EP2977125A1 - Procédé de moulage en sable - Google Patents

Procédé de moulage en sable Download PDF

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Publication number
EP2977125A1
EP2977125A1 EP14769379.0A EP14769379A EP2977125A1 EP 2977125 A1 EP2977125 A1 EP 2977125A1 EP 14769379 A EP14769379 A EP 14769379A EP 2977125 A1 EP2977125 A1 EP 2977125A1
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EP
European Patent Office
Prior art keywords
sand mold
mold
temperature
partial
approximately
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP14769379.0A
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German (de)
English (en)
Other versions
EP2977125A4 (fr
EP2977125B1 (fr
Inventor
Tetsuo Miura
Tsutomu Honda
Yoshimitsu Watanabe
Kenichi Watanabe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Techno Metal Co Ltd
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Techno Metal Co Ltd
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Publication date
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Publication of EP2977125A1 publication Critical patent/EP2977125A1/fr
Publication of EP2977125A4 publication Critical patent/EP2977125A4/fr
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Publication of EP2977125B1 publication Critical patent/EP2977125B1/fr
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Classifications

    • 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
    • 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

Definitions

  • the present invention relates to a sand casting method.
  • Patent Literature 1 proposes an austenitic heat resistant cast steel instead of ferritic heat resistant cast steels commonly adopted as materials for automotive exhaust system components such as an exhaust manifold and turbocharger.
  • the austenitic heat resistant cast steel has excellent hot strength and provides good fluidity during casting.
  • the austenitic heat resistant cast steel can meet requirements for high heat resistance while reducing casting defects.
  • a sand casting process is a metalworking method for making a product by pouring molten metal into a sand mold created by binding sand as aggregate using a binder.
  • the sands used as aggregate can be classified into natural sand and artificial sand, and these sands as well as reclamation sand thereof are used appropriately according to the intended use.
  • Known binders include organic (furan resin, phenol resin, urethane resin, gas curable binder, etc.), inorganic (e.g., water glass), and hybrid binders.
  • Patent Literatures 2 to 5 disclose hybrid binders and hybrid casting processes which use the hybrid binders.
  • the hybrid binders secure strength (strength at room temperature) of a created sand mold (including a core) using an organic binder and secure strength (hot strength) of the sand mold during casting using ceramic.
  • the hybrid binder which is called an XP alcoholic solution, is a solution composed principally of an alcoholic solution containing one or more alcohol-soluble metallic alkoxides and an alcohol-soluble alkali compound of an alkali metal or alkaline earth metal, both in a less advanced stage of hydrolysis, where the alcohol-soluble metallic alkoxides are selected from among alkoxides of the metals in the 4A group or 4B group (excluding carbon) and the metals in the 3A group or 3B group of the periodic table and partial hydrolysates of the alkoxides.
  • Patent Literatures 2 to 5 For details of the XP alcoholic solution, refer to Patent Literatures 2 to 5.
  • the hybrid binder secures strength (strength at room temperature) of a created sand mold (including a core) using an organic binder component of the hybrid binder and secures strength (hot strength) of the sand mold during casting using a ceramic component of the hybrid binder.
  • the hybrid casting process using the hybrid binder allows high-temperature molten metal to be poured into the sand mold, making it possible to cast metal with poor fluidity or cast a thin-walled product of which fluidity is required strictly.
  • An object of the present invention is to provide a sand casting method which can limit the risk that molten metal will not spread to an entire area of a product portion of a sand mold while minimizing cost increases.
  • Another object of the present invention is to provide a sand casting method which can reduce casting defects of a metal which has relatively poor fluidity and casting defects of a thin-walled product of which fluidity is required strictly.
  • Still another object of the present invention is to provide a sand casting method which can produce a relatively thin-walled casting by a gravity casting process using a metal which has relatively poor fluidity.
  • RCS resin coated sand
  • Figure 1 shows deflection strength (Kg/cm 2 ), i.e., resistance of the test pieces to bending at room temperature, 200°C, and 300°C.
  • Figure 2 shows strength degradation rate (%) of the test pieces with heating at 200°C, 300°C, 400°C, and 500°C. The strength degradation rate (%) was calculated based on room temperature.
  • the organic binder had appropriate strength (a deflection strength of approximately 40kg/cm 2 at 200°C and a deflection strength of approximately 24kg/cm 2 at 300°C).
  • the organic binder is applicable to the present invention practically at approximately 200°C to approximately 350°C, and preferably at approximately 200°C to approximately 300°C.
  • the hybrid binder (XP alcoholic solution) described above has the property of being able to maintain sand mold strength at temperatures of up to approximately 1000°C or above.
  • the XP alcoholic solution is a solution composed principally of an alcoholic solution containing one or more alcohol-soluble metallic alkoxides and an alcohol-soluble alkali compound of an alkali metal or alkaline earth metal, both in a less advanced stage of hydrolysis, where the alcohol-soluble metallic alkoxides are selected from among alkoxides of the metals in the 4A group or 4B group (excluding carbon) and the metals in the 3A group or 3B group of the periodic table and partial hydrolysates of the alkoxides.
  • Patent Literature 2 XP alcoholic solutions and sand molds using the same are described in detail in Japanese Patent No. 3139918 (Patent Literature 2) and Patent Literatures 3 to 5 cited above, and thus Patent Literatures 2 to 5 are incorporated herein by reference in their entirety by citing these related Patent Literatures.
  • HiSiMo ductile (spherical graphite) cast iron and austenitic spherical graphite cast iron (Ni-resist D5S) have excellent fluidity.
  • cast iron (FC: Ferrum Casting) and heat resistant steel (SCH) have relatively poor fluidity and that the heat resistant steel (SCH) has poorer fluidity than cast iron (FC).
  • Figures 3 to 5 show a sand mold used to cast a tabular test piece (2 mm in thickness) rectangular in planar view.
  • Figure 3 shows a cavity in the sand mold used to cast the test piece.
  • Figure 4 is a side view of the sand mold.
  • Figure 5 is a plan view of the sand mold.
  • the illustrated sand mold 10 for the test piece was made of RCS.
  • RCS stands for resin coated sand, which contains Cerabeads as aggregate, and a resin as a binder.
  • the sand mold 10 for the test piece is made up of an upper mold 12 and a lower mold 14 ( Figure 4 ).
  • the cavity 16 in the sand mold 10 is made up of a product portion 18 and a runner 20. Molten metal poured into a down sprue 22 flows into the runner 20 through a gate stick portion 24.
  • An overflow channel 26 is connected to a downstream end portion of the product portion 18, opening in a top surface of the upper mold 12.
  • the product portion 18 measures 300.0 mm in length, 95.0 mm in width, and 2.0 mm in thickness.
  • the lower mold 14 of the sand mold 10 for test pieces has a first recess 30, which faces an upstream end portion of the product portion 18 and the runner 20, as indicated by imaginary lines in Figures 6 and 7 .
  • the first recess 30 is open upward.
  • the lower mold 14 of the sand mold 10 has a second recess 32 which extends from an upstream end to a downstream end on a lateral portion (lateral portion on the side further from the gate stick portion 24) of the product portion 18 as indicated by imaginary lines in Figures 8 and 9 .
  • the second recess 32 is open upward.
  • the lower mold 14 of the sand mold 10 has a third recess 34 which faces an entire area of the downstream end portion of the product portion 18 as indicated by indicated by imaginary lines in Figures 10 and 11 .
  • the third recess 34 is open upward.
  • Figures 12 to 14 show partial sand molds 40, 42, and 44 which are detachably attached, respectively, to the first to third recesses 30, 32, and 34 described above.
  • the first partial sand mold 40 in Figure 12 has a tabular rectangular shape, which is complementary to the contour of the first recess 30 described above ( Figures 6 and 7 ).
  • the first partial sand mold 40 When the first partial sand mold 40 is assembled onto the first recess 30, the first partial sand mold 40 forms a cavity wall surface in the upstream end portion of the product portion 18 and a cavity wall surface of the runner 20 by being integrated with the lower mold 14.
  • the second partial sand mold 42 in Figure 13 has the shape of a rectangular parallelepiped, which is complementary to the contour of the second recess 32 described above ( Figures 8 and 9 ).
  • the second partial sand mold 42 forms a cavity wall surface in the lateral portion (lateral portion on the side further from the gate stick portion 24) of the product portion 18 by being integrated with the lower mold 14.
  • the third partial sand mold 44 in Figure 14 has a tabular rectangular shape, which is complementary to the contour of the third recess 34 described above ( Figures 10 and 11 ).
  • the third partial sand mold 44 forms a cavity wall surface in the downstream end portion of the product portion 18 by being integrated with the lower mold 14.
  • Figure 15 shows an example in which test pieces Tp were cast from cast iron (FC) in the sand mold 10 made of RCS. Casting conditions of the first to third test pieces Tp (1) to Tp(3) shown in (I) to (III) of Figure 15 were as following.
  • FIG 16 shows an example in which cast iron (FC) was cast in the sand mold 10 ( Figures 6 and 7 ) equipped with the first recess 30 and incorporated with the heated first partial sand mold 40 ( Figure 12 ).
  • the partial sand mold 40 was made of RCS.
  • the RCS was prepared from Cerabeads #650 and an organic binder (resin).
  • Figure 17 shows an example in which test pieces Tp were cast from heat resistant steel ( SCH22 ) using the first partial sand mold 40 ( Figure 12 ) described above.
  • the first partial sand mold 40 was made using the hybrid binder (XP alcoholic solution).
  • the aggregate used was Cerabeads #650.
  • Figure 18 shows an example in which seventh and eighth test pieces Tp (7) and Tp (8) were cast from heat resistant steel ( SCH22 ) using the second partial sand mold 42 ( Figure 13 ) described above.
  • the second partial sand mold 42 was made using the hybrid binder ( XP alcoholic solution).
  • the aggregate used was Cerabeads #650.
  • the casting conditions of (VII) and casting conditions of (VIII) in Figure 18 are compared, the casting conditions of (VIII) which provided the completed eighth test piece Tp (8) differ from the casting conditions of (VII) in that (a) the melting temperature was approximately 10°C higher and that (b) the heated sand mold 10 was used.
  • the fluidity can be improved if the melting temperature of the heat resistant steel is increased and the sand mold 10 is heated.
  • FIG 19 shows an example in which ninth and tenth test pieces Tp (9) and Tp (10) were cast from heat resistant steel (SCH22) using the third partial sand mold 44 (installed in the downstream portion of the product portion 18: Figure 19 ) described above.
  • the third partial sand mold 44 was made using the hybrid binder (XP alcoholic solution).
  • the aggregate used was Cerabeads #650.
  • the solid line in Figures 20 to 26 indicates temperatures in various places inside the sand mold 10 when molten metal at a typical temperature is poured into the sand mold 10. If these temperatures are taken as reference temperatures, the temperature of the molten metal falls while the molten metal is flowing inside the sand mold 10.
  • Figure 20 shows falls (chain double-dashed line) in the once raised temperature of molten metal poured into the sand mold 10. By raising the temperature of the molten metal, it is possible to maintain the temperature in various places of the sand mold 10 at levels higher than the reference temperatures. Figure 20 teaches that the possibility of occurrence of casting defects can be reduced by raising the temperature of the molten metal.
  • Figure 21 shows temperature falls in the molten metal flowing in the sand mold 10 heated for use in casting, where the temperature is indicated by a chain double-dashed line.
  • the chain double-dashed line in Figure 21 corresponds to casting under the casting conditions of (III) in Figure 15 .
  • the use of the heated sand mold 10 for casting can reduce the slope of the temperature fall. That is, the temperature falls in the molten metal flowing in the sand mold 10 can be reduced in magnitude.
  • Figure 21 teaches that the possibility of occurrence of casting defects can be reduced by using the heated sand mold 10 for casting.
  • Figure 22 shows temperature falls in the molten metal flowing in the sand mold 10 when casting is carried out by installing a heat source (first partial sand mold 40) in a downstream portion of the runner 20 and upstream portion of the product portion 18, where the temperature is indicated by a chain double-dashed line.
  • the molten metal introduced into the sand mold 10 enters the runner 20 while falling in temperature.
  • the temperature falls in the molten metal in the downstream portion of the runner 20 and upstream portion of the product portion 18 are retarded by the heat source (first partial sand mold 40) placed in the downstream portion of the runner 18 and upstream portion of the product portion 18.
  • the temperature of the molten metal in the entire area of the product portion 18 including the downstream portion of the product portion 18 can be maintained at a relatively high level.
  • Figure 22 teaches that the possibility of occurrence of casting defects can be reduced by placing the heat source in the upstream portion of the product portion 18 and the runner 20 located upstream of the product portion 18.
  • Figure 23 shows temperature falls in the molten metal flowing in the sand mold 10 (especially in the lateral portion where a heat source is placed) when casting is carried out by installing the heat source (second partial sand mold 42 ( Figure 13 )) in the lateral portion of the product portion 18 prone to cause casting defects, where the temperature is indicated by a chain double-dashed line.
  • the temperature falls in the molten metal introduced into the sand mold 10 and flowing in the lateral portion of the product portion 18 are retarded by the heat source (second partial sand mold 42) placed in the lateral portion.
  • the flow of the molten metal can be improved by maintaining the temperature of the molten metal in the lateral portion of the product portion 18 prone to cause casting defects at a relatively high level.
  • Figure 23 teaches that the possibility of occurrence of casting defects can be reduced by placing the heat source in that part of the product portion 18 which is prone to cause casting defects.
  • Figure 24 shows temperature falls in the molten metal flowing in the sand mold 10 (especially in the lateral portion where a heat source is placed) when casting is carried out by installing the heat source (third partial sand mold 44 ( Figure 14 )) in a recess in the downstream portion of the product portion 18, where the temperature is indicated by a chain double-dashed line.
  • the temperature falls in the molten metal introduced into the sand mold 10 and flowing in the downstream portion of the product portion 18 are retarded by the heat source (third partial sand mold 44 ) placed in the recess in the downstream portion of the product portion 18. This corresponds to the casting conditions of (IX) and (X) in Figure 19 .
  • Figure 25 shows temperature falls in the molten metal flowing in the sand mold 10 (especially in the lateral portion where a heat source is placed) when casting is carried out by installing the heat source in a recess in the downstream portion of the runner 20, where the temperature is indicated by a chain double-dashed line.
  • the temperature falls in the molten metal introduced into the sand mold 10 and flowing in the downstream portion of the runner 20 are retarded by the heat source placed in the downstream portion of the runner 20. This makes it possible to maintain the temperatures of the molten metal in various parts of the product portion 18 at relatively high levels.
  • Figure 25 teaches that the flow of molten metal in the entire area of the product portion 18 can be improved by placing the heat source (heated partial sand mold) in the downstream portion of the runner 20.
  • a heat source hereinated partial sand mold
  • a heat source may be placed in the entire area of the runner 20 in a flow direction or a heat source (heated partial sand mold) may be placed in an upstream portion or intermediate portion of the runner 20 in the flow direction.
  • Figure 26 shows temperature falls in the molten metal flowing in the sand mold 10 when casting is carried out by installing a heat source (heated partial sand mold) in a recess in the upstream portion of the product portion 18, where the temperature is indicated by a chain double-dashed line.
  • the temperature falls in the molten metal flowing into the product portion 18 are retarded by the heat source (heated partial sand mold) placed in the upstream portion of the product portion 18.
  • the temperature of the molten metal in the entire area of the product portion 18 can be maintained at a relatively high level.
  • Figure 26 teaches that the possibility of occurrence of casting defects can be reduced by placing the heat source (heated partial sand mold) in the upstream portion of the product portion 18.
  • Figure 27 shows a reference example.
  • a sand mold 100 is made up of a main mold 102 and a core 104 while the main mold 102 in turn is made up of an upper mold 106 and a lower mold 108.
  • Aggregate for the main mold 102 and core 104 may be natural sand, artificial sand, or synthetic sand obtained by mixing the natural sand and artificial sand.
  • the aggregate which can be adopted at least one type of casting sand selected from the group consisting of silica sand, mullite, synthetic mullite, alumina, quartz, zircon, fused silica, silica flour, chamotte, and synthetic chamotte can be adopted.
  • the binder to be added to the aggregate may be either an organic binder or inorganic binder.
  • Figure 27 shows an example in which casting is carried out using a heated main mold 102.
  • the main mold 102 is made using an organic binder.
  • casting is carried out in the main mold 102 heated to a temperature of approximately 200°C to approximately 300°C.
  • the main mold 102 may be heated either in a heating furnace or by blowing hot air into the main mold 102.
  • Figure 27 shows an example in which casting is carried out using a heated core 104.
  • the binder for the core 104 may be an organic binder, an inorganic binder, or the hybrid binder (XP alcoholic solution) described above. Since the hybrid binder can maintain strength at temperatures of up to 1000°C or above, casting may be carried out using the core 104, for example, at approximately 350°C to approximately 1100°C, preferably at approximately 350°C to approximately 1000°C, and more preferably at approximately 350°C to approximately 800°C.
  • the temperatures of the core 104 are only exemplary. The temperatures which can prevent casting defects may be determined experimentally according to the metal and product geometry to be used.
  • casting may be carried out by heating the core 104, for example, to approximately 200°C, approximately 250°C, approximately 300°C, or approximately 350°C.
  • the temperatures of core 104 are only exemplary. The temperatures which can prevent casting defects may be determined experimentally according to the metal and product geometry to be used. The temperatures at which a predetermined strength can be maintained may be determined experimentally by taking into consideration the type of aggregate and binder used to form the core 104.
  • the temperatures at which the strength of the core 104 can be maintained by the inorganic binder when the core 104 is heated may be determined experimentally.
  • Figure 28 shows an example in which a heated partial sand mold 120 is installed in the upper mold 106 in an embodiment of the present invention.
  • the runner 20 is illustrated as an installation location of the partial sand mold 120 by way of example, but the number and installation locations of partial sand molds 120 are arbitrary, and locations effective in making molten metal spread smoothly to the entire area of the product portion 18 may be determined experimentally.
  • Figure 29 shows an example in which a heated partial sand mold 120 is installed in a recess in that portion of the lower mold 108 which faces the runner 20.
  • the partial sand mold 120 installed in the lower mold 108 is exposed to the runner 20, forming a cavity surface which defines the runner 20.
  • Figure 29 also shows an example in which a heated partial sand mold 120 is installed in a recess in the upstream portion of the product portion 18.
  • the partial sand mold 120 is exposed to the product portion 18, forming a cavity surface which defines the product portion 18.
  • Figure 30 shows an example in which heated partial sand molds 120 are installed in the upper mold 106 and lower mold 108.
  • a recess facing the runner 20 is illustrated as an installation location of the partial sand mold 120 by way of example, but the installation location is arbitrary, and the locations effective in making molten metal spread smoothly to the entire area of the product portion 18 may be determined experimentally.
  • the partial sand molds 120 installed in the upper mold 106 and lower mold 108 are exposed to the runner 20, forming cavity surfaces which defines the runner 20.
  • Figure 30 also shows an example in which a partial sand mold 120 is installed in the core 104.
  • the partial sand mold 120 installed in the core 104 is in a state of being exposed to the product portion 18.
  • Either a single partial sand mold 120 or plural partial sand molds 120 may be installed in the core 104.
  • Figure 31 shows an example in which heated partial sand molds 120 are installed in a recess in the upstream portion of the product portion 18 and a recess in the core 104.
  • Figure 32 shows an example in which a heated partial sand mold 120 extending from the upstream portion to the downstream portion of the product portion 18 is installed in a recess in the lower mold 108. Besides, Figure 32 also shows an example in which a heated partial sand mold 120 is installed in a recess in the core 104.
  • the number and installation locations of partial sand molds 120 are not limited to those in the examples of Figures 28 to 32 .
  • the locations effective in making molten metal spread smoothly to the entire area of the product portion 18 may be determined experimentally.
  • the aggregate and binder of the partial sand mold 120 may be selected arbitrarily.
  • the partial sand mold 120 may be made using coated sand prepared by mixing aggregate and a binder or may be made before coating the aggregate with the binder.
  • the binder may be an organic binder, inorganic binder, or hybrid binder (XP alcoholic solution) which is capable of maintaining sand mold strength even at ultra-high temperatures.
  • the partial sand molds 120 may be equal in both material and temperature, may be equal in material and differ in temperature, or may differ in both material and temperature.
  • Examples of combinations of a heated main mold 102 , heated core 104, and heated partial sand mold 120 include the following.
  • the material (aggregate and binder) and temperature of the main mold, the material and temperature of the core, the material and temperature of the partial sand mold incorporated into the main mold, and the material and temperature of the partial sand mold incorporated into the core as well as combinations thereof are arbitrary.
  • the material and temperature of the main mold, the material and temperature of the partial sand mold, and the like may be selected such that the flow of metal in the product portion can be facilitated and that the occurrence of casting defects can be reduced.
  • the temperatures of the main mold, core, and partial sand mold may be determined to the extent that a predetermined strength can be maintained, by actually examining the aggregate and binder adopted. Also, if a simple geometry is selected for the partial sand mold, the required strength (deflection strength) can be limited to a relatively small value.
  • the present invention is widely applicable to metal casting.
  • the application of the present invention allows the occurrence of casting defects to be reduced even if molten metal is at a relatively low temperature. This makes it possible to reduce the amount of thermal energy used to heat metal.
  • the present invention is effective in reducing casting defects of metal which has poor fluidity in molten state.
  • the present invention enables mass production of thin-walled products 2 mm or less in wall thickness.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP14769379.0A 2013-03-19 2014-03-18 Procédé de moulage en sable Active EP2977125B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2013057386A JP5347077B1 (ja) 2013-03-19 2013-03-19 砂型鋳造方法
PCT/JP2014/057416 WO2014148516A1 (fr) 2013-03-19 2014-03-18 Procédé de moulage en sable

Publications (3)

Publication Number Publication Date
EP2977125A1 true EP2977125A1 (fr) 2016-01-27
EP2977125A4 EP2977125A4 (fr) 2016-09-28
EP2977125B1 EP2977125B1 (fr) 2017-10-18

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EP14769379.0A Active EP2977125B1 (fr) 2013-03-19 2014-03-18 Procédé de moulage en sable

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EP (1) EP2977125B1 (fr)
JP (1) JP5347077B1 (fr)
WO (1) WO2014148516A1 (fr)

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JP6214266B2 (ja) * 2013-07-29 2017-10-18 テクノメタル株式会社 砂型鋳造方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106563772A (zh) * 2016-11-10 2017-04-19 安徽龙氏机械制造有限公司 一种复杂铸件铸造砂型

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JP2014180693A (ja) 2014-09-29
EP2977125A4 (fr) 2016-09-28
JP5347077B1 (ja) 2013-11-20
EP2977125B1 (fr) 2017-10-18
WO2014148516A1 (fr) 2014-09-25

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