EP2844409B1 - Method for casting a cast part provided with at least one passage opening - Google Patents

Method for casting a cast part provided with at least one passage opening Download PDF

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Publication number
EP2844409B1
EP2844409B1 EP13719081.5A EP13719081A EP2844409B1 EP 2844409 B1 EP2844409 B1 EP 2844409B1 EP 13719081 A EP13719081 A EP 13719081A EP 2844409 B1 EP2844409 B1 EP 2844409B1
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EP
European Patent Office
Prior art keywords
casting
opening
mold
cooling
core
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EP13719081.5A
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German (de)
French (fr)
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EP2844409A1 (en
Inventor
Klaus Arnold
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Fritz Winter Eisengiesserei GmbH and Co KG
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Fritz Winter Eisengiesserei GmbH and Co KG
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Priority to PL13719081T priority Critical patent/PL2844409T3/en
Publication of EP2844409A1 publication Critical patent/EP2844409A1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
    • B22C5/08—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by sprinkling, cooling, or drying
    • B22C5/085—Cooling or drying the sand together with the castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/003—Removing cores using heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group

Definitions

  • the invention relates to a method for casting a casting, which is provided with at least one passage opening, from a molten metal.
  • the castings in question are typically cylinder crankcases for high power internal combustion engines cast from cast iron material.
  • cast iron with vermicular graphite is sometimes used instead of conventional gray cast iron or higher alloyed cast iron materials are used to achieve the required strength.
  • the castings of the type described above are usually poured into molds, which are composed of several moldings and casting cores. While the mold parts typically determine the outer shape of the casting, the casting cores are inserted into the mold to image recesses, cavities, through holes, and the like on the casting to be produced.
  • the moldings and cores are designed as permanent moldings and permanent casting cores or as lost moldings and casting cores. While permanent moldings and casting cores are made of materials that withstand the loads occurring during casting, and therefore can be used repeatedly for a variety of casting operations, lost moldings and cores usually consist of molding materials that can be easily destroyed by force or temperature. Is a mold completely or at least substantially of lost moldings and casting cores, one usually speaks of a lost form, whereas casting molds, the consist predominantly of permanent moldings, even then referred to as permanent casting molds when lost foundry cores are used in them. In the field of iron casting, lost molds are typically used, while in the field of light metal casting often permanent casting or combinations of permanent moldings and lost moldings are used.
  • the molding materials that make up the lost moldings and cores are sands mixed with a suitable binder which, upon production of the respective moldings or cores, are solidified by a chemical reaction to the point of solidification into the mold cast melt have a sufficient shape retention.
  • the constituents of the molding material can be coordinated with each other so that the respective casting core or the respective molded part breaks automatically during the cooling of the casting as a result of the stresses occurring in the process.
  • the disintegration of the lost moldings and casting cores can be effected by the application of mechanically acting forces.
  • cores can be destroyed by shaking the respective casting to such a small parts that their molding material trickles out of the casting automatically, or the destruction of the cores is accelerated by drilling, expressions or rinsing.
  • the prerequisite for this, however, is in each case that the casting is substantially completely cooled, so that in the mechanical or thermal destruction of the lost casting cores and moldings occurring stresses lead to any damage to the casting.
  • the process of cooling the casting has a decisive influence on its mechanical properties. Problems can occur during the cooling of a casting in that the casting part cools at different speeds due to non-uniform material distribution or non-uniform heat dissipation. As a result of such non-uniform cooling can lead to residual stresses of the casting, which can lead to a drastic deterioration in its mechanical strength.
  • the cooling from the casting temperature to a temperature which is generally below 600 ° C. is carried out in a deliberately slow manner.
  • the casting plants used in practice are equipped with cooling sections of a certain length, these cooling sections may additionally include so-called "cooling stations", where the molds can dwell with the castings to be cooled in them over a certain period of time to further delay the cooling , If there are no means available to guarantee a sufficiently slow cooling, or if even after such a slow cooling too high residual stresses on the casting are present, the castings must be subjected to an additional annealing to reduce the relevant voltages.
  • the sand casting mold known from this publication for producing an aluminum alloy casting comprises a portion made by means of a solvent, in particular water, soluble binder, and another portion made by a binder which is not dissolved by the solvent in question can be.
  • This division of the sections of the sand mold makes it possible to remove the core produced in each case based on the soluble binder by exposure to the solvent, for example by application of a jet of water, so that the inner areas of the casting exposed to the solvent cool more quickly than the rest of the casting.
  • this solution only refers to cavities that are present in the casting, and requires a complex design of the sand mold made of different molding materials.
  • document JPH03138068 A describes a method for producing a cylinder block, in which cooling gas is blown through a vent opening from below into the still existing in the cylinder liner sand core, once the temperature of the cylinder liner has reached the A1 transformation point.
  • the object of the invention was to provide a method which makes it possible, with little expenditure on equipment, to produce through-openings having castings with optimized mechanical properties.
  • the invention is based on the idea that, during the cooling of the cast part following casting of the molten metal by engagement with the casting mold, a state is produced by which the cast part in an interior region, which is decisive for its future loadability, can move at a speed which is significantly higher than the rate at which the casting would cool in that region when the casting mold is in conventional Continue to cool to room temperature in the state in which the casting has been made.
  • a casting channel that penetrates the casting mold and is introduced through the at least one through-opening of the casting is introduced into the casting mold.
  • cooling medium Through this passage then flows a cooling medium.
  • the flow through the cooling medium causes the material of the casting surrounding the passage opening to cool much faster than would be the case if the casting mold remained closed in a conventional manner until the casting reached the prescribed final cooling temperature.
  • cooling rates can be achieved which are higher than the cooling rates achieved on the outside of the casting mold become.
  • the temperature gradient between inner and outer regions can thus be drastically reduced and, at the same time, the cooling rate of the cast part can generally be increased.
  • thermally induced stresses in the casting are reduced to a minimum.
  • strengths are achieved significantly higher than the strengths cast in a conventional manner and cooled in the mold without additional measures castings.
  • the process according to the invention proves to be particularly effective in the production of castings from a cast iron melt.
  • the minimum temperature at which the casting is maximally cooled (step c)) until the manufacture of the passage channel to be introduced into the casting mold according to the invention is set to be above the A 1 temperature at which it is used to convert the austenite comes.
  • the minimum temperature, which does not fall below during cooling in step c) is typically in the range of 1153-600 ° C.
  • the cooling medium may be, for example, air or another gaseous medium.
  • air for example, air or another gaseous medium.
  • water vapor or an air-water vapor mixture as the cooling medium.
  • This effect can be promoted by aligning the casting with the casting mold or by making the through-channel introduced into the casting mold so that the main direction of the through-passage is vertically aligned.
  • the existing in the passage or in each case inflowing and heated air can rise unhindered in the passage.
  • the cooling medium can also be passed through the through-channel in a forced flow.
  • a conveying device which may be, for example, a fan or a pump, be forced.
  • the conveyor in question can be positioned for example in front of one of the outer side surfaces arranged openings of the passage channel or, if necessary, after insertion of the passage channel inserted into it.
  • the procedure according to the invention can also be applied to cast parts which have a plurality of passage openings.
  • a through channel is generated, which is then flowed through by the cooling medium in order to effect the invention accelerated cooling in the respective passage opening.
  • the casting treated according to the invention is a cylinder crankcase for an internal combustion engine and the passage opening is at least one cylinder opening provided in the cylinder crankcase.
  • the procedure according to the invention is particularly simple and at the same time inexpensive and flexible realize in practice that the mold is formed completely or at least in the region of the passage opening as a core package whose moldings and cores, which are arranged in the region of the passage opening and the extension of the through hole forming casting core, consist of a molding material under force - or temperature action decomposes.
  • the casting mold consists of lost casting cores or molded parts, at least in the region of the passage opening of the casting to be provided with the passage, the casting cores and moldings concerned are made of conventional molded materials which, as explained at the beginning, are usually made of a sand, an organic or inorganic binder of course, wherein the molding material, of course, certain additives may be added to optimize its properties.
  • the binder of the molding material can be designed in a manner known per se so that the binder, which ensures the dimensional stability of the molded parts and casting cores, is burnt by the heat introduced into the casting mold when the molten metal is poured therein. In this case, the affected casting cores and moldings automatically decay into small ones Pieces, which then also trickle automatically under exposure of the passageway from the mold or the casting.
  • the casting cores or shaped parts assigned to the respective through-opening of the casting can be expressed, for example, by means of a punch, or the through-channel can be introduced into the casting mold by means of a drill.
  • the at least one casting core forming the passage opening and the regions of the casting mold arranged in its extension are regularly removed completely in practice during the production of the passage channel.
  • the through-passage can thus be guided through the respective through-opening of the casting, in particular by means of mechanical processing.
  • the casting core forming the passage opening of the casting is only partially removed. Between the passageway and the inner surface of the through hole, there remains sand of the casting core, which still has a certain insulating effect. Accordingly, the cooling of the area adjacent to the passage opening does not occur as rapidly as would be the case with complete removal of the through-hole casting core and direct sweeping of the inner surfaces of the through-hole with the cooling medium, depending on the thickness of the remaining core material.
  • the economy of the method according to the invention can be further increased by the mold having at least two mold cavities for the simultaneous casting of at least two castings and the molten metal is passed through a common sprue in the mold cavities of the mold.
  • the device 1 for simultaneous casting of two cast parts Z1, Z2 comprises a casting mold 2 which is supported on a frame 3.
  • the castings Z1, Z2 are conventionally designed cylinder crankcases, which are each intended for the construction of a row four-cylinder internal combustion engine.
  • the casting mold 2 is composed of core moldings of outer moldings 4, 5, 6, 7 and casting cores 8 - 19 arranged in the interior of the casting mold 2. While the outer mold parts 4 - 7 determine the outer shape of the castings Z1, Z2 to be cast, the casting cores 8,9 form the inner shape of the crankcase K1, K2 with the crankshaft bearings L1, L2 and the casting cores 10 - 17 as through-hole 01, 02 trained cylinder openings of the castings Z1, Z2.
  • the respectively laterally arranged casting mold parts 5, 7 in each case form one end face of the respective casting Z1, Z2, while the respective casting cores 18 arranged opposite the respective associated outer mold part 5.7 represent the front side of the respective casting Z1, Z2 arranged here in the interior of the casting mold 2 ,
  • the further casting cores 19 are used, for example, to produce water or oil passages in the cast parts Z1, Z2.
  • the casting mold 2 is aligned so that the main direction H of the through holes 01,02 are aligned in the vertical direction V.
  • the mold cavities 20, 21 of the casting mold 2 delimited by the mold parts 4 - 7 and casting cores 8 - 19 when the mold 2 is unfilled are connected via notches, which are not further shown, to a common, vertically aligned gate 22 arranged centrally in the mold 2.
  • the central gate 22 is in turn connected to a likewise centrally formed at the top of the mold 2 sprue 23, via which the filling of the mold 2 with cast iron melt S takes place.
  • the gate 22 and the other not shown here sections of the mold 2 are placed so that the filling of the mold cavities 20,21 counter to the effective direction R of gravity takes place.
  • the casting mold 2 sits on a grid 24 supported by supports 24 of the frame 3.
  • the outer moldings 4, 5, 6, 7 and casting cores 8 - 19 are made of a commercially available, inorganic binder and molding a sand mixed molding material which is solidified by heat and moisture removal to the extent that it has sufficient shape retention for the maintenance of the mold 2 and the forces occurring during the casting process.
  • disintegration in particular of those moldings 4, 5, 6, 7 and casting cores 8 - 19, which are directly exposed to the casting heat of cast iron melt S, already begins.
  • the temperature of the castings Z1, Z2 is still so high that hardened structure can be produced by accelerated cooling can. Optimally, the temperature is so high that the structure of the castings Z1, Z2 is still completely austenitic.
  • through-channels G1, G2 are introduced into the casting mold 2 ( Fig. 4 ), of which in each case one of the through holes 01.02 of the casting Z1, Z2 is assigned.
  • the through-openings 01, 02 of the castings Z1, Z2 which at this time have already partially decayed into smaller fragments Imaging casting cores 10 - 17 as well as in their imaginary Extension V1, V2 overlying portions of the lid of the mold 2 forming the outer mold part 4 and lying in their imaginary extension V1, V2 underlying, the crankcase K1, K2 with the crankshaft bearings L1, L2 casting cores 8,9 and also in the Extension V1, V2 below the casting cores 8,9 lying portions of the bottom of the mold 2 forming the lower mold part 6 from the mold 2 encountered.
  • the ejected molding sections and foundry core fragments disintegrate into free-flowing, finely divided material M, which falls through the rack rust and collects at the bottom below the casting mold 2.
  • the trickling out of the molding material M from the casting mold 2 can if necessary be assisted in a manner known per se by shaking, tapping or other mechanical treatments.
  • the falling of the mold 2 down material M can be removed by a conveyor, not shown here.
  • a nozzle device 28 is placed, via which a means of a fan, not shown, accelerated cooling medium flow M1, M2 is blown from below in the vertical direction R in the mold 2 ( Fig. 5 ).
  • the cooling medium is air.
  • the respective cooling medium flow M1, M2 flows through the passage channels G1-G2 leading through the through-openings 01,02 of the castings Z1, Z2 and causes an accelerated cooling of the wall sections of the cast parts Z1, Z2 swept by it.
  • the crankshaft bearing L1, L2 and the crankshaft bearing L1, L2 respectively supporting tie rods A1, A2 formed by a fine-grained pearlite at the same time fine grain structure having a higher strength than the strength, achieved in castings that conventionally cool in a closed mold alone by natural heat loss through their exterior moldings.

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

Description

Die Erfindung betrifft ein Verfahren zum Gießen eines mit mindestens einer Durchgangsöffnung versehenen Gussteils aus einer Metallschmelze. Bei den hier in Rede stehenden Gussteilen handelt es sich typischerweise um Zylinderkurbelgehäuse für Verbrennungsmotoren mit hohen Leistungen, die aus Eisengusswerkstoff gegossen werden.The invention relates to a method for casting a casting, which is provided with at least one passage opening, from a molten metal. The castings in question are typically cylinder crankcases for high power internal combustion engines cast from cast iron material.

Moderne Verbrennungsmotoren werden zur Reduzierung des Kraftstoffverbrauchs ständig weiterentwickelt. Eine zentrale Bedeutung hat dabei die Reduzierung des Bauteilvolumens und -gewichts. Diese Entwicklungsrichtung wird in der Fachwelt mit dem Begriff "Downsizing" belegt. Ziel des "Downsizings" ist es beispielsweise, mit kleineren Motorgrößen Leistungen zu erreichen, die bisher größere Bauvolumina erforderten.Modern combustion engines are constantly evolving to reduce fuel consumption. Central to this is the reduction in component volume and weight. This trend of development is evidenced in the professional world by the term "downsizing". The goal of "downsizing", for example, is to achieve smaller engine sizes that previously required larger construction volumes.

Für ein erfolgreiches Downsizing von Verbrennungsmotoren ist es unter anderem erforderlich, die technologischen Eigenschaften ihrer Einzelteile permanent zu steigern. So konnte mit modernen Motorkonstruktionen die erreichbare Leistung bei gleicher Baugröße mehr als verdreifacht werden.For a successful downsizing of combustion engines, it is necessary, among other things, to permanently increase the technological properties of their individual parts. Thus, with modern engine designs, the achievable performance with the same size could be more than tripled.

Um bei dieser Leistungsdichte eine ausreichende Belastbarkeit von aus Eisenguss bestehenden Zylinderkurbelgehäusen sicherzustellen, wird heute an Stelle von konventionellem Grauguss teilweise Gusseisen mit Vermikulargraphit eingesetzt oder es werden höher legierte Eisengussmaterialien verwendet, um die erforderlichen Festigkeiten zu erreichen.In order to ensure a sufficient load capacity of cast iron cylinder casings at this power density, cast iron with vermicular graphite is sometimes used instead of conventional gray cast iron or higher alloyed cast iron materials are used to achieve the required strength.

Die Gussteile der voranstehend beschriebenen Art werden üblicherweise in Gießformen abgegossen, die aus mehreren Formteilen und Gießkernen zusammengesetzt sind. Während die Formteile in der Regel die äußere Form des Gussteils bestimmen, werden die Gießkerne in die Gießform eingesetzt, um Ausnehmungen, Höhlungen, Durchgangsöffnungen und desgleichen am herzustellenden Gussteil abzubilden.The castings of the type described above are usually poured into molds, which are composed of several moldings and casting cores. While the mold parts typically determine the outer shape of the casting, the casting cores are inserted into the mold to image recesses, cavities, through holes, and the like on the casting to be produced.

Abhängig von ihrer Lage im oder am Gussteil und der Entformbarkeit nach dem Erstarren des Gussteils sind die Formteile und Gießkerne als Dauerformteile und Dauergießkerne oder als verlorene Formteile und Gießkerne ausgelegt. Während Dauerformteile und -gießkerne aus Materialien bestehen, die den beim Gießen auftretenden Belastungen standhalten, und daher für eine Vielzahl von Gießvorgängen wiederholt eingesetzt werden können, bestehen verlorene Formteile und Gießkerne üblicherweise aus Formstoffen, die durch Kraft- oder Temperatureinwirkung problemlos zerstört werden können. Besteht eine Gießform vollständig oder zumindest zum wesentlichen Teil aus verlorenen Formteilen und Gießkernen, spricht man üblicherweise von einer verlorenen Form, wogegen Gießformen, die zum überwiegenden Teil aus Dauerformteilen bestehen, auch dann als Dauergießformen bezeichnet werden, wenn in sie verlorene Gießkerne eingesetzt sind. Im Bereich des Eisengusses werden typischerweise verlorene Formen eingesetzt, während im Bereich des Leichtmetallgusses häufig Dauergießformen oder Kombinationen aus Dauergießformteilen und verlorenen Formteilen zum Einsatz kommen.Depending on their position in or on the casting and the demoulding after solidification of the casting, the moldings and cores are designed as permanent moldings and permanent casting cores or as lost moldings and casting cores. While permanent moldings and casting cores are made of materials that withstand the loads occurring during casting, and therefore can be used repeatedly for a variety of casting operations, lost moldings and cores usually consist of molding materials that can be easily destroyed by force or temperature. Is a mold completely or at least substantially of lost moldings and casting cores, one usually speaks of a lost form, whereas casting molds, the consist predominantly of permanent moldings, even then referred to as permanent casting molds when lost foundry cores are used in them. In the field of iron casting, lost molds are typically used, while in the field of light metal casting often permanent casting or combinations of permanent moldings and lost moldings are used.

Typischerweise handelt es sich bei den Formstoffen, aus denen die verlorenen Formteile und Gießkerne bestehen, um mit einem geeigneten Binder vermischte Sande, die bei Herstellung der jeweiligen Formteile oder Gießkerne durch eine chemische Reaktion soweit verfestigt werden, dass sie bis zum Erstarren der in die Gießform eingegossenen Schmelze eine ausreichende Formhaltigkeit besitzen. Die Bestandteile des Formstoffs können dabei so aufeinander abgestimmt sein, dass der jeweilige Gießkern oder das jeweilige Formteil bereits im Zuge der Abkühlung des Gussteils in Folge der dabei auftretenden Spannungen selbsttätig zerbrechen. Alternativ oder zusätzlich kann der Zerfall der verlorenen Formteile und Gießkerne durch das Aufbringen mechanisch wirkender Kräfte bewirkt werden. So können beispielsweise Gießkerne durch Rütteln des jeweiligen Gussteils zu so kleinen Teilen zerstört werden, dass ihr Formstoff selbsttätig aus dem Gussteil herausrieselt, oder die Zerstörung der Gießkerne durch Aufbohren, Ausdrücken oder Ausspülen beschleunigt wird. Voraussetzung dazu ist jedoch jeweils, dass das Gussteil im Wesentlichen vollständig abgekühlt ist, damit die bei der mechanischen oder thermischen Zerstörung der verlorenen Gießkerne und Formteile auftretenden Belastungen zu keiner Beschädigung des Gussteils führen.Typically, the molding materials that make up the lost moldings and cores are sands mixed with a suitable binder which, upon production of the respective moldings or cores, are solidified by a chemical reaction to the point of solidification into the mold cast melt have a sufficient shape retention. The constituents of the molding material can be coordinated with each other so that the respective casting core or the respective molded part breaks automatically during the cooling of the casting as a result of the stresses occurring in the process. Alternatively or additionally, the disintegration of the lost moldings and casting cores can be effected by the application of mechanically acting forces. For example, cores can be destroyed by shaking the respective casting to such a small parts that their molding material trickles out of the casting automatically, or the destruction of the cores is accelerated by drilling, expressions or rinsing. The prerequisite for this, however, is in each case that the casting is substantially completely cooled, so that in the mechanical or thermal destruction of the lost casting cores and moldings occurring stresses lead to any damage to the casting.

Der Vorgang des Abkühlens des Gussteils hat entscheidenden Einfluss auf seine mechanischen Eigenschaften. Probleme können bei der Abkühlung eines Gussteils dadurch auftreten, dass das Gussteil in Folge von ungleichförmiger Materialverteilung oder ungleichförmiger Wärmeabfuhr bereichsweise unterschiedlich schnell abkühlt. In Folge einer solchen ungleichförmigen Abkühlung kann es zu Eigenspannungen des Gussteils kommen, die zu einer drastischen Verschlechterung seiner mechanischen Belastbarkeit führen können.The process of cooling the casting has a decisive influence on its mechanical properties. Problems can occur during the cooling of a casting in that the casting part cools at different speeds due to non-uniform material distribution or non-uniform heat dissipation. As a result of such non-uniform cooling can lead to residual stresses of the casting, which can lead to a drastic deterioration in its mechanical strength.

Um die Entstehung solcher Spannungen zu minimieren, wird beim Gießen von Gussteilen mit stark variierenden Wanddicken die Abkühlung von der Gießtemperatur bis zu einer in der Regel unter 600 °C liegenden Temperatur gezielt langsam durchgeführt. Hierzu sind die in der Praxis eingesetzten Gießanlagen mit Kühlstrecken einer bestimmten Länge ausgestattet, wobei diese Kühlstrecken zusätzlich so genannte "Kühlbahnhöfe" umfassen können, an denen die Gießformen mit den in ihnen abzukühlenden Gussteilen über eine bestimmte Dauer verweilen können, um die Abkühlung weiter zu verzögern. Stehen keine Mittel zur Verfügung, um eine ausreichend langsame Abkühlung zu garantieren, oder sind selbst nach einer derart langsamen Abkühlung noch zu hohe Eigenspannungen am Gussteil vorhanden, müssen die Gussteile einer zusätzlichen Glühung unterzogen werden, um die betreffenden Spannungen abzubauen.In order to minimize the formation of such stresses, when casting castings with widely varying wall thicknesses, the cooling from the casting temperature to a temperature which is generally below 600 ° C. is carried out in a deliberately slow manner. For this purpose, the casting plants used in practice are equipped with cooling sections of a certain length, these cooling sections may additionally include so-called "cooling stations", where the molds can dwell with the castings to be cooled in them over a certain period of time to further delay the cooling , If there are no means available to guarantee a sufficiently slow cooling, or if even after such a slow cooling too high residual stresses on the casting are present, the castings must be subjected to an additional annealing to reduce the relevant voltages.

Als alternative Möglichkeit, die Zugspannungen im inneren Bereich eines Zylinderkurbelgehäuses zu minimieren, ist in der DE 10 2008 048 761 A1 vorgeschlagen worden, die Gussschmelze nach dem Abgießen in die Gießform gerichtet in der Weise abzukühlen, dass die Erstarrung der Schmelze zuerst im Inneren des Gusskörpers herbeigeführt wird oder die Erstarrung von einem Bereich des Gusskörpers gerichtet zu einem Speiser erfolgt. Dies soll dadurch erreicht werden können, dass die Erstarrung des jeweiligen Gussteils mittels unterschiedlicher Kühlleistung von zumindest zwei unabhängigen, an der jeweiligen Gießform vorgesehenen Kühlkreisläufen beeinflusst wird. Dies lässt sich allerdings nur dann bewerkstelligen, wenn die jeweilige Gießform zumindest in den Bereichen, in denen die Kühlleistung gezielt aufgebracht werden soll, als Dauergießform ausgelegt ist. So sind für die Abformung der Zylinderöffnungen des jeweiligen Zylinderkurbelgehäuses speziell geformte Pinolen vorgesehen, die nach dem Erstarren zerstörungsfrei aus dem Gussteil gezogen werden. Dabei erweist es sich für das Entfernen der Pinolen nach der Erstarrung als vorteilhaft, wenn mit der Kühlung des Rands der Zylinderöffnungen zu einem anderen Zeitpunkt begonnen wird als mit der Kühlung der Zylinderfläche und die Kühlung des Zylinderrands mit einer anderen Intensität durchgeführt wird als die Kühlung der Zylinderfläche. Auf diese Weise soll die Erstarrung des gegossenen Zylinderkurbelgehäuses im Bereich der Zylinderöffnungen so vorgenommen werden können, dass das Zylinderkurbelgehäuse zu einem Zeitpunkt ausgeformt werden kann, zu dem es zwar erstarrt ist, aber noch eine hohe Temperatur aufweist.As an alternative way to minimize the tensile stresses in the inner region of a cylinder crankcase is in the DE 10 2008 048 761 A1 has been proposed to cool the casting melt after casting into the mold in such a way that the solidification of the melt is first brought about in the interior of the casting or the solidification is directed from a region of the casting body to a feeder. This should be achieved by influencing the solidification of the respective casting by means of different cooling capacities of at least two independent cooling circuits provided on the respective casting mold. However, this can only be achieved if the respective casting mold is designed as a permanent casting mold, at least in the areas in which the cooling power is to be applied selectively. Thus, specially shaped quills are provided for the molding of the cylinder openings of the respective cylinder crankcase, which are pulled without destruction from the casting after solidification. It proves to be advantageous for the removal of the sleeves after solidification, when the cooling of the edge of the cylinder openings is started at a different time than with the cooling of the cylinder surface and the cooling of the cylinder edge is performed with a different intensity than the cooling of cylindrical surface. In this way, the solidification of the cast cylinder crankcase in the region of the cylinder openings should be made so that the cylinder crankcase can be formed at a time to which it is indeed solidified, but still has a high temperature.

Eine andere Möglichkeit einer gezielten beschleunigten Abkühlung von Gussteilbereichen, die im Innern des jeweiligen Bauteils angeordnet sind, ist in der DE 11 2006 000 627 T5 beschrieben. Die aus dieser Veröffentlichung bekannte Sandgussform für die Herstellung eines Gussteils aus einer Aluminiumlegierung umfasst einen Abschnitt, der mittels eines Lösungsmittels, insbesondere Wasser, löslichen Binders hergestellt ist, und einen weiteren Abschnitt, der mittels eines Binders hergestellt ist, der mit dem betreffenden Lösungsmittel nicht gelöst werden kann. Diese Aufteilung der Abschnitte der Sandform erlaubt es, den jeweils basierend auf dem löslichen Binder hergestellten Kern durch Beaufschlagung mit dem Lösungsmittel, also beispielsweise durch Beaufschlagung durch einen Wasserstrahl, zu beseitigen, so dass die der Wirkung des Lösungsmittels ausgesetzten inneren Bereiche des Gussteils schneller abkühlen als der Rest des Gussteils. Jedoch bezieht sich diese Lösung nur auf Kavitäten, die im Gussteil vorhanden sind, und setzt eine komplexe Gestaltung der Sandform aus unterschiedlichen Formstoffen voraus.Another possibility of a targeted accelerated cooling of casting areas, which are arranged in the interior of the respective component is in the DE 11 2006 000 627 T5 described. The sand casting mold known from this publication for producing an aluminum alloy casting comprises a portion made by means of a solvent, in particular water, soluble binder, and another portion made by a binder which is not dissolved by the solvent in question can be. This division of the sections of the sand mold makes it possible to remove the core produced in each case based on the soluble binder by exposure to the solvent, for example by application of a jet of water, so that the inner areas of the casting exposed to the solvent cool more quickly than the rest of the casting. However, this solution only refers to cavities that are present in the casting, and requires a complex design of the sand mold made of different molding materials.

Einen anderen für einen speziellen Anwendungsfall bestimmten und für den Leichtmetallguss geeigneten Vorschlag zur beschleunigten Abkühlung der eine Durchgangsöffnung umgebenden Bereiche eines Gussteils ist in der DE 10 2010 003 346 A1 gemacht worden. Bei dem dort beschriebenen Verfahren zum Gießen eines Kolbens für einen Verbrennungsmotor werden nach der Randschichterstarrung im Bereich der Kolbenbolzenbohrungen die zum Abformen dieser Bohrungen vorgesehenen Pinolen zurückgezogen und der Bereich der jeweiligen Bohrung durch ein Kühlmittel gekühlt, das durch mindestens eine der Pinolen zugeführt wird.Another suitable for a specific application and suitable for light metal casting proposal for accelerated cooling of surrounding areas of a casting through a through hole is in the DE 10 2010 003 346 A1 been made. In the method described there for casting a piston for an internal combustion engine are after the surface layer solidification in the region of the piston pin bores that for molding these holes provided quills withdrawn and cooled the area of the respective bore by a coolant which is supplied through at least one of the sleeves.

Dokument JPH03138068 A beschreibt ein Verfahren zur Herstellung eines Zylinderblocks, bei dem Kühlgas durch eine Entlüftungsöffnung von unten in den noch in der Zylinderbüchse vorhandenen Sandkern eingeblasen wird, sobald die Temperatur der Zylinderbüchse die A1-Umwandlungspunkt erreicht hat.document JPH03138068 A describes a method for producing a cylinder block, in which cooling gas is blown through a vent opening from below into the still existing in the cylinder liner sand core, once the temperature of the cylinder liner has reached the A1 transformation point.

Vor dem Hintergrund des voranstehend erläuterten Standes der Technik bestand die Aufgabe der Erfindung darin, ein Verfahren anzugeben, welches es mit geringem apparativem Aufwand ermöglicht, Durchgangsöffnungen aufweisende Gussteile mit optimierten mechanischen Eigenschaften herzustellen.Against the background of the prior art explained above, the object of the invention was to provide a method which makes it possible, with little expenditure on equipment, to produce through-openings having castings with optimized mechanical properties.

Erfindungsgemäß ist diese Aufgabe durch das in Anspruch 1 angegebene Verfahren gelöst worden.According to the invention, this object has been achieved by the method specified in claim 1.

Vorteilhafte Ausgestaltungen der Erfindung sind in den abhängigen Ansprüchen angegeben und werden nachfolgend wie der allgemeine Erfindungsgedanke im Einzelnen erläutert.Advantageous embodiments of the invention are specified in the dependent claims and are explained below as the general inventive concept in detail.

Das erfindungsgemäße Verfahren zum Gießen eines mit mindestens einer Durchgangsöffnung versehenen Gussteils aus einer Metallschmelze umfasst demnach folgende Arbeitsschritte:

  1. a) Bereitstellen einer Gießform, in der mindestens ein Gießkern zum Abbilden der Durchgangsöffnung vorhanden ist, wobei der Gießkern aus einem einen Binder umfassenden Formstoff besteht, der unter Kraft- oder Temperatureinwirkung zerfällt,
  2. b) Abgießen der Metallschmelze in die Gießform zu dem Gussteil,
  3. c) Abkühlen des Gussteils in der Gießform auf eine Temperatur, die unterhalb der Liquidus-Temperatur der Metallschmelze, jedoch oberhalb einer Mindesttemperatur liegt, bis zu der es bei einer beschleunigten Abkühlung zur Ausbildung von höherfestem Gefüge kommt,
  4. d) Herstellen eines durch die Durchgangsöffnung des Gussteils führenden Durchgangskanals, der jeweils an einer Außenseite der Gießform mündet, indem der Binder des Formstoffs, aus dem der die Durchgangsöffnung abbildende Gießkern durch die beim Eingießen der Metallschmelze in die Gießform in sie eingetragene Wärme verbrennt, oder indem zur Herstellung des Durchgangskanals der die jeweilige Durchgangsöffnung abbildende Gießkern und die in seiner Verlängerung angeordneten Bereiche der Gießform zumindest teilweise mechanisch zerstört werden,
  5. e) Abkühlen des Gussteils in der Gießform unter Durchströmung des Durchgangskanals mit einem Kühlmedium.
The method according to the invention for casting a casting made of a metal melt provided with at least one passage opening accordingly comprises the following working steps:
  1. a) providing a casting mold in which there is at least one casting core for imaging the passage opening, the casting core consisting of a molding material comprising a binder which decomposes under the action of force or temperature,
  2. b) pouring the molten metal into the casting mold to the casting,
  3. c) cooling the casting in the casting mold to a temperature which is below the liquidus temperature of the molten metal, but above a minimum temperature up to which an accelerated cooling results in the formation of higher-strength structure,
  4. d) producing a passage channel leading through the passage opening of the casting, which opens in each case on an outer side of the casting mold, by burning the binder of the molding material, from which the casting core forming the passage opening burns by the heat introduced into the casting mold during casting of the molten metal, or by at least partially mechanically destroying the casting core forming the respective passage opening and the regions of the casting mold arranged in its extension for the production of the through-passage,
  5. e) cooling the casting in the mold while flowing through the passageway with a cooling medium.

Der Erfindung liegt der Gedanke zu Grunde, schon während der auf das Abgießen der Metallschmelze folgenden Abkühlung des Gussteils durch einen Eingriff in die Gießform einen Zustand herzustellen, durch den das Gussteil in einem innenliegenden Bereich, der für seine zukünftige Belastbarkeit entscheidend ist, mit einer Geschwindigkeit abkühlt, die deutlich höher ist als die Geschwindigkeit, mit der das Gussteil in diesem Bereich abkühlen würde, wenn die Gießform in konventioneller Weise bis zur Abkühlung auf Raumtemperatur in dem Zustand verbliebe, in dem der Abguss vorgenommen worden ist.The invention is based on the idea that, during the cooling of the cast part following casting of the molten metal by engagement with the casting mold, a state is produced by which the cast part in an interior region, which is decisive for its future loadability, can move at a speed which is significantly higher than the rate at which the casting would cool in that region when the casting mold is in conventional Continue to cool to room temperature in the state in which the casting has been made.

Hierzu wird erfindungsgemäß zu einem Zeitpunkt, an dem das Gussteil zwar noch nicht vollkommen abgekühlt, jedoch bereits formfest geworden ist, in die Gießform ein die Gießform durchziehender, durch die mindestens eine Durchgangsöffnung des Gussteils führender Durchgangskanal eingebracht.For this purpose, according to the invention, at a point in time at which the casting has not yet completely cooled, but has already become dimensionally stable, a casting channel that penetrates the casting mold and is introduced through the at least one through-opening of the casting is introduced into the casting mold.

Durch diesen Durchgangskanal strömt anschließend ein Kühlmedium. Die Durchströmung mit dem Kühlmedium bewirkt, dass das die Durchgangsöffnung umgebende Material des Gussteils deutlich schneller abkühlt als dies der Fall wäre, wenn die Gießform in konventioneller Weise verschlossen bliebe, bis das Gussteil die vorgeschriebene Endtemperatur der Abkühlung erreicht hat. Abhängig vom jeweils verwendeten Kühlmedium, vom Durchsatz an Kühlmedium, von der Art und Weise, wie der erfindungsgemäß in die Gießform eingebrachte Kanal ausgebildet und geführt ist, können dabei Abkühlraten erreicht werden, die höher sind als die Abkühlraten, die an der Außenseite der Gussform erzielt werden.Through this passage then flows a cooling medium. The flow through the cooling medium causes the material of the casting surrounding the passage opening to cool much faster than would be the case if the casting mold remained closed in a conventional manner until the casting reached the prescribed final cooling temperature. Depending on the cooling medium used in each case, on the throughput of cooling medium, on the way in which the channel introduced into the casting mold according to the invention is formed and guided, cooling rates can be achieved which are higher than the cooling rates achieved on the outside of the casting mold become.

Durch das erfindungsgemäße Verfahren kann so der Temperaturgradient zwischen Innen- und Außenbereichen drastisch reduziert werden und gleichzeitig die Abkühlrate des Gussteils allgemein vergrößert werden. Auf diese Weise werden einerseits thermisch bedingte Spannungen im Gussteil auf ein Minimum reduziert. Andererseits werden bei den in erfindungsgemäßer Weise hergestellten Gussteilen Festigkeiten erreicht, die deutlich über den Festigkeiten liegen, die in konventioneller Weise gegossene und in der Gießform ohne zusätzliche Maßnahmen abgekühlte Gussteile aufweisen.As a result of the method according to the invention, the temperature gradient between inner and outer regions can thus be drastically reduced and, at the same time, the cooling rate of the cast part can generally be increased. In this way, on the one hand thermally induced stresses in the casting are reduced to a minimum. On the other hand, in the castings produced according to the invention, strengths are achieved significantly higher than the strengths cast in a conventional manner and cooled in the mold without additional measures castings.

Besonders effektiv erweist sich das erfindungsgemäße Verfahren bei der Erzeugung von Gussteilen aus einer Eisengussschmelze. In diesem Fall wird die Mindesttemperatur, auf die das Gussteil bis zur Herstellung des erfindungsgemäß in die Gießform einzubringenden Durchgangskanals maximal abgekühlt wird (Arbeitsschritt c)), so eingestellt, dass sie oberhalb der A1-Temperatur liegt, bei der es zur Umwandlung des Austenits kommt. Durch die erfindungsgemäß ermöglichte beschleunigte Abkühlung im Innern des Gussteils lässt sich auf diese Weise ein höherer Anteil an Härtegefüge erzeugen, das zu einer deutlichen Festigkeitssteigerung beiträgt. Bei insbesondere im Bereich des Gusses von Zylinderkurbelgehäusen verwendeten Eisengusslegierungen liegt die Mindesttemperatur, die bei der Abkühlung im Arbeitsschritt c) nicht unterschritten wird, typischerweise im Bereich von 1153 - 600 °C.The process according to the invention proves to be particularly effective in the production of castings from a cast iron melt. In this case, the minimum temperature at which the casting is maximally cooled (step c)) until the manufacture of the passage channel to be introduced into the casting mold according to the invention is set to be above the A 1 temperature at which it is used to convert the austenite comes. As a result of the accelerated cooling in the interior of the casting, which is made possible according to the invention, a higher proportion of hardened structures can be produced in this way, which contributes to a significant increase in strength. For cast iron alloys used in particular in the casting of cylinder crankcases, the minimum temperature, which does not fall below during cooling in step c), is typically in the range of 1153-600 ° C.

Bei dem Kühlmedium kann es sich beispielsweise um Luft oder ein anderes gasförmiges Medium handeln. Beispielsweise ist es in Fällen, in denen eine bestimmte erhöhte Mindestabkühlrate gefordert wird, denkbar, Wasserdampf oder ein Luft-Wasserdampf-Gemisch als Kühlmedium zu verwenden.The cooling medium may be, for example, air or another gaseous medium. For example, in cases where a certain increased minimum cooling rate is required, it is conceivable to use water vapor or an air-water vapor mixture as the cooling medium.

Die Durchströmung des Durchgangskanals mit einem in der Umgebung der erfindungsgemäß behandelten Gießform anstehenden gasförmigen Kühlmedium setzt bereits in Folge des Kamineffekts ein, der durch die Abgabe von Wärmeenergie des Gussteils an das in den Durchgangskanal jeweils eintretende gasförmige Kühlmedium in Folge von Konvektion eintritt. Gefördert werden kann dieser Effekt dadurch, dass das Gussteil mit der Gießform so ausgerichtet oder der in die Gießform eingebrachte Durchgangskanal so ausgeführt wird, dass die Hauptrichtung des Durchgangskanals vertikal ausgerichtet ist. In diesem Fall kann die im Durchgangskanal vorhandene oder in ihn jeweils nachströmende und erwärmte Luft ungehindert im Durchgangskanal aufsteigen.The flow through the through-channel with a gaseous cooling medium present in the vicinity of the casting mold treated according to the invention already starts in succession the chimney effect, which occurs by the release of heat energy of the casting to the respectively entering into the through-channel gaseous cooling medium as a result of convection. This effect can be promoted by aligning the casting with the casting mold or by making the through-channel introduced into the casting mold so that the main direction of the through-passage is vertically aligned. In this case, the existing in the passage or in each case inflowing and heated air can rise unhindered in the passage.

Sind höhere Durchströmungsraten erforderlich, kann das Kühlmedium auch in einer erzwungenen Strömung durch den Durchgangskanal geleitet werden. Hierzu kann die Strömung des Kühlmediums mittels einer Förderreinrichtung, bei der es sich beispielsweise um einen Ventilator oder eine Pumpe handeln kann, erzwungen werden. Die betreffende Fördereinrichtung kann dazu beispielsweise vor einer der an einer der äußeren Seitenflächen angeordneten Mündungen des Durchgangskanals positioniert oder erforderlichenfalls nach dem Einbringen des Durchgangskanals in ihn eingeschoben werden.If higher flow rates are required, the cooling medium can also be passed through the through-channel in a forced flow. For this purpose, the flow of the cooling medium by means of a conveying device, which may be, for example, a fan or a pump, be forced. The conveyor in question can be positioned for example in front of one of the outer side surfaces arranged openings of the passage channel or, if necessary, after insertion of the passage channel inserted into it.

Selbstverständlich lässt sich die erfindungsgemäße Vorgehensweise auch bei Gussteilen anwenden, die mehrere Durchgangsöffnungen aufweisen. In diesem Fall wird erforderlichenfalls im Bereich jeder der Durchgangsöffnungen ein Durchgangskanal erzeugt, der anschließend vom Kühlmedium durchströmt wird, um die erfindungsgemäß beschleunigte Kühlung in der jeweiligen Durchgangsöffnung zu bewirken.Of course, the procedure according to the invention can also be applied to cast parts which have a plurality of passage openings. In this case, if necessary, in the region of each of the passage openings, a through channel is generated, which is then flowed through by the cooling medium in order to effect the invention accelerated cooling in the respective passage opening.

Besonders große Erfolge lassen sich mit der erfindungsgemäßen Vorgehensweise erzielen, wenn es sich bei dem erfindungsgemäß behandelten Gussteil um ein Zylinderkurbelgehäuse für einen Verbrennungsmotor handelt und die Durchgangsöffnung mindestens eine in dem Zylinderkurbelgehäuse vorgesehene Zylinderöffnung ist. In diesem Fall werden beispielsweise vor der vollständigen Abkühlung des Gussteils die die jeweiligen Zylinderöffnungen abbildenden Gießkerne vollständig sowie der den Kurbelraum abbildende Gießkern und die Teile der Gießform, die in Verlängerung der Zylinderöffnung angeordnet sind, zumindest soweit entfernt, dass Luft oder ein anderes gasförmiges Abkühlmedium durch die Zylinderöffnung strömen kann, während die anderen Teile des Gussstücks noch von der Gießform umgeben sind. Dadurch, dass durch die Erfindung eine beschleunigte Abkühlung im Innern des Gussteils ermöglicht wird, werden allgemein höhere Festigkeiten erreicht als dies bei konventionellen Gießverfahren möglich ist, bei denen die Gussteile in der geschlossenen Form alleine aufgrund der über die Außenseiten der Gießform erfolgende Wärmeabfuhr abkühlen. Dabei ist es denkbar, durch eine lokal beschleunigte Abkühlung im unmittelbar an die jeweilige Zylinderöffnung angrenzenden Bereich gezielt eine höhere Festigkeit zu erreichen als im weiter entfernt liegenden, umgebenden Bereich des Zylinderkurbelgehäuses, das dort langsamer abkühlt als im in erfindungsgemäßer Weise vom Kühlmedium direkt überstrichenen Bereich und so seine hohe Zähigkeit beibehält.Particularly great successes can be achieved with the procedure according to the invention if the casting treated according to the invention is a cylinder crankcase for an internal combustion engine and the passage opening is at least one cylinder opening provided in the cylinder crankcase. In this case, for example, before the complete cooling of the casting, the respective cylinder openings mapping casting cores and the crankcase casting core and the casting mold, which are arranged in extension of the cylinder opening, at least far enough removed that air or other gaseous cooling medium the cylinder opening can flow while the other parts of the casting are still surrounded by the casting mold. By allowing accelerated cooling inside the casting by the invention, generally higher strengths are achieved than is possible with conventional casting methods in which the castings cool in the closed mold solely due to the heat dissipation occurring over the outside of the casting mold. It is conceivable, by a locally accelerated cooling in the immediately adjacent to the respective cylinder opening area targeted to achieve a higher strength than in the more distant, surrounding area of the cylinder crankcase, which cools there slower than in the invention according to the cooling medium directly swept area and so maintains its high toughness.

Besonders einfach und gleichzeitig kostengünstig und flexibel lässt sich die erfindungsgemäße Vorgehensweise in der Praxis dadurch realisieren, dass die Gießform vollständig oder zumindest im Bereich der Durchgangsöffnung als Kernpaket ausgebildet ist, dessen Formteile und Gießkerne, die im Bereich der Durchgangsöffnung und der Verlängerung des die Durchgangsöffnung abbildenden Gießkerns angeordnet sind, aus einem Formstoff bestehen, der unter Kraft- oder Temperatureinwirkung zerfällt.The procedure according to the invention is particularly simple and at the same time inexpensive and flexible realize in practice that the mold is formed completely or at least in the region of the passage opening as a core package whose moldings and cores, which are arranged in the region of the passage opening and the extension of the through hole forming casting core, consist of a molding material under force - or temperature action decomposes.

Als unter den praktischen Produktionsbedingungen besonders günstig hat es sich dabei erwiesen, wenn bei der Durchführung des erfindungsgemäßen Verfahrens vollständig auf eine formkastengebundene Gießtechnik verzichtet wird und die Gießform insgesamt als Kernpaket ausgeführt wird.As under the practical production conditions particularly favorable, it has proven to be the case when completely carried out in the implementation of the method according to the invention on a molding box-bound casting and the mold is executed as a whole core package.

Da die Gießform erfindungsgemäß zumindest im Bereich der mit dem Durchgangskanal zu versehenden Durchgangsöffnung des Gussteils aus verlorenen Gießkernen oder Formteilen besteht, sind die betreffenden Gießkerne und Formteile aus konventionellen Formstoffen hergestellt, die, wie eingangs erläutert, üblicherweise aus einem Sand, einem organischen oder anorganischen Binder bestehen, wobei dem Formstoff selbstverständlich ergänzend bestimmte Additive zugesetzt sein können, um seine Eigenschaften zu optimieren. Der Binder des Formstoffs kann dabei in an sich bekannter Weise so ausgelegt sein, dass der die Formhaltigkeit der Formteile und Gießkerne gewährleistende Binder durch die beim Eingießen der Metallschmelze in die Gießform in sie eingetragene Wärme verbrennt. In diesem Fall zerfallen die betroffenen Gießkerne und Formteile selbsttätig zu kleinen Teilstücken, die anschließend ebenso selbsttätig unter Freilegung des Durchgangskanals aus der Gießform bzw. dem Gussteil rieseln.Since, according to the invention, the casting mold consists of lost casting cores or molded parts, at least in the region of the passage opening of the casting to be provided with the passage, the casting cores and moldings concerned are made of conventional molded materials which, as explained at the beginning, are usually made of a sand, an organic or inorganic binder of course, wherein the molding material, of course, certain additives may be added to optimize its properties. The binder of the molding material can be designed in a manner known per se so that the binder, which ensures the dimensional stability of the molded parts and casting cores, is burnt by the heat introduced into the casting mold when the molten metal is poured therein. In this case, the affected casting cores and moldings automatically decay into small ones Pieces, which then also trickle automatically under exposure of the passageway from the mold or the casting.

Alternativ oder ergänzend kann es insbesondere im Hinblick auf eine Steigerung der Effektivität und Zielgerichtetheit des erfindungsgemäßen Verfahrens auch vorteilhaft sein, die für die Bildung des Durchgangskanals der Gießform erforderliche Zerstörung der dem betreffenden Durchgangskanal zugeordneten Formteile und Gießkerne gezielt durch eine mechanische Bearbeitung herbeizuführen. Hierzu können die der jeweiligen Durchgangsöffnung des Gussteils zugeordneten Gießkerne oder Formteile beispielsweise mittels eines Stempels ausgedrückt oder der Durchgangskanal kann mittels eines Bohrers in die Gießform eingebracht werden.Alternatively or additionally, it can also be advantageous, in particular with regard to an increase in the effectiveness and Zielrichtungheitheit of the inventive method to bring about the formation of the passage of the mold required destruction of the respective passageway associated moldings and cores targeted by mechanical processing. For this purpose, the casting cores or shaped parts assigned to the respective through-opening of the casting can be expressed, for example, by means of a punch, or the through-channel can be introduced into the casting mold by means of a drill.

Um eine möglichst intensive, schnelle Abkühlung des die jeweilige Durchgangsöffnung umgebenden Materialbereichs des Gussteils zu ermöglichen, werden bei der Herstellung des Durchgangskanals der mindestens eine die Durchgangsöffnung abbildende Gießkern und die in seiner Verlängerung angeordneten Bereiche der Gießform in der Praxis regelmäßig vollständig entfernt werden.In order to allow the most intensive and rapid cooling of the material area of the casting surrounding the respective passage opening, the at least one casting core forming the passage opening and the regions of the casting mold arranged in its extension are regularly removed completely in practice during the production of the passage channel.

Soll jedoch im Bereich der jeweiligen Durchgangsöffnung des Gussteils zwar eine beschleunigte Abkühlung bewirkt werden, dabei das Kühlmedium aber die die jeweilige Durchgangsöffnung begrenzenden Flächen des Gussteils nicht direkt überstreichen, so kann insbesondere mittels mechanischer Bearbeitung der Durchgangskanal so durch die jeweilige Durchgangsöffnung des Gussteils geführt werden, dass der die Durchgangsöffnung des Gussteils bildende Gießkern nur teilweise entfernt wird. Zwischen dem Durchgangskanal und der Innenfläche der Durchgangsöffnung bleibt dann noch Sand des Gießkerns vorhanden, der nach wie vor eine gewisse isolierende Wirkung hat. Dementsprechend erfolgt die Abkühlung des an die Durchgangsöffnung angrenzenden Bereichs abhängig von der Dicke des verbliebenen Gießkernmaterials nicht so schnell, wie dies bei einer vollständigen Entfernung des die Durchgangsöffnung abbildenden Gießkerns und einer direkten Überstreichung der Innenflächen der Durchgangsöffnung mit dem Kühlmedium der Fall wäre.However, if an accelerated cooling is to be effected in the region of the respective through-opening of the casting, but the cooling medium does not directly cover the surfaces of the casting delimiting the respective through-opening, the through-passage can thus be guided through the respective through-opening of the casting, in particular by means of mechanical processing. the casting core forming the passage opening of the casting is only partially removed. Between the passageway and the inner surface of the through hole, there remains sand of the casting core, which still has a certain insulating effect. Accordingly, the cooling of the area adjacent to the passage opening does not occur as rapidly as would be the case with complete removal of the through-hole casting core and direct sweeping of the inner surfaces of the through-hole with the cooling medium, depending on the thickness of the remaining core material.

Die Wirtschaftlichkeit des erfindungsgemäßen Verfahrens kann dadurch noch weiter gesteigert werden, dass die Gießform mindestens zwei Formholräume zum gleichzeitigen Gießen von mindestens zwei Gussteilen aufweist und die Metallschmelze über einen gemeinsamen Eingusskanal in die Formhohlräume der Gießform geleitet wird.The economy of the method according to the invention can be further increased by the mold having at least two mold cavities for the simultaneous casting of at least two castings and the molten metal is passed through a common sprue in the mold cavities of the mold.

Nachfolgend wird die Erfindung anhand einer ein Ausführungsbeispiel darstellenden Zeichnung näher erläutert. Es zeigen jeweils vereinfacht, schematisch und nicht maßstabsgerecht:

Fig. 1
eine Vorrichtung zum Gießen von zwei Gussteilen im Längsschnitt;
Fig. 2
die Vorrichtung gemäß Fig. 1 während des Abgießens einer Eisengussschmelze in einer der Fig. 1 entsprechenden Schnittansicht;
Fig. 3
die Vorrichtung gemäß Fig. 1 nach dem Erstarren der Eisengussschmelze in einer der Fig. 1 entsprechenden Schnittansicht;
Fig. 4
die Vorrichtung gemäß Fig. 1 während des Einbringens von Durchgangskanälen in einer der Fig. 1 entsprechenden Schnittansicht;
Fig. 5
die Vorrichtung gemäß Fig. 1 während des Durchströmens der Durchgangskanäle mit einem Kühlmedium in einer der Fig. 1 entsprechenden Schnittansicht.
The invention will be explained in more detail with reference to a drawing illustrating an exemplary embodiment. It shows simplified, schematic and not to scale:
Fig. 1
a device for casting two castings in longitudinal section;
Fig. 2
the device according to Fig. 1 during the pouring of a cast iron melt in one of Fig. 1 corresponding sectional view;
Fig. 3
the device according to Fig. 1 after the solidification of the cast iron melt in one of the Fig. 1 corresponding sectional view;
Fig. 4
the device according to Fig. 1 during the introduction of passageways in one of Fig. 1 corresponding sectional view;
Fig. 5
the device according to Fig. 1 during the passage of the through channels with a cooling medium in one of Fig. 1 corresponding sectional view.

Die Vorrichtung 1 zum simultanen Gießen von zwei Gussteilen Z1,Z2 umfasst eine Gießform 2, die auf einem Gestell 3 abgestützt ist. Bei den Gussteilen Z1,Z2 handelt es sich um konventionell gestaltete Zylinderkurbelgehäuse, die jeweils für den Bau jeweils eines Reihen-Vierzylinder-Verbrennungsmotors bestimmt sind.The device 1 for simultaneous casting of two cast parts Z1, Z2 comprises a casting mold 2 which is supported on a frame 3. The castings Z1, Z2 are conventionally designed cylinder crankcases, which are each intended for the construction of a row four-cylinder internal combustion engine.

Die Gießform 2 ist als Kernpaket aus äußeren Formteilen 4,5,6,7 und im Inneren der Gießform 2 angeordneten Gießkernen 8 - 19 zusammengesetzt. Während die äußeren Formteile 4 - 7 die äußere Form der zu gießenden Gussteile Z1,Z2 bestimmen, bilden die Gießkerne 8,9 die innere Form der Kurbelgehäuse K1,K2 mit den Kurbelwellenlagern L1,L2 und die Gießkerne 10 - 17 die als Durchgangsöffnung 01,02 ausgebildeten Zylinderöffnungen der Gussteile Z1,Z2 ab. Die jeweils seitlich angeordneten Gießformteile 5,7 formen dabei jeweils die eine Stirnseite des jeweiligen Gussteils Z1,Z2, während die gegenüberliegend zum jeweils zugeordneten äußeren Formteil 5,7 angeordneten jeweiligen Gießkerne 18 die hier im Innern der Gießform 2 angeordnete Stirnseite des jeweiligen Gussteils Z1,Z2 abbilden. Die weiteren Gießkerne 19 dienen beispielsweise zur Erzeugung von Wasser- oder Ölkanälen in den Gussteilen Z1,Z2. Die Gießform 2 ist dabei so ausgerichtet, dass die Hauptrichtung H der Durchgangsöffnungen 01,02 in vertikaler Richtung V ausgerichtet sind.The casting mold 2 is composed of core moldings of outer moldings 4, 5, 6, 7 and casting cores 8 - 19 arranged in the interior of the casting mold 2. While the outer mold parts 4 - 7 determine the outer shape of the castings Z1, Z2 to be cast, the casting cores 8,9 form the inner shape of the crankcase K1, K2 with the crankshaft bearings L1, L2 and the casting cores 10 - 17 as through-hole 01, 02 trained cylinder openings of the castings Z1, Z2. The respectively laterally arranged casting mold parts 5, 7 in each case form one end face of the respective casting Z1, Z2, while the respective casting cores 18 arranged opposite the respective associated outer mold part 5.7 represent the front side of the respective casting Z1, Z2 arranged here in the interior of the casting mold 2 , The further casting cores 19 are used, for example, to produce water or oil passages in the cast parts Z1, Z2. The casting mold 2 is aligned so that the main direction H of the through holes 01,02 are aligned in the vertical direction V.

Die bei ungefüllter Gießform 2 von den Formteilen 4 - 7 und Gießkernen 8 - 19 umgrenzten Formhohlräume 20,21 der Gießform 2 sind über hier weiter nicht gezeigte Anschnitte mit einem gemeinsamen, zentral in der Gießform 2 angeordneten und vertikal ausgerichteten Anschnitt 22 verbunden. Der zentrale Anschnitt 22 ist wiederum an einen ebenso zentral an der Oberseite der Gießform 2 ausgebildeten Eingusskanal 23 angeschlossen, über den die Befüllung der Gießform 2 mit Eisengussschmelze S erfolgt. Der Anschnitt 22 und die anderen hier nicht gezeigten Anschnitte der Gießform 2 sind dabei so gelegt, dass die Befüllung der Formhohlräume 20,21 entgegen der Wirkrichtung R der Schwerkraft erfolgt.The mold cavities 20, 21 of the casting mold 2 delimited by the mold parts 4 - 7 and casting cores 8 - 19 when the mold 2 is unfilled are connected via notches, which are not further shown, to a common, vertically aligned gate 22 arranged centrally in the mold 2. The central gate 22 is in turn connected to a likewise centrally formed at the top of the mold 2 sprue 23, via which the filling of the mold 2 with cast iron melt S takes place. The gate 22 and the other not shown here sections of the mold 2 are placed so that the filling of the mold cavities 20,21 counter to the effective direction R of gravity takes place.

Die Gießform 2 sitzt auf einem von Stützen 24 getragenen Gitterrost 25 des Gestells 3.The casting mold 2 sits on a grid 24 supported by supports 24 of the frame 3.

Die äußeren Formteile 4,5,6,7 und Gießkerne 8 - 19 sind aus einem handelsüblichen, aus einem anorganischen Binder und einem Sand gemischten Formstoff geformt, der durch Wärmezufuhr und Feuchtigkeitsentzug soweit verfestigt ist, dass er für den Halt der Gießform 2 und die während des Abgießvorgangs auftretenden Kräfte ausreichende Formhaltigkeit besitzt. Durch die mit dem Eingießen der Eisengussschmelze S einhergehende Temperaturerhöhung setzt jedoch bereits ein Zerfall insbesondere derjenigen Formteile 4,5,6,7 und Gießkerne 8 - 19 ein, die unmittelbar der Gießhitze der Eisengussschmelze S ausgesetzt sind.The outer moldings 4, 5, 6, 7 and casting cores 8 - 19 are made of a commercially available, inorganic binder and molding a sand mixed molding material which is solidified by heat and moisture removal to the extent that it has sufficient shape retention for the maintenance of the mold 2 and the forces occurring during the casting process. However, due to the temperature increase associated with the pouring of cast iron melt S, disintegration, in particular of those moldings 4, 5, 6, 7 and casting cores 8 - 19, which are directly exposed to the casting heat of cast iron melt S, already begins.

Nach dem Befüllen der Gießform 2 mit der Eisengussschmelze S (Fig. 2) kühlen die Gussteile Z1,Z2 auf eine im Bereich von 850 - 650 °C liegende Mindesttemperatur ab, bei der einerseits das Eisengussmaterial erstarrt, andererseits jedoch die Temperatur der Gussteile Z1,Z2 noch so hoch ist, dass durch eine beschleunigte Abkühlung Härtegefüge erzeugt werden kann. Optimalerweise liegt dabei die Temperatur so hoch, dass das Gefüge der Gussteile Z1,Z2 noch vollständig austenitisch ist.After filling the casting mold 2 with the cast iron melt S ( Fig. 2 ) cool the castings Z1, Z2 to a lying in the range of 850-650 ° C minimum temperature, on the one hand solidifies the iron casting material, on the other hand, however, the temperature of the castings Z1, Z2 is still so high that hardened structure can be produced by accelerated cooling can. Optimally, the temperature is so high that the structure of the castings Z1, Z2 is still completely austenitic.

Ist dieser Zustand erreicht (Fig. 3), werden Durchgangskanäle G1,G2 in die Gießform 2 eingebracht (Fig. 4), von denen jeweils einer den Durchgangsöffnungen 01,02 des Gussteils Z1,Z2 zugeordnet ist. Dazu werden mit Hilfe von Ausstoßern 26,27, von denen ebenfalls jeweils einer einer der Durchgangsöffnungen 01,02 der Gussteile Z1,Z2 zugeordnet ist, die zu diesem Zeitpunkt bereits teilweise zu kleineren Bruchstücken zerfallenen, die Durchgangsöffnungen 01,02 der Gussteile Z1,Z2 abbildenden Gießkerne 10 - 17 sowie die in ihrer gedachten Verlängerung V1,V2 darüber liegenden Abschnitte des den Deckel der Gießform 2 bildenden äußeren Formteils 4 und die in ihrer gedachten Verlängerung V1,V2 darunter liegenden, die Kurbelgehäuse K1,K2 mit den Kurbelwellenlagern L1,L2 abbildenden Gießkerne 8,9 sowie die ebenfalls in der Verlängerung V1,V2 unterhalb der Gießkerne 8,9 liegenden Abschnitte des den Boden der Gießform 2 bildenden unteren Formteils 6 aus der Gießform 2 gestoßen. Die so gebildeten, durch die Durchgangsöffnungen 01,02 führenden Durchgangskanäle G1,G2 münden dementsprechend mit ihrem oberen Ende jeweils an der oberen, durch die obere Außenfläche des Deckel-Formteils 4 gebildeten Außenseite und mit ihrem unteren Ende an der unteren, durch die untere Außenfläche des Boden-Formteils 6 gebildeten Außenseite der Gießform 2.Is this state reached ( Fig. 3 ), through-channels G1, G2 are introduced into the casting mold 2 ( Fig. 4 ), of which in each case one of the through holes 01.02 of the casting Z1, Z2 is assigned. For this purpose, by means of ejectors 26, 27, one of which is also assigned to one of the through-openings 01, 02 of the castings Z1, Z2, the through-openings 01, 02 of the castings Z1, Z2, which at this time have already partially decayed into smaller fragments Imaging casting cores 10 - 17 as well as in their imaginary Extension V1, V2 overlying portions of the lid of the mold 2 forming the outer mold part 4 and lying in their imaginary extension V1, V2 underlying, the crankcase K1, K2 with the crankshaft bearings L1, L2 casting cores 8,9 and also in the Extension V1, V2 below the casting cores 8,9 lying portions of the bottom of the mold 2 forming the lower mold part 6 from the mold 2 encountered. The thus formed, through the through holes 01,02 leading through channels G1, G2 open accordingly with its upper end respectively at the upper, formed by the upper outer surface of the lid molding 4 outside and with its lower end to the lower, through the lower outer surface the bottom molding 6 formed outside of the mold. 2

Die ausgestoßenen Formteil-Abschnitte und Gießkerne-Bruchstücke zerfallen dabei zu rieselfähigem, kleinteiligen Material M, das durch das Gestell-Rost fällt und sich am Boden unterhalb der Gießform 2 sammelt. Das Ausrieseln des Formstoff-Materials M aus der Gießform 2 kann erforderlichenfalls in an sich bekannter Weise durch Rütteln, Klopfen oder andere mechanische Behandlungen unterstützt werden. Das von der Gießform 2 herab fallende Material M kann durch eine hier nicht gezeigte Fördereinrichtung abtransportiert werden.The ejected molding sections and foundry core fragments disintegrate into free-flowing, finely divided material M, which falls through the rack rust and collects at the bottom below the casting mold 2. The trickling out of the molding material M from the casting mold 2 can if necessary be assisted in a manner known per se by shaking, tapping or other mechanical treatments. The falling of the mold 2 down material M can be removed by a conveyor, not shown here.

Nachdem die Durchgangskanäle G1,G2 freigelegt sind und so eine Durchströmung der Gussteile Z1-Z2 in vertikaler Richtung V ermöglicht ist, wird unterhalb der Gießform 2 eine Düseneinrichtung 28 platziert, über die ein mittels eines hier nicht dargestellten Ventilators beschleunigter Kühlmediumstrom M1,M2 von unten her in vertikaler Richtung R in die Gießform 2 geblasen wird (Fig. 5). Beim hier erläuterten Ausführungsbeispiel handelt es sich bei dem Kühlmedium um Luft.After the through channels G1, G2 are exposed and thus a flow through the castings Z1-Z2 in the vertical direction V is possible, below the mold 2, a nozzle device 28 is placed, via which a means of a fan, not shown, accelerated cooling medium flow M1, M2 is blown from below in the vertical direction R in the mold 2 ( Fig. 5 ). In the exemplary embodiment explained here, the cooling medium is air.

Der jeweilige Kühlmediumstrom M1,M2 strömt durch die durch die Durchgangsöffnungen 01,02 der Gussteile Z1,Z2 führenden Durchgangskanäle G1-G2 und bewirkt eine beschleunigte Abkühlung der von ihm überstrichenen Wandabschnitte der Gussteile Z1,Z2. So entsteht insbesondere im Bereich der Durchgangsöffnungen 01,02, der Kurbelwellenlager L1,L2 und der die Kurbelwellenlager L1,L2 jeweils stützenden Zuganker A1,A2 ein durch feinstreifigen Perlit bei gleichzeitig feiner Körnung gekennzeichnetes Gefüge, das eine höhere Festigkeit aufweist, als die Festigkeit, die bei Gussteilen erreicht wird, die in konventioneller Weise in einer geschlossenen Gießform alleine durch natürlichen Wärmeverlust über deren Außenformteile abkühlen. Dementsprechend ist der Temperaturunterschied zwischen den im Innern der Gussteile Z1,Z2 angeordneten, an die Durchgangsöffnungen 01,02, an die Kurbelwellenlager L1,L2 und an die die Kurbelwellenlager L1,L2 jeweils stützenden Zuganker A1,A2 angrenzenden Bereiche und den weiter entfernt liegenden, äußeren Bereichen der Gussteile Z1,Z2 minimiert, die aufgrund der dort gegebenen geringeren Wandstärken mit vergleichbaren Abkühlraten abkühlen.The respective cooling medium flow M1, M2 flows through the passage channels G1-G2 leading through the through-openings 01,02 of the castings Z1, Z2 and causes an accelerated cooling of the wall sections of the cast parts Z1, Z2 swept by it. Thus, in particular in the region of the passage openings 01,02, the crankshaft bearing L1, L2 and the crankshaft bearing L1, L2 respectively supporting tie rods A1, A2 formed by a fine-grained pearlite at the same time fine grain structure having a higher strength than the strength, achieved in castings that conventionally cool in a closed mold alone by natural heat loss through their exterior moldings. Accordingly, the temperature difference between the arranged in the interior of the castings Z1, Z2, to the through holes 01.02, to the crankshaft bearings L1, L2 and to the crankshaft bearings L1, L2 respectively supporting tie rods A1, A2 adjacent areas and the farther away, outer areas of the castings Z1, Z2 minimized, which cool due to the lower wall thickness given there with comparable cooling rates.

Insgesamt wird auf diese Weise erreicht, dass die Temperaturgradienten zwischen dem Außen- und dem Innenbereich der Gussteile Z1,Z2 klein bleibt. Der geringe Temperaturgradient reduziert die Zugeigenspannungen im Innenbereich. Gleichzeitig bewirkt die höhere Abkühlrate eine höhere Zugfestigkeit des Eisengusswerkstoffs, so dass durch die erfindungsgemäße Vorgehensweise im Ergebnis bei den Gussteilen Z1,Z2 Belastbarkeiten erreicht werden, die um 50 % höher sind als die Belastbarkeit von konventionell erzeugten, langsam in der Gießform abgekühlten Zylinderkurbelgehäusen.Overall, it is achieved in this way that the temperature gradient between the outer and the inner region of the cast parts Z1, Z2 remains small. Of the low temperature gradient reduces internal tensile stresses. At the same time the higher cooling rate causes a higher tensile strength of the iron casting material, so that by the procedure according to the invention as a result in the castings Z1, Z2 load capacities are achieved, which are 50% higher than the load capacity of conventionally produced, slowly cooled in the mold cylinder crankcases.

BEZUGSZEICHENREFERENCE NUMBERS

11
Vorrichtung zum simultanen Gießen von zwei Gussteilen Z1,Z2Device for simultaneous casting of two castings Z1, Z2
22
Gießformmold
33
Gestellframe
4-74-7
äußere Formteile der Gießform 2outer moldings of the mold 2
8-198-19
Gießkernecores
20,2120.21
Formhohlräume der Gießform 2Mold cavities of the mold 2
2222
zentraler Anschnitt der Gießform 2central gate of the mold 2
2323
Eingusskanal der Gießform 2Gutter of the casting mold 2
2424
Stützen des Gestells 3Supporting the rack 3
2525
Gitterrost des Gestells 3Rack of the rack 3
26,2726.27
Ausstoßerejector
2828
Düseneinrichtungnozzle device
A1,A2A1, A2
Zuganker der Gussteile Z1,Z2Tie rod of castings Z1, Z2
G1-G2G1-G2
Durchgangskanäle der Gießform 2Passage channels of the mold 2
HH
Hauptrichtung der Durchgangsöffnungen 01,02Main direction of the through holes 01,02
K1,K2K1, K2
Kurbelgehäuse der Gussteile Z1,Z2Crankcase of castings Z1, Z2
L1,L2L1, L2
Kurbelwellenlager der Gussteile Z1,Z2Crankshaft bearing of castings Z1, Z2
MM
Formstoff-MaterialMolding material
M1,M2M1, M2
KühlmediumströmeCooling medium flows
01,0201,02
Durchgangsöffnungen (Zylinderöffnungen) der Gussteile Z1,Z2Through openings (cylinder openings) of the castings Z1, Z2
RR
Wirkrichtung der SchwerkraftEffective direction of gravity
SS
EisengussschmelzeIron melt
VV
vertikale Richtungvertical direction
V1,V2V1, V2
gedachte Verlängerung der Durchgangsöffnungen 01,02 der Gießform 2imaginary extension of the passage openings 01,02 of the mold 2
Z1,Z2Z1, Z2
Gussteile (Zylinderkurbelgehäuse)Castings (cylinder crankcase)

Claims (10)

  1. Method for casting a cast piece (Z1, Z2) made of molten metal (S) provided with at least one through-opening, comprising the following steps:
    a) Provision of a casting mould (2) in which at least one casting core (8-19) is present to represent the through opening (01, 02), wherein the casting core (8-19) consists of a moulding material comprising a binder which material disintegrates under the effect of force or temperature,
    b) Pouring of the molten metal (S) into the casting mould (2) to form the cast piece (Z1, Z2),
    c) Cooling of the cast piece (Z1, Z2) in the casting mould (2) to a temperature, which is below the liquidus temperature of the molten metal (S), but above a minimum temperature, from which minimum temperature accelerated cooling effects the formation of a high-tensile structure,
    d) Formation of a through-channel (G1, G2) leading through the through-opening (01,02) of the cast piece (Z1, Z2), which in each case opens on to an external side of the casting mould (2), by burning the binder in the moulding material out of the casting core (8-19) representing the through-opening (01, 02) by means of the heat input into the casting mould (2) when pouring the molten metal into said casting mould, or by mechanically destroying, at least in part, the respective casting core (8-19) representing the through-opening (01, 02) and the regions of the casting mould (2) arranged in the extension (V1, V2) of said core,
    e) Cooling of the cast piece (Z1, Z2) in the casting mould (2) whilst a cooling medium (M1, M2) flows through the through-channel (G1, G2).
  2. Method according to claim 1, characterised in that the molten metal is molten cast iron and the minimum temperature, above which cooling ends in step c), corresponds to the A1 temperature of the molten metal.
  3. Method according to either of the preceding claims characterised in that the molten metal (S) is molten cast iron and the temperature to which the cast piece (Z1, Z2) is cooled in the casting mould (2) in step c) is between 1153 and 600 °C.
  4. Method according to any one of the preceding claims characterised in that the cast piece (Z1, Z2) is a cylinder crankcase for a combustion engine and the through-opening (01, 02) is a cylinder opening provided in the cast piece (Z1, Z2).
  5. Method according to any one of the preceding claims characterised in that the casting mould (2) is configured as a core package, the moulded parts (4-7) and casting cores (8-19) of which, which are arranged in the region of the through-opening (01, 02) and the extension (V1, V2) of the casting core (8-19) representing the through-opening (01, 02), consist of a moulding material which disintegrates under the effect of force or temperature.
  6. Method according to any one of the preceding claims characterised in that the main direction (H) of the through-channel (G1, G2) is vertical.
  7. Method according to any one of the preceding claims, characterised in that the casting core (8-19) representing the through opening (01, 02) and the regions of the casting mould (2) arranged in the extension (V1, V2) of said core are removed completely.
  8. Method according to any one of the preceding claims characterised in that the cooling medium (M1,M2) being led through the through-channel (G1, G2) at an accelerated rate within a forced stream.
  9. Method according to any one of the preceding claims characterised in that the cooling medium is gaseous.
  10. Method according to any one of the preceding claims characterised in that the casting mould (2) has at least two cavities (20, 21) for simultaneous casting of at least two cast pieces (Z1, Z2) and that the molten metal (S) is guided into the cavities (20, 21) by means of a common feeder (23) or gate (22).
EP13719081.5A 2012-05-03 2013-04-23 Method for casting a cast part provided with at least one passage opening Active EP2844409B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL13719081T PL2844409T3 (en) 2012-05-03 2013-04-23 Method for casting a cast part provided with at least one passage opening

Applications Claiming Priority (2)

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DE201210103884 DE102012103884A1 (en) 2012-05-03 2012-05-03 Method for casting a casting provided with at least one passage opening
PCT/EP2013/058396 WO2013164225A1 (en) 2012-05-03 2013-04-23 Method for casting a cast part provided with at least one passage opening

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DE102014110826A1 (en) * 2014-07-30 2016-02-04 Fritz Winter Eisengiesserei Gmbh & Co. Kg Method for casting castings
US10434566B2 (en) * 2016-03-18 2019-10-08 Honda Motor Co., Ltd. Casting device
WO2017160303A1 (en) * 2016-03-18 2017-09-21 Siemens Aktiengesellschaft Method of manufacturing advanced features in a core for casting
DE102017100805A1 (en) * 2017-01-17 2018-07-19 Nemak, S.A.B. De C.V. Casting mold for casting complex shaped castings and use of such a casting mold
CN107309401A (en) * 2017-08-01 2017-11-03 安徽安庆市沙氏汽车配件有限公司 A kind of shaped device for automobile counterbalance
CN107755644A (en) * 2017-10-19 2018-03-06 南阳飞龙汽车零部件有限公司 A kind of casting sand type mold cavity surface cure process device and preparation method thereof
RU181962U1 (en) * 2017-12-15 2018-07-30 Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" DEVICE FOR OBTAINING LIGATURE INGOTS BY AN INCLINED CASTING METHOD
EP3725900A1 (en) 2019-04-17 2020-10-21 Mubea Performance Wheels GmbH Component and method and device for quenching a component
CN116274869A (en) * 2022-12-30 2023-06-23 哈尔滨工业大学 Aluminum alloy investment casting device and casting method using device

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PT2844409E (en) 2016-01-22
CA2872082A1 (en) 2013-11-07
IN2014DN07844A (en) 2015-04-24
CA2872082C (en) 2016-07-12
HUE027061T2 (en) 2016-08-29
MX362898B (en) 2019-02-25
JP2015515926A (en) 2015-06-04
DK2844409T3 (en) 2016-01-18
CN104302423A (en) 2015-01-21
KR20140139133A (en) 2014-12-04
PL2844409T3 (en) 2016-06-30
ZA201406842B (en) 2015-12-23
DE102012103884A1 (en) 2013-11-07
ES2557031T3 (en) 2016-01-21
MX2014012714A (en) 2015-04-08
JP5857360B2 (en) 2016-02-10
BR112014026332A2 (en) 2017-06-27
BR112014026332B1 (en) 2019-10-08
WO2013164225A1 (en) 2013-11-07
RU2584842C1 (en) 2016-05-20
US9272328B2 (en) 2016-03-01
CN104302423B (en) 2017-03-08
EP2844409A1 (en) 2015-03-11
KR101615709B1 (en) 2016-04-27

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