a waste model.

Description

La présente invention concerne un procédé de moulage en moule perdu ainsi que l'installation pour la mise en oeuvre de ce procédé.The present invention relates to a lost mold molding process and the installation for carrying out this method.

Un procédé de moulage en moule perdu (procédé PMP) consiste à placer dans un container, un ou plusieurs modèles en une matière sublimable, puis à noyer l'ensemble dans du sable en laissant subsister un orifice de coulée dans lequel on verse du métal liquide. Le modèle se sublime et le métal vient le remplacer.A lost mold molding process (PMP process) consists of placing one or more models in a container in a sublimable material, then drowning the assembly in sand leaving a pouring orifice in which liquid metal is poured. . The model sublimates and the metal comes to replace it.

Un tel procédé de moulage peut notamment être utilisé pour le moulage des culasses. Ainsi, un modèle fusible composé d'éléments en une matière sublimable tel que le polystyrène expansé (grappe de modèles) est enduit d'une fine couche réfractaire. A ce stade du processus, la grappe appelée "grappe enduite" est placée dans un container de moulage appelée cuve qui est ensuite rempli de sable.Such a molding process can in particular be used for molding the cylinder heads. Thus, a fuse model composed of elements in a sublimable material such as expanded polystyrene (model cluster) is coated with a thin refractory layer. At this stage of the process, the cluster called "coated cluster" is placed in a molding container called tank which is then filled with sand.

Lors de la coulée, l'alliage détruit le polystyrène expansé et prend progressivement sa place dans l'empreinte constituée de la fine couche d'enduit et du sable. L'alliage de la grappe se solidifie et se refroidit alors naturellement lentement dans le sable aux propriétés très isolantes. La grappe de pièce obtenue peut ensuite être extraite de la cuve (décochage).During casting, the alloy destroys the expanded polystyrene and gradually takes its place in the footprint of the thin layer of plaster and sand. The alloy of the cluster solidifies and then naturally cools slowly in the sand with highly insulating properties. The resulting piece of cluster can then be extracted from the tank (shakeout).

On a proposé dans FR 2 685 229 , un procédé de moulage en modèle perdu qui permet d'améliorer localement les propriétés métallurgiques de la pièce obtenue et en particulier d'obtenir une pièce ayant, une ou plusieurs zones dont le coefficient d'allongement est relativement élevé, en plaçant dans le container un élément réfrigérant propre à refroidir une ou plusieurs faces du modèle.It has been proposed in FR 2,685,229 , a lost model molding process which makes it possible locally to improve the metallurgical properties of the part obtained and in particular to obtain a part having one or more zones whose coefficient of elongation is relatively high, by placing in the container a cooling element capable of cooling one or more faces of the model.

Une application de ce principe avec des refroidisseurs solides fixés à l'intérieur de la cuve de moulage permet de positionner la grappe enduite de façon classique dans la cuve, les faces à refroidir venant au contact des refroidisseurs. La grappe est maintenu suspendue dans la cuve de moulage durant de son remplisage de sable très sec et fluide. La mise en vibration de la cuve permet au sable d'occuper tous les interstices et cavités du modèle de polystyrène, comme s'il s'agissait d'un liquide. L'extraction de la grappe solidifiée est décochée de façon classique.An application of this principle with solid chillers fixed inside the molding vessel makes it possible to position the cluster conventionally coated in the tank, the faces to be cooled coming into contact with the coolers. The cluster is kept suspended in the molding tank during its filling of very dry and fluid sand. The vibration of the tank allows the sand to occupy all the interstices and cavities of the polystyrene model, as if it were a liquid. The extraction of the solidified cluster is unchecked in a conventional manner.

Cependant, avec un tel procédé PMP, le refroidissement est limité à 1 face par pièce avec des propriétés mécaniques améliorées du matériau limitées aux faces refroidies.However, with such a PMP process, the cooling is limited to 1 face per piece with improved mechanical properties of the material limited to the cooled faces.

Par ailleurs, les refroidisseurs constituent des masses d'inertie qui s'opposent aux vibrations de la cuve en entrainant des sollicitations mécaniques importantes de leurs fixations pouvant entraîner des fissures de fatigue. Ces fixations ainsi que les cuves nécessitent alors une surveillance et une maintenance coûteuse.Moreover, the coolers constitute masses of inertia which oppose the vibrations of the tank causing significant mechanical stress of their fasteners may cause fatigue cracks. These fixtures as well as the tanks then require expensive monitoring and maintenance.

De plus, la vibration imposée aux refroidisseurs entraine une friction entre ceux-ci et la grappe enduite provoquant l'abrasion de l'enduit et le risque d'une infiltration de sable à l'interface ce qui peut provoquer des défauts au niveau de la pièce, un encrassement des refroidisseurs et, une usure rapide des refroidisseurs.In addition, the vibration imposed chillers causes friction between them and the coated cluster causing the abrasion of the coating and the risk of sand infiltration at the interface which can cause defects in the piece, a fouling of the coolers and, a fast wear of the coolers.

Par ailleurs, les cuves sont spécifiques et un changement de cuve est nécessaire pour couler sans refroidisseur. De plus, la mise en conditions des cuves, préalablement à la coulée suivante, est difficile du fait notamment du nettoyage et de mise en température des refroidisseurs. Un démontage des refroidisseurs pourrait alors être nécessaire ce qui à l'heure actuelle prend un certain temps.Moreover, the tanks are specific and a change of tank is necessary to sink without cooler. In addition, the conditioning of the tanks, prior to the next casting, is difficult especially because of the cleaning and heating of the coolers. A disassembly of the chillers could then be necessary which at present takes a certain time.

Le manque de précisions dimensionnelles de l'ensemble cuve et refroidisseurs, de grandes dimensions, peut être défavorable à une bonne précision dimensionnelle. La grappe enduite étant très flexible, elle est déformée par sa mise en contact avec les refroidisseurs qui se comportent comme des conformateurs. L'ensemble refroidisseur doit donc être stable et précis pour espérer obtenir des pièces avec une bonne précision.The lack of dimensional accuracy of the entire tank and chillers, large, may be unfavorable to good dimensional accuracy. The coated cluster being very flexible, it is deformed by its contact with coolers that behave as conformers. The chiller assembly must be stable and accurate to hope to obtain parts with good accuracy.

La présente invention a donc pour but de pallier ces inconvénients en proposant un procédé de moulage en moule perdu dans lequel les vibrations de la cuve ne sont plus subies par les refroidisseurs ce qui permet notamment d'améliorer la durée de vie des matériels.The present invention therefore aims to overcome these disadvantages by providing a lost mold molding process in which the vibrations of the vessel are no longer experienced by the coolers which allows in particular to improve the life of equipment.

A cet effet, l'invention concerne un procédé de moulage en modèle perdu dans lequel on place dans un container, un ou plusieurs modèles en une matière sublimable, on noie le ou les modèles dans du sable en laissant subsister un orifice de coulée et on verse du métal liquide dans cet orifice, caractérisé en ce que le ou lesdits modèles sont introduits au préalable dans une enceinte présentant au moins un élément propre à refroidir une ou plusieurs faces du modèle, l'ensemble enceinte/modèle(s) étant introduit dans le container sans contact avec ce dernier.For this purpose, the invention relates to a lost model molding process in which one or more models are placed in a container in a sublimable material, the model (s) are drowned in sand leaving a pouring orifice and poured liquid metal into this orifice, characterized in that the said model or models are introduced beforehand into an enclosure having at least an element capable of cooling one or more faces of the model, the enclosure / model (s) being introduced into the container without contact with the latter.

Ainsi, de manière très avantageuse, l'élément permettant le refroidissement n'est plus fixé au container tel qu'une cuve mais sert de support au modèle ou grappe et lorsque des vibrations sont appliquées pour permettre une bonne répartition du sable introduit dans la cuve, l'ensemble enceinte/modèles ne subit pas les vibrations ce qui permet de pallier les inconvénients cités précédemment.Thus, very advantageously, the element allowing the cooling is no longer attached to the container such as a tank but serves as a support for the model or cluster and when vibrations are applied to allow a good distribution of sand introduced into the tank , the enclosure / models do not undergo vibrations which overcomes the disadvantages mentioned above.

Selon une première variante du procédé, le modèle ou grappe est mis en place dans l'enceinte à un poste d'assemblage puis est transféré par des moyens appropriés pour être introduit et positionné dans la cuve sans contact avec celle-ci.According to a first variant of the method, the model or cluster is placed in the enclosure at an assembly station and is transferred by appropriate means to be introduced and positioned in the vessel without contact therewith.

Selon une deuxième variante du procédé, le refroidisseur peut être pré-positionné en contact avec la cuve pour permettre un déplacement de l'ensemble, avant remplissage. Dans ce cas de figure, le refroidisseur reçoit la grappe puis est repris et maintenu séparé de la cuve par un mécanisme approprié lors de l'opération de remplissage du sable par vibration.According to a second variant of the method, the cooler may be pre-positioned in contact with the tank to allow movement of the assembly, before filling. In this case, the cooler receives the cluster and is taken up and kept separate from the tank by a suitable mechanism during the sand filling operation by vibration.

La présente invention concerne également une installation pour la mise en oeuvre d'un procédé de moulage par modèle perdu du type comprenant un container monté sur un bâti vibrant, caractérisé en ce qu'elle comporte une enceinte propre à recevoir un ou des modèles et présentant au moins un élément propre à refroidir une ou plusieurs faces du modèle, ladite enceinte comportant en outre des moyens de fixation à des moyens permettant la mise en place de l'ensemble enceinte/modèle dans le container sans contact avec celui-ci.The present invention also relates to an installation for implementing a lost model molding process of the type comprising a container mounted on a vibrating frame, characterized in that it comprises a chamber adapted to receive one or more models and having at least one element adapted to cool one or more faces of the model, said enclosure further comprising fixing means to means for placing the enclosure / model assembly in the container without contact therewith.

Cette enceinte de refroidissement ou refroidisseur peut être un ensemble monobloc ou peut être constitué de plusieurs éléments assemblés tels que quatre parois. Il peut notamment comporter des éléments mobiles pour autoriser la mise en place du modèle ou grappe enduit tout en permettant le refroidissement de formes en creux par rapport aux principales faces refroidies.This cooling chamber or cooler may be a one-piece assembly or may consist of several assembled elements such as four walls. It may in particular comprise movable elements to allow the establishment of the coated model or cluster while allowing the cooling of recessed shapes with respect to the main cooled faces.

Le refroidisseur ou ses éléments peuvent être constitués de différents matériaux de propriétés mécaniques, conductivité thermiques et chaleur massique différentes tels qu'acier, fonte, aluminium, cuivre, matériaux frittés, céramiques.... Le refroidisseur peut être ainsi constitué de différentes nuances de fonte ou d'acier adaptées à leurs fonctions propres, à savoir parties servant d'élément de refroidissement et autres parties.The cooler or its elements may consist of different materials of different mechanical properties, thermal conductivity and specific heat such as steel, cast iron, aluminum, copper, sintered materials, ceramics, etc. The cooler may thus consist of different shades of cast iron or steel adapted to their own functions, namely parts serving as cooling elements and other parts.

Le refroidisseur présente au moins deux points de fixation permettant son accrochage à des moyens permettant sa mise en place dans la cuve. Ces moyens peuvent être constitués de moyens de suspension et de transport tels qu'une potence permettant de le suspendre et de le mettre en place dans la cuve, de le maintenir suspendu dedans et de l'extraire de la cuve lors de l'opération de décochage et servant également à diverses manutentions.The cooler has at least two attachment points for attachment to means for its introduction into the tank. These means may consist of suspension and transport means such as a bracket for suspending and putting it in place in the tank, to hold it suspended in and extract it from the tank during the operation of stall and also used for various handling.

Selon une forme de réalisation, l'enceinte ou refroidisseur présente quatre parois principales. Deux de ces parois à l'opposé l'une de l'autre et appelées parois principales sont aptes à absorber des calories, par exemple constituées d'un matériau absorbeur de calories constituant ainsi deux éléments de refroidissement appropriés pour venir au contact avec la grappe introduite dans l'enceinte tandis que les deux autres parois les reliant comportent les moyens de fixation à une structure de suspension du refroidisseur. Des éléments refroidisseurs additionnels peuvent permettre de refroidir d'autres parties des pièces.According to one embodiment, the enclosure or cooler has four main walls. Two of these walls opposite one another and called main walls are able to absorb calories, for example made of a caloric absorbing material thus constituting two cooling elements suitable for coming into contact with the cluster introduced into the chamber while the other two walls connecting them comprise the fixing means to a suspension structure of the cooler. Additional coolers can cool other parts of the rooms.

Le refroidisseur se présente de préférence sous la forme d'une enceinte ouverte dans sa partie supérieure. De préférence, ses parois principales de contact avec la grappe enduite forment un angle de dépouille pour permettre la mise en place de la grappe enduite et l'extraction de la grappe solidifiée.The cooler is preferably in the form of an open enclosure in its upper part. Preferably, its main walls of contact with the coated cluster form a draft angle to allow the establishment of the coated cluster and the extraction of the solidified cluster.

La grappe est composée d'au moins deux pièces et d'un système de remplissage (descendant). Les faces à mettre en contact avec le refroidisseur sont positionnées à l'opposé du descendant, avec un angle correspondant à la dépouille du refroidisseur.The cluster consists of at least two parts and a filling system (down). The faces to be in contact with the cooler are positioned opposite the descendant, with an angle corresponding to the draft of the cooler.

Durant le remplissage de la cuve par le sable (emballage), l'ensemble refroidisseur et grappe enduite est positionné et maintenu dans la cuve par les moyens de suspension et de transport indépendant de celle-ci et du bâti vibrant (table vibrante). Ce principe évite donc la transmission directe des vibrations au refroidisseur et à la grappe enduite.During the filling of the tank with the sand (packaging), the chill and coated cluster assembly is positioned and maintained in the tank by means of suspension and independent transport thereof and the vibrating frame (vibrating table). This principle therefore avoids the direct transmission of vibrations to the cooler and the coated cluster.

Après coulée, le refroidisseur absorbe la chaleur de l'alliage durant les phases de remplissage, de solidification et de refroidissement de la grappe, jusqu'à ce que cette dernière soit suffisamment solide pour permettre le décochage.After casting, the cooler absorbs the heat of the alloy during the filling, solidification and cooling phases of the cluster, until the latter is strong enough to allow the shakeout.

Après solidification, le refroidisseur et la grappe sont extraits ensemble de la cuve qui est simultanément vidée de son sable (décochage).After solidification, the cooler and the cluster are extracted together from the tank which is simultaneously emptied of sand (shakeout).

Pour permettre au refroidisseur de suivre les mouvements de la cuve en fin de compactage du sable, un système flexible peut être utilisé au niveau des points d'accrochage du refroidisseur.To allow the chiller to follow the movements of the tank at the end of compaction of the sand, a flexible system can be used at the points of attachment of the chiller.

Le refroidisseur peut fonctionner soit en absorbant simplement la chaleur de l'alliage coulé soit être lui même refroidi par un fluide (eau, air, azote gazeux ou liquide......). Ce refroidissement peut être effectué soit au moyen d'un circuit interne au refroidisseur, soit au moyen d'un fluide réfrigérant agissant au niveau des parois externes du refroidisseur. Ce refroidissement peut intervenir avant, pendant ou après le positionnement du refroidisseur dans la cuve.The cooler can operate either by simply absorbing the heat of the cast alloy or be itself cooled by a fluid (water, air, nitrogen gas or liquid ......). This cooling can be performed either by means of an internal circuit to the cooler, or by means of a refrigerant fluid acting at the outer walls of the cooler. This cooling may occur before, during or after the positioning of the cooler in the tank.

Après décochage, avant séparation de la grappe du refroidisseur, l'ensemble peut être directement refroidi par un fluide (eau, air....), par trempage ou aspersion.After shaking, before separation of the cooler cluster, the assembly can be directly cooled by a fluid (water, air ....), by dipping or spraying.

Un tel procédé de moulage est particulièrement bien adapté pour le moulage des culasses en alliages d'aluminium, mais il peut être utilisé pour d'autres pièces (ex. blocs moteur, carter chapeau de vilebrequin....) et la coulée d'autres alliages nécessitant ou supportant une solidification et/ou un refroidissement rapide.Such a molding process is particularly well suited for molding cylinder heads made of aluminum alloys, but it can be used for other parts (eg engine blocks, crankcase housing, etc.) and casting. other alloys requiring or supporting solidification and / or rapid cooling.

Un refroidisseur suspendu selon l'invention peut être utilisé avec tous systèmes de remplissage de la cuve utilisant ou non le principe de vibration (Ex.: fluidisation...), avec tout système ou mécanisme en mesure de le maintenir suspendu dans la cuve (Robot, bras mécanisé, potence, autre composant du chantier de moulage (ex. supendu sous la cuve...), avec tous principes de coulée (gravité, basse pression...) quelque soit le matériau de remplissage (Silice, Zircon, ....), avec ou sans enduction, avec une enduction partielle de la grappe de modèles en polystyrène et quelque soit l'enduit utilisé.A suspended cooler according to the invention can be used with any tank filling system using or not the vibration principle (eg fluidization ...), with any system or mechanism able to keep it suspended in the tank ( Robot, mechanized arm, stem, other component of the molding site (eg supendu under the tank ...), with all principles of casting (gravity, low pressure ...) whatever the filling material (Silica, Zircon, ....), with or without coating, with a partial coating of the model cluster polystyrene and whatever the coating used.

L'application d'une pellicule de protection sur le refroidisseur (ex.: poteyage) ou d'un revêtement sont envisageables. Ils peuvent-être permanents, semi permanents ou renouvelés à chaque cycle.The application of a protective film on the cooler (eg poteyage) or a coating are possible. They can be permanent, semi-permanent or renewed at each cycle.

On décrira maintenant l'invention plus en détails en référence au dessin dans lequel :The invention will now be described in more detail with reference to the drawing in which:

Les figures 1 à 6 représentent différentes étapes du procédé selon l'invention.The Figures 1 to 6 represent different steps of the process according to the invention.

Comme on peut le voir à la figure 1, la grappe 1 en matière sublimable tel que du polystyrène expansé enduit est composée d'au moins deux pièces et d'un système de remplissage 1 a (descendant) et est introduite dans une enceinte 2 formant le refroidisseur.As can be seen at figure 1 , the cluster 1 of sublimable material such as expanded polystyrene coated is composed of at least two parts and a filling system 1 a (down) and is introduced into a chamber 2 forming the cooler.

Ce refroidisseur 2 se présente sous la forme d'une enceinte ouverte dans sa partie supérieure et dans sa partie inférieure et est pourvu de deux parois principales 3 à l'opposé l'une de l'autre constituées d'un matériau absorbant les calories tel que fonte, acier, alliages d'aluminium ou cuivreux.... et constituant les éléments de refroidissement de l'enceinte 2. Ces parois principales 3 de contact avec la grappe enduite 1 forment un angle de dépouille pour permettre la mise en place de la grappe enduite 1 et l'extraction de la grappe solidifiée. Les faces de la grappe 1 à mettre en contact avec le refroidisseur 2 sont positionnées à l'opposé du descendant 1a, avec un angle correspondant à la dépouille du refroidisseur 2.This cooler 2 is in the form of an open chamber in its upper part and in its lower part and is provided with two main walls 3 opposite one of the other consist of a material absorbing calories such as cast iron, steel, aluminum alloys or cuprous .... and constituting the cooling elements of the enclosure 2. These main walls 3 of contact with the coated cluster 1 form a draft angle to allow the establishment of the coated cluster 1 and the extraction of the solidified cluster. The faces of the cluster 1 to be in contact with the cooler 2 are positioned opposite the descendant 1a, with an angle corresponding to the draft of the cooler 2.

Ces deux parois principales 3 sont reliées l'une à l'autre par deux parois latérales 4 comportant respectivement des moyens de fixation 2a de l'enceinte 2 à un système de suspension tel qu'un bras 5 par exemple permettant de soulever l'ensemble refroidisseur/grappe 2, 1 pour l'amener vers une cuve 6 où l'ensemble est introduit sans contact direct avec ladite cuve 6, suspendu dans ladite cuve 6.These two main walls 3 are connected to one another by two lateral walls 4 respectively comprising fixing means 2a of the enclosure 2 to a suspension system such as an arm 5 for example to lift the assembly cooler / cluster 2, 1 to bring it to a tank 6 where the assembly is introduced without direct contact with said tank 6, suspended in said tank 6.

Une fois l'ensemble 2,1 introduit et maintenu suspendu dans la cuve 6, on remplit ladite cuve 6 avec du sable 7 durant l'étape d'emballage, tout en soumettant la cuve 6 à des vibrations par l'intermédiaire d'une table vibrante (non représentée) sur laquelle repose la cuve 6 de manière à bien répartir le sable.Once the assembly 2.1 introduced and kept suspended in the tank 6, said tank 6 is filled with sand 7 during the packaging step, while subjecting the tank 6 to vibrations via a vibrating table (not shown) on which the vessel 6 rests so as to distribute the sand well.

L'ensemble refroidisseur/grappe 2,1 étant maintenu suspendu dans la cuve 6, par un système de suspension indépendant de ladite cuve 6, on évite ainsi une transmission directe des vibrations au refroidisseur 2 et à la grappe enduite 1. On effectue ensuite la coulée de l'alliage 7 et le refroidisseur 2 par l'intermédiaire de ses parois principales 3 absorbe la chaleur de l'alliage durant les phases de remplissage, de solidification et de refroidissement de la grappe 1 jusqu'à ce que cette dernière soit suffisamment solide pour permettre le décochage.The cooler / cluster 2.1 assembly being kept suspended in the tank 6, by a suspension system independent of said tank 6, thus avoiding a direct transmission of the vibrations to the cooler 2 and to the coated cluster 1. casting of the alloy 7 and the cooler 2 through its main walls 3 absorbs the heat of the alloy during the filling phases, solidifying and cooling the cluster 1 until the latter is strong enough to allow the shakeout.

Ainsi, après solidification, le refroidisseur 2 et la grappe 1 sont extraits ensemble de la cuve 6 qui est simultanément vidée de son sable (décochage). La grappe 1 formée est ensuite séparée du refroidisseur 2 et traitée suivant le processus classique.Thus, after solidification, the cooler 2 and the cluster 1 are extracted together from the tank 6 which is simultaneously emptied of sand (shake). The formed cluster 1 is then separated from the cooler 2 and treated according to the conventional process.

Le refroidisseur 2 est alors mis en condition pour un nouveau cycle de moulage au cours d'un processus secondaire dont les principales opérations sont:

  • nettoyage
  • mise à la température requise pour un nouveau cycle.
  • contrôle dimensionnel unitaire ou fréquentiel.
The cooler 2 is then conditioned for a new molding cycle during a secondary process whose main operations are:
  • cleaning
  • set to the required temperature for a new cycle.
  • unitary or frequency dimensional control.

Une installation et un procédé de moulage par modèle perdu selon l'invention permettent d'accélérer la solidification en améliorant le refroidissement. La solidification accélérée réduit le DAS (Dendritic Arm Spacing), les porosités gazeuses, les micro-retassures et le risque d'apparition d'aiguilles de fer. Les propriétés mécaniques du matériau moulé sont donc améliorées notamment avec une meilleure élasticité (allongement A%).A lost model molding apparatus and method according to the invention accelerates solidification by improving cooling. Accelerated solidification reduces DAS (Dendritic Arm Spacing), gas porosity, micro-shrinkage and the risk of iron needles. The mechanical properties of the molded material are therefore improved, in particular with better elasticity (elongation A%).

Par ailleurs, puisque les refroidisseurs ne sont pas directement soumis aux vibrations de la cuve, on élimine une sollicitation mécanique des fixations et donc on limite les interventions de maintenance.Moreover, since the coolers are not directly subjected to the vibrations of the tank, it eliminates a mechanical stress of the fasteners and therefore limited maintenance interventions.

En outre, les effets des vibrations sont très réduits quant à la friction entre refroidisseurs et grappes enduites, à l'abrasion de l'enduit, aux infiltrations de sable et à l'usure des refroidisseurs qui peuvent en être la conséquenceIn addition, the effects of vibration are very low in terms of the friction between coaters and coated clusters, the abrasion of the coating, the infiltration of sand and the wear of chillers which may be the consequence

Par ailleurs, les cuves actuellement utilisées peuvent être conservées sans modification pour les installations selon l'invention.Moreover, the tanks currently used can be kept without modification for the installations according to the invention.

Par ailleurs, les refroidisseurs peuvent facilement être mis en conditions préalablement à la coulée suivante (nettoyage et mise en température, contrôle) dans un flux indépendant de celui des cuves. Un contrôle dimensionnel unitaire ou fréquentiel est facilité. Les refroidisseurs étant compacts leur précision dimensionnelle est meilleure ce qui est favorable à l'obtention de la précision dimensionnelle des pièces produites. La compacité du refroidisseur et une bonne précision dimensionnelle permettent d'envisager des refroidissements localisés sur d'autres faces de la pièce (ex. face admission d'une culasse).Moreover, the chillers can easily be put in conditions prior to the next pour (cleaning and heating, control) in a flow independent of that of the tanks. Unit or frequency dimensional control is facilitated. Chillers being compact, their dimensional accuracy is better, which is favorable for obtaining precision dimension of the parts produced. The compactness of the cooler and a good dimensional accuracy make it possible to envisage cooling localized on other faces of the part (eg face admission of a cylinder head).

Ainsi, le refroidisseur compact, en jouant le rôle de support de la grappe, peut permettre de décocher à température plus élevée (la solidité de la grappe est moins importante que dans les autres solutions) et, donc, de réduire l'encours de grappes de pièces, le nombre de cuves et la surface occupée par la zone de refroidissement du chantier de moulage.Thus, the compact cooler, playing the role of support of the cluster, can allow to uncheck at higher temperature (the strength of the cluster is less important than in other solutions) and, therefore, reduce the outstanding cluster number of vessels, and the area occupied by the cooling zone of the molding site.

L'invention n'est bien entendu pas limitée à l'exemple décrit mais englobe les variantes entrant dans le champ de protection de l'invention.The invention is of course not limited to the example described but encompasses the variants falling within the scope of the invention.

Claims (11)

Procédé de moulage en modèle perdu dans lequel on place dans un container (6), un ou plusieurs modèles (1) en une matière sublimable, on noie le ou les modèles dans du sable (7) en laissant subsister un orifice de coulée et on verse du métal liquide dans cet orifice, caractérisé en ce que le ou lesdits modèles (1) sont mis en place au préalable dans une enceinte (2) présentant au moins un élément propre à refroidir une ou plusieurs faces du modèle (1), l'ensemble enceinte/modèle(s) (2, 1) étant positionné dans le container (6) sans contact avec ce dernier.A method of molding a lost model in which is placed in a container (6), one or more models (1) in a sublimable material, the model is drowned in sand (7) leaving a casting orifice and poured liquid metal into this orifice, characterized in that the one or more models (1) are put in place beforehand in an enclosure (2) having at least one element adapted to cool one or more faces of the model (1), enclosure / model (s) (2, 1) being positioned in the container (6) without contact therewith. Procédé selon la revendication 1, caractérisé en ce que le modèle ou grappe (1) est mis en place dans l'enceinte (2) à un poste d'assemblage puis est transféré par des moyens appropriés pour être introduit et positionné dans la cuve sans contact avec celle-ci.A method according to claim 1, characterized in that the model or cluster (1) is placed in the enclosure (2) at an assembly station and is transferred by appropriate means to be introduced and positioned in the vessel without contact with it. Procédé selon la revendication 1, caractérisé en ce que l'enceinte (2) est pré-positionnée en contact avec le container (6) et lorsqu'il reçoit la grappe (1), est repris et maintenu séparé du container (6) par un mécanisme approprié.Method according to Claim 1, characterized in that the enclosure (2) is pre-positioned in contact with the container (6) and when it receives the cluster (1), is taken up and kept separate from the container (6) by an appropriate mechanism. Procédé selon l'une des revendications 2 ou 3, caractérisé en ce que le l'ensemble enceinte/modèle (2, 1) est maintenu en suspension dans le container (6) sans contact avec celui-ci.Method according to one of claims 2 or 3, characterized in that the enclosure / model assembly (2, 1) is held in suspension in the container (6) without contact therewith. installation pour la mise en oeuvre d'un procédé de moulage par modèle perdu du type comprenant un container (6) monté sur un bâti vibrant, caractérisée en ce qu'elle comporte une enceinte (2) propre à recevoir un ou des modèles (1) et présentant au moins un élément propre à refroidir une ou plusieurs faces du modèle (1), ladite enceinte (2) comportant en outre des moyens de fixation à des moyens permettant la mise en place de l'ensemble enceinte/modèle (2, 1) dans le container (6) sans contact avec celui-ci.installation for implementing a lost model molding process of the type comprising a container (6) mounted on a vibrating frame, characterized in that it comprises an enclosure (2) adapted to receive one or more models (1). ) and having at least one element suitable for cooling one or more faces of the model (1), said enclosure (2) further comprising means for fixing means enabling the enclosure / model assembly (2, 1) in the container (6) without contact therewith. Installation selon la revendication 5, caractérisée en ce que cette enceinte de refroidissement ou refroidisseur (2) est un ensemble monobloc.Installation according to claim 5, characterized in that this cooling chamber or cooler (2) is a one-piece assembly. Installation selon la revendication 5, caractérisée en ce que cette enceinte (2) est constitué de plusieurs éléments assemblésInstallation according to Claim 5, characterized in that this enclosure (2) consists of several assembled elements Installation selon l'une des revendications 5 à 7, caractérisée en ce que le refroidisseur (2) ou ses éléments sont constitués de différents matériaux de propriétés mécaniques, conductivités thermiques et chaleur massique différentes tels qu'acier, fonte, aluminium, cuivre, matériaux frittés, céramiques.Installation according to one of claims 5 to 7, characterized in that the cooler (2) or its elements consist of different materials of mechanical properties, thermal conductivities and different specific heat such as steel, cast iron, aluminum, copper, materials sintered, ceramics. Installation selon l'une des revendications 5 à 8, caractérisée en ce que le refroidisseur (2) présente au moins deux points de fixation permettant son accrochage à des moyens permettant sa mise en place dans la cuve.Installation according to one of claims 5 to 8, characterized in that the cooler (2) has at least two attachment points for attachment to means for its introduction into the tank. Installation selon la revendication 9, caractérisée en ce que ces moyens sont constitués de moyens de suspension et de transport (5) tels qu'une potence, un bras articulé, permettant de suspendre et de mettre en place le refroidisseur (2) dans le container (6), de le maintenir suspendu dedans et de l'extraire hors du container (6) lors de l'opération de décochage.Installation according to claim 9, characterized in that these means consist of suspension and transport means (5) such as a bracket, an articulated arm, for suspending and putting in place the cooler (2) in the container (6), hold it suspended in and extract it out of the container (6) during the shakeout operation. Installation selon l'une des revendications 5 à 10, caractérisée en ce que le refroidisseur (2) est une enceinte ouverte dans sa partie supérieure et dans sa partie inférieure présentant quatre parois dont deux principales (3) de contact avec la grappe (1) enduite constituent les faces de refroidissement (3) et forment un angle de dépouille pour permettre la mise en place de la grappe (1) enduite et l'extraction de la grappe (1) solidifiée, la grappe (1) étant composée d'au moins deux pièces et d'un système de remplissage (1a) et dont les faces à mettre en contact avec le refroidisseur (2) sont positionnées à l'opposé du descendant, avec un angle correspondant à la dépouille du refroidisseur (2).Installation according to one of claims 5 to 10, characterized in that the cooler (2) is an open chamber in its upper part and in its lower part having four walls, two main (3) of contact with the cluster (1) coated surfaces constitute the cooling faces (3) and form a draft angle to allow the placing of the coated cluster (1) and the extraction of the solidified cluster (1), the cluster (1) being composed of minus two pieces and a filling system (1a) and whose faces to be in contact with the cooler (2) are positioned opposite the descendant, with an angle corresponding to the draft of the cooler (2).
EP10196190.2A 2010-01-19 2010-12-21 Lost pattern casting process and apparatus for the execution of this process Active EP2357049B1 (en)

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FR1050326A FR2955274B1 (en) 2010-01-19 2010-01-19 LOST MOLD MOLDING PROCESS AND INSTALLATION FOR CARRYING OUT SAID METHOD

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DE102012209805A1 (en) 2012-06-12 2013-12-12 Bayerische Motoren Werke Aktiengesellschaft Cooling device and method for cooling a component produced during a lost foam casting process
CN104162634A (en) * 2013-08-25 2014-11-26 浙江天瑞钢业有限公司 Casting method of narrow-tunnel wide-tunnel wall surface casting
WO2019229309A1 (en) * 2018-05-29 2019-12-05 Psa Automobiles Sa Lost pattern for moulding a metal part, comprising a metal covering plate

Families Citing this family (3)

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Publication number Priority date Publication date Assignee Title
FR2970886B1 (en) * 2011-01-27 2016-01-08 Peugeot Citroen Automobiles Sa LOST MODEL MOLDING PROCESS
FR3098422B1 (en) * 2019-07-09 2021-06-18 Psa Automobiles Sa SET INCLUDING A LOST MODEL AND A METAL COOLING PLATE
FR3123579A1 (en) 2021-06-08 2022-12-09 Psa Automobiles Sa SAND CASTING DEVICE WITH LOST PATTERN METHOD

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EP0301928A1 (en) * 1987-07-30 1989-02-01 Regie Nationale Des Usines Renault Method and device for chill casting using a gasifiable pattern in a binderless sand mould
FR2685229A1 (en) 1991-12-20 1993-06-25 Peugeot Method for consumable- (disposable-) pattern moulding and refrigerating element for implementing this method

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EP0301928A1 (en) * 1987-07-30 1989-02-01 Regie Nationale Des Usines Renault Method and device for chill casting using a gasifiable pattern in a binderless sand mould
FR2685229A1 (en) 1991-12-20 1993-06-25 Peugeot Method for consumable- (disposable-) pattern moulding and refrigerating element for implementing this method

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012209805A1 (en) 2012-06-12 2013-12-12 Bayerische Motoren Werke Aktiengesellschaft Cooling device and method for cooling a component produced during a lost foam casting process
WO2013186124A1 (en) 2012-06-12 2013-12-19 Bayerische Motoren Werke Aktiengesellschaft Cooling device and method for cooling a component produced in a lost foam casting method
CN104162634A (en) * 2013-08-25 2014-11-26 浙江天瑞钢业有限公司 Casting method of narrow-tunnel wide-tunnel wall surface casting
WO2019229309A1 (en) * 2018-05-29 2019-12-05 Psa Automobiles Sa Lost pattern for moulding a metal part, comprising a metal covering plate
FR3081734A1 (en) * 2018-05-29 2019-12-06 Psa Automobiles Sa LOST MODEL FOR MOLDING A METAL PART COMPRISING A METAL COVERING PLATE

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