EP3089841B1 - Method for casting a cast part - Google Patents

Method for casting a cast part Download PDF

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Publication number
EP3089841B1
EP3089841B1 EP15705479.2A EP15705479A EP3089841B1 EP 3089841 B1 EP3089841 B1 EP 3089841B1 EP 15705479 A EP15705479 A EP 15705479A EP 3089841 B1 EP3089841 B1 EP 3089841B1
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EP
European Patent Office
Prior art keywords
mold
pouring
casting
flask
metal melt
Prior art date
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EP15705479.2A
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German (de)
French (fr)
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EP3089841A1 (en
Inventor
Wolfgang RATHNER
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Nemak SAB de CV
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Fill GmbH
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Application filed by Fill GmbH filed Critical Fill GmbH
Priority to PL15705479T priority Critical patent/PL3089841T3/en
Publication of EP3089841A1 publication Critical patent/EP3089841A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04Casting aluminium or magnesium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00Treatment of fused masses in the ladle or the supply runners before casting
    • B22D1/002Treatment with gases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002Castings of light metals
    • B22D21/007Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/027Casting heavy metals with low melting point, i.e. less than 1000 degrees C, e.g. Zn 419 degrees C, Pb 327 degrees C, Sn 232 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/006Casting by filling the mould through rotation of the mould together with a molten metal holding recipient, about a common axis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/003Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using inert gases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/08Shaking, vibrating, or turning of moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D33/00Equipment for handling moulds
    • B22D33/02Turning or transposing moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D39/00Equipment for supplying molten metal in rations
    • B22D39/02Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume
    • B22D39/026Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume using a ladler
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D41/00Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
    • B22D41/04Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like tiltable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D41/00Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
    • B22D41/12Travelling ladles or similar containers; Cars for ladles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00Casting plants
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent

Definitions

  • the invention relates to a method for casting a casting according to the Kippg discernkar, according to the preamble of claim 1.
  • a method of the type mentioned is from the DE102009023881A1 known.
  • a method for Kippgie call is from the WO2010 / 058003A1 known.
  • the process of Umgie Hs by tilting the casting container is set in motion.
  • the casting container or the level of the melt in the casting container is higher than the casting mold, so that the melt enters the casting container with relatively high kinetic energy.
  • the melt is scooped from a scoop with a ladle and then recast from the ladle into the casting container, with which then the mold is filled.
  • Other casting methods are from the US2012 / 325424A1 , of the DE102006058142A1 , of the WO2010 / 068113A1 , of the US5704413A as well as the GB1164173 known.
  • a disadvantage of the known method that it already before the start of the Umgie went the molten metal from the casting into the mold as a result of filling the casting container with the ladle to turbulence in the melt and to a mixing of metal oxide and molten metal and thus severe deterioration of the microstructure of the resulting casting may occur.
  • a particularly low-turbulence encapsulation can be achieved by floating at least 80% of the metal oxide skin on the surface of the molten metal.
  • the metal oxide skin remains in the casting container until reaching the end position. In this case, it is particularly favorable if a region of the metal oxide skin facing away from the casting mold leaves the casting container last on reaching the end position and comes to rest on the surface of the molten metal in the casting mold.
  • more than 80%, preferably more than 95%, of the metal oxide skin come to rest in the region of a feeder of the casting mold in a setting position subsequent to time in the final position.
  • a variant of the invention with which a particularly high quality of the casting can be achieved, provides that the encapsulation takes place at such a speed that the metal oxide skin remains elastic and undamaged until reaching the end position.
  • a particularly low-turbulence Umge is achieved by the fact that the surface of the metal oxide skin located in the casting container during the pouring of the molten metal increased from the casting container into the mold. This embodiment ensures that the casting of the molten metal takes place at an optimum speed.
  • the casting container is connected to the casting mold prior to casting and a relative position of the casting container with respect to the casting mold during the Umuzie hits between the starting position and the end position is maintained ,
  • An optimal solidification behavior of the molten metal in the mold can be achieved in that the axis of rotation extends in the starting position through the mold and either lies under the mold cavity or viewed from the casting container behind the mold cavity or through the mold cavity or over the mold cavity.
  • the metal oxide skin falls after reaching the end position on a feeder of the casting mold or slides into it over the entire width.
  • the casting container is brought after the ladling of molten metal from the scoop to the feeder of the mold, wherein the casting container has a pouring region, via which the molten metal is poured into the casting mold via the feeder, the contour of the pouring region corresponding to the contour of a section of the feeder lying below in the starting position in the vertical direction, the pouring region being directly and congruent with the feeder is connected.
  • the contour of the feeder and the contour of the pouring are in a horizontal position or are pivoted by an angle of 30 ° maximum from the horizontal position.
  • Very good results with regard to the quality of the casting can be achieved in that in the end position, the contour of the feeder and the contour of the pouring area are rotated by an angle of at most 120 ° and at least 60 ° relative to the starting position.
  • the casting container is connected to the casting mold immediately after completion of the filling with the molten metal within a period of not more than 5 seconds, in particular within a period of at most 3.5 seconds, and brought into the starting position. Due to the short docking time of the casting container to the casting mold, an optimal casting temperature of the molten metal and an optimal flow behavior of the same can be ensured. Also, optimal elastic properties of the metal oxide skin can be achieved with the indicated periods.
  • An optimum condition of the metal oxide skin and the molten metal for casting can be achieved by filling the casting container with the molten metal in the scooping furnace within a period of time, the maximum duration of which is 3.5 seconds.
  • Very good results with regard to the microstructure of the casting can be achieved by moving the casting container and the casting mold from the starting position to the final position within a maximum period of 8 seconds, in particular within a maximum period of 6.5 seconds.
  • an average temperature of the molten metal in the scooping furnace has a value derived from a range of values whose lower limit is 680 ° Celsius and its upper limit is 780 ° Celsius.
  • a particularly low-turbulence and gentle and low-oxide scooping of the molten metal from the scoop can be achieved in addition to the above-mentioned period for the scooping of the molten metal that the casting container at a remote in the starting position of the mold has a slot-shaped opening, wherein the casting container for scooping the molten metal is dipped from the scoop with the opening in advance in the molten metal in the scoop.
  • provision may be made for the casting container and the casting mold to be brought from the starting position into the end position in an overpressure atmosphere.
  • At least three molds are used, which are arranged on a carousel, wherein the carousel the three molds in turn from a casting position, in which a pouring the molten metal from the casting container into the casting mold, into a solidification position in which the molten metal solidifies in the casting mold, and then rotates to an operating position in which the casting mold is opened and a casting is removed from the casting mold and the casting mold is cleaned. It can be operated in parallel according to an advantageous development, two carousels.
  • a very high productivity with an optimum quality of the castings produced can be achieved by further turning the carousel at a constant rate having a value coming from a value range whose lower limit is 70 seconds and whose upper limit is 80 seconds.
  • a molten metal 1 is recast from a tiltable casting container 2 into a casting mold 3 with a mold cavity 4 depicting the casting.
  • an aluminum alloy is particularly preferably used, for example AC-Al Si 10 Mg (Cu), AC-Al Si8 Cu3, Al Si7 Cu3, Al Si6 Cu4.
  • the casting mold 3 is particularly preferably a casting mold for highly stressed aluminum components, such as cylinder heads or other components of vehicle engines.
  • the casting container 2 and the casting mold 3 are shown in different temporally successive positions.
  • the Umgie D can also be done by means of two or more parallel to each other, also referred to as a ladle, casting container 2.
  • the casting container 2 is preferably brought by a robot arm to the mold 3 and connected to this, for example hooked.
  • the robot arm can release the casting container 2 after connecting the casting container 2 with the casting mold 3 and is available for another working process.
  • the filling of the casting container 2 is preferably carried out by means of the robot arm, which dips the casting container 2 into the molten metal 1 of the scoop 5.
  • the molten metal 1 is scooped with the casting 2 directly from a scoop 5.
  • a metal oxide skin 6 forms in the casting container 2 on the surface of the molten metal 1.
  • An average temperature of the molten metal in the scoop 5 6 has a value derived from a range of values whose lower limit is 680 ° Celsius and whose upper limit is 780 ° Celsius.
  • the casting container 2 containing the molten metal 1 and the metal oxide skin 6 floating thereon is brought to the casting mold 3.
  • the molten metal 1 is poured from the casting container 2 into the casting mold 3 by a common rotation of the casting container 2 and the casting mold 3 from an initial position to an end position about a rotation axis a.
  • the metal oxide skin 6 floats predominantly, at least 80%, or even completely, on the molten metal 1 and remains essentially on the surface of the molten metal until it reaches the end position.
  • the metal oxide skin 6 can also remain in the casting container 2 until reaching the end position.
  • a region of the metal oxide skin 6 facing away from the casting mold 3 leaves the casting container 2 last when it reaches the end position and comes to lie on the surface of the molten metal 1 in the casting mold 3.
  • more than 80%, preferably more than 95%, of the metal oxide skin 6 come to rest in the region of a feeder 7 of the casting mold 3 in a solidification position subsequent to time in the final position.
  • the metal oxide skin 6 remains elastic and undamaged until reaching the end position.
  • the surface of the metal oxide skin 6 located in the casting container 2 can also increase, in particular in the direction of a pouring region of the pouring container 2. By enlarging the surface of the metal oxide skin during the casting, a particularly smooth flow of the molten metal is achieved.
  • the casting container 2 is connected to the casting mold 3 before casting.
  • a relative position of the pouring container 2 with respect to the mold 3 is maintained during the overmolding between the starting position and the end position. That is, the casting container 2 follows a movement of the casting mold 3 about the axis of rotation a.
  • the axis of rotation a runs in the starting position through the casting mold 3. In this case, the axis of rotation a can either be below the mold cavity 4 or from the casting container 2 Seen from behind the mold cavity 4 or through the mold cavity 4 or over the mold cavity 4.
  • the casting mold 3 can have a feeder 7.
  • the casting container 2 can be brought in this case after scooping the molten metal 1 from the scoop 5 to the feeder 7 of the mold 3 and connected to this feeder 7.
  • the casting container 2 has a pouring region 8, via which the molten metal 1 flows into the feeder 7 and from there into the mold cavity 4.
  • the contour of the pouring region 8 corresponds to the contour of a section of the feeder 7 which is located below in the starting position in the vertical direction.
  • the pouring region 8 is preferably connected directly and congruently to the feeder 7.
  • the term "contour" is understood primarily to mean the shaping of a bottom region and the adjacent outer edges and outer surfaces of the feeder 7 and the pouring region 8 of the casting container 2.
  • the metal oxide skin 6 falls onto the feeder 7 of the casting mold 3 or slides into the feeder 7.
  • the metal oxide skin preferably slides into the feeder 7 substantially over its entire width.
  • the casting container 2 may have a slot-shaped opening 9 at a region facing away from the starting position of the casting mold 3.
  • the casting container 2 with the opening 9 is immersed in advance in the molten metal 6 located in the scooping furnace 5.
  • Through the slot-shaped during the scooping vertically in the molten metal 1 of the scoop 5 standing opening 9 ensures that only clean oxide-free metal flows into the casting container 2 during the scooping process.
  • the filling of the casting container 2 in the scooping furnace 5 with the molten metal 6 takes place within a period of time whose maximum duration is 3.5 seconds.
  • the casting container 2 is connected to the casting mold 3 within a maximum period of 5 seconds, in particular within a maximum period of 3.5 seconds, and brought into the starting position.
  • FIG. 5 how out FIG. 5 it can be seen, are in the initial position, the contour of the feeder 7 and the contour of the pouring 8 in a horizontal position. It should be noted at this point that the contours of the feeder 7 and of the pouring region in the starting position can also be pivoted about an axis of rotation a up to an angle of at most 30 ° from the horizontal position. In the end position, the contour of the feeder 7 and the contour of the pouring region 8 are rotated by an angle of at most 120 ° and at least 60 ° relative to the starting position. The casting container 2 and the casting mold 3 are moved from the starting position to the end position within a maximum period of 8 seconds, in particular within a maximum period of 6.5 seconds.
  • the entire process according to the invention or even only the step of pouring the molten metal 1 out of the casting container 2 into the casting mold 3 can be carried out in an overpressure atmosphere.
  • the casting container 2 and the casting mold 3 can be arranged in a closed space which can be filled with a gas or gas mixture, for example an inert protective gas, so that an overpressure relative to the ambient atmosphere arises outside the space.
  • the scoop oven 5 could also be arranged in the room.
  • Fig. 6 illustrated embodiment has at least three molds 10,11, 12, which are arranged on a carousel.
  • This embodiment constitutes an independent embodiment in its own right, which can also be used with other casting methods than those described above.
  • the carousel rotates the three casting molds 10, 11, 12 in turn from a casting position I, in which the molten metal 6 is poured from the casting container 2 into the casting mold 10, 11, 12, into a solidification position II, in which the molten metal 1 in the casting Mold 10, 11, 12 solidifies, and then in an operating position III, in which the mold 10, 11, 12 is opened and removed a casting from the mold 10, 11, 12 and the mold 10, 11, 12 is cleaned.
  • the carousel is further rotated at a constant rate having a value coming from a range of values whose lower limit is 70 seconds and whose upper limit is 80 seconds.
  • this cycle is 75 seconds and is as follows: In the pouring position I, the docking of the pouring vessel 2 to the casting mold 11 takes 3.5 seconds, while the tilting of the pouring vessel 2 and the casting mold 11 from the starting position to the end position Takes 6.5 seconds. After reaching the end position of the casting is undocked from the mold and is available for a new scooping again. Another 56 seconds, the molten metal solidifies in the casting position I. For further rotation of the mold 11 in the position II 9 seconds are required.
  • the molten metal 1 or the casting in the casting mold 10 solidifies for a further 66 seconds, again requiring 9 seconds for further rotation into the operating position III.
  • the casting solidifies for another 10 seconds, for the opening of the casting mold it takes 9 seconds and for the removal of the casting by means of a robot 8 seconds are needed.
  • the cleaning of the mold 3 takes 20 seconds and the insertion of new sand cores takes 10 seconds.
  • For the closing of the mold 3 and the further rotation in the casting position I 9 seconds are required in each case. This results in a cycle time of 75 seconds for the further rotation of one of the positions I, II, III in the next position.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Gießen eines Gussteils nach dem Kippgießprinzip, gemäß dem Oberbegriff von Anspruch 1.The invention relates to a method for casting a casting according to the Kippgießprinzip, according to the preamble of claim 1.

Ein Verfahren der eingangs genannten Art ist aus der DE102009023881A1 bekannt geworden.A method of the type mentioned is from the DE102009023881A1 known.

Ein Verfahren zum Kippgießen ist aus der WO2010/058003A1 bekannt geworden. Bei dem bekannten Verfahren wird der Prozess des Umgießens durch Kippen des Gießbehälters in Gang gesetzt. Hierbei befindet sich der Gießbehälter bzw. das Niveau der Schmelze in dem Gießbehälter höher als die Gießform, sodass die Schmelze mit relativ hoher kinetischer Energie in den Gießbehälter eintritt. Bei der bekannten Lösung wird, wie es bei derartigen Verfahren üblich ist, die Schmelze aus einem Schöpfofen mit einem Schöpflöffel geschöpft und dann aus dem Schöpflöffel in den Gießbehälter umgegossen, mit welchem dann die Gießform befüllt wird. Weitere Gießverfahren sind aus der US2012/325424A1 , der DE102006058142A1 , der WO2010/068113A1 , der US5704413A sowie der GB1164173 bekannt geworden.A method for Kippgießen is from the WO2010 / 058003A1 known. In the known method, the process of Umgießens by tilting the casting container is set in motion. In this case, the casting container or the level of the melt in the casting container is higher than the casting mold, so that the melt enters the casting container with relatively high kinetic energy. In the known solution, as is customary in such methods, the melt is scooped from a scoop with a ladle and then recast from the ladle into the casting container, with which then the mold is filled. Other casting methods are from the US2012 / 325424A1 , of the DE102006058142A1 , of the WO2010 / 068113A1 , of the US5704413A as well as the GB1164173 known.

Nachteilig an den bekannten Verfahren ist es unter anderem, dass es bereits vor Beginn des Umgießens der Metallschmelze von dem Gießbehälter in die Gießform als Folge des Befüllens des Gießbehälters mit dem Schöpflöffel zu Verwirbelungen in der Schmelze sowie zu einem Vermischen von Metalloxidhaut und Metallschmelze und somit zu starken Beeinträchtigungen der Gefügestruktur des resultierenden Gussteils kommen kann.A disadvantage of the known method, among other things, that it already before the start of the Umgießens the molten metal from the casting into the mold as a result of filling the casting container with the ladle to turbulence in the melt and to a mixing of metal oxide and molten metal and thus severe deterioration of the microstructure of the resulting casting may occur.

Es ist daher eine Aufgabe der Erfindung, ein neues Kippgießverfahren zu schaffen, welches die oben genannten Nachteile nicht aufweist.It is therefore an object of the invention to provide a new Kippgießverfahren, which does not have the disadvantages mentioned above.

Diese Aufgabe wird mit einem Verfahren der eingangs genannten Art erfindungsgemäß durch die Merkmale des kennzeichnenden Teils von Anspruch 1 gelöstThis object is achieved by a method of the type mentioned according to the invention by the features of the characterizing part of claim 1

Mit der erfindungsgemäßen Lösung lässt sich ein besonders homogener und turbulenzarmer Gießvorgang realisieren. Dadurch können Unregelmäßigkeiten in dem Materialgefüge des Gussstückes sehr gut vermieden werden. Vor allem lässt sich durch Verzicht auf ein Umgießen der Schmelze von dem Schöpflöffel in den Gießbehälter ein besonders verwirbelungsarmes Schöpfen und Transportieren der Schmelze zur Gießform erreichen. Da die Metallschmelze bereits vor dem Umfüllen aus dem Gießbehälter in die Gießform beruhigt ist, kann auch ein Eingießen der Schmelze in die Gussform sehr gleichmäßig und verwirbelungsfrei erfolgen. Das Umgießen erfolgt hierbei mit einer solchen Geschwindigkeit, dass die Metalloxidhaut bis zum Ende des Umgießens auf der Metallschmelze aufschwimmt. Dadurch wird ein gleichmäßiges Eingießen der Metallschmelze in die Gießform sichergestellt.With the solution according to the invention, a particularly homogeneous and low-turbulence casting process can be realized. As a result, irregularities in the material structure of the casting can be avoided very well. Above all, by dispensing with the pouring of the melt from the ladle into the casting container, it is possible to achieve a particularly low swirling and transporting of the melt to the casting mold. Since the molten metal has calmed down before being transferred from the casting container into the casting mold, casting of the melt into the casting mold can also take place very evenly and without turbulence. The casting is carried out at such a speed that the metal oxide skin floats on the molten metal until the end of the overmolding. This ensures a uniform pouring of the molten metal into the casting mold.

Ein besonders turbulenzarmes Umgießen lässt sich dadurch erzielen, dass mindestens 80% der Metalloxidhaut auf der Oberfläche der Metallschmelze aufschwimmen.A particularly low-turbulence encapsulation can be achieved by floating at least 80% of the metal oxide skin on the surface of the molten metal.

Als besonders vorteilhaft hat es sich herausgestellt, wenn die Metalloxidhaut bis zum Erreichen der Endposition in dem Gießbehälter verbleibt. Hierbei ist es besonders günstig, wenn ein der Gießform abgewendeter Bereich der Metalloxidhaut bei Erreichen der Endposition den Gießbehälter als letztes verlässt und an der Oberfläche der Metallschmelze in der Gießform zu liegen kommt.It has proven to be particularly advantageous if the metal oxide skin remains in the casting container until reaching the end position. In this case, it is particularly favorable if a region of the metal oxide skin facing away from the casting mold leaves the casting container last on reaching the end position and comes to rest on the surface of the molten metal in the casting mold.

Vorteilhafter Weise kommen mehr als 80%, bevorzugt mehr als 95%, der Metalloxidhaut in einer der Endposition zeitlich nachfolgenden Erstarrungsposition im Bereich eines Speisers der Gießform zu liegen.Advantageously, more than 80%, preferably more than 95%, of the metal oxide skin come to rest in the region of a feeder of the casting mold in a setting position subsequent to time in the final position.

Eine Variante der Erfindung, mit welcher sich eine besonders hohe Qualität des Gussstückes erzielen lässt, sieht vor, dass das Umgießen mit einer solchen Geschwindigkeit erfolgt, dass die Metalloxidhaut bis zum Erreichen der Endposition elastisch und unbeschädigt bleibt.A variant of the invention, with which a particularly high quality of the casting can be achieved, provides that the encapsulation takes place at such a speed that the metal oxide skin remains elastic and undamaged until reaching the end position.

Ein besonders turbulenzarmes Umgießen, wird dadurch erzielt, dass sich die Oberfläche der in dem Gießbehälter befindlichen Metalloxidhaut während des Umgießens der Metallschmelze von dem Gießbehälter in die Gießform vergrößert. Durch diese Ausführungsform wird gewährleistet, dass das Umgießen der Metallschmelze mit einer optimalen Geschwindigkeit erfolgt.A particularly low-turbulence Umge, is achieved by the fact that the surface of the metal oxide skin located in the casting container during the pouring of the molten metal increased from the casting container into the mold. This embodiment ensures that the casting of the molten metal takes place at an optimum speed.

Gemäß einer bevorzugten Weiterbildung, welche ein sehr exaktes und definiertes Umgießen ermöglicht, kann es vorgesehen sein, dass der Gießbehälter mit der Gießform vor dem Umgießen verbunden und eine Relativposition des Gießbehälters in Bezug auf die Gießform während des Umgießens zwischen der Ausgangsposition und der Endposition beibehalten wird.According to a preferred embodiment, which allows a very precise and defined encapsulation, it may be provided that the casting container is connected to the casting mold prior to casting and a relative position of the casting container with respect to the casting mold during the Umuzießens between the starting position and the end position is maintained ,

Ein optimales Erstarrungsverhalten der Metallschmelze in der Gießform lässt sich dadurch erzielen, dass die Drehachse in der Ausgangsposition durch die Gießform verläuft und entweder unter dem Formhohlraum liegt oder von dem Gießbehälter aus betrachtet hinter dem Formhohlraum oder durch den Formhohlraum oder über dem Formhohlraum verläuft.An optimal solidification behavior of the molten metal in the mold can be achieved in that the axis of rotation extends in the starting position through the mold and either lies under the mold cavity or viewed from the casting container behind the mold cavity or through the mold cavity or over the mold cavity.

Um eine Beschädigung des Gussstückes durch die Metalloxidhaut zu verhindern, kann es gemäß einer Weiterbildung des erfindungsgemäßen Verfahrens vorgesehen sein, dass die Metalloxidhaut nach Erreichen der Endposition auf einen Speiser der Gießform fällt oder in diesen auf ganzer Breite hineingleitet.In order to prevent damage to the casting by the metal oxide skin, it may be provided according to a development of the method according to the invention, that the metal oxide skin falls after reaching the end position on a feeder of the casting mold or slides into it over the entire width.

Nach einer Variante der Erfindung, welche sich durch ein besonders ruhiges und verwirbelungsfreies Umgießen der Metallschmelze von dem Gießbehälter in die Gießform auszeichnet, kann es vorgesehen sein, dass der Gießbehälter nach dem Schöpfen der Metallschmelze aus dem Schöpfofen an den Speiser der Gießform herangeführt wird, wobei der Gießbehälter einen Ausgießbereich aufweist, über welche die Metallschmelze über den Speiser in die Gießform gegossen wird, wobei die Kontur des Ausgießbereiches der Kontur eines in der Ausgangsposition in vertikaler Richtung betrachtet unten liegenden Abschnittes des Speisers entspricht, wobei der Ausgießbereich unmittelbar und deckungsgleich mit dem Speiser verbunden wird.According to a variant of the invention, which is characterized by a particularly smooth and turbulence-free Umgeießen the molten metal from the casting into the mold, it may be provided that the casting container is brought after the ladling of molten metal from the scoop to the feeder of the mold, wherein the casting container has a pouring region, via which the molten metal is poured into the casting mold via the feeder, the contour of the pouring region corresponding to the contour of a section of the feeder lying below in the starting position in the vertical direction, the pouring region being directly and congruent with the feeder is connected.

Als besonders günstig hat es sich herausgestellt, wenn sich in der Ausgangsposition die Kontur des Speisers und die Kontur des Ausgießbereiches in einer horizontalen Lage befinden oder um einen Winkel von maximal 30° aus der horizontalen Lage geschwenkt sind.To be particularly favorable, it has been found in the starting position, the contour of the feeder and the contour of the pouring are in a horizontal position or are pivoted by an angle of 30 ° maximum from the horizontal position.

Sehr gute Ergebnisse hinsichtlich der Qualität des Gussstückes lassen sich dadurch erzielen, dass in der Endposition die Kontur des Speisers und die Kontur des Ausgießbereiches um einen Winkel von maximal 120° und mindestens 60° gegenüber der Ausgangsposition verdreht sind.Very good results with regard to the quality of the casting can be achieved in that in the end position, the contour of the feeder and the contour of the pouring area are rotated by an angle of at most 120 ° and at least 60 ° relative to the starting position.

Als besonders vorteilhaft hat es sich herausgestellt, wenn der Gießbehälter unmittelbar nach Abschluss des Befüllens mit der Metallschmelze innerhalb eines Zeitraumes von maximal 5 Sekunden, insbesondere innerhalb eines Zeitraumes von maximal 3,5 Sekunden, mit der Gießform verbunden und in die Ausgangsposition gebracht wird. Durch die kurze Andockzeit des Gießbehälters an die Gießform lassen sich eine optimale Gießtemperatur der Metallschmelze sowie ein optimales Flussverhalten derselben gewährleisten. Auch lassen sich optimale elastische Eigenschaften der Metalloxidhaut mit den angegebenen Zeiträumen erzielen.It has proven to be particularly advantageous if the casting container is connected to the casting mold immediately after completion of the filling with the molten metal within a period of not more than 5 seconds, in particular within a period of at most 3.5 seconds, and brought into the starting position. Due to the short docking time of the casting container to the casting mold, an optimal casting temperature of the molten metal and an optimal flow behavior of the same can be ensured. Also, optimal elastic properties of the metal oxide skin can be achieved with the indicated periods.

Ein für das Gießen optimaler Zustand der Metalloxidhaut sowie der Metallschmelze lassen sich dadurch erzielen, dass der Gießbehälters in dem Schöpfofen mit der Metallschmelze innerhalb eines Zeitraumes, dessen maximale Dauer 3,5 Sekunden beträgt, befüllt wird.An optimum condition of the metal oxide skin and the molten metal for casting can be achieved by filling the casting container with the molten metal in the scooping furnace within a period of time, the maximum duration of which is 3.5 seconds.

Sehr gute Ergebnisse hinsichtlich der Gefügestruktur des Gussstückes können dadurch erreicht werden, dass der Gießbehälter und die Gießform innerhalb eines Zeitraumes von maximal 8 Sekunden, insbesondere innerhalb eines Zeitraumes von maximal 6,5 Sekunden, von der Ausgangsposition in die Endposition bewegt werden.Very good results with regard to the microstructure of the casting can be achieved by moving the casting container and the casting mold from the starting position to the final position within a maximum period of 8 seconds, in particular within a maximum period of 6.5 seconds.

Als besonders vorteilhaft hat es sich erwiesen, dass eine Durchschnittstemperatur der Metallschmelze in dem Schöpfofen einen Wert aufweist, der aus einem Wertebereich stammt, dessen untere Grenze 680° Celsius und dessen obere Grenze 780° Celsius beträgt.To be particularly advantageous, it has been found that an average temperature of the molten metal in the scooping furnace has a value derived from a range of values whose lower limit is 680 ° Celsius and its upper limit is 780 ° Celsius.

Ein besonders turbulenzarmes und sanftes sowie oxidarmes Schöpfen der Metallschmelze aus dem Schöpfofen kann neben dem oben erwähnten Zeitraum für das Schöpfen der Metallschmelze dadurch erzielt werden, dass der Gießbehälter an einem in der Ausgangsposition der Gießform abgewandten Bereich eine schlitzförmige Öffnung aufweist, wobei der Gießbehälter zum Schöpfen der Metallschmelze aus dem Schöpfofen mit der Öffnung voraus in die in dem Schöpfofen befindliche Metallschmelze getaucht wird.A particularly low-turbulence and gentle and low-oxide scooping of the molten metal from the scoop can be achieved in addition to the above-mentioned period for the scooping of the molten metal that the casting container at a remote in the starting position of the mold has a slot-shaped opening, wherein the casting container for scooping the molten metal is dipped from the scoop with the opening in advance in the molten metal in the scoop.

Gemäß einer weiteren sehr vorteilhaften Variante der Erfindung kann es vorgesehen sein, dass der Gießbehälter und die Gießform in einer Überdruckatmosphäre von der Ausgangsposition in die Endposition gebracht werden.According to a further very advantageous variant of the invention, provision may be made for the casting container and the casting mold to be brought from the starting position into the end position in an overpressure atmosphere.

Gemäß einer hinsichtlich der Produktivität und der kurzen Prozesszeiten optimalen Ausführungsform kann es vorgesehen sein, dass zumindest drei Gießformen verwendet werden, die auf einem Karussell angeordnet sind, wobei das Karussell die drei Gießformen reihum von einer Gießposition, in welcher ein Umgießen der Metallschmelze von dem Gießbehälter in die Gießform erfolgt, in eine Erstarrungsposition, in welcher die Metallschmelze in der Gießform erstarrt, und hierauf in eine Bedienposition dreht, in welcher die Gießform geöffnet und ein Gussteil aus der Gießform entnommen und die Gießform gereinigt wird. Es können gemäß einer vorteilhaften Weiterbildung auch zwei Karusselle parallel betrieben werden.According to an optimal embodiment in terms of productivity and short process times, it can be provided that at least three molds are used, which are arranged on a carousel, wherein the carousel the three molds in turn from a casting position, in which a pouring the molten metal from the casting container into the casting mold, into a solidification position in which the molten metal solidifies in the casting mold, and then rotates to an operating position in which the casting mold is opened and a casting is removed from the casting mold and the casting mold is cleaned. It can be operated in parallel according to an advantageous development, two carousels.

Eine sehr hohe Produktivität bei einer optimalen Qualität der hergestellten Gussstücke lässt sich dadurch erzielen, dass das Karussell in einem konstanten Takt weitergedreht wird, der einen Wert aufweist, der aus einem Wertebereich stammt dessen untere Grenze 70 Sekunden und dessen obere Grenze 80 Sekunden beträgt.A very high productivity with an optimum quality of the castings produced can be achieved by further turning the carousel at a constant rate having a value coming from a value range whose lower limit is 70 seconds and whose upper limit is 80 seconds.

Zum besseren Verständnis der Erfindung wird diese anhand der nachfolgenden Figuren näher erläutert.For a better understanding of the invention, this will be explained in more detail with reference to the following figures.

Es zeigen jeweils in stark vereinfachter, schematischer Darstellung:

Fig. 1
einen Gießbehälter, eine Gießform und einen Schöpfofen wie sie bei einem erfindungsgemäßen Verfahren verwendet werden;
Fig. 2
eine Ausgangsposition des Gießbehälters und der Gießform aus Fig. 1 vor einem Umgießen einer Metallschmelze aus dem Gießbehälter in die Gießform;
Fig. 3
eine Endposition des Gießbehälters und der Gießform aus Fig. 2 nach dem Umgießen der Metallschmelze aus dem Gießbehälter in die Gießform;
Fig. 4
eine perspektivische Ansicht des Gießbehälters und der Gießform aus Fig. 2;
Fig. 5
einen Schnitt durch den Gießbehälter und die Gießform aus Fig. 4;
Fig. 6
ein Karussell mit drei Gießformen.
In each case, in a highly simplified, schematic representation:
Fig. 1
a casting container, a casting mold and a scoop furnace as used in a method according to the invention;
Fig. 2
a starting position of the casting container and the mold from Fig. 1 prior to pouring a molten metal from the casting container into the casting mold;
Fig. 3
an end position of the casting container and the mold Fig. 2 after pouring the molten metal from the casting container into the casting mold;
Fig. 4
a perspective view of the casting container and the mold Fig. 2 ;
Fig. 5
a section through the casting container and the mold Fig. 4 ;
Fig. 6
a carousel with three molds.

Einführend sei festgehalten, dass in den unterschiedlich beschriebenen Ausführungsformen gleiche Teile mit gleichen Bezugszeichen bzw. gleichen Bauteilbezeichnungen versehen werden, wobei die in der gesamten Beschreibung enthaltenen Offenbarungen sinngemäß auf gleiche Teile mit gleichen Bezugszeichen bzw. gleichen Bauteilbezeichnungen übertragen werden können. Auch sind die in der Beschreibung gewählten Lageangaben, wie z.B. oben, unten, seitlich usw. auf die unmittelbar beschriebene sowie dargestellte Figur bezogen und sind diese Lageangaben bei einer Lageänderung sinngemäß auf die neue Lage zu übertragen.By way of introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, the disclosures contained in the entire description can be mutatis mutandis to the same parts with the same reference numerals or component names. Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and these position information in a change in position mutatis mutandis to transfer to the new location.

Die Ausführungsbeispiele zeigen mögliche Ausführungsvarianten der erfindungsgemäßen Lösung, wobei an dieser Stelle bemerkt sei, dass die Erfindung nicht auf die speziell dargestellten Ausführungsvarianten derselben eingeschränkt ist, sondern vielmehr auch diverse Kombinationen der einzelnen Ausführungsvarianten untereinander möglich sind und diese Variationsmöglichkeit aufgrund der Lehre zum technischen Handeln durch gegenständliche Erfindung im Können des auf diesem technischen Gebiet tätigen Fachmannes liegt.The embodiments show possible embodiments of the solution according to the invention, it being noted at this point that the invention is not limited to the specifically illustrated embodiments thereof, but rather various combinations of the individual embodiments are possible with each other and this variation possibility due to the teaching of technical action representational invention in the skill of those skilled in this technical field.

Weiters können auch Einzelmerkmale oder Merkmalskombinationen aus den gezeigten und beschriebenen unterschiedlichen Ausführungsbeispielen für sich eigenständige, erfinderische oder erfindungsgemäße Lösungen darstellen.Furthermore, individual features or combinations of features from the different exemplary embodiments shown and described can also represent independent, inventive or inventive solutions.

Die den eigenständigen erfinderischen Lösungen zugrundeliegende Aufgabe kann der Beschreibung entnommen werden.The task underlying the independent inventive solutions can be taken from the description.

Sämtliche Angaben zu Wertebereichen in gegenständlicher Beschreibung sind so zu verstehen, dass diese beliebige und alle Teilbereiche daraus mitumfassen, z.B. ist die Angabe 1 bis 10 so zu verstehen, dass sämtliche Teilbereiche, ausgehend von der unteren Grenze 1 und der oberen Grenze 10 mit umfasst sind, d.h. sämtliche Teilbereiche beginnen mit einer unteren Grenze von 1 oder größer und enden bei einer oberen Grenze von 10 oder weniger, z.B. 1 bis 1,7, oder 3,2 bis 8,1, oder 5,5 bis 10.All information on ranges of values in objective description should be understood to include these arbitrary and all sub-ranges thereof, eg the indication 1 to 10 should be understood to encompass all sub-ranges, starting from the lower limit 1 and the upper limit 10 that is, all portions begin with a lower limit of 1 or greater and end at an upper limit of 10 or less, eg, 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.

Vor allem kann die in der Fig. 6 gezeigte Ausführungsform den Gegenstand einer eigenständigen Erfindung bilden. Die diesbezüglichen, erfindungsgemäßen Aufgaben und Lösungen sind den Detailbeschreibungen dieser Figur zu entnehmen.Especially in the Fig. 6 embodiment shown form the subject of an independent invention. The relevant objects and solutions according to the invention can be found in the detailed descriptions of this figure.

Der Ordnung halber sei abschließend darauf hingewiesen, dass zum besseren Verständnis des Aufbaus der Komponenten der zur Durchführung des Verfahrens verwendeten Gießvorrichtung diese bzw. deren Bestandteile teilweise unmaßstäblich und/oder vergrößert und/oder verkleinert dargestellt wurden.For the sake of order, it should finally be pointed out that in order to better understand the structure of the components of the casting apparatus used for carrying out the method, these or their components have been shown partially unevenly and / or enlarged and / or reduced in size.

Gemäß den Figuren 1 - 3 erfolgt das Gießen bei einem erfindungsgemäßen Verfahren zum Gießen eines Gussteils nach dem Kippgießprinzip. Hierbei wird eine Metallschmelze 1 aus einem kippbaren Gießbehälter 2 in eine Gießform 3 mit einem den Gussteil abbildenden Formhohlraum 4 umgegossen. Als Metallschmelze 1 kommt besonders bevorzugt eine Aluminiumlegierung zum Einsatz, beispielsweise AC-Al Si 10 Mg (Cu), AC-Al Si8 Cu3, Al Si7 Cu3, Al Si6 Cu4. Die Gießform 3 ist besonders bevorzugt eine Gießform für hochbeanspruchte Aluminiumkomponenten, wie beispielsweise Zylinderköpfe oder andere Komponenten von Fahrzeugmotoren.According to the Figures 1 - 3 the casting takes place in a method according to the invention for casting a casting according to the Kippgießprinzip. In this case, a molten metal 1 is recast from a tiltable casting container 2 into a casting mold 3 with a mold cavity 4 depicting the casting. As the molten metal 1, an aluminum alloy is particularly preferably used, for example AC-Al Si 10 Mg (Cu), AC-Al Si8 Cu3, Al Si7 Cu3, Al Si6 Cu4. The casting mold 3 is particularly preferably a casting mold for highly stressed aluminum components, such as cylinder heads or other components of vehicle engines.

In den Figuren 1 - 3 sind der Gießbehälter 2 und die Gießform 3 in unterschiedlichen zeitlich aufeinander folgenden Positionen dargestellt. Das Umgießen kann auch mittels zweier oder mehrerer parallel zueinander angeordneter, auch als Gießlöffel bezeichneten, Gießbehälter 2 erfolgen.In the Figures 1 - 3 the casting container 2 and the casting mold 3 are shown in different temporally successive positions. The Umgießen can also be done by means of two or more parallel to each other, also referred to as a ladle, casting container 2.

Der Gießbehälter 2 wird bevorzugt von einem Roboterarm an die Gießform 3 herangeführt und mit dieser verbunden, beispielsweise eingehängt. Der Roboterarm kann nach Verbinden des Gießbehälters 2 mit der Gießform 3 den Gießbehälter 2 freigeben und steht für einen anderen Arbeitsvorgang zur Verfügung. Auch das Befüllen des Gießbehälters 2 erfolgt bevorzugt mithilfe des Roboterarms, der den Gießbehälter 2 in die Metallschmelze 1 des Schöpfofens 5 eintaucht. Hierbei wird die Metallschmelze 1 mit dem Gießbehälter 2 direkt aus einem Schöpfofen 5 geschöpft. Während des Schöpfens bzw. unmittelbar danach bildet sich in dem Gießbehälter 2 an der Oberfläche der Metallschmelze 1 eine Metalloxidhaut 6 aus. Eine Durchschnittstemperatur der in dem Schöpfofen 5 befindlichen flüssigen Metallschmelze 6 weist einen Wert auf, der aus einem Wertebereich stammt, dessen untere Grenze 680° Celsius und dessen obere Grenze 780° Celsius beträgt.The casting container 2 is preferably brought by a robot arm to the mold 3 and connected to this, for example hooked. The robot arm can release the casting container 2 after connecting the casting container 2 with the casting mold 3 and is available for another working process. Also, the filling of the casting container 2 is preferably carried out by means of the robot arm, which dips the casting container 2 into the molten metal 1 of the scoop 5. Here, the molten metal 1 is scooped with the casting 2 directly from a scoop 5. During the scooping or immediately thereafter, a metal oxide skin 6 forms in the casting container 2 on the surface of the molten metal 1. An average temperature of the molten metal in the scoop 5 6 has a value derived from a range of values whose lower limit is 680 ° Celsius and whose upper limit is 780 ° Celsius.

Nach seinem Befüllen wird der die Metallschmelze 1 und die darauf aufschwimmende Metalloxidhaut 6 enthaltende Gießbehälter 2 an die Gießform 3 herangeführt. Sodann wird die Metallschmelze 1 von dem Gießbehälter 2 in die Gießform 3 durch ein gemeinsames Drehen des Gießbehälters 2 und der Gießform 3 aus einer Ausgangsposition in eine Endposition um eine Drehachse a umgegossen. Während des Umgießens schwimmt die Metalloxidhaut 6 zu einem überwiegenden Teil, zu mindestens 80%, oder aber auch zur Gänze auf der Metallschmelze 1 auf und verbleibt bis zum Erreichen der Endposition im Wesentlichen an der Oberfläche der Metallschmelze.After it has been filled, the casting container 2 containing the molten metal 1 and the metal oxide skin 6 floating thereon is brought to the casting mold 3. Then, the molten metal 1 is poured from the casting container 2 into the casting mold 3 by a common rotation of the casting container 2 and the casting mold 3 from an initial position to an end position about a rotation axis a. During the overmolding, the metal oxide skin 6 floats predominantly, at least 80%, or even completely, on the molten metal 1 and remains essentially on the surface of the molten metal until it reaches the end position.

Die Metalloxidhaut 6 kann gemäß einer Variante der Erfindung auch bis zum Erreichen der Endposition in dem Gießbehälter 2 verbleiben. Ein der Gießform 3 abgewendeter Bereich der Metalloxidhaut 6 verlässt bei Erreichen der Endposition den Gießbehälter 2 als letztes und kommt an der Oberfläche der Metallschmelze 1 in der Gießform 3 zu liegen. Günstiger Weise kommen mehr als 80%, bevorzugt mehr als 95%, der Metalloxidhaut 6 in einer der Endposition zeitlich nachfolgenden Erstarrungsposition im Bereich eines Speisers 7 der Gießform 3 zu liegen.According to a variant of the invention, the metal oxide skin 6 can also remain in the casting container 2 until reaching the end position. A region of the metal oxide skin 6 facing away from the casting mold 3 leaves the casting container 2 last when it reaches the end position and comes to lie on the surface of the molten metal 1 in the casting mold 3. Conveniently, more than 80%, preferably more than 95%, of the metal oxide skin 6 come to rest in the region of a feeder 7 of the casting mold 3 in a solidification position subsequent to time in the final position.

Die Metalloxidhaut 6 bleibt bis zum Erreichen der Endposition elastisch und unbeschädigt. Während des Umgießens der Metallschmelze 1 kann sich auch die Oberfläche der in dem Gießbehälter 2 befindlichen Metalloxidhaut 6 vergrößern, insbesondere in Richtung eines Ausgießbereiches des Gießbehälters 2. Durch das Vergrößern der Oberfläche der Metalloxidhaut während des Umgießens wird ein besonders ruhiger Fluss der Metallschmelze erreicht.The metal oxide skin 6 remains elastic and undamaged until reaching the end position. During the pouring over of the molten metal 1, the surface of the metal oxide skin 6 located in the casting container 2 can also increase, in particular in the direction of a pouring region of the pouring container 2. By enlarging the surface of the metal oxide skin during the casting, a particularly smooth flow of the molten metal is achieved.

Der Gießbehälter 2 wird mit der Gießform 3 vor dem Umgießen verbunden. Eine Relativposition des Gießbehälters 2 in Bezug auf die Gießform 3 wird während des Umgießens zwischen der Ausgangsposition und der Endposition beibehalten. D.h. der Gießbehälter 2 folgt einer Bewegung der Gießform 3 um die Drehachse a. Als besonders günstig hat es sich herausgestellt, dass die Drehachse a in der Ausgangsposition durch die Gießform 3 verläuft. Hierbei kann die Drehachse a entweder unter dem Formhohlraum 4 liegt oder von dem Gießbehälter 2 aus betrachtet hinter dem Formhohlraum 4 oder durch den Formhohlraum 4 oder über dem Formhohlraum 4 verlaufen.The casting container 2 is connected to the casting mold 3 before casting. A relative position of the pouring container 2 with respect to the mold 3 is maintained during the overmolding between the starting position and the end position. That is, the casting container 2 follows a movement of the casting mold 3 about the axis of rotation a. To be particularly favorable, it has been found that the axis of rotation a runs in the starting position through the casting mold 3. In this case, the axis of rotation a can either be below the mold cavity 4 or from the casting container 2 Seen from behind the mold cavity 4 or through the mold cavity 4 or over the mold cavity 4.

Eingießseitig kann die Gießform 3 einen Speiser 7 aufweisen. Der Gießbehälter 2 kann in diesem Fall nach dem Schöpfen der Metallschmelze 1 aus dem Schöpfofen 5 an den Speiser 7 der Gießform 3 herangeführt und mit diesem Speiser 7 verbunden werden. Der Gießbehälter 2 weist einen Ausgießbereich 8 auf, über welche die Metallschmelze 1 in den Speiser 7 und von dort weiter in Formhohlraum 4 fließt. Die Kontur des Ausgießbereiches 8 entspricht der Kontur eines in der Ausgangsposition in vertikaler Richtung betrachtet unten liegenden Abschnittes des Speisers 7. Der Ausgießbereich 8 wird bevorzugt unmittelbar und deckungsgleich mit dem Speiser 7 verbunden. Unter Kontur wird in dem vorliegenden Zusammenhang in erster Linie die Formgebung eines Bodenbereiches und der aneinander anliegenden Außenkanten und Außenflächen von Speiser 7 und Ausgießbereich 8 des Gießbehälters 2 verstanden.On the pouring side, the casting mold 3 can have a feeder 7. The casting container 2 can be brought in this case after scooping the molten metal 1 from the scoop 5 to the feeder 7 of the mold 3 and connected to this feeder 7. The casting container 2 has a pouring region 8, via which the molten metal 1 flows into the feeder 7 and from there into the mold cavity 4. The contour of the pouring region 8 corresponds to the contour of a section of the feeder 7 which is located below in the starting position in the vertical direction. The pouring region 8 is preferably connected directly and congruently to the feeder 7. In the present context, the term "contour" is understood primarily to mean the shaping of a bottom region and the adjacent outer edges and outer surfaces of the feeder 7 and the pouring region 8 of the casting container 2.

Nach Erreichen der Endposition fällt die Metalloxidhaut 6 auf den Speiser 7 der Gießform 3 oder gleitet in den Speiser 7 hinein. Bevorzugt gleitet die Metalloxidhaut im Wesentlichen auf ganzer Breite des Speisers 7 in diesen hinein.After reaching the end position, the metal oxide skin 6 falls onto the feeder 7 of the casting mold 3 or slides into the feeder 7. The metal oxide skin preferably slides into the feeder 7 substantially over its entire width.

Gemäß Fig. 4 kann der Gießbehälter 2 an einem in der Ausgangsposition der Gießform 3 abgewandten Bereich eine schlitzförmige Öffnung 9 aufweisen. Zum Schöpfen der Metallschmelze 6 aus dem Schöpfofen 5 wird der Gießbehälter 2 mit der Öffnung 9 voraus in die in dem Schöpfofen 5 befindliche Metallschmelze 6 getaucht. Durch die schlitzförmige, während des Schöpfvorganges senkrecht in der Metallschmelze 1 des Schöpfofens 5 stehende Öffnung 9 wird sichergestellt, dass während des Schöpfvorganges nur sauberes oxidfreies Metall in den Gießbehälter 2 fließt. Das Befüllen des der Gießbehälters 2 in dem Schöpfofen 5 mit der Metallschmelze 6 erfolgt innerhalb einer Zeitraumes, dessen maximale Dauer 3,5 Sekunden beträgt.According to Fig. 4 For example, the casting container 2 may have a slot-shaped opening 9 at a region facing away from the starting position of the casting mold 3. To scoop the molten metal 6 from the scoop 5, the casting container 2 with the opening 9 is immersed in advance in the molten metal 6 located in the scooping furnace 5. Through the slot-shaped, during the scooping vertically in the molten metal 1 of the scoop 5 standing opening 9 ensures that only clean oxide-free metal flows into the casting container 2 during the scooping process. The filling of the casting container 2 in the scooping furnace 5 with the molten metal 6 takes place within a period of time whose maximum duration is 3.5 seconds.

Unmittelbar nach Abschluss des Befüllens mit der Metallschmelze 6 wird der Gießbehälter 2 innerhalb eines Zeitraumes von maximal 5 Sekunden, insbesondere innerhalb eines Zeitraumes von maximal 3,5 Sekunden, mit der Gießform 3 verbunden und in die Ausgangsposition gebracht.Immediately after completion of the filling with the molten metal 6, the casting container 2 is connected to the casting mold 3 within a maximum period of 5 seconds, in particular within a maximum period of 3.5 seconds, and brought into the starting position.

Wie aus Figur 5 ersichtlich ist, befinden sich in der Ausgangsposition die Kontur des Speisers 7 und die Kontur des Ausgießbereiches 8 in einer horizontalen Lage. An dieser Stelle sei darauf hingewiesen, dass die Konturen des Speisers 7 und des Ausgießbereiches in der Ausgangsposition aber auch bis zu einen Winkel von maximal 30° aus der horizontalen Lage um eine Drehachse a geschwenkt sein können. In der Endposition sind die Kontur des Speisers 7 und die Kontur des Ausgießbereiches 8 um einen Winkel von maximal 120° und mindestens 60° gegenüber der Ausgangsposition verdreht. Der Gießbehälter 2 und die Gießform 3 werden innerhalb eines Zeitraumes von maximal 8 Sekunden, insbesondere innerhalb eines Zeitraumes von maximal 6,5 Sekunden, von der Ausgangsposition in die Endposition bewegt.How out FIG. 5 it can be seen, are in the initial position, the contour of the feeder 7 and the contour of the pouring 8 in a horizontal position. It should be noted at this point that the contours of the feeder 7 and of the pouring region in the starting position can also be pivoted about an axis of rotation a up to an angle of at most 30 ° from the horizontal position. In the end position, the contour of the feeder 7 and the contour of the pouring region 8 are rotated by an angle of at most 120 ° and at least 60 ° relative to the starting position. The casting container 2 and the casting mold 3 are moved from the starting position to the end position within a maximum period of 8 seconds, in particular within a maximum period of 6.5 seconds.

An dieser Stelle sei auch noch darauf hingewiesen, dass das gesamte erfindungsgemäße Verfahren oder auch nur der Schritt des Umgießens der Metallschmelze 1 aus dem Gießbehälter 2 in die Gießform 3 in einer Überdruckatmosphäre durchgeführt werden kann. Zur Erzeugung des Überdruckes können der Gießbehälter 2 und die Gießform 3 in einem geschlossenen Raum angeordnet werden, der mit einem Gas oder Gasgemisch, beispielsweise einem inerten Schutzgas, gefüllt werden kann, sodass ein Überdruck gegenüber der Umgebungsatmosphäre außerhalb des Raumes entsteht. Grundsätzlich könnte auch der Schöpfofen 5 in dem Raum angeordnet sein.At this point it should also be pointed out that the entire process according to the invention or even only the step of pouring the molten metal 1 out of the casting container 2 into the casting mold 3 can be carried out in an overpressure atmosphere. To generate the overpressure, the casting container 2 and the casting mold 3 can be arranged in a closed space which can be filled with a gas or gas mixture, for example an inert protective gas, so that an overpressure relative to the ambient atmosphere arises outside the space. In principle, the scoop oven 5 could also be arranged in the room.

Die in Fig. 6 dargestellte Ausführungsform weist mindestens drei Gießformen 10,11, 12 auf, die auf einem Karussell angeordnet sind. Diese Ausführungsform stellt für sich eine eigenständige Ausführungsform dar, die auch mit anderen Gießverfahren als dem oben beschriebenen zum Einsatz kommen kann. Das Karussell dreht die drei Gießformen 10, 11, 12 reihum von einer Gießposition I, in welcher ein Umgießen der Metallschmelze 6 von dem Gießbehälter 2 in die Gießform 10, 11, 12 erfolgt, in eine Erstarrungsposition II, in welcher die Metallschmelze 1 in der Gießform 10, 11, 12 erstarrt, und hierauf in eine Bedienposition III, in welcher die Gießform 10, 11, 12 geöffnet und ein Gussteil aus der Gießform 10, 11, 12 entnommen und die Gießform 10, 11, 12 gereinigt wird. Das Karussell wird in einem konstanten Takt weitergedreht, der einen Wert aufweist, der aus einem Wertebereich stammt dessen untere Grenze 70 Sekunden und dessen obere Grenze 80 Sekunden beträgt. In einer bevorzugten Ausführungsform beträgt dieser Takt 75 Sekunden und ergibt sich wie folgt: In der Gießposition I dauert das Andocken des Gießbehälters 2 an die Gießform 11 3,5 Sekunden, während das Kippen des Gießbehälters 2 und der Gießform 11 von der Ausgangsposition in die Endposition 6,5 Sekunden in Anspruch nimmt. Nach Erreichen der Endposition wird der Gießbehälter von der Gießform abgedockt und steht für einen erneuten Schöpfvorgang wieder zur Verfügung. Weitere 56 Sekunden erstarrt die Metallschmelze in der Gießposition I. Für das Weiterdrehen der Gießform 11 in die Position II werden 9 Sekunden benötigt.In the Fig. 6 illustrated embodiment has at least three molds 10,11, 12, which are arranged on a carousel. This embodiment constitutes an independent embodiment in its own right, which can also be used with other casting methods than those described above. The carousel rotates the three casting molds 10, 11, 12 in turn from a casting position I, in which the molten metal 6 is poured from the casting container 2 into the casting mold 10, 11, 12, into a solidification position II, in which the molten metal 1 in the casting Mold 10, 11, 12 solidifies, and then in an operating position III, in which the mold 10, 11, 12 is opened and removed a casting from the mold 10, 11, 12 and the mold 10, 11, 12 is cleaned. The carousel is further rotated at a constant rate having a value coming from a range of values whose lower limit is 70 seconds and whose upper limit is 80 seconds. In a preferred embodiment, this cycle is 75 seconds and is as follows: In the pouring position I, the docking of the pouring vessel 2 to the casting mold 11 takes 3.5 seconds, while the tilting of the pouring vessel 2 and the casting mold 11 from the starting position to the end position Takes 6.5 seconds. After reaching the end position of the casting is undocked from the mold and is available for a new scooping again. Another 56 seconds, the molten metal solidifies in the casting position I. For further rotation of the mold 11 in the position II 9 seconds are required.

In der Erstarrungsposition II erstarrt die Metallschmelze 1 bzw. der Gussteil in der Gießform 10 weitere 66 Sekunden, wobei für das Weiterdrehen in die Bedienposition III wiederum 9 Sekunden benötigt werden. In der Bedienposition erstarrt der Gussteil weitere 10 Sekunden, für das Öffnen der Gießform werden 9 Sekunden benötigt und für die Entnahme des Gussteils mittels eines Roboters 8 Sekunden. Die Reinigung der Gießform 3 dauert 20 Sekunden und das Einlegen neuer Sandkerne beansprucht 10 Sekunden. Für das Schließen der Gießform 3 und das Weiterdrehen in die Gießposition I werden jeweils 9 Sekunden benötigt. Somit ergibt sich eine Taktzeit von 75 Sekunden für das Weiterdrehen von einer der Positionen I, II, III in die nächste Position.In the solidification position II, the molten metal 1 or the casting in the casting mold 10 solidifies for a further 66 seconds, again requiring 9 seconds for further rotation into the operating position III. In the operating position the casting solidifies for another 10 seconds, for the opening of the casting mold it takes 9 seconds and for the removal of the casting by means of a robot 8 seconds are needed. The cleaning of the mold 3 takes 20 seconds and the insertion of new sand cores takes 10 seconds. For the closing of the mold 3 and the further rotation in the casting position I 9 seconds are required in each case. This results in a cycle time of 75 seconds for the further rotation of one of the positions I, II, III in the next position.

BezugszeichenaufstellungREFERENCE NUMBERS

11
Metallschmelzemolten metal
22
Gießbehältergooseneck
33
Gießformmold
44
Formhohlraummold cavity
55
Schöpfofenladle furnace
66
MetalloxidhautMetalloxidhaut
77
SpeiserSpeiser
88th
Ausgießbereichpouring zone
99
Öffnungopening
1010
Gießformmold
1111
Gießformmold
1212
Gießformmold
AA
Drehachseaxis of rotation
II
Gießpositioncasting position
IIII
Erstarrungspositionsolidification position
IIIIII
Bedienpositionoperating position

Claims (20)

  1. A method for casting a cast part according to the tilt casting principle, wherein a metal melt (1) is cast out of at least one tiltable pouring flask (2) into a mold (3) with a mold cavity (4) that replicates the cast part, wherein the metal melt (1) is scooped directly out of a bale-out furnace (5) with the pouring flask (2), a metal oxide skin (6) forms in the pouring flask (2) on the surface of the metal melt (1), and the pouring flask (2) containing the metal melt (1) and metal oxide skin (6) floating thereon is moved toward the mold (3), and the metal melt (1) is poured from the pouring flask (2) into the mold (3) by jointly rotating the pouring flask (2) and mold (3) from an initial position into an end position around a rotational axis (a), characterized in that the pouring flask (2) has a slotted opening (9) at an area facing away from the mold (3) in the initial position, wherein the pouring flask is dipped into the metal melt (6) located in the bale-out furnace (5) with the opening in front (9) to scoop the metal melt (6) out of the bale-out furnace (5).
  2. The method according to claim 1, characterized in that, during recasting, at least 80% of the metal oxide skin (6) floats on the surface of the metal melt (1), and remains on the surface of the metal melt (1).
  3. The method according to claim 1 or 2, characterized in that the metal oxide skin (6) remains in the pouring flask (2) until the end position has been reached.
  4. The method according to one of claims 1 to 3, characterized in that an area of the metal skin (6) facing away from the mold (3) exits the pouring flask (2) last once the end position has been reached, and comes to lie on the surface of the metal melt (1) in the mold (3).
  5. The method according to one of claims 1 to 4, characterized in that more than 80% of the metal oxide skin (6) comes to lie in the area of a feeder (7) of the mold (3) in a solidification position that chronologically follows the end position.
  6. The method according to one of claims 1 to 5, characterized in that the metal oxide skin (6) remains elastic and undamaged until the end position has been reached.
  7. The method according to claims 1 to 6, characterized in that the surface of the metal oxide skin (6) located in the pouring flask (2) enlarges while pouring the metal melt (1) from the pouring flask (2) into the mold (3).
  8. The method according to one of claims 1 to 7, characterized in that the pouring flask (2) is connected with the mold (3) before recasting, and a relative position of the pouring flask (2) is retained in relation to the mold (3) while recasting between the initial position and end position.
  9. The method according to one of claims 1 to 8, characterized in that the rotational axis (a) runs through the mold (3) in the initial position, and either lies under the mold cavity (4) or runs behind the mold cavity (4) or through the mold cavity (4) or over the mold cavity as viewed from the pouring flask (2).
  10. The method according to one of claims 1 to 9, characterized in that, once the end position has been reached, the metal oxide skin (6) falls onto a feeder (7) of the mold (3) or slides into the latter over the entire width of the feeder (7).
  11. The method according to claim 10, characterized in that, once the metal melt (1) has been scooped out of the bale-out furnace (5), the pouring flask (2) is moved toward the feeder (7) of the mold (3), wherein the pouring flask has a pouring zone (8) via which the metal melt is poured by way of the feeder (7) into the mold (3), wherein the contour of the pouring zone (8) corresponds to the contour of a section of the feeder (7) that in the initial position lies at the bottom as viewed in the vertical direction, wherein the pouring zone (8) is directly and congruently connected with the feeder (7).
  12. The method according to claim 11, characterized in that, in the initial position, the contour of the feeder (7) and contour of the pouring zone (8) lie in a horizontal position, or are pivoted out of the horizontal position by an angle of at most 30°.
  13. The method according to claim 12, characterized in that, in the end position, the contour of the feeder (7) and contour of the pouring zone (8) are twisted by an angle of at most 120° and at least 60° relative to the initial position.
  14. The method according to one of claims 1 to 13, characterized in that, immediately after filled with the metal melt (6) within a period of at most 5 seconds, the pouring flask (2) is connected with the mold (3) and brought into the initial position.
  15. The method according to one of claims 1 to 14, characterized in that the pouring flask (2) in the bale-out furnace (5) is filled with the metal melt (6) within a period lasting at most 3.5 seconds.
  16. The method according to one of claims 1 to 15, characterized in that the pouring flask (2) and mold (3) are moved from the initial position into the end position within a period lasting at most 8 seconds.
  17. The method according to one of claims 1 to 16, characterized in that an average temperature of the metal melt (6) in the bale-out furnace (5) has a value originating from a range of values with a lower limit of 680 °C and upper limit of 780 °C.
  18. The method according to one of claims 1 to 17, characterized in that the pouring flask (2) and mold (3) are brought from the initial position into the end position in an overpressure atmosphere.
  19. The method according to one of claims 1 to 18, characterized in that use is made of at least three molds (10, 11, 12) arranged on a carousel, wherein the carousel turns the three molds (10, 11, 12) uniformly from a pouring position (I) in which the metal melt (6) is recast from the pouring flask (2) into the mold (10, 11, 12) into a solidification position (II) in which the metal melt (1) in the mold (10, 11, 12) solidifies, and then into an operating position (III) in which the mold (10, 11, 12) is opened, and a cast part is removed from the mold (10, 11, 12), and the mold (10, 11, 12) is cleaned.
  20. The method according to claim 19, characterized in that the carousel continues to be turned at a constant rate having a value originating from a range of values with a lower limit of 70 seconds and an upper limit of 80 seconds.
EP15705479.2A 2014-01-03 2015-01-02 Method for casting a cast part Active EP3089841B1 (en)

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KR20160106106A (en) 2016-09-09
WO2015100465A1 (en) 2015-07-09
RU2016131456A3 (en) 2018-10-02
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US9925586B2 (en) 2018-03-27
MX2016007706A (en) 2016-09-09

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