EP3208013B1 - Procédé de moulage d'un élément structurel ayant une géométrie complexe à l'aide d'un moule segmenté - Google Patents

Procédé de moulage d'un élément structurel ayant une géométrie complexe à l'aide d'un moule segmenté Download PDF

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Publication number
EP3208013B1
EP3208013B1 EP17153442.3A EP17153442A EP3208013B1 EP 3208013 B1 EP3208013 B1 EP 3208013B1 EP 17153442 A EP17153442 A EP 17153442A EP 3208013 B1 EP3208013 B1 EP 3208013B1
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EP
European Patent Office
Prior art keywords
mould
mold
segments
casting
lost
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German (de)
English (en)
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EP3208013A1 (fr
Inventor
Christoph Pille
Franz-Josef Wöstmann
Jan Clausen
Marco Haesche
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Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes

Definitions

  • the present invention relates to a method for casting an electrical coil, in particular by means of die casting, in which a casting mold is used, of which at least one molded part is designed as a lost mold.
  • a well-known method for casting electrical coils is the lost-mold investment casting method.
  • a positively formed model of the coil is made from wax or a polymer, for example, which is then coated with a non-solid investment material is poured around, which then sets and hardens.
  • the model is melted out of the hardened investment material and, if necessary, the investment material is additionally fired in order to achieve maximum strength and stability. In this case, any remaining or unmelted residue from the model burns almost completely.
  • the resulting cavity in the embedding compound is then filled with molten metal. After the molten metal has solidified, the investment compound is then destroyed in order to expose the cast part.
  • the EP 2387135 A2 describes a method for manufacturing an electrical coil using casting technology, in which a negative mold containing the coil geometry is used as a lost mold or as a permanent mold. Sand or an embedding compound is proposed as the molding material for the lost form.
  • the publication also mentions the use of multi-part segments that are joined before or during the forming process to produce the negative mold, but without going into more detail on this.
  • the DE 102012006572 A1 describes a process in which a lost casting mold is first produced as a block mold and then inserted as a mold insert into permanent metallic molds in order to produce the component by means of pressure die casting.
  • a ceramic embedding compound is used as the mold material for the lost form.
  • Salt cores of this type are produced in one piece from salts and salt mixtures and can be removed again after the casting has been cast.
  • the surface quality of the manufactured component is very important, especially in the manufacture of electrical coils.
  • a smooth, defect-free or defect-free surface is required for the subsequent application of a homogeneous electrical insulation coating.
  • edge effect which leads to non-homogeneous layer formation of the coating at the edges of the coil, must be avoided.
  • an edge rounding must be carried out, which is carried out as post-processing of the cast part and thus causes additional work.
  • the object of the present invention is to specify a method for casting an electrical coil, in which the component is obtained with a high surface quality.
  • the process should manage without draft angles in the casting mold used.
  • a mold is used, of which at least one molded part is designed as a lost mold.
  • the at least one molded part designed as a lost mold is produced from a salt or a salt mixture.
  • at least one outer part of the casting mold, which defines an external geometry of the component, or at least one inner part of the casting mold, which defines an internal geometry of the component is composed of more than two mold segments.
  • a mold composed of more than two mold segments from which at least one molded part is produced as a lost mold from a salt or a salt mixture
  • complex components with undercuts and/or cavities with high surface quality can be produced, for example electrical coils.
  • the production of molded parts from salt by casting, in particular in the pressure die-casting process enables the molded part to have very smooth surfaces. These smooth surfaces are also reflected in the component cast with them, which then has a correspondingly high surface quality.
  • the one or more lost mold molded parts are preferably produced by casting, particularly preferably by means of die casting.
  • the entire casting mold is made entirely as a lost mold.
  • the casting mold is preferably composed of more than two mold segments stacked on top of one another.
  • several of the mold segments can be designed identically, i.e. as identical parts. This simplifies the production and also enables a corresponding scaling of the components to be produced, for example the number of coil turns using the example of an electrical coil, without having to produce different casting molds for this purpose.
  • the form segments can also vary individually or be mixed and matched.
  • the mold segments in a modular manner up, in or plugged together and thus gradually build up a complete casting mold.
  • the mold segments can be connected to one another, for example, via a groove-key connection or via a dowel pin connection.
  • the segment construction described above is not used as the entire casting mold, but as a mold insert for a permanent mold.
  • the mold insert can specify the entire geometry of the component to be cast.
  • the outer part of the casting mold, which defines the outer geometry of the component to be cast is designed as a permanent mold and the inner part through the mold insert as a lost mold in the segment construction described above.
  • the dismantling of the casting mold or the mold insert into individual mold segments enables flexible, cost-effective production of complex components, which also have a high surface quality through the use of salts or salt mixtures as molding material for the resulting lost mold.
  • Each mold segment is preferably designed without undercuts and can accordingly be manufactured using simple manufacturing processes, preferably again using a casting process or also sintering or pressing processes.
  • the mold segments have no draft angles in the area of the cavity, which is filled with molten metal to form the component.
  • complex components with several plane-parallel, flat sub-areas or windings - in the geometry of electric coils - can be cast with high quality.
  • the mold segments preferably have corresponding structures, so that after assembly, a sprue that can be used for casting is obtained.
  • An overflow or a ventilation system can also be implemented in the same way.
  • the sprue is preferably carried out on the (short) side of the end winding. This serves to reduce mechanical reworking.
  • the assembled mold can either be used directly as a casting mold and filled with molten metal or used as a mold insert in a permanent mold and stabilized by the permanent mold.
  • the individual mold segments can be designed in such a way that the edges of the inner component edges are rounded. Corresponding post-processing of the component is then no longer necessary.
  • the mold segments can be dimensioned and manufactured in such a way that they each define one turn of the coil.
  • the inner and outer parts of the mold can be made to interlock. This avoids burrs on the inside of the coil turns and moves them to the surface of these turns or to the area of the edge rounding.
  • Components with very complex geometries can be produced with the proposed method.
  • the process for the production of an electrical coil enables the realization of edge roundings on the inside when using a permanent mold in connection with a mold insert as a lost molded part, the realization of edge roundings on the outside of the component in connection with the elimination of draft angles when using a permanent mold or of permanent mold elements as well as the omission of draft angles in combination with a targeted shifting of the burr formation. Due to the use of lost molded parts as lost cores or mold inserts, no draft angles are required.
  • the method has cost advantages in complex systems, since complex slide technology is not required in many configurations.
  • FIG. 1 shows an example of an electrical coil 10 in the upper part of the figure, as it can be cast with the proposed method.
  • the lower part of the figure figure 1 FIG. 12 shows the coil 10 again in an exploded form, just for illustration, around the individual turns 11 to be able to recognize better.
  • a mold insert for a metallic permanent mold is used in the present example, which is formed from lost mold segments stacked on top of one another.
  • the individual mold segments 1 are made from a salt or a salt mixture, preferably in a casting process (particularly pressure-assisted casting) or in a pressing or sintering process.
  • Suitable techniques are known to the person skilled in the art from the prior art, for example also from that already mentioned DE 102012022331 A1 , known.
  • the production of these mold segments 1 by casting from a salt or a salt mixture results in a high surface quality of the segments, which is transferred to the windings of the electrical coil to be produced.
  • FIG. 2 shows four such mold segments 1 stacked on top of each other to form the mold insert. They can, for example, be connected to one another via a groove and feather key connection, not shown in the figure, in order to ensure correct and true-to-position assembly of the mold segments.
  • figure 3 shows the mold segments 1 stacked on top of each other, figure 4 a cut through this stack of shape segments.
  • figure 5 shows an example of a mold segment 1, which has holes 12 for a dowel pin connection and lateral openings 14 for filling and/or venting.
  • FIG. 12 again shows a plurality of mold segments 1 stacked one on top of the other with corresponding openings for filling and/or venting, wherein alignment pins 13 can be seen in this example.
  • the assembled mold segments 1 are then placed in a permanent mold 2 and filled with molten metal.
  • An example of such a permanent form 2 is in figure 7 shown.
  • the melt is guided into the cavity of the mold segments and vented via a gating and venting system 3a, 3b suitable for the casting process.
  • this gating and ventilation system 3a, 3b is implemented in the permanent mold and can optionally also be shown in the mold segments 1 (cf. figure 5 and 6 ).
  • figure 8 shows an example of the permanent mold 2 with the mold segments 1 inserted therein.
  • the cavity for the individual winding to depict the cast part can only be introduced into the mold segment 1 on one side, as is the case in the example in FIG figure 9 is shown.
  • This figure shows how the Figures 10 and 11 , Four stacked mold segments 1 in cross section, in which the cavity 4 for the formation of the coil windings 11 can be clearly seen.
  • the cavity 4 is introduced on one side in the upper and lower side of the mold segment 1 to depict the cast part, as shown in figure 10 is shown as an example.
  • the burr formation is preferably targeted at the level of Edge rounding of the casting relocated.
  • the cavity 4 for imaging the cast part is made with a larger proportion in the upper side and with a smaller proportion in the lower side of the respective mold segment 1 with a corresponding mold offset. this is in figure 11 shown as an example.
  • Mold segments 1 shown can also be used without an outer permanent mold, so that they form the complete casting mold. However, using an external permanent shape is advantageous for reasons of stability.
  • the cavity for the production of the complex casting geometry by casting is formed by the combination of metallic permanent mold elements, which define an outer shape of the casting, with lost mold segments, which define the inner geometry of the casting.
  • FIG 12 a combination of an inner core 5 made of lost core material (salt core) with outer permanent mold elements 6, 7 is shown, which are preferably made of two mold halves of the permanent mold or as pullable slide elements.
  • the exposed inner cavity 4 forms the casting.
  • the one in the figure 12 The arrows shown indicate the structure of the permanent mold elements 6, 7 as a large number of slide elements that can be pulled.
  • the permanent mold elements 6, 7 and the inner core 5 are so designed so that an edge rounding of the casting - shown on the inside in the inner lost core 5 and on the outside shown by the permanent mold elements 6, 7 - is obtained.
  • the formation of burrs on the inside is determined at the height of the edge rounding. This is achieved by the positioning of the parting plane between the inner core 1 and permanent mold elements 6, 7, as is also the case in FIG figure 13 is shown.
  • a burr formation on the outside is also selected at the level of the edge rounding, produced by one-sided cavity formation in the permanent mold element, as is shown in FIG figure 14 is illustrated.
  • figure 15 shows an example where the burr formation on the outside is variably positioned along the edge rounding.
  • a two-sided cavity formation in the permanent mold elements 6, 7 is selected.
  • part of the cavity for the turns of the electric coil is formed by the inner core 5 .
  • the cavity 4 is formed proportionately by the inner core 1 and by the permanent mold elements 6, 7, as in FIG figure 16 is shown.
  • the permanent mold is again designed with slide elements that can be pulled.
  • two mold halves with a corresponding inner contour can also be used.
  • figure 17 shows the design of the figure 16 again with a detail.
  • the edge rounding of the cast part is achieved on the inside by the lost core 1 and imaged on the outside by the permanent mold elements 6,7.
  • figure 19 shows an embodiment in which the formation of burrs on the outside is variably positioned along the edge rounding. This is achieved by two-sided cavity formation in the permanent mold elements 6, 7.
  • the design of figure 20 shows an inner core 1 made of lost core material with raised webs that engage in the cavities of the outer permanent mold elements 6, 7.
  • the permanent mold elements can in turn consist of two mold halves or—as in the present example—be designed as slide elements that can be pulled.
  • the exposed inner cavity 4 in turn forms the cast part.
  • the design of figure 20 with the raised webs on the inner core 5 has the advantage that the permanent shaped elements 6, 7 engage in the lost core 5 (or vice versa) and thus both support each other.
  • figure 21 shows a further development of this embodiment, in which the edge rounding of the cast part is reproduced on the inside by the webs of the inner lost core 1 and on the outside by the permanent mold element 6, 7.
  • a two-sided burr formation on the inside is produced by pushing the web 8 from the inner lost core 5 into the cavity of the permanent mold elements 6, 7.
  • This burr formation can occur on the outside at the level of the edge rounding if a one-sided cavity formation in the permanent mold elements 6, 7 is chosen.
  • the formation of burrs can, as in figure 23 shown, can also be variably positioned along the edge rounding if a two-sided cavity formation is selected in the permanent mold elements 6, 7.
  • FIG. 1 shows an embodiment in which the expendable core 5 has an integrated insert 9 which is integrated during the manufacture of this expendable core 5.
  • the integrated insert 9 can be pulled out and destroys or damages the lost core in order to demould it more easily.
  • This insert 9 can be a mechanically stable element made of steel, iron, plastic, etc., or it can be a wire, a rope or a fabric.
  • the insert 9 is designed in such a way that it leads to damage or destruction of the core 5 when it is pulled out of the lost core 5 .
  • the proposed method can be used with different casting techniques for metal casting, for example die casting, the semi-solid method/thixocasting, low-pressure casting, gravity die casting or metal injection molding.
  • the casting mold is filled with a metallic melt, preferably with a melt of aluminum, copper, zinc, magnesium, steel, iron, cast iron and their alloys.
  • the casting mold can be thermally heated before casting.
  • the molded parts designed as a lost mold can be designed in such a way that they are blown up or broken open by the solidifying molten metal after being filled with the molten metal due to thermal and/or mechanical stresses.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (16)

  1. Procédé de moulage d'une bobine électrique (10), notamment par moulage sous pression, dans lequel un moule de moulage est utilisé, dont au moins une pièce moulée (1, 5) est configurée comme un moule perdu, dans lequel
    - au moins une pièce moulée sous forme perdue (1, 5) est fabriquée à partir d'un sel ou d'un mélange de sel, et
    - au moins une partie extérieure du moule, à travers laquelle une géométrie extérieure de la bobine (10) est définie, ou au moins une partie intérieure du moule, à travers laquelle une géométrie intérieure de la bobine (10) est définie, est composée de plus de deux segments de moule (1) empilés les uns sur les autres, qui définissent respectivement une spire de la bobine (10) .
  2. Procédé selon la revendication 1, caractérisé en ce que le moule de moulage est complètement fabriqué sous forme perdue.
  3. Procédé selon la revendication 1, caractérisé en ce que le moule de moulage est formé à partir d'un moule permanent avec un insert de moule renfermé à l'intérieur, dans lequel l'insert de moule est complètement fabriqué sous forme perdue.
  4. Procédé selon la revendication 2, caractérisé en ce que le moule de moulage est composé de plus de deux segments de moule (1) empilés l'un sur l'autre.
  5. Procédé selon la revendication 3, caractérisé en ce que l'insert de moule est composé de plus de deux segments de moule (1) empilés l'un sur l'autre.
  6. Procédé selon une des revendications 1 à 5, caractérisé en ce que les segments de moule (1) sont conçus de manière à ne présenter aucun angle de dépouille.
  7. Procédé selon la revendication 1, caractérisé en ce que la partie extérieure du moule est configurée comme un moule permanent (2) et la au moins une partie intérieure est fabriquée sous forme de moule perdu.
  8. Procédé selon la revendication 7, caractérisé en ce que la partie intérieure est composée de plus de deux segments partiels empilés les uns sur les autres.
  9. Procédé selon la revendication 7 ou 8, caractérisé en ce que la partie intérieure est configurée de manière à ce que les bords des bobines intérieures soient arrondis.
  10. Procédé selon une quelconque des revendications 7 à 9, caractérisé en ce que la partie intérieure et la partie extérieure du moule sont configurées de manière à s'emboîter.
  11. Procédé selon une quelconque des revendications 1 à 10, caractérisé en ce que au moins une pièce moulée sous forme perdue (1, 5) à partir du sel ou du mélange de sel est fabriquée par une technique de moulage, en particulier au moyen du moulage sous pression.
  12. Procédé selon une des revendications 1 à 11, caractérisé en ce que les segments de moule (1) sont choisis et dimensionnés de manière à ne pas avoir des contre-dépouilles.
  13. Procédé selon une des revendications 1 à 12, caractérisé en ce que plusieurs des segments de moule (1) sont identiques.
  14. Procédé selon une des revendications 1 à 13, caractérisé en ce que les segments de moule (1) sont reliés les uns aux autres par une liaison rainure-clavette ou une liaison à goupille de positionnement.
  15. Procédé selon une des revendications 1 à 14, caractérisé en ce que les segments de forme (1) sont conçus de telle sorte qu'un arrondi de bord soit obtenu sur les bords de la bobine (10).
  16. Procédé selon la revendication 15, caractérisé en ce que les segments de moule (1) sont conçus de telle sorte que les bavures résultant de la conception de segment soient situées sur la bobine (10) au niveau de l'arrondi de bord.
EP17153442.3A 2016-02-22 2017-01-27 Procédé de moulage d'un élément structurel ayant une géométrie complexe à l'aide d'un moule segmenté Active EP3208013B1 (fr)

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Application Number Priority Date Filing Date Title
DE102016202657.7A DE102016202657A1 (de) 2016-02-22 2016-02-22 Verfahren zum Gießen eines Bauteils komplexer Geometrie mit einer Gießform in Segmentbauweise

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EP3208013A1 EP3208013A1 (fr) 2017-08-23
EP3208013B1 true EP3208013B1 (fr) 2023-08-16

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DE102018205588A1 (de) * 2018-04-12 2019-10-17 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung eines gewendelten Körpers
DE102018109380A1 (de) * 2018-04-19 2019-10-24 Breuckmann GmbH & Co. KG Spulenanordnung und Verfahren zum Herstellen einer Spulenanordnung
DE102018215974B3 (de) * 2018-09-19 2020-03-12 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Wälzgießverfahren zum Herstellen einer Spiralstruktur
DE102018215975A1 (de) 2018-09-19 2020-03-19 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Wälzformverfahren zum Herstellen einer Spiralstruktur
DE102018215987B4 (de) * 2018-09-19 2020-07-30 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Herstellung einer Wendel, Dauerform für eine Wendel sowie Wendel
DE102018215955A1 (de) * 2018-09-19 2020-03-19 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Gießform zur Herstellung von wendelförmigen Gusskörpern
DE102018215986A1 (de) * 2018-09-19 2020-03-19 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Herstellung einer Wendel, Dauerform für eine Wendel sowie Wendel
WO2020071532A1 (fr) * 2018-10-04 2020-04-09 三菱電機株式会社 Procédé de fabrication d'un composant de bobine, procédé de fabrication d'une machine électrique, composant de bobine et machine électrique
DE102019209047B4 (de) * 2019-06-21 2021-09-16 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung einer Gussform und mit dem Verfahren hergestellte Gussform
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EP3208013A1 (fr) 2017-08-23

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