EP2397245B1 - Schichteinheit, Modell, Herstellungsverfahren dieses Modells sowie Herstellungsverfahren eines Werkstücks aus diesem Modell - Google Patents
Schichteinheit, Modell, Herstellungsverfahren dieses Modells sowie Herstellungsverfahren eines Werkstücks aus diesem Modell Download PDFInfo
- Publication number
- EP2397245B1 EP2397245B1 EP11166679.8A EP11166679A EP2397245B1 EP 2397245 B1 EP2397245 B1 EP 2397245B1 EP 11166679 A EP11166679 A EP 11166679A EP 2397245 B1 EP2397245 B1 EP 2397245B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- model
- functional
- stratum
- refractory material
- projection
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 28
- 238000000034 method Methods 0.000 title claims description 20
- 239000011819 refractory material Substances 0.000 claims description 47
- 238000002844 melting Methods 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 17
- 238000000465 moulding Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 15
- 230000015572 biosynthetic process Effects 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 18
- 229910052782 aluminium Inorganic materials 0.000 description 18
- 239000004793 Polystyrene Substances 0.000 description 10
- 229920002223 polystyrene Polymers 0.000 description 10
- 238000005266 casting Methods 0.000 description 8
- 239000007788 liquid Substances 0.000 description 7
- 239000004576 sand Substances 0.000 description 7
- 238000005060 molding of refractory Methods 0.000 description 6
- 230000035939 shock Effects 0.000 description 5
- 235000009508 confectionery Nutrition 0.000 description 4
- 230000004927 fusion Effects 0.000 description 4
- 238000003860 storage Methods 0.000 description 3
- 238000000859 sublimation Methods 0.000 description 3
- 230000008022 sublimation Effects 0.000 description 3
- 239000011344 liquid material Substances 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 230000001464 adherent effect Effects 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000005495 investment casting Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
Images
Classifications
-
- 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 breech of a 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 that the model 8 is immersed in this refractory material 6.
- the functional projections are thus protrusions that affect the final shape of the part made with the mold 2.
- the projections 16 and 18 extend for example according to In this example, the projections 16 and 18 are ports 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 the projections 16 and 18.
- the flat surface is for example the face of a plan for storing the strata.
- 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 model 8 can be built digitally 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 bar 13.
- the connection 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 able to receive 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.
Landscapes
- 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)
Claims (8)
- Schichteinheit für das Herstellen eines Modells zur Fertigung eines Werkstücks durch Formen in einer verlorenen Form aus feuerfestem Material, wobei diese Einheit Folgendes umfasst:- eine erste Schicht (10) und- eine zweite Schicht (12), die geeignet ist, auf der ersten Schicht (10) gemäß einer Stapelungsrichtung (14) gestapelt zu werden, dadurch gekennzeichnet, dass:- die erste Schicht (10) einen zu schützenden funktionalen Vorsprung (18) umfasst, wobei der funktionale Vorsprung ein Vorsprung ist, der mit dem feuerfesten Material in Berührung ist, wenn die zwei Schichten gestapelt sind, und einen nicht funktionalen Vorsprung (22), der sich gemäß der Stapelungsrichtung (14) erstreckt und dazu bestimmt ist, den funktionalen Vorsprung (18) zu schützen,- wobei die zweite Schicht (12) eine Verstärkung (28) umfasst, die geeignet ist, um den nicht funktionalen Vorsprung (22) vollständig zu schützen, wenn diese zwei Schichten (10, 12) derart gestapelt sind, dass sie eine Berührung zwischen dem nicht funktionalen Vorsprung (22) und dem feuerfesten Material verhindern,und dass:- die Höhe des nicht funktionalen Vorsprungs (22) gemäß der Stapelungsrichtung (14) größer ist als die Höhe des funktionalen Vorsprungs (18) gemäß derselben Stapelungsrichtung (14).
- Einheit nach dem vorhergehenden Anspruch, wobei:- die erste Schicht (10) mehrere funktionale Vorsprünge (16, 18) umfasst, und- die Höhe des nicht funktionalen Vorsprungs (22) gemäß der Stapelungsrichtung (14) größer ist als die Höhe aller funktionalen Vorsprünge (16, 18) gemäß derselben Stapelungsrichtung (14).
- Einheit nach einem der vorhergehenden Ansprüche, wobei:- die erste Schicht (10) mindestens drei nicht funktionale Vorsprünge (20, 21, 22) umfasst, die sich gemäß der Stapelungsrichtung (14) erstrecken und entlang von mindestens zwei nicht kolinearen Achsen angeordnet sind, und- die zweite Schicht (12) eine oder mehrere Vertiefungen (26, 28) umfasst, die geeignet sind, um die drei nicht funktionalen Vorsprünge (20, 21, 22) vollständig zu bedecken, wenn diese zwei Schichten (10, 12) derart gestapelt sind, dass sie eine Berührung zwischen den nicht funktionalen Vorsprüngen und dem feuerfesten Material verhindern.
- Einheit nach einem der vorhergehenden Ansprüche, wobei das Modell ein Modell für einen Zylinderkopf eines Fahrzeugmotors ist.
- Verlorene Form, die Folgendes umfasst:- eine Wanne (4), die ein feuerfestes Material (6) enthält, und- ein Modell (8) in dem Inneren des feuerfesten Materials (6) für die Fertigung eines Werkstücks durch Formen mit verlorener Form,dadurch gekennzeichnet, dass das Modell (8) durch Stapelungen einer Schichteneinheit gemäß einem der vorhergehenden Ansprüche hergestellt ist.
- Verfahren zum Anfertigen eines Modells für die Fertigung eines Werkstücks durch Formen mit verlorener Form aus einem feuerfesten Material, das Folgendes umfasst:- die Herstellung einer ersten Schicht (10), und- die Herstellung einer zweiten Schicht (12), die geeignet ist, auf der ersten Schicht gemäß einer Stapelungsrichtung (14) gestapelt zu werden, dadurch gekennzeichnet, dass:- die Herstellung der ersten Schicht (10) das Bilden eines zu schützenden funktionalen Vorsprungs (18) umfasst, wobei ein funktionaler Vorsprung ein Vorsprung ist, der mit dem feuerfesten Material in Berührung ist, wenn die zwei Schichten gestapelt sind, und einen nicht funktionalen Vorsprung (22), der sich entlang der Stapelungsrichtung (14) erstreckt und dazu bestimmt ist, den funktionalen Vorsprung (18) zu schützen, wobei die Höhe des nicht funktionalen Vorsprungs (22) gemäß der Stapelungsrichtung (14) höher ausgewählt wird als die Höhe des funktionalen Vorsprungs (18) gemäß derselben Stapelungsrichtung (14),- die Herstellung der zweiten Schicht (12) das Bilden einer Vertiefung (28) umfasst, die geeignet ist, um den nicht funktionalen Vorsprung (22) vollständig abzudecken, wenn diese zwei Schichten (10, 12) derart gestapelt sind, dass sie eine Berührung zwischen dem nicht funktionalen Vorsprung (22) und dem feuerfesten Material verhindern.
- Verfahren nach dem vorhergehenden Anspruch, wobei das Verfahren einen Schritt des Zusammenfügens der ersten und zweiten Schicht (10, 12) zum Bilden des Modells (8) umfasst.
- Fertigungsverfahren eines Werkstücks durch Formen mit verlorener Form aus feuerfestem Material, wobei das Verfahren Folgendes umfasst:- das Anfertigen eines Modells (8) dieses Werkstücks, wobei das Modell aus einem verlorenen Material angefertigt wird,- die Herstellung einer Form ausgehend von diesem Modell, wobei die Form aus einem feuerfesten Material hergestellt ist, wobei die Schmelztemperatur des feuerfesten Materials höher ist als die Schmelztemperatur des verlorenen Materials, und- sobald das Formen des Werkstücks ausgehend von der Form hergestellt ist, das Werkstück aus einem Material hergestellt ist, dessen Schmelztemperatur zwischen der Schmelztemperatur des verlorenen Materials und der des feuerfesten Materials liegt,dadurch gekennzeichnet, dass die Anfertigung des Modells (8) einem der Ansprüche 6 oder 7 entspricht.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR1054148A FR2960457B1 (fr) | 2010-05-28 | 2010-05-28 | Ensemble de strates, moule, procedes de confection de ce modele et de fabrication d'une piece a partir de ce modele |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2397245A1 EP2397245A1 (de) | 2011-12-21 |
EP2397245B1 true EP2397245B1 (de) | 2018-11-21 |
Family
ID=43413686
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11166679.8A Active EP2397245B1 (de) | 2010-05-28 | 2011-05-19 | Schichteinheit, Modell, Herstellungsverfahren dieses Modells sowie Herstellungsverfahren eines Werkstücks aus diesem Modell |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP2397245B1 (de) |
FR (1) | FR2960457B1 (de) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR3021567B1 (fr) | 2014-05-27 | 2016-05-27 | Peugeot Citroen Automobiles Sa | Procede de realisation d'un modele perdu destine a etre utilise en fonderie |
FR3051129B1 (fr) * | 2016-05-12 | 2018-05-18 | Peugeot Citroen Automobiles Sa | Strate de modele perdu destine a etre utilise en fonderie |
FR3098422B1 (fr) * | 2019-07-09 | 2021-06-18 | Psa Automobiles Sa | Ensemble comprenant un modele perdu et une plaque metallique de refroidissement |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH0780034B2 (ja) * | 1986-02-17 | 1995-08-30 | トヨタ自動車株式会社 | 内燃機関用シリンダヘツドの鋳造用消失性模型 |
FR2768068B1 (fr) * | 1997-09-10 | 1999-10-08 | Peugeot | Procede d'assemblage par collage de pieces en matiere synthetique pyrolysable pour le moulage en fonderie du type a modele perdu |
WO2006075344A2 (en) * | 2005-01-14 | 2006-07-20 | Meccanica Bassi S.P.A. | Lost foam casting method, in particular for an engine cylinder head |
-
2010
- 2010-05-28 FR FR1054148A patent/FR2960457B1/fr not_active Expired - Fee Related
-
2011
- 2011-05-19 EP EP11166679.8A patent/EP2397245B1/de active Active
Non-Patent Citations (1)
Title |
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None * |
Also Published As
Publication number | Publication date |
---|---|
FR2960457B1 (fr) | 2012-07-20 |
FR2960457A1 (fr) | 2011-12-02 |
EP2397245A1 (de) | 2011-12-21 |
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