EP3188860B1 - Method for producing iron metal castings - Google Patents
Method for producing iron metal castings Download PDFInfo
- Publication number
- EP3188860B1 EP3188860B1 EP15753958.6A EP15753958A EP3188860B1 EP 3188860 B1 EP3188860 B1 EP 3188860B1 EP 15753958 A EP15753958 A EP 15753958A EP 3188860 B1 EP3188860 B1 EP 3188860B1
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- European Patent Office
- Prior art keywords
- mould
- mold
- broken
- casting
- cooling
- 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.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/065—Cooling or heating equipment for moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
- B22D15/04—Machines or apparatus for chill casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
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- 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
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- 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
- B22D29/04—Handling or stripping castings or ingots
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- 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
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D33/00—Equipment for handling moulds
- B22D33/005—Transporting flaskless moulds
Definitions
- the invention relates to a method for the production of ferrous metal casts.
- Casting processes are typically differentiated according to their method of production, with particular distinction being made between casting in a lost mold and casting in a permanent mold, for example chill casting and die casting.
- the inventive method combines the two casting techniques by a lost mold is used with a cavity for receiving the casting in an open multi-part mold. Even such a combination of a lost form with a mold is known in principle. Exemplary is the writings JP S59-97740 A . EP 0 760 723 B1 . EP 1 131 175 B1 and DE 10 2010 035 440 A1 directed.
- the casting apparatus has a wet-cast sand mold.
- the closure takes place in one embodiment by means of a movable, hollow member through which the melt flows and which is pressed in the axial direction in the form of a sufficiently large axially directed force and in this way closes the inlet.
- a plug of molding sand is provided, which is pressed after the completion of the melt inlet into an inlet channel, so that the inlet channel is closed.
- the EP 1 131 175 B1 is concerned with a method and apparatus for casting cast iron in a mold, the inner walls of which are in contact with a mold of hardening mold material or green sand. After the mold has been introduced into the mold, the side parts of the mold are closed and subjected to a variable contact pressure by means of a pressure device. The mold is cooled by means of a cooling device after introduction of the melt. It is proposed for this purpose to control the cooling rate throughout the cooling process until the pearlite transformation is complete in order to ensure the desired mechanical properties of the casting. Further, it is proposed to increase the cooling rate in the phase of pearlite transformation by opening the mold, the resulting air cooling increasing the cooling rate and resulting in increased strength of the casting.
- the casting should be embedded in an insulating medium immediately after opening or covered with this and held in this state until the temperature of the casting has fallen below the pearlite transformation temperature.
- the DE 10 2010 035 440 A1 proposes to provide a better controllability of the cooling of the casting between the inner wall of the mold and the outer wall of the lost mold (sand mold) at least one coolant flowed space or a spiral arranged around the sand mold coolant channel.
- This or a similar device consisting of a lost mold and a mold enclosing this lost mold makes use of the following invention. On this basis, it is an object of the present invention to make the process for producing metal castings even more efficient and flexible.
- the lost molds are made of sand, in particular of chemically bonded molding sand, in a customary manner, for example in a Croning, Coldbox, Hotbox, Furan, or water glass CO 2 process and hereinafter also referred to as sand mold or Kernpacket.
- Ferrous metal casts combine casts of all iron-carbon compounds, regardless of carbon content, ie cast iron and steels. Casting material in the sense of this document is understood to mean the melt of the iron metal casting. Is this (at least partially) solidified, it is spoken by casting or casting.
- the mold is preferably a metallic mold, for example of steel, cast iron or brass, but may also consist of another mold material, such as graphite.
- the basic difference of the method according to the invention for producing iron metal castings in comparison to the known methods is a two-stage cooling and demolding process.
- a first cooling (first cooling stage) of the casting at least until it falls below the liquidus temperature, preferably until it falls below the solidus temperature and preferably before the casting has reached the eutectoid transformation temperature, takes place in the mold still within the mold.
- the preferred lower temperature limit up to which the core is cooled at most in the first chill stage can be stated to be 723 ° C.
- the method according to the invention preferably provides that the lost form is cooled by a coolant flowing through a cavity arranged between the inner wall of the mold and the outer wall of the lost mold.
- the cooling medium is preferably air or an inert gas.
- the cavity may be formed in the form of one or more cooling channels extending spirally around the mold.
- the cooling process is preferably controlled or regulated and preferably begins after filling the mold. In exceptional cases, it can also start during mold filling.
- the casting temperature of the lost mold is measured in the latter case during cooling prior to removal of the mold preferably on the suspension. This can be done without contact, for example optically by means of an infrared camera, or by means of temperature sensors.
- this can also be time-controlled, mass-controlled, and / or module-controlled (ie, depending on the surface-to-volume ratio, also called the solidification ratio) by previously (computationally) determining a coolant requirement for a predetermined cooling rate and correspondingly the coolant flow is programmed.
- the desired material properties are known to be determined by the choice of the carbon content, the alloy composition and, depending on the individual microstructure transformation temperatures, adjusted by respectively adapted cooling programs.
- the removal of the mold-casting unit from the mold plays a decisive role, which ends the first cooling stage during Austenit Bear or solidification or after their completion and initiates a second cooling stage.
- the time of removal is accordingly at the earliest after reaching the liquidus temperature. Taking into account a temperature gradient towards the walls of the casting, superficial solidification has already been used, which gives the casting sufficient stability, while the core of the casting can then still contain fractions of melt.
- the casting in the core has reached the eutectoid transformation temperature.
- the exact temperature depends in each case on the desired structural state (austenite, coarse / fine-grained pearlite, coarse-fine-grained ferrite, etc.) and the chemical composition, the alloying elements, in particular the carbon content in the material.
- the second cooling stage is thus at the earliest initiated, depending on the desired structure and the casting properties, if the casting is at least partially solidified, so the Austenit Guess sets or advantageously completed, and preferably until reaching the eutectoid transformation temperature (723 ° C).
- the mold is opened and removed the form with the solidified casting from this non-destructive.
- the mold remains surrounding the casting and acts thereafter as a heat-insulating or -regulierendes material. Without further measures, a uniform cooling over the surface of the casting, which is still enclosed in the mold, is ensured while the mold is exposed to the ambient conditions. Only at the end of the second cooling step, the casting is removed from the mold.
- the mold For an effective and, above all, even cooling of the casting in the second cooling stage, the mold must be designed according to the required cooling capacity, i. In particular, the wall thickness of the mold is to be designed taking into account the surface-to-volume ratio of the casting, the environmental conditions and the desired material structure of the casting.
- environmental conditions in this sense, for example, the thermal conditions in a refrigerator understood that the lost form including casting supplied to the support hanging and in which it is further cooled.
- constant thermal conditions and a rapid removal of the heat introduced by sufficient circulation / sufficient replacement of the coolant preferably turn air or an inert gas can be adjusted.
- the cooling is controlled or regulated by monitoring the temperature of the mold and / or the casting.
- the casting temperature of the lost mold is again measured during cooling after removal of the mold again preferably on the suspension. Again, this can be done without contact, for example optically by means of an infrared camera, or by means of temperature sensors.
- the second cooling stage is completed when the desired target temperature for removal of the casting from the core package, the unpacking temperature of preferably ⁇ 300 ° C is reached, at which the temperature profile of the further cooling has no influence on the microstructure.
- the carrying device is used together with a feeder cap in the lost mold before it is inserted into the opened mold.
- a feeder cap with suspension is for example from the Scriptures DE 10 2010 051 348 A known.
- the mold can be prepared immediately after removal of the mold for the next casting operation, i. Among other things, be equipped with the next lost form.
- the method is therefore very efficient and cost-effective, because at the same throughput a smaller number of molds is needed. Also, the process is very flexible and again inexpensive, because different castings can be made with the same mold by using different lost shapes.
- the foundry does not need to hold a large number of different molds. The most versatile is a cylindrical mold for this purpose.
- the cavity of the lost mold is filled with melt from below in ascending order.
- Particularly preferred in this case is the application of the low-pressure casting process.
- this can advantageously be closed by means of a gate valve.
- the cooling of the lost mold starts immediately after the closure thereof by means of a gate valve.
- An advantageous development of the invention provides that, during the filling of the cavity of the lost mold with casting material, casting gases are sucked off through a cavity arranged between the inner wall of the mold and the outer wall of the lost mold.
- the cavity for the primary cooling and the cavity for sucking off the casting gases is preferably the same.
- the cavity thus preferably has a dual function, as an exhaust pipe during casting and as coolant supply and discharge to the casting or to the lost form during the first cooling stage of the casting. It is advantageous that the cavity can be easily connected to a closed exhaust system that disposed of the exhaust gases targeted before they can get into the environment. Large-dimensioned exhaust hoods and corresponding piping systems, which circulate a lot of secondary air, can thus be avoided.
- the mold i. the mold walls
- secondary cooling is done in specially provided for in the mold wall cooling lines, which are also flowed through with coolant.
- Another advantageous development of the invention provides that the lost mold is held by means of negative pressure in the mold during insertion into the open multi-part mold.
- the lost form and the mold on matching elements that are inserted into each other when inserting the lost form in the open multi-part mold and so a defined position of the mold in the mold to ensure.
- the cooperating mating elements are therefore also called core bearings.
- the fitting elements and the vacuum holder can be combined, as will be explained below with reference to embodiments.
- a lost mold 10 having a cavity 12 for receiving casting material is shown.
- the cavity 12 has an inner surface which images the outer contour of the casting to be produced.
- the lost mold 10 consists of a preferably chemically bonded molding sand, which forms an intrinsically stable structure.
- a carrying device 14 is fixed by means of two first anchor elements 16.
- the carrying device is already sufficiently connected to the mold 10 in order to carry its own weight.
- the carrying device furthermore has a second anchor element 18, which projects through the wall of the mold 10 into the cavity 12, in order later to be partially encapsulated therewith with the casting material.
- the subsequent filling of the cavity 12 in the lost mold 10 is carried out in a conventional manner by one or more gates 20, which preferably opens from below into the cavity 12, so that the cavity 12 of the lost form rising from below with cast material, particularly preferred can be filled in the low pressure casting process.
- the lost form 10 is filled with casting material in the before FIG. 1 shown first in a first part, here in a first half 22, an open multi-part mold used before the mold is closed by the second half 24 is assembled with the first half 22.
- the lost form 10 is first recorded in the first half 22 of the mold and after closing the mold and in the second half 24 of the mold, both the lost form 10 and the halves of the mold 22, 24 fitting elements 26 and 28, which are complementary to each other.
- the mating elements of the lost form 10 are in Shape of a plurality of circumferentially projecting from an outer wall 30 of the mold 10 lugs 26 formed.
- the mold halves 22, 24 each have complementary recesses 28 in their inner walls 32.
- the cooperating fitting elements 26 and 28 form the so-called core bearings 34.
- the mold halves 22, 24 also have connecting channels 36 between the recesses 28 on the one hand and an outer side 38 of the mold halves 22 and 24.
- a suction line (not shown) can be connected on the outside 34, so that between the inner wall 32 and the outer wall 30, a negative pressure can be generated.
- the mold 10 is thereby sucked with its projections 26 into the recess 28 of the Kokillenhnature 22 and held by the sustained negative pressure in this until the mold is closed. Thereafter, the negative pressure is no longer needed and the suction line can be removed or the negative pressure can be deactivated.
- connection 32 can also engage at another location of the interface between the lost mold 10 and the multi-part mold, so that the fitting elements and the connection channels for vacuum fixing are spatially separated from each other. In the manner shown, however, the fitting elements and the means for vacuum fixation are combined in an advantageous manner.
- a cavity 40 is arranged, which serves as a conduit for a cooling medium for cooling the lost mold, so the primary cooling.
- the cavity 40 as circumferentially closed coolant line is formed only when joining the lost mold 10 and the mold, because it is formed in half in the outer wall 30 in the form of an open spiral or helical channel 42 and 44, respectively.
- a circumferential cavity can also be provided several cavities. Also, this does not have to be arranged in a spiral or helical shape around the lost mold 10 but can for example also be configured in a meandering or intersecting manner in a lattice-like manner.
- the cavity 40 has at least two connection channels 46 and 48 to the outside of the mold, so that it can be connected to a circulation system or a supply system for a cooling medium.
- a further conduit system 50 is provided in the mold walls, which in turn is guided by connections not shown to the outside and can be connected to a circulation or supply system for a further cooling medium.
- FIG. 2 the process step of filling the cavity 12 of the lost mold 10 with cast material 54 is shown.
- the casting material 54 is introduced from below through the gate 20 into the cavity 12 of the lost mold 10 after the mold has been closed by joining the Kokillenhworthn 22 and 24.
- casting gases in the cavity 12 are led out through the porous structure of the sand mold 10 into the cavity 40 between the inner wall of the mold and the outer wall of the sand mold 10 and from there through the connecting channel 48 from the mold.
- the connecting channel 48 is marked as an exhaust air duct.
- the connecting channel 46 is kept closed in this case, for example by means of a plug or a valve (both not shown). However, the casting gas can also be sucked in the opposite direction via the connecting channel 46 or simultaneously via both connecting channels 46 and 48.
- the lost mold 10 over the cavity 12 for the casting on another cavity in the previously a feeder cap 52 has been used, as in the document DE 10 2010 051 348 A is described.
- the feeder cap 52 serves to receive casting material 54 and has heat-insulating and / or exothermic properties in order to keep the enclosed casting material liquid for a longer time while it is already beginning to solidify in the cavity 12. The onset of solidification shrinkage of the casting material 54 is thus compensated with the warmer and lower-viscosity melt in the feeder cap 52.
- the carrying device 14 is designed differently in this example. This has an engaging into the cavity of the feeder cap 52 anchoring element 18, which is sufficiently firmly connected to the feeder cap and / or the mold 10 in order to carry their own weight can. After the introduced casting material 54 is solidified around the anchor member 18 around, the load is also or even predominantly supported by the resulting compound and the casting can be held together with mold 10 on the support device.
- the gate 20 is closed by means of a locking slide 55, so that the mold with the lost form can be removed from the filling station.
- FIG. 3 is the process step of cooling the lost mold 10 in the mold after filling, so the primary cooling illustrated.
- This step preferably begins after the closure of the lost mold 10 by means of the gate valve 55, so that the solidification of the casting material does not start during filling.
- a cooling medium is introduced through the previously described connection channel 46 into the cavity 40 and out through the connection channel 48 therefrom, whereby heat is removed from the lost mold 10.
- the cavity 40 in a simple way, the dual function as an exhaust pipe during the in FIG. 2 illustrated casting and as supply and discharge of a cooling medium during the in FIG. 3
- a valve is preferably provided in each case.
- the supply lines can thus either be closed, connected to coolant lines or to exhaust pipes.
- the primary cooling is carried out until the casting is at least partially solidified and the casting 56 has a stable structure.
- the primary cooling and thus the first cooling stage can take longer. Basically, it makes sense for Efficiency reasons to turn off the primary cooling with the removal of the mold-casting unit from the mold and thus immediacy with the completion of the first cooling stage.
- FIG. 4 is the subsequent to the primary cooling step of opening the mold illustrated.
- the two halves 22 and 24 of the mold are moved away from each other, while the lost mold 10 is held suspended from the support device 14.
- the carrying device 14 corresponds in the embodiment shown here in FIG. 1 shown. Because the cast is already solidified at least partially, particularly at the surface, it has inherent stability so that the load of the mold and cast is supported both through the connection of the support 14 to the mold 10 and to the casting 56 ,
- the mold is removed without destruction from the mold and fed to the second cooling stage.
- the mold 10 is transported into a cold room by desirably cooling down further under controlled or at least controlled thermal conditions until the molding temperature, preferably measured at the support 14, has reached the preset value, preferably then the case is when the desired unpacking temperature of For example, it has reached or fallen below 300 ° C. and the further cooling no longer has any influence on the microstructure and the casting properties.
- FIG. 5 shows the combined lost mold 10 with mold with an alternative embodiment of the carrying device 14. This is simplified in comparison with the two carrying devices described above in that it has only a single anchor element 18, which through the lost mold 10 through into the casting 56th protrudes.
- the anchor member 18 may be formed so that it is not suitable to carry the mold 10 without a casting, so that it will be handled in other ways when inserted into the mold.
- structures (hooks or the like), not shown, may be provided along the surface of the anchoring element 18, which provide sufficient connection with the sand mold 10 to withstand the tensile stress of lifting and transporting the empty sand mold 10 to the support 14.
- the lower end of the anchor member 18 otherwise protrudes into the cavity of the sand mold 10 in the manner already described above, so that it is connected after the solidification of the casting in the manner shown here with the casting 56 and is suitable by means of this connection, the sand mold 10 including casting 56 to wear.
- FIG. 6 shows a modified embodiment of a combined lost mold 10 with mold again with respect to the carrying device 14.
- This embodiment combines the two first anchor elements 16, which according to the first embodiment in FIG. 1 extend into the sand mold 10, with a second, passing through the sand mold 10 anchor member 18, that according to the second embodiment in FIG. 2 extends into the casting 56 and then a feeder cap 52 is provided, which is integrated into the sand mold 10 and provides a cavity for the casting material.
- FIG. 7 shows a fifth embodiment of a combined lost mold 10 with mold, which, for example, from the in FIG. 5 shown embodiment distinguished by additional blind holes 58 in the sand mold 10.
- the blind hole 58 in the mold 10 opens into a portion of the cavity 40 and thus expands its volume for receiving a cooling medium.
- the arrangement of the blind holes 58 corresponds to portions of the sand mold 10 having a greater wall thickness to bring the coolant at these locations closer to the surface of the casting 56 or before solidification at the interface of the casting material to the mold 10.
- a more uniform cooling of the surface of the casting or, if necessary, but also a targeted accelerated cooling of the casting at selected portions of the surface can be achieved with different wall thicknesses of the mold 10.
- the blind holes and through holes and / or channels may be provided which accelerate the heat exchange and the cooling process at the appropriate points again or allow more precise control. In particular, targeted cooling of larger local masses (thermal centers) and / or local microstructure optimization are thus possible.
- the method comprises further method steps, which are preceded or followed by the actual casting process. It begins with a core manufacturing step 100 in which the lost mold is in a cold box process, a hot box process, a croning process, a furan resin process or a water glass CO 2 process as a preferably chemically bound sand mold, for example will be produced.
- This step 100 is preferably carried out under optical monitoring and computer-controlled.
- Kernemontage 102 takes place.
- This step may be supplemented, as necessary, by additional core finishing, e.g., depending on mold release mold release requirements and surface finish requirements. by means of a spray robot.
- the core package assembly 102 is optionally followed by storage 104 of the core package. It is available in the warehouse on call. Depending on the number of pieces, process speed, core manufacturing conditions, and production process requirements, usually a certain number of core packages will be provided, or just-in-time production may be provided at optimum core production conditions without inventory if their production is just as fast or faster than those described below Work steps succeed.
- the core package is removed from the core storage and fed to the next process step 106.
- the removal and feeding is again preferably carried out fully automatically by a robot R2.
- the central module for carrying out the method according to the invention is a so-called production island I1, also referred to as a "carousel", on which at least 5, here 6, of the process steps essential to the invention are executed.
- a first step 106 the core package is inserted into an open, multi-part mold at a first work station of the production island I1 and this is closed. This is preferably done in the above with reference to FIG. 1 described way.
- the workstation changes and in a step 108, the cavity of the lost mold with casting material, preferably filled in the low-pressure casting process.
- the lost mold is closed by means of a gate valve and can then be supplied to the next step 110.
- the mold changes again to the next workstation at which the first cooling step, so the primary cooling of the mold, and optionally simultaneously or sequentially use the secondary cooling of the mold.
- the mold or more precisely the connection channels 46 and 48 described above, are connected to a coolant system, preferably to a coolant circuit.
- conduit system 50 in the mold walls can also be connected to a coolant system, preferably a coolant circuit, and the coolant system (s) can be started.
- the cooling operations of this operation 110 are carried out particularly preferably controlled by monitoring the casting or mold temperature. This in turn can preferably be measured on the carrying device described above.
- the cooling takes place in this embodiment, a total of three workstations, including in the steps 112 and 114.
- the manufacturing island I1 moves so two working positions, so that the previous workstations in the meantime again to perform the steps 106 and 108 To be available.
- the ratio of the time required for inserting the mold 10 into the mold in step 106 and the filling in step 108 for the duration of the primary cooling process determines the number of workstations reserved for cooling.
- the mold with the cooled lost mold 10 is subjected to the operation 116, in which the multi-part mold is opened, at the earliest after the casting, as described above, is at least partially solidified.
- the lost shape on the carrying device becomes suspended in the manner described above taken from the opened mold. This is again done preferably fully automated by means of a robot R3 to ensure a non-destructive removal of the lost form.
- the robot R3 then transfers the lost form to a cooling line, in which it is still cooled on the carrying device, step 118.
- step 120 is then carried out, in which the casting is finally demoulded by mechanical removal of the lost mold. This step is also referred to as "emptying" or "gross embarrassment".
- the casting mold preferably fully automated by means of another robot R4, is fed to a separating station, which as the next step comprises the separation 124 of the feeder and / or the carrying device. This is followed in a conventional manner, the final control 126 and the transfer 128 to the shipping or parts warehouse.
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Description
Die Erfindung betrifft ein Verfahren zur Herstellung von Eisenmetallgüssen. Gießverfahren werden typischerweise nach ihrer Herstellungsart unterschieden, wobei insbesondere das Gießen in einer verlorenen Form und das Gießen in einer Dauerform, zum Beispiel der Kokillenguss und der Druckguss, unterschieden werden. Das erfindungsgemäße Verfahren kombiniert die beiden Gusstechniken, indem eine verlorene Form mit einem Hohlraum zur Aufnahme des Gusses in eine geöffnete mehrteilige Kokille eingesetzt wird. Auch eine solche Kombination einer verlorenen Form mit einer Kokille ist grundsätzlich bekannt. Beispielhaft wird auf die Schriften
Aus der
In der
Die
Die
Diese oder eine vergleichbare Vorrichtung bestehend aus einer verlorenen Form und einer diese verlorene Form einschließenden Kokille macht sich die folgende Erfindung zu Nutze. Hiervon ausgehend ist es Aufgabe der vorliegenden Erfindung, das Verfahren zur Herstellung von Metallgüssen noch effizienter und flexibler zu gestalten.This or a similar device consisting of a lost mold and a mold enclosing this lost mold makes use of the following invention. On this basis, it is an object of the present invention to make the process for producing metal castings even more efficient and flexible.
Die Aufgabe wird durch ein Verfahren zur Herstellung von Eisenmetallgüssen mit den Merkmalen des Patentanspruchs 1 gelöst. Das Verfahren weist die folgenden Schritte auf:
- eine verlorene Form mit einem Hohlraum zur Aufnahme von Gussmaterial wird in eine geöffnete mehrteilige Kokille eingesetzt,
- die mehrteilige Kokille wird geschlossen,
- der Hohlraum der verlorenen Form wird mit Gussmaterial gefüllt, wobei eine in den Hohlraum der verlorenen Form teilweise hineinragende Tragevorrichtung teilweise mit dem Gussmaterial umgossen wird,
- die verlorene Form wird nach dem Füllen in der Kokille gekühlt,
- die mehrteilige Kokille wird während des Abkühlens nach dem Unterschreiten der Liquidustemperatur, vorzugsweise nach dem Unterschreiten der Solidustemperatur und besonders bevorzugt noch bevor der Guss die eutektoide Umwandlungstemperatur erreicht hat, geöffnet und die verlorene Form mit dem Guss zerstörungsfrei aus der geöffneten Kokille entnommen,
- an der Tragvorrichtung hängend weiter gekühlt, mindestens bis die Gefügebildung des Gusses abgeschlossen ist,
- der Guss wird durch Entfernen der verlorenen Form entformt.
- a lost mold with a cavity for receiving casting material is inserted into an open multi-part mold,
- the multi-part mold is closed,
- the cavity of the lost mold is filled with casting material, wherein a partially projecting into the cavity of the lost mold carrying device is partially encapsulated with the casting material,
- the lost mold is cooled after filling in the mold,
- the multi-part mold is opened during cooling after falling below the liquidus temperature, preferably after falling below the solidus temperature and particularly preferably before the casting has reached the eutectoid transformation temperature, and removing the lost mold with the casting from the opened mold in a non-destructive manner,
- on the support device hanging further cooled, at least until the structure of the casting is completed,
- the casting is removed from the mold by removing the lost mold.
Die verlorenen Formen werden aus Sand, insbesondere aus chemisch gebundenem Formsand, in üblicher Weise beispielsweise in einem Croning-, Coldbox-, Hotbox-, Furan-, oder Wasserglas- CO2-Verfahren hergestellt und hierin nach folgend auch als Sandform oder Kernpacket bezeichnet.The lost molds are made of sand, in particular of chemically bonded molding sand, in a customary manner, for example in a Croning, Coldbox, Hotbox, Furan, or water glass CO 2 process and hereinafter also referred to as sand mold or Kernpacket.
Unter Eisenmetallguss werden Güsse aus allen Eisen-Kohlenstoff-Verbindungen, unabhängig vom Kohlenstoffgehalt zusammengefasst, also Gusseisen und Stähle. Unter Gussmaterial im Sinne dieser Schrift wird die Schmelze des Eisenmetallgusses verstanden. Ist diese (zumindest teilweise) erstarrt, wird von Guss oder Gussteil gesprochen.Ferrous metal casts combine casts of all iron-carbon compounds, regardless of carbon content, ie cast iron and steels. Casting material in the sense of this document is understood to mean the melt of the iron metal casting. Is this (at least partially) solidified, it is spoken by casting or casting.
Die Kokille ist vorzugsweise eine metallische Kokille, beispielsweise aus Stahl, Gusseisen oder Messing, kann aber auch aus einem anderen Kokillenwerkstoff, wie zum Beispiel aus Graphit, bestehen.The mold is preferably a metallic mold, for example of steel, cast iron or brass, but may also consist of another mold material, such as graphite.
Der grundlegende Unterschied des erfindungsgemäßen Verfahrens zum Herstellen von Eisenmetallgüssen im Vergleich zu den bekannten Verfahren ist ein zweistufiger Abkühl- und Entformungsprozess. Ein erstes Abkühlen (erste Abkühlstufe) des Gusses mindestens bis zum Unterschreiten der Liquidustemperatur, vorzugsweise bis zum Unterschreiten der Solidustemperatur und vorzugsweise noch bevor der Guss die eutektoide Umwandlungstemperatur erreicht hat, erfolgt in der Form noch innerhalb der Kokille. Die bevorzugte Temperaturuntergrenze, bis zu der der Guss im Kern in der ersten Abküflstufe höchstens herunter gekühlt wird, kann mit 723°C angegeben werden. Hierbei kommt vorteilhafter Weise die in der
Die gewünschten Materialeigenschaften (Festigkeit, Härte, Duktilität, etc.) werden bekanntlich durch Wahl des Kohlenstoffgehaltes, der Legierungszusammensetzung und, in Abhängigkeit von den individuellen Gefügeumwandlungstemperaturen, durch jeweils angepasste Abkühlprogramme eingestellt. Dabei spielt die Entnahme der Form-Guss-Einheit aus der Kokille eine entscheidende Rolle, die die erste Abkühlstufe während der Austenitbildung bzw. Erstarrung oder nach deren Abschluss beendet und eine zweite Abkühlstufe einleitet. Der Zeitpunkt der Entnahme ist demgemäß frühestens nach Erreichen der Liquidustemperatur. Unter Berücksichtigung eines Temperaturgefälles zu den Wandungen des Gusses hin, hat bereits eine oberflächliche Erstarrung eingesetzt, die dem Guss eine ausreichende Stabilität verleiht, während der Kern des Gusses dann noch Anteile von Schmelze enthalten kann. Vorzugsweise wartet man mit der Entnahme, bis der Guss auch im Inneren die Solidustemperatur erreicht hat, und nicht länger, als bis der Guss im Kern die eutektoide Umwandlungstemperatur erreicht hat. Die genaue Temperatur hängt jeweils von dem gewünschten Gefügezustand (Austenit, grober/ feinstreifiger Perlit, grober-feinkörniger Ferrit, etc.) und der chemischen Zusammensetzung, den Legierungselementen, insbesondere dem Kohlenstoffanteil in dem Werkstoff ab.The desired material properties (strength, hardness, ductility, etc.) are known to be determined by the choice of the carbon content, the alloy composition and, depending on the individual microstructure transformation temperatures, adjusted by respectively adapted cooling programs. In this case, the removal of the mold-casting unit from the mold plays a decisive role, which ends the first cooling stage during Austenitbildung or solidification or after their completion and initiates a second cooling stage. The time of removal is accordingly at the earliest after reaching the liquidus temperature. Taking into account a temperature gradient towards the walls of the casting, superficial solidification has already been used, which gives the casting sufficient stability, while the core of the casting can then still contain fractions of melt. It is preferable to wait until the casting has reached inside the solidus temperature inside, and not longer, until the casting in the core has reached the eutectoid transformation temperature. The exact temperature depends in each case on the desired structural state (austenite, coarse / fine-grained pearlite, coarse-fine-grained ferrite, etc.) and the chemical composition, the alloying elements, in particular the carbon content in the material.
Die zweite Abkühlstufe wird also in Abhängigkeit vom gewünschten Gefüge und den Gussteileigenschaften frühestens dann eingeleitet, wenn der Guss zumindest teilweise erstarrt ist, also die Austenitbildung einsetzt oder vorteilhafter Weise abgeschlossen ist, und vorzugsweise bis zum Erreichen der eutektoiden Umwandlungstemperatur (723°C). Hierzu wird die Kokille geöffnet und die Form mit dem erstarrten Guss aus dieser zerstörungsfrei entnommen. Dabei bleibt die Form das Gussteil umschließend erhalten und wirkt hiernach als wärmedämmendes bzw. -regulierendes Material. Ohne weitere Maßnahmen wird so eine gleichmäßige Abkühlung über die Oberfläche des in der Form noch immer eingeschlossenen Gusses sicher gestellt, während die Form den Umgebungsbedingungen ausgesetzt ist. Erst am Ende der zweiten Abkühlstufe wird der Guss entformt.The second cooling stage is thus at the earliest initiated, depending on the desired structure and the casting properties, if the casting is at least partially solidified, so the Austenitbildung sets or advantageously completed, and preferably until reaching the eutectoid transformation temperature (723 ° C). For this purpose, the mold is opened and removed the form with the solidified casting from this non-destructive. The mold remains surrounding the casting and acts thereafter as a heat-insulating or -regulierendes material. Without further measures, a uniform cooling over the surface of the casting, which is still enclosed in the mold, is ensured while the mold is exposed to the ambient conditions. Only at the end of the second cooling step, the casting is removed from the mold.
Für eine effektive und vor allem gleichmäßige Abkühlung des Gusses in der zweiten Abkühlstufe ist die Form nach der benötigten Kühlleistung auszulegen, d.h. insbesondere ist die Wandstärke der Form unter Berücksichtigung des Oberflächen-zu-Volumenverhältnisses des Gusses, der Umgebungsbedingungen und dem gewünschten Materialgefüge des Gusses auszulegen. Als Umgebungsbedingungen in diesem Sinne werden beispielsweise die thermischen Bedingungen in einem Kühlraum verstanden, dem die verlorene Form einschließlich Guss an der Tragevorrichtung hängend zugeführt und in dem sie weiter gekühlt wird. In einem solchen Kühlraum können konstante thermische Bedingungen und ein schneller Abtransport der eingetragenen Wärme durch ausreichende Umwälzung/ausreichenden Austausch des Kühlmittels, bevorzugt wiederum Luft oder ein inertes Gas, eingestellt werden. Vorzugsweise wird die Kühlung unter Temperaturüberwachung der Form und/oder des Gusses gesteuert oder geregelt. Die Gusstemperatur der verlorenen Form wird hierzu während des Kühlens nach dem Entfernen der Kokille wiederum vorzugsweise an der Aufhängung gemessen. Dies kann abermals berührungsfrei, beispielsweise optisch mittels Infrarotkamera, oder mittels Thermofühler geschehen. Die zweite Abkühlstufe ist beendet, wenn die gewünschte Zieltemperatur zur Entfernung des Abgusses aus dem Kernpaket, die Auspacktemperatur von vorzugsweise < 300°C, erreicht ist, bei der der Temperaturverlauf der weiteren Abkühlung keinen Einfluss mehr auf die Gefügeausbildung hat.For an effective and, above all, even cooling of the casting in the second cooling stage, the mold must be designed according to the required cooling capacity, i. In particular, the wall thickness of the mold is to be designed taking into account the surface-to-volume ratio of the casting, the environmental conditions and the desired material structure of the casting. As environmental conditions in this sense, for example, the thermal conditions in a refrigerator understood that the lost form including casting supplied to the support hanging and in which it is further cooled. In such a cooling space constant thermal conditions and a rapid removal of the heat introduced by sufficient circulation / sufficient replacement of the coolant, preferably turn air or an inert gas can be adjusted. Preferably, the cooling is controlled or regulated by monitoring the temperature of the mold and / or the casting. The casting temperature of the lost mold is again measured during cooling after removal of the mold again preferably on the suspension. Again, this can be done without contact, for example optically by means of an infrared camera, or by means of temperature sensors. The second cooling stage is completed when the desired target temperature for removal of the casting from the core package, the unpacking temperature of preferably <300 ° C is reached, at which the temperature profile of the further cooling has no influence on the microstructure.
Eine entscheidende Rolle, insbesondere in der zweiten Abkühlstufe, spielt das freie Aufhängen der Form samt Gussteil an der Tragevorrichtung. Dieses verringert zum einen die Gefahr, die verlorene Form beim Entnehmen aus der Kokille zu beschädigen. Eine Beschädigung würde den Guss partiell oder vollständig der Umgebung aussetzen und eine unkontrollierte Gefügeausbildung zur Folgen haben können. Zum anderen ermöglicht das Aufhängen im Gegensatz zum liegenden Transport, dass die Form von allen Seiten gleichmäßig von Kühlmittel umspült werden kann, und erhöht somit die Effizienz und Gleichmäßigkeit der Kühlung.A crucial role, especially in the second cooling stage, plays the free hanging of the mold including casting on the support device. On the one hand, this reduces the risk of damaging the lost mold when removing it from the mold. Damage may partially or completely expose the casting to the environment and may result in uncontrolled microstructure formation. On the other hand, in contrast to the horizontal transport, suspension makes it possible for the mold to be evenly distributed from all sides to the coolant can be washed around, thus increasing the efficiency and uniformity of the cooling.
Vorzugsweise wird die Tragevorrichtung zusammen mit einer Speiserkappe in die verlorene Form eingesetzt, bevor diese in die geöffnete Kokille eingesetzt wird. Eine solche Speiserkappe mit Aufhängevorrichtung ist beispielsweise aus der Schrift
Die Kokille kann unmittelbar nach der Entnahme der Form für den nächsten Gießvorgang vorbereitet, d.h. unter anderem mit der nächsten verlorenen Form bestückt werden. Das Verfahren ist deshalb sehr effizient und kostengünstig, weil bei gleichem Durchsatz eine geringere Anzahl von Kokillen benötigt wird. Auch ist das Verfahren sehr flexibel und wiederum kostengünstig, weil mit derselben Kokille durch Verwendung unterschiedlicher verlorener Formen unterschiedliche Gusserzeugnisse hergestellt werden können. Die Gießerei muss also keine Vielzahl unterschiedlicher Kokillen vorhalten. Am vielseitigsten ist hierfür eine zylindrische Kokillenform.The mold can be prepared immediately after removal of the mold for the next casting operation, i. Among other things, be equipped with the next lost form. The method is therefore very efficient and cost-effective, because at the same throughput a smaller number of molds is needed. Also, the process is very flexible and again inexpensive, because different castings can be made with the same mold by using different lost shapes. The foundry does not need to hold a large number of different molds. The most versatile is a cylindrical mold for this purpose.
Weiterhin vorteilhaft ist es, dass der Hohlraum der verlorenen Form von unten aufsteigend mit Schmelze gefüllt wird. Besonders bevorzugt hierbei ist die Anwendung des Niederdruckgussverfahrens.It is furthermore advantageous that the cavity of the lost mold is filled with melt from below in ascending order. Particularly preferred in this case is the application of the low-pressure casting process.
Nach dem Füllen der Form von unten kann diese vorteilhafter Weise mittels eines Absperrschiebers verschlossen werden.After filling the mold from below, this can advantageously be closed by means of a gate valve.
Dies ermöglicht, dass die Kokille mit der Form und dem Guss nach dem Füllen von der Füllstation entnommen werden kann, so dass die Füllstation für das Füllen der nächsten Form/Kokille schon wieder bereitsteht.This allows the mold with the mold to be removed from the filling station after filling, so that the filling station is ready for filling the next mold / mold again.
Besonders bevorzugt setzt das Kühlen der verlorenen Form unmittelbar nach dem Verschließen derselben mittels Absperrschieber ein.Particularly preferably, the cooling of the lost mold starts immediately after the closure thereof by means of a gate valve.
Eine vorteilhafte Weiterbildung der Erfindung sieht vor, dass während des Füllens des Hohlraumes der verlorenen Form mit Gussmaterial Gießgase durch eine zwischen der Innenwand der Kokille und der Außenwand der verlorenen Form angeordnete Kavität abgesaugt werden.An advantageous development of the invention provides that, during the filling of the cavity of the lost mold with casting material, casting gases are sucked off through a cavity arranged between the inner wall of the mold and the outer wall of the lost mold.
Die Kavität für die primäre Kühlung und die Kavität zum Absaugen der Gießgase ist bevorzugt dieselbe. Die Kavität hat somit bevorzugt eine Doppelfunktion, als Abgasleitung während des Gießens und als Kühlmittelzu- und abführung zum Guss bzw. zur verlorenen Form während der ersten Abkühlstufe des Gusses. Dabei ist von Vorteil, dass die Kavität einfach an ein geschlossenes Abluftsystem angeschlossen werden kann, das die Abgase gezielt entsorgt, bevor sie in die Umgebung gelangen können. Großdimensionierte Ablufthauben und entsprechend Leitungssysteme, die viel Nebenluft umwälzen, können so vermieden werden.The cavity for the primary cooling and the cavity for sucking off the casting gases is preferably the same. The cavity thus preferably has a dual function, as an exhaust pipe during casting and as coolant supply and discharge to the casting or to the lost form during the first cooling stage of the casting. It is advantageous that the cavity can be easily connected to a closed exhaust system that disposed of the exhaust gases targeted before they can get into the environment. Large-dimensioned exhaust hoods and corresponding piping systems, which circulate a lot of secondary air, can thus be avoided.
Vorzugsweise wird zusätzlich zu der primären Kühlung der verlorenen Form auch die Kokille, d.h. die Kokillenwände, nach dem Füllen direkt gekühlt ("sekundäre Kühlung"). Dies erfolgt in eigens dafür in der Kokillenwand vorgesehenen Kühlleitungen, die ebenfalls mit Kühlmittel durchströmt werden.Preferably, in addition to the primary cooling of the lost mold, the mold, i. the mold walls, directly cooled after filling ("secondary cooling"). This is done in specially provided for in the mold wall cooling lines, which are also flowed through with coolant.
Eine andere vorteilhafte Weiterbildung der Erfindung sieht vor, dass die verlorene Form beim Einsetzen in die geöffnete mehrteilige Kokille mittels Unterdruck in der Kokille gehalten wird.Another advantageous development of the invention provides that the lost mold is held by means of negative pressure in the mold during insertion into the open multi-part mold.
Besonders bevorzugt weisen die verlorene Form und die Kokille Passelemente auf, die beim Einsetzen der verlorenen Form in die geöffnete mehrteilige Kokille ineinander gefügt werden und so eine definierte Lage der Form in der Kokille sicherstellen. Die zusammenwirkenden Passelemente werden deshalb auch als Kernlager bezeichnet. Die Passelemente und die Unterdruckhalterung lassen sich dabei kombinieren, wie nachfolgend anhand von Ausführungsbeispielen erläutert wird.Particularly preferably, the lost form and the mold on matching elements that are inserted into each other when inserting the lost form in the open multi-part mold and so a defined position of the mold in the mold to ensure. The cooperating mating elements are therefore also called core bearings. The fitting elements and the vacuum holder can be combined, as will be explained below with reference to embodiments.
Es zeigen:
- Figur 1
- eine erste Ausführungsform einer verlorenen Form während des Einsetzens derselben in die Kokille;
- Figur 2
- eine Illustration des Füllschrittes anhand einer zweiten Ausführungsform der kombinierten verlorenen Form mit Kokille;
- Figur 3
- eine Illustration der primären Kühlung der kombinierten verlorenen Form mit Kokille;
- Figur 4
- eine Illustration des Öffnens der kombinierten verlorenen Form mit Kokille;
- Figur 5
- eine dritte Ausführungsform einer kombinierten verlorenen Form mit Kokille zur Verwendung in dem erfindungsgemäßen Verfahren;
- Figur 6
- eine vierte Ausführungsform einer kombinierten verlorenen Form mit Kokille zur Verwendung in dem erfindungsgemäßen Verfahren;
- Figur 7
- eine fünfte Ausführungsform einer kombinierten verlorenen Form mit Kokille zur Verwendung in dem erfindungsgemäßen Verfahren und
- Figur 8
- eine schematische Darstellung des Ablaufs des erfindungsgemäßen Verfahrens auf einer weitgehend automatisierten Gießlange.
- FIG. 1
- a first embodiment of a lost form during the insertion of the same in the mold;
- FIG. 2
- an illustration of the filling step using a second embodiment of the combined lost mold with mold;
- FIG. 3
- an illustration of the primary cooling of the combined lost mold with mold;
- FIG. 4
- an illustration of opening the combined lost form with mold;
- FIG. 5
- a third embodiment of a combined mold-lost mold for use in the method of the invention;
- FIG. 6
- a fourth embodiment of a combined mold-lost mold for use in the method of the invention;
- FIG. 7
- a fifth embodiment of a combined lost mold with mold for use in the inventive method and
- FIG. 8
- a schematic representation of the sequence of the method according to the invention on a largely automated Gießlange.
In
In der Form 10 ist eine Tragevorrichtung 14 mittels zweier erster Ankerelemente 16 fixiert. Die Tragevorrichtung ist so bereits ausreichend mit der Form 10 verbunden, um deren Eigengewicht zu tragen. Die Tragevorrichtung weist ferner ein zweites Ankerelement 18 auf, welches durch die Wand der Form 10 hindurch bis in den Hohlraum 12 hineinragt, um dort später teilweise mit dem Gussmaterial umgossen zu werden.In the
Das spätere Füllen des Hohlraums 12 in der verlorenen Form 10 erfolgt in üblicher Weise durch einen oder mehrere Anschnitte 20, der oder die bevorzugt von unten in den Hohlraum 12 münden, so dass der Hohlraum 12 der verlorenen Form von unten aufsteigend mit Gussmaterial, besonders bevorzugt im Niederdruckgussverfahren gefüllt werden kann.The subsequent filling of the
Die verlorene Form 10 wird vor dem Füllen mit Gussmaterial in der in
Die Kokillenhälften 22, 24 weisen weiterhin Verbindungskanäle 36 zwischen den Ausnehmungen 28 einerseits und einer Außenseite 38 der Kokillenhälften 22 und 24 auf. An die Verbindungskanäle 32 kann auf der Außenseite 34 eine Saugleitung (nicht gezeigt) angeschlossen werden, so dass zwischen der Innenwand 32 und der Außenwand 30 ein Unterdruck erzeugt werden kann. Die Form 10 wird dadurch mit ihren Vorsprünge 26 in die Ausnehmung 28 der Kokillenhälfte 22 hineingesogen und durch den anhaltenden Unterdruck in dieser gehalten, bis die Kokille geschlossen ist. Danach wird der Unterdruck nicht mehr benötigt und die Saugleitung kann entfernt bzw. der Unterdruck deaktiviert werden.The mold halves 22, 24 also have connecting
Selbstverständlich kann die Verbindung 32 auch an einer anderen Stelle der Grenzfläche zwischen der verlorenen Form 10 und der mehrteiligen Kokille angreifen, so dass die Passelemente und die Verbindungskanäle zur Unterdruckfixierung räumlich voneinander getrennt sind. In der gezeigten Weise jedoch sind die Passelemente und die Mittel zur Unterdruckfixierung in vorteilhafter Weise kombiniert.Of course, the
Zwischen der Innenwand 32 der Kokille und der Außenwand 30 der verlorenen Form 10 ist eine Kavität 40 angeordnet, die als Leitung für ein Kühlmedium zum Kühlen der verlorenen Form, also der primären Kühlung dient. Die Kavität 40 als umfänglich geschlossene Kühlmittelleitung wird erst beim Zusammenfügen der verlorenen Form 10 und der Kokille gebildet, weil sie zur Hälfte in der Außenwand 30 in der Form jeweils eines offenen spiral- oder schneckenförmigen Kanals 42 bzw. 44 ausgebildet ist. Anstelle einer umlaufenden Kavität können auch mehrere Kavitäten vorgesehen sein. Auch muss diese nicht spiral- oder schneckenförmig um die verlorene Form 10 umlaufend angeordnet sein sondern kann beispielsweise auch meanderförmig oder sich mehrfach gitterförmig kreuzend ausgestaltet werden. Die Kavität 40 weist wenigstens zwei Verbindungskanäle 46 und 48 zur Außenseite der Kokille auf, so dass diese an ein Kreislaufsystem oder ein Zuführsystem für ein Kühlmedium angeschlossen werden kann.Between the
Als Mittel für eine sekundäre Kühlung der Kokillenwände ist eine weiteres Leitungssystem 50 in den Kokillenwänden vorgesehen, das seinerseits durch nicht gezeigte Anschlüsse nach außen geführt ist und an ein Kreislauf- oder Zuführsystem für ein weiteres Kühlmedium angeschlossen werden kann.As a means for a secondary cooling of the mold walls, a
In
Bei der hier gezeigten Ausführungsform weist die verlorene Form 10 über dem Hohlraum 12 für das Gussteil einen weiteren Hohlraum auf, in den zuvor eine Speiserkappe 52 eingesetzt wurde, wie dies in der Schrift
Aufgrund der Verwendung einer Speiserkappe 52 ist in diesem Beispiel auch die Tragevorrichtung 14 anders ausgestaltet. Diese weist ein in den Hohlraum der Speiserkappe 52 eingreifendes Ankerelement 18 auf, welches ausreichend fest mit der Speiserkappe und/oder der Form 10 verbunden ist, um deren Eigengewicht tragen zu können. Nachdem das eingebrachte Gussmaterial 54 um das Ankerelement 18 herum erstarrt ist, wird die Last auch oder sogar überwiegend durch die so entstandene Verbindung getragen und das Gussteil kann samt Form 10 an der Tragevorrichtung gehalten werden.Due to the use of a
Am Ende des in
In
In
Auf diese Weise wird die Form zerstörungsfrei aus der Kokille entnommen und der zweiten Abkühlstufe zugeführt. Wie vorstehend beschrieben, wird die Form 10 so beispielsweise in einen Kühlraum transportiert, indem sie unter geregelten oder zumindest gesteuerten thermischen Bedingungen in gewünschter Weise weiter heruntergekühlt wird, bis die Gusstemperatur, vorzugsweise an der Tragevorrichtung 14 gemessen, den voreingestellten Wert erreicht hat, was vorzugsweise dann der Fall ist, wenn die gewünschte Auspacktemperatur von beispielsweise 300°C erreicht oder unterschritten wurde und die weitere Abkühlung keinen Einfluss mehr auf das Gefüge und die Gussteileigenschaften hat.In this way, the mold is removed without destruction from the mold and fed to the second cooling stage. For example, as described above, the
Anhand des Ablaufschemas in
Ist die Sandform hergestellt, wird sie manuell, teilautomatisch oder vorzugsweise mittels einem Roboter R1 vollautomatisch an die nächste Station übergeben. An dieser findet die sogenannte Kernpaketmontage 102 statt. Hierbei werden mehrere Teilformen zu dem Kernpaket, der verlorenen Form, wie Sie für den Guss benötigt wird, zusammengesetzt. Dieser Schritt kann je nach Entformbarkeit und Anforderung an die Oberflächengüte des Gussteils bei Bedarf durch ein zusätzliches Kernschlichten, z.B. mittels Sprühroboter, ergänzt werden.Once the sand mold has been produced, it is transferred to the next station fully automatically, manually or semi-automatically or preferably by means of a robot R1. At this the so-called
Auf die Kernpaketmontage 102 folgt optional das Lagern 104 des Kernpaketes. Es steht im Lager auf Abruf bereit. Je nach Stückzahl, Prozessgeschwindigkeit, Kernfertigungsgegebenheiten und Produktions-Prozesserfordernissen wird üblicherweise eine bestimmte Anzahl von Kernpaketen vorgehalten oder es kann eine just-in-time-Produktion bei optimalen Kernproduktionsgegebenheiten ohne Lagerhaltung vorgesehen sein, wenn deren Herstellung genauso schnell oder schneller als die im Folgenden beschriebenen Arbeitsschritte gelingt.The
Aus dem Kernlager wird das Kernpaket bei Bedarf entnommen und dem nächsten Prozessschritt 106 zugeführt. Das Entnehmen und Zuführen wird abermals vorzugsweise vollautomatisiert durch einen Roboter R2 erfolgen.If necessary, the core package is removed from the core storage and fed to the
Zentrales Modul zur Ausführung des erfindungsgemäßen Verfahrens ist eine sogenannte Fertigungsinsel I1, auch als "Karussell" bezeichnet, auf der wenigstens 5, hier 6 der erfindungswesentlichen Verfahrensschritte ausgeführt werden. Als erster Arbeitsschritt 106 wird an einer ersten Arbeitsstation der Fertigungsinsel I1 das Kernpaket in eine geöffnete, mehrteilige Kokille eingesetzt und diese verschlossen. Dies geschieht vorzugsweise in der zuvor unter Bezugnahme auf
Ist die mehrteilige Kokille geschlossen, wechselt die Arbeitsstation und in einem Arbeitsschritt 108 wird der Hohlraum der verlorenen Form mit Gussmaterial, vorzugsweise im Niederdruck-Gießverfahren gefüllt. Ist das Füllen beendet, wird die verlorene Form mittels einem Absperrschiebers verschlossen und kann danach dem nächsten Arbeitsschritt 110 zugeführt werden. Hierzu wechselt die Kokille erneut zur nächsten Arbeitsstation, an der der ersten Abkühlschritt, also das primäre Kühlen der Form, und wahlweise gleichzeitig oder nacheinander das sekundäre Kühlen der Kokille einsetzen. Hierzu wird die Kokille, bzw. genauer die zuvor beschriebenen Verbindungskanäle 46 und 48 an ein Kühlmittelsystem, vorzugsweise an einen Kühlmittelkreislauf, angeschlossen. Ferner kann auch das zuvor beschriebene Leitungssystem 50 in den Kokillenwänden an ein Kühlmittelsystem, vorzugsweise einem Kühlmittelkreislauf, angeschlossen werden und das oder die Kühlmittelsysteme in Gang gesetzt werden. Die Kühlvorgänge dieses Arbeitsschrittes 110 erfolgen besonders bevorzugt geregelt unter Überwachung der Guss- oder Kokillentemperatur. Diese kann wiederum bevorzugt an der zuvor beschriebenen Tragevorrichtung gemessen werden.If the multi-part mold is closed, the workstation changes and in a
Das Abkühlen erfolgt bei dieser Ausführungsform über insgesamt drei Arbeitsstationen, also auch in den Arbeitsschritten 112 und 114. Während des gesamten primären Kühlvorgangs bewegt sich die Fertigungsinsel I1 also zwei Arbeitspositionen weiter, so dass die vorausgegangenen Arbeitsstationen zwischenzeitlich wieder zur Ausführung der Arbeitsschritte 106 und 108 zur Verfügung stehen. Das Verhältnis der Dauer für das Einlegen der Form 10 in die Kokille in Schritt 106 und das Füllen in Schritt 108 zur Dauer des primären Kühlvorgangs (ggfs. mit Kühlung der Kokille) bestimmt die Anzahl der für die Kühlung reservierten Arbeitsstationen.The cooling takes place in this embodiment, a total of three workstations, including in the
An der letzten Arbeitsstation der Fertigungsinsel wird die Kokille mit der abgekühlten verlorenen Form 10 dem Arbeitsschritt 116 unterzogen, bei dem die mehrteilige Kokille geöffnet wird, frühestens nachdem der Guss, wie vorstehend beschrieben, zumindest teilweise erstarrt ist. Gleichzeitig wird die verlorene Form an der Tragevorrichtung hängend in der oben beschriebenen Weise aus der geöffneten Kokille entnommen. Dies geschieht abermals vorzugsweise mittels eines Roboters R3 vollautomatisiert, um eine zerstörungsfreie Entnahme der verlorenen Form sicherzustellen.At the last work station of the manufacturing island, the mold with the cooled lost
Der Roboter R3 übergibt die verlorene Form dann an eine Kühlstrecke, in der sie noch immer an der Tragevorrichtung hängend weiter gekühlt wird, Schritt 118.The robot R3 then transfers the lost form to a cooling line, in which it is still cooled on the carrying device,
Hat der in der verlorenen Form eingeschlossene Guss mit dem gewünschten Gefüge schließlich die Auspacktemperatur von beispielsweise 300°C erreicht, erfolgt im Anschluss Schritt 120, in dem der Guss schließlich durch mechanisches Entfernen der verlorenen Form entformt wird. Dieser Schritt wird auch als "Ausleeren" oder "Grobentsandung" bezeichnet.Finally, if the casting having the desired texture enclosed in the lost mold has reached the unpacking temperature of, for example, 300 ° C.,
Hierauf erfolgt ein Strahlen 122, um den Guss von Sandresten zu befreien. Ist dieser Prozessschritt abgeschlossen, wird die Gussform, vorzugsweise mittels eines weiteren Roboters R4 voll automatisiert, einer Trennstation zugeführt, die als nächsten Schritt die Abtrennung 124 des Speisers und/oder der Tragevorrichtung umfasst. Hieran schließen sich in an sich bekannter Weise die Endkontrolle 126 sowie die Übergabe 128 an den Versand oder das Teilelager an.This is followed by blasting 122 to rid the cast of sand residue. Once this process step has been completed, the casting mold, preferably fully automated by means of another robot R4, is fed to a separating station, which as the next step comprises the
- 1010
- verlorene Form, Kernpaketlost form, core package
- 1212
- Hohlraumcavity
- 1414
- Tragevorrichtungcarrying device
- 1616
- erste Ankerelementefirst anchor elements
- 1818
- zweites Ankerelementsecond anchor element
- 2020
- Anschnittbleed
- 2222
- erste Kokillenhälftefirst mold half
- 2424
- zweite Kokillenhälftesecond mold half
- 2626
- Passelement, NaseFitting element, nose
- 2828
- Passelement, AusnehmungFitting element, recess
- 3030
- Außenwand der FormOuter wall of the mold
- 3232
- Innenwand der KokilleInner wall of the mold
- 3434
- Kernlagercore storage
- 3636
- Verbindungskanalconnecting channel
- 3838
- Außenseite der KokilleOutside of the mold
- 4040
- Kavitätcavity
- 4242
- spiral- oder schneckenförmiger Kanalspiral or helical channel
- 4444
- spiral- oder schneckenförmiger Kanalspiral or helical channel
- 4646
- Verbindungskanalconnecting channel
- 4848
- Verbindungskanalconnecting channel
- 5050
- Leitungssystemline system
- 5252
- Speiserkappefeeder cap
- 5454
- Gussmaterialcast material
- 5555
- Sperrschieberblocking slide
- 5656
- Guss oder GussteilCasting or casting
- 5858
- SacklochbohrungBlind hole
- 100100
- Kernfertigungcore production
- 102102
- KernpaketmontageCore package assembly
- 104104
- Kernlagercore storage
- 106106
- Einsetzen der verlorenen Form und Schließen der KokilleInserting the lost mold and closing the mold
- 108108
- FüllenTo fill
- 110110
- KühlenCool
- 112112
- KühlenCool
- 114114
- KühlenCool
- 116116
- Öffnen der Kokille und Entnehmen der geöffneten FormOpen the mold and remove the open mold
- 118118
- Kühlen der verlorenen FormCooling the lost form
- 120120
- Entformen des GussteilsRemoval of the casting
- 122122
- Strahlenradiate
- 124124
- Abtrennen der TragevorrichtungDisconnect the carrying device
- 126126
- Endkontrollefinal check
- 128128
- Lagern oder VersendenStoring or shipping
Claims (15)
- Method for producing ferrous metal castings, in which:- a broken mould (10) having a hollow space (12) for receiving casting material (54) is placed in an open multi-component permanent mould (22, 24) (step 106),- the multi-component permanent mould (22, 24) is closed (step 106),- the hollow space (12) of the broken mould is filled with casting material (54), wherein a carrier device (14) which partially protrudes into the hollow space (12) of the broken mould (10) is partially cast round with the casting material (54) (step 108),- the broken mould (10) is cooled after being placed in the permanent mould (22, 24) (steps 110, 112, 114),- the multi-component permanent mould (22, 24) is opened during the cooling, at the earliest after the value has fallen below the liquidus temperature, preferably after the value has fallen below the solidus temperature and, in a particularly preferred manner, even before the cast has reached the eutectoid transformation temperature, and the broken mould (10) is removed with the cast in a nondestructive manner from the open permanent mould (step 116),- the broken mould (10) is further cooled with the cast suspended on the carrier device (14), at least until the structure formation of the cast is complete (step 118),- the cast is removed from the mould by removing the broken mould (10) (step 120).
- Method according to claim 1, characterised in that the carrier device (14) together with a feeder cap (52) is inserted into the broken mould (10) before the broken mould is inserted into the open permanent mould.
- Method according to claim 1 or 2, characterised in that the hollow space (12) of the broken mould (10) is filled from below with casting material (54).
- Method according to claim 3, characterised in that the hollow space (12) of the broken mould (10) is filled using the low-pressure casting method.
- Method according to claim 3 or 4, characterised in that the broken mould (10) after being filled with casting material (54) is closed by means of a closing sliding member.
- Method according to claim 5, characterised in that the permanent mould with the broken mould (10) and cast is transported away from the casting station after being closed.
- Method according to claim 5 or 6, characterised in that the cooling of the broken mould (10) begins after the broken mould has been closed.
- Method according to any one of the preceding claims, characterised in that the broken mould (10) is cooled by means of a cooling medium which flows through a cavity (40) which is arranged between the inner wall of the permanent mould (32) and the outer wall of the broken mould (30).
- Method according to claim 8, characterised in that the cooling medium flow is carried out in a temperature-controlled and/or mass-controlled, time-controlled and/or module-controlled manner.
- Method according to any one of the preceding claims, characterised in that the broken mould (10) and cast (56) are supplied to a cooling space suspended on the carrier device (14) and further cooled therein, optionally in a controlled or regulated manner with temperature monitoring.
- Method according to any one of the preceding claims, characterised in that the cast temperature during the cooling of the broken mould (10) before and/or after the permanent mould (22, 24) has been removed is measured on the carrier device (14).
- Method according to any one of the preceding claims, characterised in that during the filling (108) of the hollow space (12) of the broken mould (10) with casting material (54) casting gases are drawn off through a cavity (40) which is arranged between the inner wall (32) of the permanent mould (22, 24) and the outer wall of the broken mould (30).
- Method according to any one of the preceding claims, characterised in that the permanent mould (22, 24) is cooled after the filling operation (108).
- Method according to any one of the preceding claims, characterised in that the broken mould (10) during insertion into the open multi-component permanent mould (22, 24) is retained in the permanent mould by means of reduced pressure.
- Method according to any one of the preceding claims, characterised in that the broken mould (10) and the permanent mould have fitting elements (26, 28) which are fitted one inside the other when the broken mould (10) is inserted into the open multi-component permanent mould (22, 24).
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102014217701.4A DE102014217701A1 (en) | 2014-09-04 | 2014-09-04 | Process for producing metal casts |
PCT/EP2015/069509 WO2016034467A1 (en) | 2014-09-04 | 2015-08-26 | Method for producing iron metal castings |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3188860A1 EP3188860A1 (en) | 2017-07-12 |
EP3188860B1 true EP3188860B1 (en) | 2018-07-04 |
Family
ID=53969369
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15753958.6A Active EP3188860B1 (en) | 2014-09-04 | 2015-08-26 | Method for producing iron metal castings |
Country Status (9)
Country | Link |
---|---|
US (1) | US10086430B2 (en) |
EP (1) | EP3188860B1 (en) |
KR (1) | KR102139349B1 (en) |
CN (1) | CN106715003B (en) |
BR (1) | BR112017004311A2 (en) |
DE (1) | DE102014217701A1 (en) |
ES (1) | ES2687103T3 (en) |
MX (1) | MX362145B (en) |
WO (1) | WO2016034467A1 (en) |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US20210245238A1 (en) * | 2018-08-24 | 2021-08-12 | Grouper Casting, Llc | Molding tool with high-performance cooling system |
CN109849376B (en) * | 2018-12-21 | 2023-07-04 | 四川明日宇航工业有限责任公司 | Half-and-half type composite pipe fitting forming tool and demolding method thereof |
CN114247869B (en) * | 2021-12-14 | 2023-03-24 | 昆山恒特工业机械有限公司 | Mold mixed cooling structure and low-pressure hub mold with same |
CN113953466B (en) * | 2021-12-23 | 2022-04-05 | 晋西装备制造有限责任公司 | Sand box with adjustable height and rib plate position |
DE102021006413A1 (en) * | 2021-12-30 | 2023-07-06 | Wolfgang Leisenberg | Process and casting machine for the production of molded parts |
US11766716B2 (en) * | 2022-01-04 | 2023-09-26 | GM Global Technology Operations LLC | System and method of increasing cooling rate of metal sand casting during solidification |
CN114734006B (en) * | 2022-04-20 | 2023-04-25 | 辽宁科技大学 | Control method for improving solidification quality of cast ingot |
PL441972A1 (en) * | 2022-08-08 | 2023-07-10 | Krakodlew Spółka Akcyjna | Method of vertical mould pouring of large-size solid slab castings |
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DE3134159A1 (en) * | 1981-08-28 | 1983-03-10 | Norddeutsche Affinerie, 2000 Hamburg | Method for the transportation of solidified cast shapes and its application |
JPS5997740A (en) * | 1982-11-26 | 1984-06-05 | Mitsubishi Heavy Ind Ltd | Casting mold |
JPH0195867A (en) * | 1987-10-05 | 1989-04-13 | Mazda Motor Corp | Casting taking out method |
CN2093049U (en) * | 1991-03-16 | 1992-01-15 | 王玉峰 | Cold hard casting hard mould for ball body |
RU2127172C1 (en) | 1994-05-27 | 1999-03-10 | Георг Фишер Диса А/С | Method of closing mold inlet after nongravity casting of noniron alloy in green-sand molds of row plant (versions) |
SE513287C2 (en) | 1998-11-06 | 2000-08-21 | Volvo Lastvagnar Ab | Method and apparatus for mold casting |
DE19932116A1 (en) | 1999-07-09 | 2001-01-18 | Daimler Chrysler Ag | Casting apparatus for die casting light metal parts has a hood that can move relative to the casting mold, covers at least the region of the feeder and is provided with a connection for pressurized air |
SE0001388D0 (en) * | 2000-04-13 | 2000-04-13 | Mikael Wennberg | Device and method of thermal treatment in a casting process |
IT1316255B1 (en) * | 2000-12-06 | 2003-04-03 | Ct Sviluppo Materiali Spa | PROCESS FOR THE MANUFACTURE OF MOLDS. |
CN1439469A (en) * | 2003-01-26 | 2003-09-03 | 孙柏良 | Vacuum feeding hydrocooling mould cast technology |
CN1318159C (en) * | 2004-12-22 | 2007-05-30 | 华南理工大学 | Method for manufacturing die containing interior passageway and its application in directional solidification |
CA2689475C (en) * | 2007-09-10 | 2018-03-20 | Weir Minerals Australia Ltd | A method and apparatus for the production of a casting |
JP5056606B2 (en) * | 2008-06-16 | 2012-10-24 | 横浜ゴム株式会社 | Casting method |
DE102010035440B4 (en) | 2010-08-26 | 2012-04-12 | Huppert Engineering Gmbh & Co. Kg | Apparatus for casting cast iron in a mold |
DE102010051348B3 (en) | 2010-11-13 | 2011-11-03 | Huppert Engineering Gmbh & Co. Kg | Feeder cap for maintaining volume shrinkage of casting material occurring during solidification of casting through integrated transport device, comprises anchor arms plunging into feeder body, and coupling part |
CN203437623U (en) * | 2013-08-16 | 2014-02-19 | 重庆市极鼎金属铸造有限责任公司 | Die used for casting |
-
2014
- 2014-09-04 DE DE102014217701.4A patent/DE102014217701A1/en not_active Ceased
-
2015
- 2015-08-26 EP EP15753958.6A patent/EP3188860B1/en active Active
- 2015-08-26 US US15/508,248 patent/US10086430B2/en not_active Expired - Fee Related
- 2015-08-26 MX MX2017002802A patent/MX362145B/en active IP Right Grant
- 2015-08-26 ES ES15753958.6T patent/ES2687103T3/en active Active
- 2015-08-26 BR BR112017004311A patent/BR112017004311A2/en not_active IP Right Cessation
- 2015-08-26 KR KR1020177009073A patent/KR102139349B1/en active IP Right Grant
- 2015-08-26 WO PCT/EP2015/069509 patent/WO2016034467A1/en active Application Filing
- 2015-08-26 CN CN201580047050.8A patent/CN106715003B/en not_active Expired - Fee Related
Non-Patent Citations (1)
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None * |
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CN106715003B (en) | 2020-03-03 |
KR102139349B1 (en) | 2020-07-29 |
DE102014217701A1 (en) | 2016-03-10 |
MX2017002802A (en) | 2018-01-12 |
WO2016034467A1 (en) | 2016-03-10 |
EP3188860A1 (en) | 2017-07-12 |
MX362145B (en) | 2018-12-24 |
CN106715003A (en) | 2017-05-24 |
US20170355015A1 (en) | 2017-12-14 |
US10086430B2 (en) | 2018-10-02 |
BR112017004311A2 (en) | 2017-12-05 |
KR20170049566A (en) | 2017-05-10 |
ES2687103T3 (en) | 2018-10-23 |
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