EP2397245A1 - Set of strata, mould, methods for producing said model and for manufacturing a part using said model - Google Patents

Set of strata, mould, methods for producing said model and for manufacturing a part using said model Download PDF

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Publication number
EP2397245A1
EP2397245A1 EP11166679A EP11166679A EP2397245A1 EP 2397245 A1 EP2397245 A1 EP 2397245A1 EP 11166679 A EP11166679 A EP 11166679A EP 11166679 A EP11166679 A EP 11166679A EP 2397245 A1 EP2397245 A1 EP 2397245A1
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EP
European Patent Office
Prior art keywords
functional
model
layer
refractory material
projection
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Granted
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EP11166679A
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German (de)
French (fr)
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EP2397245B1 (en
Inventor
Franck Hautefeuille
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PSA Automobiles SA
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Peugeot Citroen Automobiles SA
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Publication of EP2397245A1 publication Critical patent/EP2397245A1/en
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    • 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
    • B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts

Definitions

  • the invention relates to a set of layers for producing a model for the manufacture of a part by non-permanent mold molding of refractory material.
  • the invention also relates to a non-permanent mold for the manufacture of a part by non-permanent mold molding.
  • the invention also relates to a method of making a model for the manufacture of a part by non-permanent mold molding of refractory material.
  • the invention finally relates to a method for manufacturing a part by non-permanent mold molding of refractory material.
  • non-permanent mold means a mold which is destroyed during demolding of a molded part in this mold. Unlike a permanent mold, a non-permanent mold is not reusable after demolding the part.
  • Such non-permanent molds are generally made of refractory materials.
  • refractory material denotes a material having a thermal resistance greater than that of aluminum and, preferably, greater than that of cast iron or steel. Refractory materials are, for example, sand or ceramic. The melting temperature of these materials is greater than the melting temperature of the material in which the piece is made.
  • non-permanent molds of refractory material known are lost wax molds.
  • model is meant an exact replica of the part to be manufactured.
  • the model is made of wax.
  • the model is coated with a refractory liquid.
  • the model is then parboiled so that the liquid dries and solidifies to form a shell around this model.
  • the model is then placed in a tank and then fully silted.
  • the sand is compacted to a solid structure that perfectly matches the contours of the model.
  • the structure formed by the sand and enclosing the model thus forms a non-permanent mold for the part to be manufactured.
  • the manufacture of a part by molding using these molds is performed by casting a liquid material at high temperature through a mold inlet that can be provided for this purpose.
  • the liquid material is liquid aluminum.
  • the high temperature of aluminum causes the sublimation of the wax.
  • the aluminum then flushes the wax out of the mold and occupies the part formerly occupied by the wax. After cooling the aluminum until solidification, the final piece can be released by breaking the mold.
  • the invention aims to solve one or more of these disadvantages.
  • the invention proposes to protect the functional projections from shocks or friction by arranging non-functional projections so that when the layer is stored, these non-functional projections are more exposed to shocks and friction than the functional projections. Thus, they protect the functional projections from shocks and friction
  • the figure 1 illustrates a non-permanent mold 2.
  • This mold 2 comprises a tank 4 containing a refractory material 6.
  • the refractory material 6 is sand.
  • the mold 2 also comprises a model 8.
  • This model 8 is a replica of a part to be produced by molding.
  • the model 8 is immersed in the refractory material 6.
  • This model 8 is preferably made of a material whose melting temperature is lower than the melting temperature of the material in which the part is manufactured.
  • the model 8 is a model for a cylinder head of an engine of an aluminum vehicle.
  • the model 8 is made of polystyrene.
  • Model 8 has several layers stacked on top of each other.
  • the description is made in the particular case where the model 8 comprises only two layers 10 and 12 capable of being stacked in a stacking direction 14.
  • the two layers 10 and 12 extend essentially in two planes parallel.
  • the stacking direction 14 is perpendicular to these planes.
  • the mold 2 also comprises a junction bar 13 providing the junction between the model 8 and a second model 9.
  • the model 9 is identical to the model 8.
  • the connecting bar 13 is in the same material as the models 8 and 9.
  • the connecting bar is polystyrene.
  • the assembly formed by the models 8 and 9 and the connecting bar 13 is designated by the term "cluster".
  • the cluster is connected to a power system 13A. This includes an orifice through which liquid aluminum can be cast.
  • the power system is a funnel.
  • the funnel communicates with the cluster via the connecting bar.
  • the figures 2 and 3 further illustrate a portion of the stratum 10.
  • This includes a bonding seal 15.
  • bonding seal is meant the surface of the upper face of the stratum 10 in contact with the stratum 12 when the strata 10 and 12 are stacked in the stacking direction 14.
  • the upper face of the stratum 10 also includes functional projections 16 and 18.
  • functional projection is meant a protrusion which is in contact with the refractory material 6 when the strata 10 and 12 are stacked and the model 8 is immersed in this refractory material 6.
  • the protrusions functional are thus projections that affect the final shape of the part made with the mold 2.
  • the projections 16 and 18 extend for example in the stacking direction 14. In this example, the projections 16 and 18 are orifices communicating with the outlet of tubings of an internal combustion engine.
  • the upper face of the stratum 10 also comprises non-functional projections 20, 21 and 22.
  • non-functional projection is meant a protrusion that is not in contact with the refractory material when the strata 10 and 12 are stacked and that the model 8 is immersed in the refractory material.
  • the projections 20, 21 and 22 are such that when the upper face of the stratum 10 is disposed on a flat surface, the stratum 10 rests solely on the projections 20, 21 and 22 rather than on the projections 16 and 18.
  • a flat surface is the face of a layer storage plane. The projections 20, 21 and 22 thus make it possible to limit the friction between the projections 16 and 18 and this flat surface, during the storage of the stratum 10, for example.
  • the height of the projections 20, 21 and 22 in the stacking direction 14 is greater than the height of the projections 16 and 18 in the same stacking direction 14.
  • the height of the projections 20, 21 and 22 in the stacking direction 14 is greater than the height of all the functional projections of the stratum 10 in the same stacking direction 14.
  • the heights of the projections 20, 21 and 22 in the direction of 14 stack are equal.
  • the projections 20, 21 and 22 are advantageously arranged along non-collinear axes so that when the layer 10 is disposed on the flat surface, it is stable.
  • the projections 20, 21 and 22 have the shape of cylindrical studs of circular cross section.
  • the figure 4 illustrates in detail a portion of the stratum 12.
  • This stratum 12 comprises three recesses able to receive, respectively, the projections 20, 21 and 22 when the strata 10 and 12 are stacked.
  • the recesses 26 and 28 receiving the projections 20 and 22 are shown.
  • the recesses 26 and 28, and the projections 20 and 22 have complementary geometric shapes so that when the layers 10 and 12 are stacked and the model 8 is immersed in the refractory material 6, the projections 20 and 22 are not in contact with the refractory material 6.
  • the recesses 26 and 28 have a cylindrical geometric shape with a circular cross section.
  • the recess capable of receiving the projection 21 has the same properties as the recesses 26 and 28.
  • the layer 12 also includes orifices 30 and 32 adapted to receive, respectively, the projections 16 and 18 when the layers 10 and 12 are stacked. In this case and when the model 8 is immersed, the projections 16 and 18 are in contact with the refractory material 6.
  • the orifices 30 and 32 have a generally circular shape. Here, the diameter of these orifices is greater than the diameter of the projections 16 and 18.
  • the geometrical shape of the layers 10 and 12 is determined to form the model 8 when they are stacked.
  • the shape of the model 8 can be constructed numerically using computer-assisted drawing software. Still by numerical construction, the model 8 is divided into strata so as to obtain the shape of the strata 10 and 12.
  • the stratum 10 is made.
  • non-functional projections 20, 21 and 22 are formed.
  • the stratum 10 is made by a non-permanent mold molding process or by machining a polystyrene raw material or by some other method.
  • the stratum 12 is made. During this step 44 recesses adapted to cover the non-functional projections 20, 21 and 22 when the layers 10 and 12 are stacked are formed.
  • the stratum 12 is also made by a non-permanent mold molding process or by machining a polystyrene raw material or by some other method.
  • Stacking the layers involves assembling them in the stacking direction so that the layers are pressed against each other along the bonding seam (s).
  • a glue or an adherent substance is applied to the bonding joint of strata 10 and 12.
  • strata 10 and 12 are centered before being pressed against each other. The centering of the layers 10 and 12 may be assisted by a machine provided for this purpose.
  • models 8 and 9 of the part to be manufactured are made.
  • models 8 and 9 can be made according to the manufacturing method described above.
  • a step 52 the models 8 and 9 are assembled on the connecting rod 13.
  • the assembly between the models 8 and the connecting bar 13 is made by interlocking or gluing.
  • the cluster is connected to the power supply system 13A.
  • the cluster is coated with a liquid refractory material.
  • the melting temperature of this refractory material is greater than the melting point of aluminum.
  • the cluster is parboiled so that the refractory coating solidifies to form a shell around the polystyrene.
  • the cluster is arranged in an oven.
  • the assembly formed by the cluster and the funnel is placed in the tank 4.
  • the sand is then poured into the tank 4 so that the cluster is immersed.
  • the tank 4 is vibrated so as to allow the sand to be housed in all the asperities of the outer periphery of the cluster and to compact to form a mold.
  • the tank 4 is for example arranged on a vibrating table.
  • the aluminum is brought to its melting temperature.
  • the aluminum is raised to a temperature higher than the sublimation temperature of the polystyrene but lower than the melting temperature of the shell of refractory material.
  • the aluminum is then poured into the funnel.
  • the liquid aluminum diffuses its heat to the polystyrene thus causing the sublimation of the latter.
  • the temperature of the aluminum being lower than the melting temperature of the shell, the shell remains rigid during casting.
  • the shell prevents the sand from mixing with the aluminum.
  • the shape of the mold is thus unchanged during casting.
  • the polystyrene is removed from the mold and the liquid aluminum takes the place of polystyrene.
  • the casting is prolonged until the volume which was occupied by the polystyrene before the casting is entirely occupied by the aluminum.
  • a step 60 the aluminum is cooled until solidification.
  • a step 62 the aluminum part is released by breaking the mold.
  • the piece obtained is formed of a connecting bar and two aluminum heads.
  • the cylinder heads are then separated from the connecting bar.
  • the stratum 10 is not limited to the case where it comprises three nonfunctional protrusions.
  • Stratum 10 may comprise more than three non-functional projections.
  • the stratum 12 also includes additional recesses able to cover these projections when the strata 10 and 12 are stacked.
  • non-functional projections are not all arranged on the stratum 10.
  • Non-functional projections may be arranged on the stratum 12.
  • the stratum 10 comprises recesses capable of receiving these non-functional protrusions when the strata 10 and 12 are stacked.
  • the guide pads on the strata 10 or 12 or both so as to facilitate the positioning of the stratum 10 on the stratum 12 during the stacking of these strata.
  • the stratum 10 or the stratum 12 or both comprise recesses able to receive these guide pads when the strata 10 and 12 are stacked.
  • Model 8 is not limited to the case where it comprises two layers. Model 8 may comprise more than two strata.
  • the cluster is not limited to the case where it includes two models. It is conceivable that the cluster comprises a single model 8. It is also conceivable that the cluster comprises more than two models.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

The set of layers comprises a first layer (10), and a second layer to be stacked on the first layer in a direction of stacking. The first layer includes three non-functional projections (20, 21, 22) that extend in the direction of stacking and along non-colinear axis, and a functional projection (16, 18) with shield, where the functional projection is in contact with a refractory material when the two layers are stacked. The second layer comprises a recess capable of completely covering the non-functional projections when the two layers are stacked. The set of layers comprises a first layer (10), and a second layer to be stacked on the first layer in a direction of stacking. The first layer includes three non-functional projections (20, 21, 22) that extend in the direction of stacking and along non-colinear axis, and a functional projection (16, 18) with shield, where the functional projection is in contact with a refractory material when the two layers are stacked. The second layer comprises a recess capable of completely covering the non-functional projections when the two layers are stacked so as to prevent contact between the non-functional projection and the refractory material. A height of the non-functional projection in the direction of stacking is greater than a height of the functional projection in the same direction of stacking. Independent claims are included for: (1) a non-permanent mold; and (2) a process for making a model for manufacturing a part by a non-permanent mold made of refractory material.

Description

L'invention concerne un ensemble de strates pour la réalisation d'un modèle pour la fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire. L'invention concerne également un moule non permanent pour la fabrication d'une pièce par moulage à moule non permanent. L'invention concerne par ailleurs un procédé de confection d'un modèle pour la fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire. L'invention concerne enfin un procédé de fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire.The invention relates to a set of layers for producing a model for the manufacture of a part by non-permanent mold molding of refractory material. The invention also relates to a non-permanent mold for the manufacture of a part by non-permanent mold molding. The invention also relates to a method of making a model for the manufacture of a part by non-permanent mold molding of refractory material. The invention finally relates to a method for manufacturing a part by non-permanent mold molding of refractory material.

Le déposant connaît des procédés de fabrication par moulage utilisant des moules non permanents. Par « moule non permanent » on désigne un moule qui est détruit lors du démoulage d'une pièce moulée dans ce moule. A l'inverse d'un moule permanent, un moule non permanent n'est pas réutilisable après démoulage de la pièce. De tels moules non permanents sont généralement fabriqués dans des matériaux réfractaires. Par « matériau réfractaire » on désigne un matériau possédant une résistance thermique supérieure à celle de l'aluminium et, de préférence, supérieure à celle de la fonte ou de l'acier. Des matériaux réfractaires sont, par exemple, du sable ou de la céramique. La température de fusion de ces matériaux est supérieure à la température de fusion du matériau dans lequel la pièce est réalisée. Par exemple, des moules non permanents en matériau réfractaire connus sont les moules à cire perdue.The applicant knows molding manufacturing processes using non-permanent molds. By "non-permanent mold" means a mold which is destroyed during demolding of a molded part in this mold. Unlike a permanent mold, a non-permanent mold is not reusable after demolding the part. Such non-permanent molds are generally made of refractory materials. The term "refractory material" denotes a material having a thermal resistance greater than that of aluminum and, preferably, greater than that of cast iron or steel. Refractory materials are, for example, sand or ceramic. The melting temperature of these materials is greater than the melting temperature of the material in which the piece is made. For example, non-permanent molds of refractory material known are lost wax molds.

La fabrication d'un tel type de moule nécessite la confection d'un modèle de la pièce à fabriquer. Par « modèle » on désigne une réplique exacte de la pièce à fabriquer. Par exemple, dans le cas d'un moule à cire perdue, le modèle est réalisé en cire. D'une manière connue en elle-même, le modèle est enduit d'un liquide réfractaire. Le modèle est alors étuvé de manière à ce que le liquide sèche et se solidifie pour former une carapace autour de ce modèle. Le modèle est alors disposé dans une cuve puis ensablé entièrement. Le sable est compacté jusqu'à obtenir une structure solide épousant parfaitement les contours du modèle. La structure formée par le sable et enfermant le modèle forme ainsi un moule non permanent pour la pièce à fabriquer.The manufacture of such a type of mold requires the making of a model of the part to be manufactured. By "model" is meant an exact replica of the part to be manufactured. For example, in the case of a lost wax mold, the model is made of wax. In a manner known in itself, the model is coated with a refractory liquid. The model is then parboiled so that the liquid dries and solidifies to form a shell around this model. The model is then placed in a tank and then fully silted. The sand is compacted to a solid structure that perfectly matches the contours of the model. The structure formed by the sand and enclosing the model thus forms a non-permanent mold for the part to be manufactured.

La fabrication d'une pièce par moulage à l'aide de ces moules est réalisée en coulant un matériau liquide à haute température à travers une entrée du moule qui peut être prévue à cet effet. Par exemple, le matériau liquide est de l'aluminium liquide. La température élevée de l'aluminium entraîne la sublimation de la cire. L'aluminium chasse alors la cire hors du moule et occupe la partie autrefois occupée par la cire. Après refroidissement de l'aluminium jusqu'à solidification, la pièce finale peut être libérée en brisant le moule.The manufacture of a part by molding using these molds is performed by casting a liquid material at high temperature through a mold inlet that can be provided for this purpose. For example, the liquid material is liquid aluminum. The high temperature of aluminum causes the sublimation of the wax. The aluminum then flushes the wax out of the mold and occupies the part formerly occupied by the wax. After cooling the aluminum until solidification, the final piece can be released by breaking the mold.

La fabrication de pièces par moulage à cire perdue est très répandue dans l'industrie. En effet, ce procédé permet la réalisation de pièces complexes possédant d'excellents états de surface. Cependant, le moulage de pièces complexes a pour conséquence la confection de modèles complexes. Dans ce cas, il est connu de diviser le modèle en strates. L'utilisation de strates permet alors de simplifier la confection de ces modèles. Un inconvénient d'un tel type de modèle reste sa fragilité. En effet, les matériaux utilisés pour la confection de ces strates sont facilement déformables. Lors de leur stockage ou de leur manipulation, les strates formant le moule peuvent faire l'objet de chocs ou de frottements. Ces chocs ou frottements peuvent abîmer, par exemple, des saillies fragiles disposées en surface de ces modèles. Dans la suite de la description, on désigne par saillie d'une strate l'ensemble des faces extérieures d'une protubérance de cette strate. Le modèle obtenu à partir de ces strates est alors déformé. Il en résulte que la qualité des pièces issues d'un moule réalisé à partir d'un modèle déformé est inéluctablement insatisfaisante.The manufacture of parts by lost wax casting is widespread in the industry. Indeed, this method allows the realization of complex parts having excellent surface conditions. However, the molding of complex parts results in the making of complex models. In this case, it is known to divide the model into layers. The use of strata makes it possible to simplify the making of these models. A disadvantage of such a type of model remains its fragility. Indeed, the materials used for making these layers are easily deformable. During storage or handling, the layers forming the mold may be subject to shocks or friction. These shocks or friction can damage, for example, fragile projections disposed on the surface of these models. In the remainder of the description, a projection of a stratum denotes the set of outer faces of a protuberance of this stratum. The model obtained from these strata is then deformed. As a result, the quality of parts from a mold made from a deformed model is inevitably unsatisfactory.

L'invention vise à résoudre un ou plusieurs de ces inconvénients.The invention aims to solve one or more of these disadvantages.

L'invention porte ainsi sur un ensemble de strates pour la réalisation d'un modèle, cet ensemble comportant :

  • une première strate comprenant une saillie non fonctionnelle s'étendant selon une direction d'empilement, et
  • une seconde strate apte à être empilée sur la première strate selon la direction d'empilement, cette seconde strate comprenant un renfoncement apte à recouvrir la saillie non fonctionnelle en totalité lorsque ces deux strates sont empilées de manière à empêcher un contact entre la saillie non fonctionnelle et le matériau réfractaire.
The invention thus relates to a set of strata for producing a model, this assembly comprising:
  • a first stratum comprising a non-functional projection extending in a stacking direction, and
  • a second layer capable of being stacked on the first layer in the stacking direction, this second layer comprising a recess able to cover the completely non-functional projection when these two layers are stacked so as to prevent contact between the non-functional projection; and the refractory material.

L'invention propose de protéger les saillies fonctionnelles des chocs ou frottements en disposant des saillies non fonctionnelles de manière à ce que lorsque la strate est stockée, ces saillies non fonctionnelles soient davantage exposées aux chocs et frottements que les saillies fonctionnelles. Ainsi, elles protègent les saillies fonctionnelles des chocs et frottementsThe invention proposes to protect the functional projections from shocks or friction by arranging non-functional projections so that when the layer is stored, these non-functional projections are more exposed to shocks and friction than the functional projections. Thus, they protect the functional projections from shocks and friction

Les modes de réalisation de cet ensemble peuvent comporter une ou plusieurs des caractéristiques suivantes :

  • â–  la première strate comprend une saillie fonctionnelle à protéger, une saillie fonctionnelle étant une saillie qui est en contact avec le matériau réfractaire lorsque les deux strates sont empilées, et la hauteur de la saillie non fonctionnelle selon la direction d'empilement est supérieure à la hauteur de la saillie fonctionnelle selon la même direction d'empilement,
  • â–  la première strate comprend plusieurs saillies fonctionnelles, et la hauteur de la saillie non fonctionnelle selon la direction d'empilement est supérieure à la hauteur de l'ensemble des saillies fonctionnelles selon la même direction d'empilement,
  • â–  le modèle est un modèle pour une culasse d'un moteur d'un véhicule, et
  • â–  la première strate comprend au moins trois saillies non fonctionnelles s'étendant selon la direction d'empilement et disposées le long d'au moins deux axes non colinéaires, et la seconde strate comprend un ou plusieurs renfoncements aptes à recouvrir les trois saillies non fonctionnelles en totalité lorsque ces deux strates sont empilées de manière à empêcher un contact entre les saillies non fonctionnelles et le matériau réfractaire.
Embodiments of this set may include one or more of the following features:
  • The first layer comprises a functional projection to be protected, a functional projection being a projection which is in contact with the refractory material when the two layers are stacked, and the height of the non-functional projection in the stacking direction is greater than the height of the functional projection in the same stacking direction,
  • The first layer comprises several functional projections, and the height of the non-functional projection in the stacking direction is greater than the height of the set of functional projections in the same stacking direction,
  • The model is a model for a cylinder head of a motor of a vehicle, and
  • The first layer comprises at least three non-functional projections extending in the stacking direction and arranged along at least two non-collinear axes, and the second layer comprises one or more recesses able to cover the three non-functional projections; completely when these two layers are stacked so as to prevent contact between the non-functional projections and the refractory material.

Les modes de réalisation peuvent présenter en outre les avantages suivants :

  • jouer sur la hauteur des saillies non fonctionnelle présente l'avantage de protéger de manière préférentielle une ou plusieurs ou toutes les saillies fonctionnelles lors du stockage des strates.
Embodiments may further have the following advantages:
  • playing on the height of the non-functional projections has the advantage of preferably protecting one or more or all the functional projections during storage strata.

L'invention concerne également un moule non permanent comprenant :

  • une cuve contenant un matériau réfractaire, et
  • un modèle à l'intérieure du matériau réfractaire, ce modèle étant réalisé par l'empilement d'un ensemble de strates conforme à l'un des modes de réalisation précédent.
The invention also relates to a non-permanent mold comprising:
  • a vessel containing a refractory material, and
  • a model inside the refractory material, this model being made by stacking a set of layers according to one of the previous embodiments.

L'invention concerne également un procédé de confection d'un modèle pour la fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire, comportant :

  • la réalisation d'une première strate comprenant la formation d'une saillie non fonctionnelle s'étendant selon une direction d'empilement, et
  • la réalisation d'une seconde strate apte à être empilée sur la première strate selon la direction d'empilement, comprenant la formation d'un renfoncement apte à recouvrir la saillie non fonctionnelle de la première strate en totalité lorsque ces deux strates sont empilées de manière à empêcher un contact entre la saillie non fonctionnelle et le matériau réfractaire.
The invention also relates to a method of making a model for the manufacture of a part by non-permanent mold molding of refractory material, comprising:
  • performing a first layer comprising forming a non-functional projection extending in a stacking direction, and
  • the production of a second layer capable of being stacked on the first layer in the stacking direction, comprising the formation of a recess able to cover the non-functional projection of the first layer completely when these two layers are stacked in a manner to prevent contact between the non-functional projection and the refractory material.

Les modes de réalisation de ce procédé peuvent comporter la caractéristique suivante :

  • â–  le procédé comporte une étape d'assemblage des première et seconde strates pour former le modèle.
Embodiments of this method may include the following feature:
  • The method comprises a step of assembling the first and second layers to form the model.

L'invention concerne enfin un procédé de fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire, dans lequel le procédé comporte :

  • la confection d'un modèle de cette pièce, le modèle étant confectionné dans un matériau perdu, la confection du modèle étant conforme à l'un des procédés de confection décrit plus haut,
  • la réalisation d'un moule à partir de ce modèle, le moule étant réalisé dans un matériau réfractaire, la température de fusion du matériau réfractaire étant plus élevée que la température de fusion du matériau perdu, et
  • le moulage de la pièce à partir du moule réalisé, la pièce étant réalisée dans un matériau dont la température de fusion est comprise entre la température de fusion du matériau perdu et du matériau réfractaire.
The invention finally relates to a method for manufacturing a part by non-permanent mold molding of refractory material, wherein the method comprises:
  • the making of a model of this piece, the model being made of a lost material, the making of the model being in accordance with one of the manufacturing methods described above,
  • producing a mold from this model, the mold being made of a refractory material, the melting temperature of the refractory material being higher than the melting temperature of the lost material, and
  • the molding of the piece from the formed mold, the part being made of a material whose melting temperature is between the melting temperature of the lost material and the refractory material.

D'autres caractéristiques et avantages de l'invention ressortiront clairement de la description qui en est faite ci-après, à titre indicatif et nullement limitatif, en référence aux dessins annexés, dans lesquels :

  • la figure 1 est une illustration schématique d'un moule non permanent avec son modèle,
  • la figure 2 est une illustration schématique d'une première strate du modèle de la figure 1,
  • la figure 3 est une illustration schématique d'une vue grossie d'une partie de la strate de la figure 2,
  • la figure 4 est une illustration d'une vue grossie d'une partie d'une seconde strate du modèle de la figure 1,
  • la figure 5 est un organigramme d'un procédé de confection d'un modèle pour le moule de la figure 1, et
  • la figure 6 est un organigramme d'un procédé de fabrication d'une pièce à l'aide du moule non permanent de la figure 1.
Other characteristics and advantages of the invention will emerge clearly from the description which is given hereinafter, by way of indication and in no way limitative, with reference to the appended drawings, in which:
  • the figure 1 is a schematic illustration of a non-permanent mold with its model,
  • the figure 2 is a schematic illustration of a first stratum of the model of the figure 1 ,
  • the figure 3 is a schematic illustration of an enlarged view of part of the stratum of the figure 2 ,
  • the figure 4 is an illustration of a magnified view of part of a second layer of the model of the figure 1 ,
  • the figure 5 is a flowchart of a process of making a model for the mold of the figure 1 , and
  • the figure 6 is a flowchart of a process for manufacturing a part using the non-permanent mold of the figure 1 .

Dans ces figures, les mêmes références sont utilisées pour désigner les mêmes éléments.In these figures, the same references are used to designate the same elements.

Dans la suite de cette description, les caractéristiques et fonctions bien connues de l'homme du métier ne sont pas décrites en détail.In the remainder of this description, the features and functions well known to those skilled in the art are not described in detail.

La figure 1 illustre un moule 2 non permanent. Ce moule 2 comprend une cuve 4 contenant un matériau réfractaire 6. Par exemple, le matériau réfractaire 6 est du sable.The figure 1 illustrates a non-permanent mold 2. This mold 2 comprises a tank 4 containing a refractory material 6. For example, the refractory material 6 is sand.

Le moule 2 comprend également un modèle 8. Ce modèle 8 est une réplique d'une pièce à fabriquer par moulage. Le modèle 8 est immergé dans le matériau réfractaire 6. Ce modèle 8 est de préférence réalisé dans un matériau dont la température de fusion est inférieure à la température de fusion du matériau dans lequel la pièce est fabriquée. Dans l'exemple, le modèle 8 est un modèle pour une culasse d'un moteur d'un véhicule en aluminium. Ici, le modèle 8 est réalisé en polystyrène.The mold 2 also comprises a model 8. This model 8 is a replica of a part to be produced by molding. The model 8 is immersed in the refractory material 6. This model 8 is preferably made of a material whose melting temperature is lower than the melting temperature of the material in which the part is manufactured. In the example, the model 8 is a model for a cylinder head of an engine of an aluminum vehicle. Here, the model 8 is made of polystyrene.

Le modèle 8 comprend plusieurs strates empilées les unes sur les autres. Pour simplifier, la description est faite dans le cas particulier où le modèle 8 comprend seulement deux strates 10 et 12 aptes à être empilées selon une direction d'empilement 14. Par exemple, les deux strates 10 et 12 s'étendent essentiellement selon deux plans parallèles. Ici, la direction d'empilement 14 est perpendiculaire à ces plans.Model 8 has several layers stacked on top of each other. For simplicity, the description is made in the particular case where the model 8 comprises only two layers 10 and 12 capable of being stacked in a stacking direction 14. For example, the two layers 10 and 12 extend essentially in two planes parallel. Here, the stacking direction 14 is perpendicular to these planes.

Le moule 2 comprend également un barreau de jonction 13 assurant la jonction entre le modèle 8 et un second modèle 9. Ici, le modèle 9 est identique au modèle 8. De préférence, le barreau de jonction 13 est dans le même matériau que les modèles 8 et 9. Dans l'exemple, le barreau de jonction est en polystyrène. Dans la suite de la description, l'ensemble formé par les modèles 8 et 9 et le barreau de jonction 13 est désigné par le terme « grappe ». La grappe est connectée à un système d'alimentation 13A. Celui-ci comporte un orifice à travers lequel de l'aluminium liquide peut être coulé. Dans cet exemple, le système d'alimentation est un entonnoir. Ici, l'entonnoir communique avec la grappe par l'intermédiaire du barreau de jonction.The mold 2 also comprises a junction bar 13 providing the junction between the model 8 and a second model 9. Here, the model 9 is identical to the model 8. Preferably, the connecting bar 13 is in the same material as the models 8 and 9. In the example, the connecting bar is polystyrene. In the remainder of the description, the assembly formed by the models 8 and 9 and the connecting bar 13 is designated by the term "cluster". The cluster is connected to a power system 13A. This includes an orifice through which liquid aluminum can be cast. In this example, the power system is a funnel. Here, the funnel communicates with the cluster via the connecting bar.

Les figures 2 et 3 illustrent plus en détail une partie de la strate 10. Celle-ci comprend un joint de collage 15. Par « joint de collage » on désigne la surface de la face supérieure de la strate 10 en contact avec la strate 12 lorsque les strates 10 et 12 sont empilées selon la direction d'empilement 14. La face supérieure de la strate 10 comprend également des saillies fonctionnelles 16 et 18. Par « saillie fonctionnelle », on désigne une saillie qui est en contact avec le matériau réfractaire 6 lorsque les strates 10 et 12 sont empilées et que le modèle 8 est immergé dans ce matériau réfractaire 6. Les saillies fonctionnelles sont donc des saillies qui influent sur la forme finale de la pièce réalisée avec le moule 2. Les saillies 16 et 18 s'étendent par exemple selon la direction d'empilement 14. Dans cet exemple, les saillies 16 et 18 sont des orifices communicants avec la sortie de tubulures d'un moteur à combustion interne.The figures 2 and 3 further illustrate a portion of the stratum 10. This includes a bonding seal 15. By "bonding seal" is meant the surface of the upper face of the stratum 10 in contact with the stratum 12 when the strata 10 and 12 are stacked in the stacking direction 14. The upper face of the stratum 10 also includes functional projections 16 and 18. By "functional projection" is meant a protrusion which is in contact with the refractory material 6 when the strata 10 and 12 are stacked and the model 8 is immersed in this refractory material 6. The protrusions functional are thus projections that affect the final shape of the part made with the mold 2. The projections 16 and 18 extend for example in the stacking direction 14. In this example, the projections 16 and 18 are orifices communicating with the outlet of tubings of an internal combustion engine.

La face supérieure de la strate 10 comprend également des saillies non fonctionnelles 20, 21 et 22. Par « saillie non fonctionnelle » on désigne une saillie qui n'est pas en contact avec le matériau réfractaire lorsque les strates 10 et 12 sont empilées et que le modèle 8 est immergé dans le matériau réfractaire. Avantageusement, les saillies 20, 21 et 22 sont telles que lorsque la face supérieure de la strate 10 est disposée sur une surface plane, la strate 10 repose uniquement sur les saillies 20, 21 et 22 plutôt que sur les saillies 16 et 18. La surface plane est par exemple la face d'un plan de stockage des strates. Les saillies 20, 21 et 22 permettent ainsi de limiter les frottements entre les saillies 16 et 18 et cette surface plane, lors du stockage de la strate 10 par exemple. A cet effet, la hauteur des saillies 20, 21 et 22 selon la direction d'empilement 14 est supérieure à la hauteur des saillies 16 et 18 selon cette même direction d'empilement 14. De préférence, la hauteur des saillies 20, 21 et 22 selon la direction d'empilement 14 est supérieure à la hauteur de toutes les saillies fonctionnelles de la strate 10 selon cette même direction d'empilement 14. D'une manière encore préférentielle les hauteurs des saillies 20, 21 et 22 selon la direction d'empilement 14 sont égales. Dans ce cas, les saillies 20, 21 et 22 sont avantageusement disposées le long d'axes non colinéaires de manière à ce que lorsque la strate 10 est disposée sur la surface plane, celle-ci soit stable. Dans cet exemple, les saillies 20, 21 et 22 ont la forme de plots cylindriques de section transversale circulaire.The upper face of the stratum 10 also comprises non-functional projections 20, 21 and 22. By "non-functional projection" is meant a protrusion that is not in contact with the refractory material when the strata 10 and 12 are stacked and that the model 8 is immersed in the refractory material. Advantageously, the projections 20, 21 and 22 are such that when the upper face of the stratum 10 is disposed on a flat surface, the stratum 10 rests solely on the projections 20, 21 and 22 rather than on the projections 16 and 18. For example, a flat surface is the face of a layer storage plane. The projections 20, 21 and 22 thus make it possible to limit the friction between the projections 16 and 18 and this flat surface, during the storage of the stratum 10, for example. For this purpose, the height of the projections 20, 21 and 22 in the stacking direction 14 is greater than the height of the projections 16 and 18 in the same stacking direction 14. Preferably, the height of the projections 20, 21 and 22 in the stacking direction 14 is greater than the height of all the functional projections of the stratum 10 in the same stacking direction 14. In a still preferred manner the heights of the projections 20, 21 and 22 in the direction of 14 stack are equal. In this case, the projections 20, 21 and 22 are advantageously arranged along non-collinear axes so that when the layer 10 is disposed on the flat surface, it is stable. In this example, the projections 20, 21 and 22 have the shape of cylindrical studs of circular cross section.

La figure 4 illustre en détail une partie de la strate 12. Cette strate 12 comprend trois renfoncements aptes à recevoir, respectivement, les saillies 20, 21 et 22 lorsque les strates 10 et 12 sont empilées. Pour simplifier la figure, seul les renfoncements 26 et 28 recevant les saillies 20 et 22 sont représentés. Les renfoncements 26 et 28, et les saillies 20 et 22 ont des formes géométriques complémentaires de manière à ce que lorsque les strates 10 et 12 sont empilées et que le modèle 8 est immergé dans le matériau réfractaire 6, les saillies 20 et 22 ne sont pas en contact avec le matériau réfractaire 6. Dans l'exemple, les renfoncements 26 et 28 ont une forme géométrique cylindrique à section transversale circulaire. Dans l'exemple, le renfoncement apte à recevoir la saillie 21 possède les mêmes propriétés que les renfoncements 26 et 28.The figure 4 illustrates in detail a portion of the stratum 12. This stratum 12 comprises three recesses able to receive, respectively, the projections 20, 21 and 22 when the strata 10 and 12 are stacked. To simplify the figure, only the recesses 26 and 28 receiving the projections 20 and 22 are shown. The recesses 26 and 28, and the projections 20 and 22 have complementary geometric shapes so that when the layers 10 and 12 are stacked and the model 8 is immersed in the refractory material 6, the projections 20 and 22 are not in contact with the refractory material 6. In the example, the recesses 26 and 28 have a cylindrical geometric shape with a circular cross section. In the example, the recess capable of receiving the projection 21 has the same properties as the recesses 26 and 28.

La strate 12 comprend également des orifices 30 et 32 aptes à recevoir, respectivement, les saillies 16 et 18 lorsque les strates 10 et 12 sont empilées. Dans ce cas et lorsque le modèle 8 est immergé, les saillies 16 et 18 sont en contact avec le matériau réfractaire 6. Dans l'exemple, les orifices 30 et 32 ont une forme globalement circulaire. Ici, le diamètre de ces orifices est supérieur au diamètre des saillies 16 et 18.The layer 12 also includes orifices 30 and 32 adapted to receive, respectively, the projections 16 and 18 when the layers 10 and 12 are stacked. In this case and when the model 8 is immersed, the projections 16 and 18 are in contact with the refractory material 6. In the example, the orifices 30 and 32 have a generally circular shape. Here, the diameter of these orifices is greater than the diameter of the projections 16 and 18.

La confection du modèle 8 va maintenant être décrite en référence à la figure 5.The making of the model 8 will now be described with reference to the figure 5 .

Lors d'une étape préliminaire 40, la forme géométrique des strates 10 et 12 est déterminée pour former le modèle 8 lorsqu'elles sont empilées. Par exemple, la forme du modèle 8 peut être construite numériquement à l'aide d'un logiciel de dessin assisté par ordinateur. Toujours par construction numérique, le modèle 8 est divisé en strates de manière à obtenir la forme des strates 10 et 12.In a preliminary step 40, the geometrical shape of the layers 10 and 12 is determined to form the model 8 when they are stacked. For example, the shape of the model 8 can be constructed numerically using computer-assisted drawing software. Still by numerical construction, the model 8 is divided into strata so as to obtain the shape of the strata 10 and 12.

Lors d'une étape 42, la strate 10 est réalisée. Lors de cette étape 42 des saillies non fonctionnelles 20, 21 et 22 sont formées. Par exemple, la strate 10 est réalisée par un procédé de moulage à moule non permanent ou par usinage d'un brut de polystyrène ou par un autre procédé.In a step 42, the stratum 10 is made. In this step 42 non-functional projections 20, 21 and 22 are formed. For example, the stratum 10 is made by a non-permanent mold molding process or by machining a polystyrene raw material or by some other method.

Lors d'une étape 44, la strate 12 est réalisée. Lors de cette étape 44 des renfoncements apte à recouvrir les saillies non fonctionnelles 20, 21 et 22 lorsque les strates 10 et 12 sont empilées sont formés. La strate 12 est également réalisée par un procédé de moulage à moule non permanent ou par usinage d'un brut de polystyrène ou par un autre procédé.In a step 44, the stratum 12 is made. During this step 44 recesses adapted to cover the non-functional projections 20, 21 and 22 when the layers 10 and 12 are stacked are formed. The stratum 12 is also made by a non-permanent mold molding process or by machining a polystyrene raw material or by some other method.

Enfin, lors d'une étape 46 les strates 10 et 12 sont empilées. L'empilement des strates consiste à les assembler dans la direction d'empilement de manière à ce que les strates soient plaquées les unes contre les autres le long du ou des joints de collage. Ici, dans un premier temps une colle ou une substance adhérente est appliquée sur le joint de collage des strates 10 et 12. Dans un second temps, les strates 10 et 12 sont centrées avant d'être plaquées l'une contre l'autre le long du joint de collage de manière à former le modèle 8. Le centrage des strates 10 et 12 peut être assisté par une machine prévue à cet effet.Finally, during a step 46 the layers 10 and 12 are stacked. Stacking the layers involves assembling them in the stacking direction so that the layers are pressed against each other along the bonding seam (s). Here, initially a glue or an adherent substance is applied to the bonding joint of strata 10 and 12. In a second step, strata 10 and 12 are centered before being pressed against each other. The centering of the layers 10 and 12 may be assisted by a machine provided for this purpose.

La fabrication d'une pièce par moulage à moule non permanent à l'aide du modèle 8 va maintenant être décrit en référence à la figure 6.The manufacture of a piece by non-permanent mold molding using the model 8 will now be described with reference to the figure 6 .

Lors d'une étape 50, deux modèles 8 et 9 de la pièce à fabriquer sont confectionnés. Par exemple, les modèles 8 et 9 peuvent être réalisés selon le procédé de confection décrit ci-dessus.During a step 50, two models 8 and 9 of the part to be manufactured are made. For example, models 8 and 9 can be made according to the manufacturing method described above.

Lors d'une étape 52, les modèles 8 et 9 sont assemblés sur le barreau de jonction 13. Ici, l'assemblage entre les modèles 8 et le barreau de jonction 13 est réalisé par emboitement ou par collage. Par ailleurs, lors de l'étape 52 la grappe est connectée au système d'alimentation 13A.In a step 52, the models 8 and 9 are assembled on the connecting rod 13. Here, the assembly between the models 8 and the connecting bar 13 is made by interlocking or gluing. Furthermore, in step 52 the cluster is connected to the power supply system 13A.

Lors d'une étape 54, la grappe est enduite d'un matériau réfractaire liquide. Avantageusement, la température de fusion de ce matériau réfractaire est supérieure à la température de fusion de l'aluminium.In a step 54, the cluster is coated with a liquid refractory material. Advantageously, the melting temperature of this refractory material is greater than the melting point of aluminum.

Lors d'une étape 56, la grappe est étuvée de manière à ce que l'enduit réfractaire se solidifie pour former une carapace autour du polystyrène. Par exemple, la grappe est disposée dans un four.In a step 56, the cluster is parboiled so that the refractory coating solidifies to form a shell around the polystyrene. For example, the cluster is arranged in an oven.

Lors d'une étape 58, l'ensemble formé par la grappe et l'entonnoir est disposé dans la cuve 4. Le sable est alors versé dans la cuve 4 de manière à ce que la grappe soit immergée. Avantageusement, la cuve 4 est vibrée de manière à permettre au sable de se loger dans l'ensemble des aspérités de la périphérie extérieure de la grappe et de se compacter pour former un moule. A cet effet, la cuve 4 est par exemple disposée sur une table vibrante.During a step 58, the assembly formed by the cluster and the funnel is placed in the tank 4. The sand is then poured into the tank 4 so that the cluster is immersed. Advantageously, the tank 4 is vibrated so as to allow the sand to be housed in all the asperities of the outer periphery of the cluster and to compact to form a mold. For this purpose, the tank 4 is for example arranged on a vibrating table.

Lors d'une étape 59 de moulage, l'aluminium est porté à sa température de fusion. Ici, l'aluminium est porté à une température plus élevée que la température de sublimation du polystyrène mais moins élevée que la température de fusion de la carapace en matériau réfractaire. L'aluminium est alors coulé dans l'entonnoir. Lors de la coulée, l'aluminium liquide diffuse sa chaleur au polystyrène entraînant alors la sublimation de ce dernier. Par ailleurs, la température de l'aluminium étant inférieure à la température de fusion de la carapace, la carapace reste rigide lors de la coulée. La carapace empêche alors le sable de se mêler à l'aluminium. La forme du moule est ainsi inchangée pendant la coulée. Lors de cette étape, par le procédé venant d'être décrit le polystyrène est évacué du moule et l'aluminium liquide prend la place du polystyrène. La coulée est prolongée jusqu'à ce que le volume qui était occupé par le polystyrène avant la coulée soit entièrement occupé par l'aluminium.During a molding step 59, the aluminum is brought to its melting temperature. Here, the aluminum is raised to a temperature higher than the sublimation temperature of the polystyrene but lower than the melting temperature of the shell of refractory material. The aluminum is then poured into the funnel. During the casting, the liquid aluminum diffuses its heat to the polystyrene thus causing the sublimation of the latter. Furthermore, the temperature of the aluminum being lower than the melting temperature of the shell, the shell remains rigid during casting. The shell then prevents the sand from mixing with the aluminum. The shape of the mold is thus unchanged during casting. During this step, by the method just described, the polystyrene is removed from the mold and the liquid aluminum takes the place of polystyrene. The casting is prolonged until the volume which was occupied by the polystyrene before the casting is entirely occupied by the aluminum.

Lors d'une étape 60, l'aluminium est refroidi jusqu'à solidification.In a step 60, the aluminum is cooled until solidification.

Lors d'une étape 62, la pièce en aluminium est libérée en brisant le moule. La pièce obtenue est formée d'un barreau de jonction et de deux culasses en aluminium. Les culasses sont alors séparées du barreau de jonction.In a step 62, the aluminum part is released by breaking the mold. The piece obtained is formed of a connecting bar and two aluminum heads. The cylinder heads are then separated from the connecting bar.

De nombreux autres modes de réalisation sont possibles. Par exemple, la strate 10 n'est pas limitée au cas où elle comprend trois saillies non fonctionnelles. La strate 10 peut comprendre plus de trois saillies non fonctionnelles. Dans ce cas, la strate 12 comprend également des renfoncements supplémentaires aptes à recouvrir ces saillies lorsque les strates 10 et 12 sont empilées.Many other embodiments are possible. For example, the stratum 10 is not limited to the case where it comprises three nonfunctional protrusions. Stratum 10 may comprise more than three non-functional projections. In this case, the stratum 12 also includes additional recesses able to cover these projections when the strata 10 and 12 are stacked.

En variante, les saillies non fonctionnelles ne sont pas toutes disposées sur la strate 10. Des saillies non fonctionnelles peuvent être disposées sur la strate 12. Dans ce cas, la strate 10 comprend des renfoncements aptes à recevoir ces saillies non fonctionnelles lorsque les strates 10 et 12 sont empilées.As a variant, the non-functional projections are not all arranged on the stratum 10. Non-functional projections may be arranged on the stratum 12. In this case, the stratum 10 comprises recesses capable of receiving these non-functional protrusions when the strata 10 and 12 are stacked.

Il est également envisageable de disposer des plots de guidage sur les strates 10 ou 12 ou les deux de manière à faciliter le positionnement de la strate 10 sur la strate 12 lors de l'empilement de ces strates. Dans ce cas, la strate 10 ou la strate 12 ou les deux comprennent des renfoncements aptes à recevoir ces plots de guidage lorsque les strates 10 et 12 sont empilées.It is also conceivable to have the guide pads on the strata 10 or 12 or both so as to facilitate the positioning of the stratum 10 on the stratum 12 during the stacking of these strata. In this case, the stratum 10 or the stratum 12 or both comprise recesses able to receive these guide pads when the strata 10 and 12 are stacked.

Le modèle 8 n'est pas limité au cas où celui-ci comprend deux strates. Le modèle 8 peut comprendre plus de deux strates.Model 8 is not limited to the case where it comprises two layers. Model 8 may comprise more than two strata.

Dans le procédé de fabrication décrit en référence à la figure 6, la grappe n'est pas limitée au cas où celle-ci comprend deux modèles. Il est envisageable que la grappe comprennent un seul modèle 8. Il est également envisageable que la grappe comprenne plus de deux modèles.In the manufacturing process described with reference to the figure 6 , the cluster is not limited to the case where it includes two models. It is conceivable that the cluster comprises a single model 8. It is also conceivable that the cluster comprises more than two models.

Claims (9)

Ensemble de strates pour la réalisation d'un modèle pour la fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire, cet ensemble comportant : - une première strate (10), et - une seconde strate (12) apte à être empilée sur la première strate (10) selon une direction (14) d'empilement, caractérisé en ce que : - la première strate (10) comprend une saillie (22) non fonctionnelle s'étendant selon la direction (14) d'empilement, et - la seconde strate (12) comprend un renfoncement (28) apte à recouvrir la saillie (22) non fonctionnelle en totalité lorsque ces deux strates (10, 12) sont empilées de manière à empêcher un contact entre la saillie (22) non fonctionnelle et le matériau réfractaire. Set of strata for producing a model for the manufacture of a part by non-permanent mold molding of refractory material, this assembly comprising: a first layer (10), and a second layer (12) capable of being stacked on the first layer (10) in a stacking direction (14), characterized in that the first layer (10) comprises a non-functional projection (22) extending in the direction (14) of stacking, and - The second layer (12) comprises a recess (28) adapted to cover the projection (22) completely non-functional when these two layers (10, 12) are stacked so as to prevent contact between the projection (22) non-functional and the refractory material. Ensemble selon la revendication 1, dans lequel : - la première strate (10) comprend une saillie (18) fonctionnelle à protéger, une saillie fonctionnelle étant une saillie qui est en contact avec le matériau réfractaire lorsque les deux strates sont empilées, et - la hauteur de la saillie (22) non fonctionnelle selon la direction (14) d'empilement est supérieure à la hauteur de la saillie (18) fonctionnelle selon la même direction (14) d'empilement. An assembly according to claim 1 wherein: the first layer (10) comprises a protrusion (18) to be protected, a functional projection being a projection which is in contact with the refractory material when the two layers are stacked, and - The height of the projection (22) not functional in the direction (14) of stacking is greater than the height of the projection (18) functional in the same direction (14) of stacking. Ensemble selon la revendication 2, dans lequel : - la première strate (10) comprend plusieurs saillies (16, 18) fonctionnelles, et - la hauteur de la saillie (22) non fonctionnelle selon la direction (14) d'empilement est supérieure à la hauteur de l'ensemble des saillies () fonctionnelles selon la même direction d'empilement. An assembly according to claim 2 wherein: the first stratum (10) comprises a plurality of functional projections (16, 18), and - The height of the projection (22) non-functional in the direction (14) of stacking is greater than the height of all the projections () functional in the same direction of stacking. Ensemble selon l'une quelconque des revendications précédentes, dans lequel: - la première strate (10) comprend au moins trois saillies (20, 21, 22) non fonctionnelles s'étendant selon la direction (14) d'empilement et disposées le long d'au moins deux axes non colinéaires, et - la seconde strate (12) comprend un ou plusieurs renfoncements (26, 28) aptes à recouvrir les trois saillies (20, 21, 22) non fonctionnelles en totalité lorsque ces deux strates (10, 12) sont empilées de manière à empêcher un contact entre les saillies non fonctionnelles et le matériau réfractaire. An assembly according to any one of the preceding claims, wherein: the first layer (10) comprises at least three non-functional projections (20, 21, 22) extending in the direction (14) of stacking and arranged along at least two non-collinear axes, and the second layer (12) comprises one or more recesses (26, 28) capable of covering the three completely non-functional projections (20, 21, 22) when these two layers (10, 12) are stacked in such a way as to prevent contact between the non-functional projections and the refractory material. Ensemble selon l'une quelconque des revendications précédentes, dans lequel le modèle est un modèle pour une culasse d'un moteur d'un véhicule.An assembly as claimed in any one of the preceding claims, wherein the model is a model for a cylinder head of an engine of a vehicle. Moule non permanent comprenant : - une cuve (4) contenant un matériau réfractaire (6), et - un modèle (8) à l'intérieur du matériau réfractaire (6) pour la fabrication d'une pièce par moulage à moule non permanent, caractérisé en ce que le modèle (8) est réalisé par l'empilement d'un ensemble de strates conformes à l'une quelconque des revendications précédentes .Non-permanent mold comprising: a tank (4) containing a refractory material (6), and a model (8) inside the refractory material (6) for manufacturing a part by non-permanent mold molding, characterized in that the model (8) is made by stacking a set of strata according to any one of the preceding claims. Procédé de confection d'un modèle pour la fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire, comportant : - la réalisation d'une première strate (10), et - la réalisation d'une seconde strate (12) apte à être empilée sur la première strate selon une direction (14) d'empilement, caractérisé en ce que : - la réalisation de la première strate (10) comprend la formation d'une saillie non fonctionnelle (22) s'étendant selon la direction (14) d'empilement, et - la réalisation de la seconde strate (12) comprend la formation d'un renfoncement (28) apte à recouvrir la saillie (22) non fonctionnelle de la première strate (10) en totalité lorsque ces deux strates (10, 12) sont empilées de manière à empêcher un contact entre la saillie (22) non fonctionnelle et le matériau réfractaire. A method of making a model for the manufacture of a part by non-permanent mold molding of refractory material, comprising: the realization of a first layer (10), and the production of a second layer (12) capable of being stacked on the first layer in a stacking direction (14), characterized in that the realization of the first layer (10) comprises the formation of a non-functional projection (22) extending in the direction (14) of stacking, and - The realization of the second layer (12) comprises the formation of a recess (28) capable of covering the non-functional projection (22) of the first layer (10) completely when these two layers (10, 12) are stacked in order to prevent contact between the non-functional projection (22) and the refractory material. Procédé selon la revendication 7, dans lequel le procédé comporte une étape d'assemblage des première et seconde strates (10, 12) pour former le modèle (8).The method of claim 7, wherein the method comprises a step of assembling the first and second layers (10, 12) to form the model (8). Procédé de fabrication d'une pièce par moulage à moule non permanent en matériau réfractaire, dans lequel le procédé comporte : - la confection d'un modèle (8) de cette pièce, le modèle étant confectionné dans un matériau perdu, - la réalisation d'un moule à partir de ce modèle, le moule étant réalisé dans un matériau réfractaire, la température de fusion du matériau réfractaire étant plus élevée que la température de fusion du matériau perdu, et - le moulage de la pièce à partir du moule réalisé, la pièce étant réalisée dans un matériau dont la température de fusion est comprise entre la température de fusion du matériau perdu et du matériau réfractaire, caractérisé en ce que la confection du modèle (8) est conforme à l'une quelconque des revendications 7 à 8. A method of manufacturing a piece by non-permanent mold molding of refractory material, wherein the method comprises: - the making of a model (8) of this piece, the model being made of a lost material, - Making a mold from this model, the mold being made of a refractory material, the melting temperature of the refractory material being higher than the melting temperature of the lost material, and - The molding of the piece from the mold made, the part being made of a material whose melting temperature is between the melting temperature of the lost material and the refractory material, characterized in that the manufacture of the model (8) is according to any one of claims 7 to 8.
EP11166679.8A 2010-05-28 2011-05-19 Set of strata, mould, methods for producing said model and for manufacturing a part using said model Active EP2397245B1 (en)

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FR1054148A FR2960457B1 (en) 2010-05-28 2010-05-28 ASSEMBLY OF STRATES, MOLD, METHODS OF MAKING THIS MODEL AND MANUFACTURING A WORKPIECE THEREOF

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2949409A1 (en) 2014-05-27 2015-12-02 Peugeot Citroën Automobiles Sa Method for producing a lost pattern for use in foundry
FR3051129A1 (en) * 2016-05-12 2017-11-17 Peugeot Citroen Automobiles Sa LOST MODEL STRATE FOR USE IN FOUNDRIES
FR3098422A1 (en) * 2019-07-09 2021-01-15 Psa Automobiles Sa SET INCLUDING A LOST MODEL AND A METAL COOLING PLATE

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62282747A (en) * 1986-02-17 1987-12-08 Toyota Motor Corp Expendable pattern for casting cylinder head for internal combustion engine
EP0901850A1 (en) * 1997-09-10 1999-03-17 Automobiles Peugeot Glue-based method for bonding synthetic pyrolysable materials used in lost pattern casting
WO2006075344A2 (en) * 2005-01-14 2006-07-20 Meccanica Bassi S.P.A. Lost foam casting method, in particular for an engine cylinder head

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62282747A (en) * 1986-02-17 1987-12-08 Toyota Motor Corp Expendable pattern for casting cylinder head for internal combustion engine
EP0901850A1 (en) * 1997-09-10 1999-03-17 Automobiles Peugeot Glue-based method for bonding synthetic pyrolysable materials used in lost pattern casting
WO2006075344A2 (en) * 2005-01-14 2006-07-20 Meccanica Bassi S.P.A. Lost foam casting method, in particular for an engine cylinder head

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2949409A1 (en) 2014-05-27 2015-12-02 Peugeot Citroën Automobiles Sa Method for producing a lost pattern for use in foundry
FR3051129A1 (en) * 2016-05-12 2017-11-17 Peugeot Citroen Automobiles Sa LOST MODEL STRATE FOR USE IN FOUNDRIES
FR3098422A1 (en) * 2019-07-09 2021-01-15 Psa Automobiles Sa SET INCLUDING A LOST MODEL AND A METAL COOLING PLATE

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FR2960457B1 (en) 2012-07-20
EP2397245B1 (en) 2018-11-21

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