EP3119545B1 - Procédé servant à couler des pièces en fonte - Google Patents

Procédé servant à couler des pièces en fonte Download PDF

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Publication number
EP3119545B1
EP3119545B1 EP15738697.0A EP15738697A EP3119545B1 EP 3119545 B1 EP3119545 B1 EP 3119545B1 EP 15738697 A EP15738697 A EP 15738697A EP 3119545 B1 EP3119545 B1 EP 3119545B1
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EP
European Patent Office
Prior art keywords
filling
casting
mold
binder
casting mould
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP15738697.0A
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German (de)
English (en)
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EP3119545A1 (fr
Inventor
Klaus Arnold
Dirk Rogowski
Jürgen Schmidt
Rolf SÜSSMANN
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.)
Fritz Winter Eisengiesserei GmbH and Co KG
Original Assignee
Fritz Winter Eisengiesserei GmbH and Co KG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Fritz Winter Eisengiesserei GmbH and Co KG filed Critical Fritz Winter Eisengiesserei GmbH and Co KG
Priority to PL15738697T priority Critical patent/PL3119545T3/pl
Priority to EP19193631.9A priority patent/EP3597329B1/fr
Priority to SI201531007T priority patent/SI3119545T1/sl
Priority to RS20191524A priority patent/RS59702B1/sr
Publication of EP3119545A1 publication Critical patent/EP3119545A1/fr
Application granted granted Critical
Publication of EP3119545B1 publication Critical patent/EP3119545B1/fr
Priority to HRP20192115TT priority patent/HRP20192115T1/hr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
    • B22C5/06—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by sieving or magnetic separating
    • 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
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • 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
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—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
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/003—Removing cores using heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D45/00—Equipment for casting, not otherwise provided for
    • B22D45/005—Evacuation of fumes, dust or waste gases during manipulations in the foundry
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
    • B22C5/08—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose by sprinkling, cooling, or drying
    • B22C5/085—Cooling or drying the sand together with the castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots

Definitions

  • the invention relates to a method for casting cast parts, in which a molten metal is poured into a casting mold, which surrounds a cavity forming the casting to be produced, wherein the casting mold consists of one or more mold parts or cores as a lost mold.
  • the mold parts or casting cores are formed from a molding material which consists of a core sand, a binder and optionally one or more additives for adjusting certain properties of the molding material.
  • the casting mold is usually first provided, the casting cores and moldings have been prefabricated in separate operations.
  • the casting mold can be composed as a so-called "core package" of a plurality of casting cores.
  • core package of a plurality of casting cores.
  • Typical examples of castings produced by a method according to the invention are cylinder crankcases and cylinder heads. For larger and highly stressed engines, they are made of cast iron by sand casting.
  • quartz sands mixed with bentonites, lustrous carbon formers and water are usually used in the region of iron casting.
  • the casting cores reproducing the internal cavities and channels of the casting are usually formed from commercially available core sands, which are filled with an organic or inorganic binder, eg. B. with a synthetic resin or water glass, are mixed.
  • the basic principle in the production of molds formed from molding materials of the above-mentioned type is that after the molding of the binder is cured by a suitable thermal or chemical treatment, so that the grains of the core sand stick together and over a sufficient period the dimensional stability of the respective molded part or core is ensured.
  • the pressure on the mold after pouring the molten metal internal pressure can be very high.
  • either thick-walled, large-volume molds or support structures are used, which support the mold on its outside.
  • a support structure which is slipped over the mold.
  • the housing is usually formed in the manner of a jacket which surrounds the mold on its peripheral sides, but on its upper side has a sufficiently large opening to allow the pouring of the melt into the mold.
  • the enclosure is dimensioned so that after filling at least in the decisive for the support of the mold sections between the inner surfaces of the housing and the outer surfaces of the mold remains a filling space.
  • This filling space is filled with a free-flowing filling material, so that a large-area support of the respective surface portion is ensured at the housing.
  • the molten metal is poured into the mold at high temperature, so that the mold parts and cores from which the mold is composed, are heated strongly. As a result, the mold begins to radiate heat. If the temperature of the mold exceeds a certain minimum temperature, the binder of the molding material begins to evaporate and burn with the release of further heat. The binder loses its effect. As a result of this decomposition of the binder, the bonding of the grains of the molding material from which the mold parts and cores of the mold are made is lost, and the mold or its parts made of molding material and cores disintegrate into individual fragments.
  • the then automatically falling from the casting, consisting of molding fragments of the mold are still in the heat treatment furnace in a Sandbed caught. There they linger over a certain period of time in order to continue the disintegration of the fragments of the mold parts and cores.
  • the crushing of the falling off of the mold molding material fragments can be supported by the fact that the sand bed is fluidized by blowing a hot gas stream.
  • the sufficiently shredded shaped material fragments are finally fed to a treatment, in which the core sand is recovered so that it can be used for the production of new mold parts and cores.
  • the object of the invention was to provide a method which enables the casting production of castings with optimized Energyeffiziens and in a particularly economical manner.
  • the invention has achieved this object by the method specified in claim 1.
  • the invention thus provides a method for casting castings, wherein a molten metal is poured into a mold enclosing a cavity forming the casting to be formed.
  • the mold is formed as a lost mold composed of one or more mold parts or cores. These mold parts are each formed from a molding material consisting of a core sand, a binder and optionally one or more additives for adjusting certain properties of the molding material.
  • the filling material filled in the filling space now has such a low bulk density that a gas flow can flow through the filling product pack formed there from the filling material after filling the filling space.
  • the filling material in the inventive method when filling the filling chamber to a minimum temperature of at least 500 ° C, starting from the temperature of the filling by process heat, which is formed by the radiated heat from the mold and by the heat released during the combustion of the binder will rise above a limit temperature of 700 ° C.
  • the method according to the invention is therefore based on the idea to use the filling material in the sense of a heat storage and to temper and form this heat storage so that the decomposition of the binder of the molding material from which the mold parts and cores of the mold are made, already during the Dwell time in the enclosure is largely decomposed by the effect of temperature.
  • the cores that break channels or cavities in the interior of the casting are also disintegrated at this time, so that the core sand and the shaped material fragments of these cores automatically trickle out of the casting already in the enclosure or in a manner known per se, for example by mechanical methods such as shaking, or by flushing with a suitable fluid, can be removed from the casting.
  • the present invention filled in the formed between the casting and housing filling space filling material is free-flowing, so that it also completely fills the filling space when in the area of the outer surfaces of the mold undercuts, cavities and the like are present.
  • the filling material has a bulk density which is so low that it is still permeable by a gas flow after filling the filling space and an optionally carried out compression of the filled into the filling space filling material.
  • expressly no highly compressed packing is produced in the filling space, which indeed ensures optimum support of the casting mold, but is largely gas-impermeable.
  • the filling material used according to the invention is to be selected such that it is suitable for a Gas flow is permeable, which sets, for example, as a result of thermal convection. This occurs when the mold is heated by the molten metal poured into it and the vaporizing binder components of the molding material of the mold parts and cores begin to evaporate and begin to burn with the release of heat.
  • the inventively provided flowability of the filled into the filling space filling with a gas stream not only creates the possibility that the evaporating from the mold binder in the region of the medium itself burns and thereby further heats the contents, but additionally allows the supply of oxygen, the Combustor combustion supported.
  • the contents are heated by the supplied via the molten metal and released by the combustion of the binder process heat to a temperature which is so high that the coming into contact with the filling material, emerging from the mold binder components of the moldings and cores burn or thermally decomposed at least so that they no longer have the effect of damaging the environment more or can be deducted as exhaust from the enclosure and fed to an exhaust gas purification.
  • the pre-tempered product according to the invention is preferably introduced into the filling space at a short time interval before the casting of the molten metal in order to minimize temperature losses.
  • the combustion begins by the contact with the heated product.
  • the combustion of the binder emerging from the casting mold proceeds and the contents are kept at a temperature as long as possible. This process continues until only such small amounts of binder escape from the casting mold that no combustible atmosphere forms in the enclosure.
  • the hot medium now holds in the manner of a heat storage a temperature above the limit temperature at which it comes to the combustion of the binder. Accordingly, the casting mold remains at least likewise at this temperature, so that binder residues remaining in the casting mold are thermally decomposed.
  • Casting molds whose shaped parts and cores are made of molding material which is bound by an organic binder are particularly suitable for the process according to the invention.
  • Commercially available solvent-borne binders or binders are suitable for this purpose, the effect of which is triggered by a chemical reaction.
  • Corresponding binder systems are used today in the so-called "cold-box process”.
  • the limit temperature is 700 ° C., especially when processing cast iron melt. At above 700 ° C burn in particular safe organic binders. At the same time, other pollutants emanating from the mold are oxidized or otherwise rendered harmless at these temperatures. The same applies to the cracking products which form in the casting mold as a consequence of the temperature-induced decomposition of the binder and which also decompose safely at such high temperatures.
  • the contents are pre-heated to a certain temperature in the filling space is filled, it is ensured that the filling material heats up as a result of the supplied process heat to a temperature above the limit temperature. Practical experiments have shown here that a minimum temperature of 500 ° C is sufficient when filling into the filling space.
  • the mold-molded parts and cores of the mold disintegrate into loose fragments, which may either be disposed of after removal of the casing and sent for treatment or, advantageously, during the interval between them Discharge of the molten metal and the removal of the housing can be deducted from the housing.
  • the mold can be placed on a sieve and collected by the sieve bottom trickling fragments of the mold.
  • the openings of the sieve tray are designed so that the fragments of the mold and the contents trickle together through the sieve tray, collected, processed and separated from each other after the preparation. This has the Advantage that no loose filling material is more in the housing is available when the housing is removed.
  • the enclosure of the mold can accordingly by a mold surrounding the mold with a sufficient for the formation of the filling space, consisting of a thermally insulating and sufficiently dimensionally stable material jacket, acting as a sieve plate perforated support plate on which the mold is placed, and also thermally be formed insulating cover, which is placed after filling the mold.
  • a mold surrounding the mold with a sufficient for the formation of the filling space, consisting of a thermally insulating and sufficiently dimensionally stable material jacket, acting as a sieve plate perforated support plate on which the mold is placed, and also thermally be formed insulating cover, which is placed after filling the mold.
  • an exhaust gas opening may additionally be provided.
  • the filling material filled in the filling space can be compressed to produce a bias between the mold and the enclosure, through which a secure, positionally accurate cohesion of the mold is also guaranteed if the mold as from a variety of moldings and Nuclear composite core package is formed.
  • the flowability is secured with a gas stream.
  • the effectiveness of the present invention achieved destruction of the moldings and cores of the mold can be further increased by not only the contents, but also the mold itself is designed to flow through gas.
  • channels can be deliberately introduced into the casting mold, through which the hot exhaust gas forming in the filling space or correspondingly preheated oxygen-containing gas flows. In this way, a rapid evaporation, burning and other thermal decomposition of the molding material binder is also within the mold. The disintegration of the mold is thus additionally accelerated.
  • Targeted channels introduced into the casting mold can also be used to accelerate cooling of certain zones on or in the casting or to avoid such accelerated cooling in order to achieve certain properties of the casting in the respective zone.
  • the bias is transmitted by the contacting grains of the medium after the compression.
  • the housing can be equipped on its inner surface associated with the mold with a textured surface on which the abutting against this surface grains are at least partially positively supported ,
  • the contents should at the same time have a low suitability for storing heat, so that the product heats up quickly and can be kept at a temperature above the limit temperature for as long as possible.
  • suitable filling thus combines a low bulk density with a low specific heat capacity of the material from which the items that make up the contents are made.
  • granules or other granular bulk material have proven to be good as filling material.
  • Such bulk materials with bulk densities of max. 4 kg / dm 3 in particular less than 1 kg / dm 3 or even less than 0.5 kg / dm 3 , particularly suitable for the purposes of the invention.
  • the mean diameter of the grains is 1.5-100 mm, with optimum use of filling material whose grain sizes are in the range of 1.5 - 40 mm.
  • non-metallic bulk materials such as granules of ceramic materials are suitable.
  • these can be irregularly shaped, spherical or with cavities be provided in order to achieve a good gasification of the filling material filled in the filling space at the same time low heat storage property.
  • the contents may consist of annular or polygonal elements that touch each other only in point contact upon contact, so that between them enough space remains to ensure a good flow.
  • the gas stream can be heated to a temperature above room temperature before it enters the filling space.
  • the temperature of the gas stream is at least at the level of the minimum temperature of the medium.
  • the hot exhaust gas can be used, which is deducted from the enclosure.
  • a known heat exchanger can be used. If a sieve bottom is provided, over which the fragments of the casting mold can optionally pass out of the housing together with the contents, the oxygen-containing gas stream can also be passed through this sieve bottom. This not only has the advantage of a large-scale introduction, but also causes the supplied gas stream is heated by contact with the hot, trickling out of the housing molding material fragments and the equally hot contents.
  • the oxygen-containing gas stream fed into the filling space consists of 10 to 90% by volume of waste gas.
  • the oxygen-containing gas stream supplied to the filling space may be, for example, ambient air.
  • the oxygen-containing gas stream supplied to the filling space can be sucked into the filling space via a suitably formed inlet as a result of the flow triggered by heat convection within the filling space.
  • a suitably formed inlet as a result of the flow triggered by heat convection within the filling space.
  • An optional regulation of the gas flow introduced into the filling space can take place as a function of the exhaust gas volume flow exiting the housing in order to prevent the formation of overpressure in the atmosphere prevailing in the filling space.
  • the respective gas inlet can be equipped with a mechanism which regulates the supply air as a function of the flow velocity. Suitable for this purpose is, for example, a per se known pendulum flap, which is suspended and loaded so that the flow pressure of the gas flow passing it regulates the flow rate and thus the combustion air supply automatically depending on counterweights.
  • a minimization of pollutant emissions can also be achieved in the method according to the invention in that the housing is equipped with a catalyst device for the decomposition of pollutants contained in the combustion products of the binder.
  • the cast part exposed after demoulding according to the invention can be subjected to a heat treatment after the decay of the casting mold, in which it is cooled in a controlled manner according to a specific cooling curve in order to produce a specific state of the casting.
  • a plurality of casting molds can be accommodated simultaneously in an enclosure and these casting molds can be filled with molten metal in parallel or in a chronologically closely successive sequence.
  • the method according to the invention is suitable for any type of metallic cast materials, the processing of which produces a sufficiently high process heat.
  • the method according to the invention is particularly suitable for the production of castings from cast iron, because due to the high temperature of the cast iron melt, the temperatures provided for the combustion of the binder according to the invention are achieved particularly reliably.
  • the mold used in the invention consists of molded parts or cores, which are molded from molding material, so of course includes the possibility to produce within such a mold items, such as chills, supports and the like, from other materials . It is only important that the mold contains so much molding material volume that it comes in the course of pouring the respective molten metal for evaporation of binder, which then burns in the filling and heats up the contents to the extent that it has a for a complete complete decomposition of the binder of the Formstoffs sufficient duration maintains a temperature above the limit temperature.
  • the cleaning of the effluent gas stream exiting from the housing provided according to the invention can be carried out by combusting the flammable substances still present in the exhaust gas in an exhaust air combustion system.
  • the heat released in turn can be used to preheat the oxygen-containing gas stream fed into the enclosure.
  • castings are produced in accordance with the invention with several casting molds according to the invention in parallel, it may be expedient if the casting molds together with the housings assigned to them are in a tunnel or the like and the forming exhaust gases are removed via a common exhaust pipe.
  • the inventive method is particularly suitable for the casting production of cylinder crankcases and cylinder heads for internal combustion engines.
  • the components in question are intended for commercial vehicles, they and the respective mold required for their production have a comparably large volume, in which the advantages of the procedure according to the invention have a particularly pronounced effect.
  • the core sand fragments obtained according to the invention when they emerge from the enclosure, are usually still so hot that they can be comminuted in a conventional grinder without additional heat input. If the core sand fragments are present as a mixture with the contents, the separation takes place after the grinding. This is very simple, because the grain size of the core sand obtained after milling is much smaller than the grain size of the medium.
  • the grinder can be designed so that it causes a mechanical preconditioning of the core sand.
  • Such a preconditioning can consist, for example, in the fact that the surface roughness of the sand grains is increased by the contact of the core sand with the product granulate and thus the adhesion of the binder to the core sand is improved in the subsequent processing into a molded part or core.
  • the regenerated sand obtained after the preparation can be mixed in a conventional manner with new sand.
  • Fig. 1 is shown as a diagram of the cycle that results in the execution of the method according to the invention. It is started with mold parts and cores made of molding material, the new, previously unused core sand, z.
  • quartz sand, and a conventional binder for example, a commercial cold box binder is mixed.
  • new filler material for example, ceramic granules with a mean particle size of 1.5 - 25 mm, used, which for the first use to the required minimum temperature, eg. B. 500 ° C, must be heated before it can be used.
  • these starting materials can be reused in the circulation, as explained below.
  • Thermoreactor T shown in different phases of the process according to the invention has a screen plate 1, on which a casting mold 2 prepared for pouring an iron casting melt is placed.
  • the casting mold 2 is intended for the casting production of a casting G, which in the present example is a cylinder crankcase for a commercial vehicle engine.
  • the mold 2 is conventionally assembled as a core package from a plurality of outer cores or moldings arranged externally and internally arranged casting cores.
  • the casting mold 2 may comprise components made of steel or other indestructible materials. These include, for example, chill molds and the like, which are arranged in the mold 2, to achieve a directional solidification of the casting G by accelerated solidification of each coming in contact with the chill melt.
  • the casting mold 2 delimits a mold cavity 3 from the environment U into which the iron casting melt is poured off to form the casting G.
  • the molten iron flows through a gate system in the mold cavity 3, which is not shown here for clarity.
  • the cores and moldings of the mold 2 are made in a conventional manner in a cold box process from a conventional molding material, which is a mixture of a commercially available core sand, an equally commercial organic binder and optionally added additives, for example, the better Wetting of the grains of the core sand by the binder serve. From the molding material, the cores and moldings of the mold 2 are formed. Subsequently, the obtained cores and moldings are gassed with a reaction gas to cure the binder by a chemical reaction and thereby giving the cores and moldings the necessary stiffness.
  • a conventional molding material which is a mixture of a commercially available core sand, an equally commercial organic binder and optionally added additives, for example, the better Wetting of the grains of the core sand by the binder serve.
  • the cores and moldings of the mold 2 are formed. Subsequently, the obtained cores and moldings are gassed with a reaction gas to cure the binder by a chemical reaction and thereby giving the
  • the screen plate 1 is supported with its edge on a peripheral edge shoulder 4 of a collecting container 5.
  • a sealing element 6 is incorporated.
  • the housing 7 is formed in the manner of a hood and encases the mold 2 at its outer peripheral surfaces 8.
  • the circumference of the space enclosed by the housing 7 an excess of the circumference of the mold 2, so that after placing the housing 7 on the sieve bottom 1 between the outer peripheral surface of the mold 2 and the inner surface 9 of the housing 7, a filling space 10 is formed.
  • their collection container 5 associated edge of the enclosure sits on the sealing element 6, so that here a tight closure of the filling space 10 is ensured with respect to the environment U.
  • the enclosure consists of a thermally insulating material, which may consist of several layers, of which one layer ensures the necessary dimensional stability of the enclosure 7 and another layer thermal insulation.
  • the housing 7 delimits a large opening 11, via which the casting mold 2 can be filled with iron casting melt and the filling space 10 with filling material F ( Fig. 3 ).
  • a reservoir V is positioned over the opening 11, from which then the hot medium F via a distribution system 12 into the filling space 10th trickle down ( Fig. 4 ).
  • the filled in the filling space 10 filling package can be compacted if necessary.
  • a lid 13 is placed on the opening 11, which also has an opening 14 through which the molten cast iron can be filled into the mold 2 ( Fig. 5 ).
  • the cast iron melt is then poured into the casting mold 2 (FIG. Fig. 6 ).
  • oxygen-containing ambient air may enter the filling space 10 via a gas inlet 15 formed in the lower edge region of the housing 7.
  • ambient air which passes through an access 16 in the collecting container 5, sucked through the sieve bottom 1 in the filling space 10 ( Fig. 7 ).
  • solvent contained in the binder evaporates.
  • the emerging from the mold 2 vaporous solvent reaches in the filling chamber 10, a concentration at which it ignites and burns off automatically.
  • the granular product F which has been brought to a temperature Tmin of about 500 ° C., is heated above the limit temperature TGrenz of 700 ° C. until its temperature reaches the maximum temperature Tmax of approximately 900 ° C.
  • the product heated in this way assumes the function of a heat accumulator, through which the temperature of the casting mold 2 and in the filling chamber 10 are at a temperature above 700 ° C. Level is maintained. In this way, the combustion of leaving the mold 2 Binder components and other potential pollutants stops until no more binder from the mold 2 evaporates. The then possibly still emerging from the mold 2 vaporous substances are oxidized by the prevailing in the filling chamber 10 high temperature or rendered harmless in any other way.
  • filling material package Since the bulk density of the product F is so low that even after compression a good gas permeability ensured in the filling chamber 10 filling material package is a good mixing of the emerging from the mold 2 gases with the oxygen for its combustion-providing gas streams S1, S2 guaranteed. At the same time, the filling material pack in the filling space 10 supports the casting mold 2 at its peripheral surfaces and thus prevents the iron casting melt from breaking through.
  • the flow through the gases emerging from the casting mold 2 through the filling material F causes a good mixing with the supplied gas flow S1, S2, a longer residence time and a good reactivity.
  • the casting mold 2 is thus heated both by the combustion of the binder system and the heat introduced by the metal poured into the casting mold 2, as well as by the preheated filling F.
  • the binding parts and cores of the mold 2 cohesive binder system is almost completely destroyed.
  • the moldings and cores then break up into fragments B or individual grains of sand.
  • the fragments B and the loose sand fall through the sieve tray 1 in the sump 5 and is collected there.
  • the sieve bottom 1 can be opened in such a way that also contents F reach the collecting container 5 ( Fig. 8 ).
  • thermoreactor T For optimal combustion of outgassing from the mold 2 gases and for the regeneration of the core sand already in the enclosure are the Temperatures of product F and the gases flowing in the filling chamber 10 optimally each well above 700 ° C.
  • the conditions in the thermoreactor T are designed in such a way that the regeneration process and the exhaust gas treatment are independent of system availability. Determining and set sizes are the starting temperature of the filler F, the oxygen-containing gas streams S1, S2 flowing in via the gas inlet 15 and the inlet 16 and the casting mold 2 itself.
  • the progress of the destruction of the casting mold 2 and the solidification course of the cast iron melt poured into the casting mold 2 are adapted to each other so that the casting G is sufficiently solidified when the disintegration of the casting mold 2 begins.
  • the collecting container 5 with the molding material / product mixture contained in it is separated from the sieve bottom 1 and the housing 7 likewise removed from the sieve bottom 1.
  • the largely sanded casting G is now freely accessible and can be cooled in a controlled tunnel-like space 17 controlled ( Fig. 10 ). Due to the process, the casting G has a high picking temperature at which the austenite transformation is not yet completed and rapid cooling would lead to residual stresses and thus to cracks. For this reason, the casting G is cooled in a cooling tunnel 17 slowly according to the glow curves during stress relief annealing. The supplied cooling air is measured so that the cooling profile is achieved product specific.
  • the still contained in the container 5, still hot mixture of filling F, core sand and fragments B is in a grinder 18, which may be, for example, a rotary tube, mixed intensively and mixed with sufficient oxidation air, so that possibly still existing binder residues afterburn.
  • a grinder 18 which may be, for example, a rotary tube, mixed intensively and mixed with sufficient oxidation air, so that possibly still existing binder residues afterburn.
  • the contents F of core sand can be separated and both fed to a separate cooling.
  • Such post-regeneration ensures the safe maintenance of complete combustion of the binder system and additionally prepares by mechanical friction, the core sand surface for a good adhesion of the binder for reuse as core sand.
  • the resulting core sand is cooled down to near room temperature and, after fractionation, recycled to casting moldings or casting cores for a new casting mold 2.
  • the amount of combustion gas conducted into the filling chamber 10 as gas streams S1, S2 is regulated by means of mechanically adjustable flaps or slides, with which the opening cross-sections of the gas inlet 15 and of the access 16 can be adjusted.
  • the respective setting can first be determined via the stoichiometrically required air quantity for combustion of the binder system and then finely adjusted via measurements of CO, NO x and O 2 at the exhaust outlet 19 formed here through the opening 14 of the cover 13, which is molded into the cover 13 and over the resulting in the filling chamber 10 exhaust gases are discharged from the enclosure 7.
  • Fig. 16 shows, in the filling chamber 10 immediately after the casting by the evaporation of the solvent from the binder system of the mold 2 and the other fumes of the mold 2 a high pollutant concentration represented by the curve KSchadstoff achieved, which would burn even at room temperatures independently.
  • phase 1 intensive combustion of the evaporating from the mold 2 binder continues until the concentration KSchadstoff of reaching into the filling chamber 10 from the mold 2, essentially formed by the vaporizing binder combustible gases decreases so much that at Room temperature no combustion would take place.
  • the temperature at which the filling material is filled in the filling chamber 10 is determined that this is reached before by low pollutant concentrations KSchadstoff the process of combustion in the filling space 10 is no longer reliably takes place with the necessary intensity.
  • the then highly heated filling material F then ensures that the decomposition and residual combustion of the gases still evaporating from the casting mold 2 takes place, even if the concentration of combustible gases present in the filling space would be too low at temperatures below the temperature limit.
  • the filling material F which is, for example, ceramic filling body
  • care is taken that the individual grains of the filling material F have a high compressive strength in order to absorb the pressure forces during casting and to keep the abrasion loss as low as possible in circulation.
  • Another selection criterion is a low heat capacity in Combination with the bulk density of the product F to get a temperature rise above the 700 ° C as quickly as possible from phase 1. Due to the oxidation in the bulk material, with adapted combustion air supply and relatively low temperature, a nitrogen oxide formation is largely avoided.
  • the gas streams are then rectified and can sufficiently afterburn in the hottest region of the exhaust system in the combustion chamber between the lid 13 and filling F before exiting the exhaust outlet 19 above the sprue.
  • the thermal energy Qa released by the cooling of the melt and the combustion of the binder as well as for the heating of the contents and the heating of the core sand of the mold required heat energy Qb has been determined.
  • the moldings and cores are made in the conventional cold box process of molding material, which consists of conventional core sand, d. H. made of quartz sand, and for this purpose just as common binder.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mold Materials And Core Materials (AREA)
  • Casting Devices For Molds (AREA)
  • Separation By Low-Temperature Treatments (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (14)

  1. Procédé pour couler des pièces moulées (G), dans lequel un métal en fusion est coulé dans un moule qui confine un espace creux (3) représentant la pièce moulée à produire, le moule (2) étant un moule perdu composé d'une ou plusieurs parties de moule ou d'un ou plusieurs noyaux de coulée, lesquel(le)s sont façonnés à partir d'un matériau de moulage qui se compose d'un sable à noyau, d'un liant et, optionnellement, d'un ou plusieurs additifs pour régler des propriétés spécifiques du matériau de moulage, le procédé comprenant les étapes suivantes :
    - Mise à disposition du moule (2) ;
    - logement du moule (2) dans un boîtier (7) en formant un espace de remplissage (10) entre au moins une portion de surface interne (9) du boîtier (7) et une portion de surface externe (8) associée du moule (2) ;
    - remplissage de l'espace de remplissage (10) avec un matériau de remplissage (F) apte à l'écoulement ;
    - versement du métal en fusion dans le moule (2),
    - la coulée du bain de fusion étant accompagnée par le fait que le moule (2) commençant à rayonner de la chaleur du fait du versement du métal en fusion, laquelle chaleur étant la conséquence de l'apport de chaleur suscité par le métal en fusion chaud, et
    - en conséquence de l'apport de chaleur produit par le métal en fusion, le liant du matériau de moulage commençant à s'évaporer et à se consumer, de sorte qu'il perde son effet et le moule (2) se désagrège en fragments (B)
    caractérisé en ce que
    la matière de remplissage (F) qui remplit l'espace de remplissage (10) possède une densité apparente tellement faible, que le bourrage de matière de remplissage qui est formé par la matière de remplissage (F) dans l'espace de remplissage (10) après le remplissage de celui-ci peut être traversé par un flux de gaz (S1, S2), et en ce que la matière de remplissage (F) présente une température minimale (Tmin) d'au moins 500 °C lors du remplissage de l'espace de remplissage (10), à partir de laquelle la température de la matière de remplissage (F), sous l'effet la chaleur du processus qui est formée par la chaleur rayonnée par le moule (2) et par la chaleur libérée lors de la combustion du liant, augmente jusqu'au-dessus d'une température limite (TGrenz), à laquelle température limite le liant s'évaporant hors du moule (2) et entrant en contact avec la matière de remplissage (F) s'allume et engage sa combustion.
  2. Procédé selon la revendication 1, caractérisé en ce que le produit P de la densité apparente Sd et de la capacité calorifique spécifique cp est égal au maximum à 1 kJ/dm3K.
  3. Procédé selon l'une des revendications précédentes, caractérisé en ce que la densité apparente Sd est égale au maximum à 4 kg/dm3.
  4. Procédé selon l'une des revendications précédentes, caractérisé en ce que la matière de remplissage (F) possède une capacité calorifique spécifique cp égale au maximum à 1 kJ/kgK.
  5. Procédé selon l'une des revendications précédentes, caractérisé en ce que la matière de remplissage (F) est formée de grains de granulat ayant un diamètre moyen de 1,5 à 100 mm.
  6. Procédé selon l'une des revendications précédentes, caractérisé en ce que la température limite (TGrenz) est de 700 °C.
  7. Procédé selon l'une des revendications précédentes, caractérisé en ce que le logement comporte une entrée de gaz (15) et une sortie de gaz d'échappement (19) et en ce que la matière de remplissage (F) contenue dans l'espace de remplissage (10) est traversée au moins temporairement et par portions par un flux de gaz (S1, S2) contenant de l'oxygène.
  8. Procédé selon la revendication 6, caractérisé en ce que le flux de gaz (S1, S2) est chauffé à une température supérieure à la température ambiante.
  9. Procédé selon l'une des revendications 6 à 8, caractérisé en ce que le flux de gaz (S1, S2) est régulé en fonction du débit volumique de gaz d'échappement qui émane de la sortie de gaz d'échappement (19).
  10. Procédé selon l'une des revendications 6 à 9, caractérisé en ce qu'une mesure de gaz d'échappement est effectuée au niveau de la sortie des de gaz d'échappement (19) et en ce que le flux de gaz (S1, S2) est régulé en fonction du résultat de cette mesure.
  11. Procédé selon l'une des revendications 6 à 10, caractérisé en ce qu'un flux partiel des gaz de combustion qui émane de la sortie de gaz d'échappement (19) est mélangé avec le flux de gaz (S1, S2) contenant de l'oxygène et le mélange obtenu est conduit dans le boîtier (7).
  12. Procédé selon l'une des revendications précédentes, caractérisé en ce que le boîtier (7) est équipé d'un dispositif catalyseur destiné à décomposer les substances nocives contenues dans les produits de combustion du liant.
  13. Procédé selon l'une des revendications précédentes, caractérisé en ce que le moule (2) est posé sur un fond à tamis (1) et en ce que les fragments (B) du moule (2) et la matière de remplissage (F) s'écoulent ensemble à travers le fond à tamis (1), sont collectés, sont préparés et sont séparés les uns des autres après la préparation.
  14. Procédé selon l'une des revendications précédentes, caractérisé en ce que la pièce moulée (G) est soumise à un traitement thermique après la désagrégation du moule (2), lors duquel traitement thermique elle est refroidie de manière contrôlée d'après l'indication d'une courbe de refroidissement définie.
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EP19193631.9A EP3597329B1 (fr) 2014-07-30 2015-07-20 Procédé de coulée de pièces coulées
SI201531007T SI3119545T1 (sl) 2014-07-30 2015-07-20 Postopek za ulivanje ulitkov
RS20191524A RS59702B1 (sr) 2014-07-30 2015-07-20 Metod za livenje odlivaka
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DE102014110826.4A DE102014110826A1 (de) 2014-07-30 2014-07-30 Verfahren zum Gießen von Gussteilen
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JP6275324B2 (ja) 2018-02-07
US20170198366A1 (en) 2017-07-13
MX2016012496A (es) 2017-01-09
EP3597329B1 (fr) 2024-01-03
JP2017525570A (ja) 2017-09-07
BR112016023696B8 (pt) 2021-11-16
CA2948750C (fr) 2018-01-02
EP3119545A1 (fr) 2017-01-25
RS59702B1 (sr) 2020-01-31
CN106536083B (zh) 2018-09-28
PT3119545T (pt) 2019-12-09
RS65376B1 (sr) 2024-04-30
EP3597329C0 (fr) 2024-01-03
ZA201606111B (en) 2017-09-27
EP3597329A1 (fr) 2020-01-22
BR112016023696B1 (pt) 2021-08-31
CA2948750A1 (fr) 2016-02-04
ES2759264T3 (es) 2020-05-08
HUE046428T2 (hu) 2020-03-30
CN106536083A (zh) 2017-03-22
SI3119545T1 (sl) 2020-01-31
HUE066606T2 (hu) 2024-08-28
RU2645824C1 (ru) 2018-02-28
PL3119545T3 (pl) 2020-03-31
HRP20240471T1 (hr) 2024-09-27
PL3597329T3 (pl) 2024-07-08
WO2016016035A1 (fr) 2016-02-04
ES2984524T3 (es) 2024-10-29
HRP20192115T1 (hr) 2020-02-21
KR20170028392A (ko) 2017-03-13
US9890439B2 (en) 2018-02-13
BR112016023696A2 (fr) 2017-08-22
KR101845505B1 (ko) 2018-05-18
MX361595B (es) 2018-12-10
DE102014110826A1 (de) 2016-02-04
DK3119545T3 (da) 2019-12-02

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