EP2448698B1 - Device and its use as well as gutter for tilt-casting of cast components - Google Patents

Description

The invention relates to a device and its use and a runner for Kippgießen of components.

When Kippgießverfahren, generally in the standard work " Foundry Lexicon ", 16th Edition, 1994, p. 244 and p. 655 is described, a mold is rotated about a tilt axis by up to 90 °, while the melt flows into the mold. The mold can advantageously be filled with the melt without flow turbulence. It is particularly advantageous that the possibly occurring during casting spilling melt can be avoided by passing the melt on a wall of the mold.

From the DE 10 2004 015 649 B3 are known a method for casting of components made of light metal, in particular of aluminum alloys, according to the Kippgießprinzip and a corresponding device for carrying out such a method. In this method, the melt is poured in the head casting in a located on the longitudinal side of a mold cross run. The casting mold is initially tilted at an angle of 45 ° to 70 ° about its longitudinal axis. Thereafter, the filling of the liquid melt in the cross-flow begins until about 1/5 of the melt required for the casting of the component is filled in the cross-section, without the melt already flows into the mold cavity of the mold. Subsequently, the casting mold is rotated from the tilted position into the vertical with continuous introduction of further melt in such a way that the melt flows into the mold cavity along a casting wall.

A disadvantage of in the DE 10 2004 015 649 B3 disclosed method is that the melt is initially only partially filled in the cross-flow, before starting to pour into the mold. There may be a risk that temperature losses occur. Another disadvantage is that the remaining melt required for the casting process must be continuously refilled during the tilt casting and thus very expensive by means of a ladle in a Gießtümpel the cross run. The ladle must therefore be carried along synchronously with the tilting of the mold and is at this time no other or further pouring available.

By tilting the mold, the melt flow is deflected by 90 ° in cross-section and then flows through several outlets in the mold. In this case, in particular by the continuous refilling of the melt by means of a ladle there is the risk that the melt may flow unevenly, in particular too quickly or too slowly, too little or too much through the individual outlets into the casting mold.

Based on this prior art, the present invention seeks to provide an apparatus for casting of light metal components according to the Kippgießprinzip, with the elimination of the aforementioned disadvantages new degrees of freedom and opportunities in the process of casting the components are created, creating new Component geometries, but in particular new component properties, for example, regarding the internal structure and / or the external nature of the components are obtained.

The invention is also based on the object to provide a device for casting of components made of light metal according to the Kippgießprinzip, with the without considerable technical effort, a mold filling is achieved, the even with complicated component geometries cavities, porosities and / or inclusions in the cast component avoids.

The invention is also based on the object to provide a device for casting of components made of light metal according to the Kippgießprinzip, with a homogeneous filling of the mold with the melt is largely possible without temperature losses.

The invention is also based on the object to provide a device for casting of light metal components according to the Kippgießprinzip with which a plurality of components can be poured simultaneously, the technical complexity is kept low.

To solve the invention, a device for casting of components, preferably those made of light metal, according to the Kippgießprinzip is provided which comprises a tiltable about its longitudinal axis mold or mold and a longitudinal direction of the mold arranged on this runner. On its longitudinal side facing the casting mold, the runner has at least two outlets to the mold cavity or in each case at least one outflow to at least two mold cavities arranged side by side and not in flow communication with one another. According to the invention, the runner also has a subdivision, which is designed such that when tilting the mold from a starting position into an end position predetermined or certain volumes of the casting melt through the spouts in the mold cavity or the mold cavities of the mold flow, wherein between the spouts within the runner a boundary is provided for subdivision, wherein the boundary in each case drops towards the spouts ..

With such a device, new degrees of freedom or new possibilities in process management, in particular in terms of flow technology, created for casting of components. If only one mold cavity is filled by at least two outlets, it can be specified how much melt flows through which outlet into the mold cavity. As a result, new component geometries with new component properties, concerning the internal structure and / or the external nature, can be obtained. It is essential to the invention that a boundary is provided for subdivision between the parallel outlets within the runner, the boundary preferably dropping towards the outlets. This ensures that the melt flows more evenly through the respective outlet when tilting the mold.

If a plurality of mutually separate mold cavities or cavities of a casting mold are filled via a respective outlet, a uniform, defined filling of the individual mold cavities of the casting mold is achieved by the device according to the invention. Without significant technical complexity complicated component geometries can be produced, which have fewer voids, porosities and / or inclusions in the cast component. In particular, with such a device according to the invention, a plurality of components can be cast in a particularly simple, fast and parallel manner.

The subdivided volumes are preferably in flow connection within the runner in the region of the longitudinal side opposite the outlets. As a result, the runner can be filled in a particularly simple manner by filling or introducing the melt at only one point in or on the runner.

It may be advantageous if the flow connection in the transverse direction is 1/4 to 3/4, preferably 1/3 to 2/3, of the length of the runner in the transverse direction. The wider the flow connection, the faster and more evenly distributed the melt during filling in the runner, with no temperature losses are to be feared. It has been found that an inventively provided subdivision in the lower, the mold cavity pointing third or quarter the runner is sufficient to divide the melt in predetermined amounts on the existing spouts.

Expediently, the runner is arranged on the casting mold in such a way that the runner is upwardly open in the initial position of the casting mold, ie before tilting. This makes it particularly easy to bring the melt into the runner.

It may be advantageous if the subdivision in the region of the spouts funnel or cup-shaped. Preferably, such a funnel is rectangular in plan view, wherein preferably one side is missing when the runner is open on one side.

It may be expedient if the respective outlet in the end position of the casting mold, that is to say after tilting, is arranged at the lowest point of the subdivision, as a result of which the predetermined amount of melt largely flows completely into the casting mold.

It may be advantageous if at least some of the given volumes are equal or different in size. As a result, in particular new degrees of freedom or possibilities in the process control for casting the components can be created, as a result of which new component geometries, but in particular also new component properties, for example regarding the internal structure and / or the external nature of the components, are obtained.

It may be advantageous if at least some of the spouts are the same or different. As a result, the above can equally be achieved.

Preferably, the mold including casting trough can be tilted by up to 90 °. Such a limited tilting range is sufficient to meet the demands placed on complicated component geometries.

The runner expediently has a pouring basin on one of its end faces. The capacity of the runner is preferably such that in the starting position of the casting mold, ie before tilting, it completely absorbs the melt required for the casting, without the melt flowing into the mold cavity or the mold cavities.

It has been found to be particularly advantageous if at least one further casting mold with one or more mold cavities and a separate runner is arranged next to the first casting mold, these being tiltable via a common tilting axis. As a result, a plurality of components simultaneously or in parallel, in particular easy and fast, pour, the technical complexity is low.

Preferably, a robot arm is provided, which has a number of runners corresponding number of ladles, preferably two ladles, for parallel scooping and transporting the casting melt and for parallel filling of the casting melt in the runner. This allows a variety of components simultaneously or parallel and very fast and easy to pour, the technical complexity is low.

It can be advantageous if the casting mold including the runner is arranged such that the runner can be filled with melt from the end face. As a result, the melt is distributed very quickly in the runner. In addition, a space-saving arrangement, in particular in a device with multiple molds including runners is possible.

It may be advantageous if the device has a retaining part, preferably a retaining plate, which in the pouring point of the runner, preferably between pouring point and first outlet or first subdivision, is retractable to a predetermined depth in the runner, so in that, during the filling of the runner, the pouring melt passes under the retaining part and distributes itself in the runner, whereby an oxide layer floating on top of the casting melt during filling of the runner is retained on the retaining part and can be removed later. This avoids that this oxide layer penetrates through the runners of the runner into the mold cavity or cavities and adversely affects the quality of the castings.

It can be advantageous if the device has a number of outlets corresponding number of further preferably on a common web arranged retaining parts, preferably retaining plates, which are each retractable in front of an outlet to a predetermined depth in the runner, such that the casting melt as the mold is tilted, it passes under the retaining member and flows into the mold cavity (s), retaining an oxide layer floating on top of the casting melt in the runner at the retaining member and later removing it. This avoids that the oxide layer penetrates through the runners of the runner into the mold cavity or cavities and adversely affects the quality of the castings.

Preferably, the retaining members are arranged on a common web in the manner of a comb, which can be moved out before pouring into the runner and after pouring out of the runner can be moved out, preferably such that the oxide layer adheres to the comb when moving out and manually or elsewhere preferably automatically removed from the comb, preferably strippable, is.

After all, the invention also relates to a corresponding runner for placement on a mold or mold, comprising at least two outlets, wherein it is provided according to the invention that the runner has a subdivision, which is designed such that predetermined volumes of the casting melt through the outlets in the Form cavity or in at least two juxtaposed and not in flow communication mold cavities of the mold or mold flow, wherein between the spouts within the runner a boundary is provided for subdivision, wherein the boundary in each case drops towards the spouts ..

It may be particularly advantageous if the runner made of ductile iron, which is also referred to as GJS or GGG, is made. Such a material is particularly suitable to obtain the desired geometry of the runner, the runner simultaneously having steel-like mechanical properties.

Advantageously, the casting trough, preferably only the inside thereof, has a ceramic coating, which is preferably sprayed in several layers in order to avoid adhesion of the melt in the casting trough. E may be advantageous if the coating is repeated after a few runs.

It may be advantageous if the runner is thin-walled, preferably with a wall thickness of up to 20 mm, preferably up to 12 mm, particularly preferably up to 7 mm. This ensures that the temperature can be kept within the melt.

In order to increase the service life of the runner, it may be advantageous if the runner is provided with at least one stiffening element. It may be advantageous if the runner has at least one stiffener notch. It may be advantageous if the runner additionally or alternatively at least has a stiffening rib. It may be advantageous if, as an alternative to the two aforementioned variants or in addition to at least one of the two aforementioned variants, the runner has at least one stiffening bead. It may be advantageous if, as an alternative to the aforementioned variants or in addition to at least one of the aforementioned variants, the runner has at least one reinforcing bead. Such stiffening notches, ribs, beads and / or beads can advantageously be provided on the outside of the casting trough. However, it may also be advantageous if such stiffening notches, ribs, beads and / or beads are provided alternatively or additionally on the inside of the casting trough. Stiffening ribs or ribs on the outside of the bottom of the runner have proved to be particularly advantageous, wherein these ribs or webs are preferably arranged over the length of the runner and particularly preferably have at least one interruption.

Finally, the invention also relates to the use of a device according to one of claims 1 to 13 for casting a pump housing, in particular a high-pressure pump housing, or a turbocharger housing.

Fig. 1

die schematische Darstellung einer Gießrinne mit trichterförmiger Unterteilung in perspektivischer Ansicht,

Fig. 2

die schematische Darstellung einer Gießrinne mit trichterförmiger Unterteilung in Draufsicht,

Fig. 3

die schematische Darstellung einer Gießformhälte in perspektivischer Ansicht,

Fig. 4

die schematische Darstellung von zwei parallel, auf nur einer Kippachse angeordneten Gießformen als Gießformhälften mit jeweils daran angeordneter Gießrinne in perspektivischer Ansicht,

Fig. 5

die schematische Darstellung von zwei parallel, auf nur einer Kippachse angeordneten Gießformen als Gießformhälften mit jeweils daran angeordneter Gießrinne in Draufsicht,

Fig. 6

die schematische Darstellung einer Gießform aus zwei Gießformhälften mit daran angeordneter Gießrinne in Ausgangsstellung in Seitenansicht,

Fig. 7

die schematische Darstellung einer Gießform aus zwei Gießformhälften mit daran angeordneter Gießrinne in Zwischenstellung in Seitenansicht und

Fig. 8

die schematische Darstellung einer Gießform aus zwei Gießformhälften mit daran angeordneter Gießrinne in Endstellung in Seitenansicht.

The invention will be explained with reference to an embodiment shown in the drawing. In this show

Fig. 1

the schematic representation of a runner with funnel-shaped subdivision in perspective view,

Fig. 2

the schematic representation of a runner with funnel-shaped subdivision in plan view,

Fig. 3

the schematic representation of a Gießformhälte in a perspective view,

Fig. 4

the schematic representation of two parallel, arranged on only one tilting axis casting molds as mold halves with respectively arranged thereon trough in a perspective view,

Fig. 5

the schematic representation of two parallel, arranged on only one tilting molds as mold halves with respectively arranged thereon gutter in plan view,

Fig. 6

the schematic representation of a mold of two mold halves with thereon disposed gutter in the starting position in side view,

Fig. 7

the schematic representation of a mold of two mold halves with thereon disposed gutter in the intermediate position in side view and

Fig. 8

the schematic representation of a mold of two mold halves with arranged thereon gutter in the end position in side view.

Become in the Fig. 1 to 8 the same reference numerals used, they designate the same parts, so that in order to avoid repetition not every description of the figures on an already described component must be re-entered.

In Fig. 1 schematically a pouring trough 12 according to the invention with a funnel-shaped subdivision 20 and a pouring basin 30 at one of the end faces 28 of the pouring trough 12 is shown in a perspective view.

The runner 12 has on the side facing the mold 10 longitudinal side 14 five spouts 16, each for a separate mold cavity 16 of a mold, as in Fig. 3 shown, are connectable.

Correspondingly juxtaposed and non-flow-connected mold cavities 18 of a casting mold 10 are shown in FIG Fig. 3 shown, for the sake of clarity, only one mold half of the mold 10 is shown. Fig. 3 Thus, only one mold half 10 with correspondingly half mold cavity 18 is shown.

According to the invention, the runner 12 has a funnel-shaped subdivision 20 in the third side of the runner 12, which faces the longitudinal side 14. This subdivision 20 is designed in such a way that, when the casting mold 10 together with the runner 12 is tilted, predetermined volumes of the casting melt flow through the outlets 16 through the subdivision.

In the present case, the volumes of the casting melt flowing through the respective outlet 16 are the same. The respective outlets 16 of the trough 12 are the same size.

This ensures that the mold cavities 18 adjoining the spouts 16 are all filled uniformly with the same volume of casting melt. This is useful if by means of the mold cavities 16, a plurality of identical components, in particular pump housing, at the same time, ie synchronously, are poured.

It can be clearly seen that the subdivided volumes within the runner 12 are generously in fluid communication in the area of the longitudinal side 22 opposite the outlets 16, the flow connection in the transverse direction 24 being approximately two One third of the length of the runner 12 in the transverse direction 24 claimed. However, such a subdivision is already sufficient to assign the individual outlets 16 a predetermined volume of casting melt and to fill the respective mold cavity 18 uniformly and homogeneously.

As in Fig. 8 can be seen well, the respective outlet 16 in the end position of the mold 10, ie after tilting, at the low point 26 of the subdivision 20 is arranged.

The casting trough 12 has a pouring basin 30 at one of its end faces 28.

In the Fig. 2 schematically illustrated runner 12 corresponds substantially to the in Fig. 1 shown, but is shown in plan view.

Fig. 3 represents - as already mentioned - schematically a mold half of a mold 10 with five separate mold cavities 18, each mold cavity 18, also shown here only half, pads 34 for a core 32, wherein the core 32 by way of example in Fig. 3 is shown in the left mold cavity 18.

Fig. 4 shows in perspective a device according to the invention with two parallel molds 10 and molds, each of which has a arranged in the longitudinal direction of the mold 10 to this runner 12 each. For better clarity, however, only one mold half 10 of each mold 10 is shown.

According to the invention, it is provided that the two casting molds 10 together with runners 12 can be tilted via only one common tilting axis 8 (not shown here).

Preferably, the device also comprises a robot arm, not shown here, which has two ladles for parallel scooping and transporting the casting melt and for parallel filling of the casting melt in the runners 12 and in the pouring basins 30.

Fig. 5 shows the invention provided on a common tilting axis 8 two molds 10 with the respective arranged runner 12 according to the invention Fig. 4 in plan view.

Fig. 6 to 8 show the mold 10 according to the invention, this time composed of two mold halves, with inventive trough 12 in three snapshots during casting.

In this method for casting a material by bringing the same into a flowable state by heating and introducing it into the, about a tilt axis 8 tiltable mold 10 according to the Kippgießprinzip the mold 10 is first by 90 ° in an initial position on the side or rotated or tilted in the horizontal, so that the casting mold 10 associated with the mold 10 and provided with at least two spouts 16 Gutter 12 comes to rest horizontally next to the mold 10, Fig. 6 , Then, the flowable material is introduced from above into the trough 12. Subsequently, the casting mold 10 together with runner 12 is tilted by 90 ° into the vertical, so that the flowable material during tilting with predetermined volumes by the individual volumes assigned to spouts 16 in the at least one mold cavity, preferably in several, each having at least one outlet and non-communicating mold cavities 18, flows, Fig. 8. Fig. 7 shows an intermediate position of the mold 10th

Preferably, each mold cavity 18 has a core 32 which is formed from core molding material, preferably from sand, and an inorganic binder.

List of Reference Numerals (is part of the description)

8th

tilt axis

10

Mold or mold half

12

launder

14

long side

16

outlet

18

mold cavity

20

subdivision

22

Area opposite longitudinal side

24

transversely

26

low

28

front

30

Eingießtümpel

32

core

34

core edition

Claims (15)

1. A device for casting structural components, preferably made of light metal, according to the tilt casting principle with a casting mould (10) that can be tilted about its longitudinal axis (8), a casting channel (12) which is arranged in the longitudinal direction of and on the casting mould (10) and of which the longitudinal side (14) facing the casting mould (10) has at least two outlets to the mould cavity or rather at least one outlet (16) each to at least two mould cavities (18), which are arranged next to one another and which are not in fluid communication with one another, wherein the casting channel (12) has a subdivision (20), which is formed such that when the casting mould (10), together with the casting channel (12), is tilted, predetermined volumes of the casting molten mass flow through the outlets (16), wherein a boundary for the subdivision (20) is provided between the outlets (16) within the casting channel (12), wherein in each case the boundary slopes down to the outlets (16).
2. The device according to Claim 1, characterised in that the divided volumes within the casting channel (12) are in fluid communication in the region of the longitudinal side (22) located opposite the outlets (16).
3. The device according to Claim 2, characterised in that the fluid communication, in the transverse direction (24), is 1/4 to 3/4, preferably 1/3 to 2/3, of the length of the casting channel (12) in the transverse direction.
4. The device according to any one of Claims 1 to 3, characterised in that the casting channel (12) is arranged on the casting mould such that the casting channel (12) is open at the top while the casting mould (10) is in the initial position, i.e. prior to tilting.
5. The device according to any one of Claims 1 to 4, characterised in that the subdivision (20) is funnel-shaped or shell-shaped in the region of the outlets (16).
6. The device according to any one of Claims 1 to 5, characterised in that the respective outlet (16) is arranged at the lowest point (26) of the subdivision (20) while the casting mould (10) is in the end position, i.e. after tilting.
7. The device according to any one of Claims 1 to 6, characterised in that at least some of the predetermined volumes are equal or different in size.
8. The device according to any one of Claims 1 to 7, characterised in that at least some of the outlets (16) are equal or different in size.
9. The device according to any one of Claims 1 to 8, characterised in that the casting mould (10), together with the casting channel (12), can be tilted by up to 90°.
10. The device according to any one of Claims 1 to 9, characterised in that the casting mould (12) has a runner basin (30) at one of its end faces (28).
11. The device according to any one of Claims 1 to 10, characterised in that the volumetric capacity of the casting channel (12) is such that, while the casting mould (10) is in the starting position, i.e. prior to tilting, it (12) accommodates the entire molten mass required for the casting, without the molten mass flowing into the mould cavity or mould cavities (18).
12. The device according to any one of Claims 1 to 11, characterised in that at least one additional casting mould (10) with one or more mould cavities (18) and separate casting channel (12) is arranged next to the first casting mould (10), wherein these (10) can be tilted over a common tilting axis (8).
13. The device according to any one of Claims 1 to 12, characterised in that a robotic arm is provided, which has a number of casting ladles which corresponds to the number of casting channels (12), preferably two casting ladles, for concurrently ladling out and transporting the casting molten mass, as well as for concurrently filling the casting molten mass into the casting channel (12).
14. A casting channel (12) for arranging on a casting mould (10) or die cast, comprising at least two outlets (16), characterised in that the casting channel (12) has a subdivision (20), which is formed such that predetermined volumes of the casting molten mass flow through the outlets (16) into the moulding cavity, or into at least two moulding cavities (18) of the casting mould (10) or die cast, which are arranged next to one another and which are not in fluid communication with one another, wherein a boundary for the subdivision (20) is provided between the outlets (16) within the casting channel (12), wherein the boundary slopes down respectively to the outlets (16).
15. The use of a device according to any one of Claims 1 to 13, for casting a pump case, in particular a high pressure pump case, or a turbocharger case.

Images