EP3277451A1 - Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields - Google Patents

Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields

Info

Publication number
EP3277451A1
EP3277451A1 EP16712064.1A EP16712064A EP3277451A1 EP 3277451 A1 EP3277451 A1 EP 3277451A1 EP 16712064 A EP16712064 A EP 16712064A EP 3277451 A1 EP3277451 A1 EP 3277451A1
Authority
EP
European Patent Office
Prior art keywords
shell
sand
production
automotive
aeronautics
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.)
Withdrawn
Application number
EP16712064.1A
Other languages
German (de)
French (fr)
Inventor
Emile Thomas Di Serio
Guillaume MALHERBE
Lionel DUPERRAY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Jean Industries SAS
Original Assignee
Saint Jean Industries SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Jean Industries SAS filed Critical Saint Jean Industries SAS
Publication of EP3277451A1 publication Critical patent/EP3277451A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/002—Hybrid process, e.g. forging following casting

Definitions

  • the invention relates to the technical sector of the foundry, including aluminum alloy, magnesium, copper or other similar materials.
  • the invention relates to a sand shell molding process, for the production of a part in the field of automotive and aeronautics.
  • thermosetting resin which, in contact with a model plate heated to a temperature of about 200 ° C, hardens on a layer of a few millimeters, constituting the shell.
  • Each carapace corresponds to a half-mold, which is then polymerized, then glued.
  • Croning processes hot box, cold box, warm box, inorganic, .
  • This molding process has several advantages, among which can be mentioned the possibility of making very complex geometries, as well as the ability to integrate different functions on the part in question, for example an exhaust manifold on a motor vehicle cylinder head automobiles. Other advantages are to be noted, for example, in terms of the reduction in the weight of the parts obtained. Such a process requires, in addition, low investment, and reduces the machining operations.
  • a metal or an alloy is cast into the shell to make a part
  • sand shell is manufactured, in a known manner, according to a process adapted to the nature of the part to be obtained (hot box, cold box, warm box, 3D printing, .).
  • the thicknesses of the shell are also adapted, depending on the characteristics of the part to be obtained, to achieve the best possible compromise between metalostatic pressure resistance and interface thermal resistance.
  • the sand shell, containing said metal or said alloy still in the liquid state, or in the solidification phase is then cooled, for example, by quenching.
  • this quenching can be with water, with oil, with air, or any other means allowing such a cooling. Rapid and forced cooling means that the shell is hardened while the alloy is still liquid.
  • the temperature of the quenching is less than 100 ° C.
  • the preform is subjected to a combined operation of pressing and forging, as is apparent from the process known under the trade name COBAP ESS.
  • COBAPRESS process emerges, for example, from the teaching of patent EP 0 1 19 365.
  • This sand-shell molding process makes it possible to obtain mechanical characteristics that are much greater than those obtained in the case of a sand-shell molding process, according to the prior state of the art. as is apparent from the test results below, made with the same type of metal or alloy.
  • o A% 6-8% formulas according to which SDAS corresponds to interdendritic space, Rp to elastic limit, Rm, to mechanical strength and A% to elongation.
  • the process makes it possible to combine the advantages of a sand-shell casting that makes it possible to obtain complex geometry pieces, with a reduction in weight, a reduction in machining operations, while requiring low investment, with high characteristics, as shown by the comparative tests above. It is also noted that the COBAPRESS process application allows a sharp decrease in porosity and skin phenomenon.

Abstract

The invention relates to a sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields, in which: a metal or alloy is poured into the shell mould in order to produce a part; the shell is cooled forcibly and rapidly; and the part is removed.

Description

PROCEDE DE MOULAGE EN CARAPACE SABLE POUR LA REALISATION D'UNE PIECE DANS LE DOMAINE DE  PROCESS FOR SANDING CARAPLE MOLDING FOR THE PRODUCTION OF A WORKPIECE IN THE FIELD OF
L'AUTOMOBILE ET DE L'AERONAUTIQUE.  AUTOMOBILE AND AERONAUTICS.
L'invention se rattache au secteur technique de la fonderie, notamment d'alliage en aluminium, de magnésium, de cuivre ou autres matériaux similaires. The invention relates to the technical sector of the foundry, including aluminum alloy, magnesium, copper or other similar materials.
Plus particulièrement, l'invention concerne un procédé de moulage en carapace sable, pour la réalisation d'une pièce dans le domaine de l'automobile et de l'aéronautique. More particularly, the invention relates to a sand shell molding process, for the production of a part in the field of automotive and aeronautics.
Le procédé de moulage en carapace sable est parfaitement connu pour un homme du métier. The sand shell molding process is well known to those skilled in the art.
Il consiste à utiliser un sable pré-enrobé d'une résine thermodurcissable qui, au contact d'une plaque modèle chauffée à une température d'environ 200°C, durcit sur une couche de quelques millimètres, constituant la carapace. Chaque carapace correspond à un demi-moule, qui est ensuite polymérisé, puis collé.  It consists in using a sand pre-coated with a thermosetting resin which, in contact with a model plate heated to a temperature of about 200 ° C, hardens on a layer of a few millimeters, constituting the shell. Each carapace corresponds to a half-mold, which is then polymerized, then glued.
Parmi les différents procédés de moulage en carapace sable, on peut citer les procédés Croning, boite chaude, boite froide, boite tiède, inorganique, ....).  Among the various processes for molding in a sand shell, there may be mentioned Croning processes, hot box, cold box, warm box, inorganic, ....).
Ce procédé de moulage présente plusieurs avantages, parmi lesquels on peut citer la possibilité de réaliser des géométries très complexes, ainsi que la possibilité d'intégrer différentes fonctions sur la pièce considérée, par exemple un collecteur d'échappement sur une culasse de moteur de véhicules automobiles. D'autres avantages sont à noter, par exemple, au niveau de la diminution du poids des pièces obtenues. Un tel procédé nécessite, par ailleurs, de faibles investissements, et permet de diminuer les opérations d'usinage. This molding process has several advantages, among which can be mentioned the possibility of making very complex geometries, as well as the ability to integrate different functions on the part in question, for example an exhaust manifold on a motor vehicle cylinder head automobiles. Other advantages are to be noted, for example, in terms of the reduction in the weight of the parts obtained. Such a process requires, in addition, low investment, and reduces the machining operations.
Par contre, les pièces obtenues par ce procédé de moulage en carapace, présentent des caractéristiques mécaniques, qui ne sont pas toujours suffisantes dans certains domaines d'application, en considérant des vitesses de solidification très faibles. On the other hand, the parts obtained by this carapace molding process have mechanical characteristics, which are not always sufficient in certain fields of application, considering very low solidification rates.
Il apparaît, donc, qu'un procédé de moulage en carapace est particulièrement bien adapté pour la réalisation de pièces de géométries complexes, lorsque ces pièces ne nécessitent pas des caractéristiques mécaniques élevées.  It appears, therefore, that a shell molding process is particularly well suited for producing parts of complex geometries, when these parts do not require high mechanical characteristics.
Or, il est apparu que, non seulement, la géométrie des pièces se complexifie, mais que les caractéristiques mécaniques de telles pièces, doivent atteindre des niveaux élevés, et afin de répondre aux cahiers des charges. Now, it has become clear that not only does the geometry of the parts become more complex, but that the mechanical characteristics of such parts must reach high levels, and in order to meet the specifications.
A partir de cet état de la technique et de cette situation, il est donc apparu important de pouvoir améliorer le procédé de moulage en carapace sable, afin de pouvoir obtenir des pièces de géométrie très complexes, présentant des caractéristiques mécaniques élevées. From this state of the art and from this situation, it has therefore appeared important to be able to improve the sand-shell molding process, in order to be able to obtain very complex geometry pieces having high mechanical characteristics.
Pour résoudre un tel problème, il a été conçu, selon l'invention, un procédé de moulage en carapace sable, selon lequel, dans une première forme de réalisation : To solve such a problem, it has been conceived, according to the invention, a sand-shell molding process, according to which, in a first embodiment:
- on coule un métal ou un alliage dans la carapace pour réaliser une pièce,  a metal or an alloy is cast into the shell to make a part,
- on refroidit de manière forcée et rapide la carapace,  the forks are forced and rapidly cooled,
- on réalise une opération de débourrage de la pièce. Un tel procédé trouve une application particulièrement avantageuse dans le domaine de l'automobile et de l'aéronautique, pour la réalisation de pièces très complexes, devant présenter des caractéristiques mécaniques élevées. La carapace sable est fabriquée, d'une manière connue, selon un procédé adapté à la nature de la pièce à obtenir (boite chaude, boite froide, boite tiède, impression 3D, ....). Les épaisseurs de la carapace sont également adaptées, en fonction des caractéristiques de la pièce à obtenir, pour atteindre le meilleur compromis possible entre tenue de pression métalo-statique et résistance thermique d'interface. - Performing a stripping operation of the room. Such a method finds a particularly advantageous application in the field of automotive and aerospace, for the production of very complex parts, having to have high mechanical characteristics. The sand shell is manufactured, in a known manner, according to a process adapted to the nature of the part to be obtained (hot box, cold box, warm box, 3D printing, ....). The thicknesses of the shell are also adapted, depending on the characteristics of the part to be obtained, to achieve the best possible compromise between metalostatic pressure resistance and interface thermal resistance.
Comme indiqué, après avoir coulé le métal ou l'alliage, la carapace sable, contenant ledit métal ou ledit alliage encore à l'état liquide, ou en phase de solidification, est ensuite refroidie, par exemple, via une trempe. De manière connue, cette trempe peut être à l'eau, à l'huile, à l'air, ou tout autre moyen permettant un tel refroidissement. Refroidissement rapide et forcé signifie que la carapace est trempée alors que l'alliage est encore liquide. A titre indicatif nullement limitatif, la température de la trempe est inférieure à 100°C. As indicated, after casting the metal or alloy, the sand shell, containing said metal or said alloy still in the liquid state, or in the solidification phase, is then cooled, for example, by quenching. In a known manner, this quenching can be with water, with oil, with air, or any other means allowing such a cooling. Rapid and forced cooling means that the shell is hardened while the alloy is still liquid. By way of non-limiting indication, the temperature of the quenching is less than 100 ° C.
Ces deux opérations de coulage et de refroidissement ont un double intérêt, qui est, d'une part, de permettre l'orientation du front de solidification en établissant lors de la trempe, un gradient thermique, et d'autre part, d'augmenter les vitesses de solidification, et par conséquent, les caractéristiques mécaniques de la pièce en résultant. These two pouring and cooling operations have a double interest, which is, on the one hand, to allow the orientation of the solidification front by establishing during the quenching, a thermal gradient, and on the other hand, to increase solidification rates, and therefore the mechanical characteristics of the resulting part.
Il suffit, ensuite, de soumettre la pièce à une opération de débourrage classique, lequel débourrage peut être chimique, thermique ou mécanique. Dans une autre forme de réalisation du procédé selon l'invention, on coule un métal ou un alliage dans la carapace pour réaliser, non plus une pièce finale, mais une préforme. Le profil de la carapace est, bien évidemment, adapté en conséquence. Puis, comme indiqué précédemment, on refroidit, de manière forcée et rapide, la carapace et on réalise une opération de débourrage de la pré forme. It suffices, then, to submit the piece to a conventional stripping operation, which débourrage can be chemical, thermal or mechanical. In another embodiment of the process according to the invention, a metal or an alloy is cast into the shell to produce, no longer a final part, but a preform. The profile of the carapace is, of course, adapted accordingly. Then, as indicated above, the shell is rapidly and forcibly cooled, and a stripping operation of the preform is carried out.
Dans cette forme de réalisation du procédé de moulage selon l'invention, la préforme est soumise à une opération combinée de pressage et de forgeage, comme il ressort du procédé connu sous la marque COBAP ESS. Ce procédé COBAPRESS ressort, par exemple, de l'enseignement du brevet EP 0 1 19 365. In this embodiment of the molding process according to the invention, the preform is subjected to a combined operation of pressing and forging, as is apparent from the process known under the trade name COBAP ESS. This COBAPRESS process emerges, for example, from the teaching of patent EP 0 1 19 365.
Ce procédé de moulage en carapace sable, selon les caractéristiques de l'invention, permet d'obtenir des caractéristiques mécaniques très supérieures à celles obtenues dans le cas d'un procédé de moulage en carapace sable, selon l'état antérieur de la technique, comme il ressort des résultats d'essais ci-après, effectués avec le même type de métal ou d'alliage. This sand-shell molding process, according to the characteristics of the invention, makes it possible to obtain mechanical characteristics that are much greater than those obtained in the case of a sand-shell molding process, according to the prior state of the art. as is apparent from the test results below, made with the same type of metal or alloy.
Procédé de moulage en carapace selon l'état de la technique : Carapace molding process according to the state of the art:
o SDAS : 60-7(^m  o SDAS: 60-7 (^ m
o Rp0.2=200-220 MPa  o Rp0.2 = 200-220 MPa
o Rm=240-260 MPa  o Rm = 240-260 MPa
o A%=l-2%  o A% = l-2%
Procédé de moulage en carapace selon l'invention : Carapace molding process according to the invention:
o SDAS : 30-35μιη  o SDAS: 30-35μιη
o Rp0.2= 220 -260 MPa o Rm=290-310 MPa o Rp0.2 = 220 -260 MPa o Rm = 290-310 MPa
o A%=6-8% formules selon lesquelles SDAS correspond à l'espace inter dendritique, Rp à la limite élastique, Rm, à la résistance mécanique et A% à l'allongement.  o A% = 6-8% formulas according to which SDAS corresponds to interdendritic space, Rp to elastic limit, Rm, to mechanical strength and A% to elongation.
Il ressort des caractéristiques du procédé selon l'invention que le procédé permet de cumuler les avantages d'une coulée en carapace sable permettant d'obtenir des pièces de géométrie complexes, avec diminution du poids, diminution des opérations d'usinage, tout en nécessitant de faibles investissements, en présentant des caractéristiques élevées, comme il ressort des essais comparatifs ci-dessus. On note également que l'application de procédé COBAPRESS permet une forte diminution des porosités, et du phénomène de peau. It emerges from the characteristics of the process according to the invention that the process makes it possible to combine the advantages of a sand-shell casting that makes it possible to obtain complex geometry pieces, with a reduction in weight, a reduction in machining operations, while requiring low investment, with high characteristics, as shown by the comparative tests above. It is also noted that the COBAPRESS process application allows a sharp decrease in porosity and skin phenomenon.

Claims

R E V E N D I C A T I O N S R E V E N D I C A T IO N S
-1- Procédé de moulage en carapace sable pour la réalisation d'une pièce dans le domaine de l'automobile et de l'aéronautique, selon lequel : -1- Sand-shell molding process for producing a part in the field of the automobile and aeronautics, according to which:
- on coule un métal ou un alliage dans la carapace pour réaliser une pièce,  a metal or an alloy is cast into the shell to make a part,
- on refroidit la carapace de manière forcée et rapide,  the shell is forcibly and quickly cooled,
- on réalise une opération de débourrage de la pièce.  - Performing a stripping operation of the room.
-2- Procédé de moulage en carapace sable pour la réalisation d'une pièce dans le domaine de l'automobile et de l'aéronautique, selon lequel : A process for molding a sand shell for the production of a part in the field of the automobile and aeronautics, according to which:
- on coule un métal ou un alliage dans la carapace pour réaliser une préforme,  a metal or an alloy is cast into the shell to form a preform,
- on refroidit la carapace de manière forcée et rapide,  the shell is forcibly and quickly cooled,
- on réalise une opération de débourrage de la préforme  - Performing a stripping operation of the preform
- on soumet la préforme à une opération combinée de pressage et de forgeage.  the preform is subjected to a combined pressing and forging operation.
EP16712064.1A 2015-04-01 2016-03-16 Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields Withdrawn EP3277451A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1552788A FR3034332A1 (en) 2015-04-01 2015-04-01 PROCESS FOR SANDING CARAPLE MOLDING FOR THE PRODUCTION OF A PART IN THE AUTOMOTIVE AND AERONAUTICS FIELD
PCT/FR2016/050579 WO2016156692A1 (en) 2015-04-01 2016-03-16 Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields

Publications (1)

Publication Number Publication Date
EP3277451A1 true EP3277451A1 (en) 2018-02-07

Family

ID=53274664

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Application Number Title Priority Date Filing Date
EP16712064.1A Withdrawn EP3277451A1 (en) 2015-04-01 2016-03-16 Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields

Country Status (10)

Country Link
US (1) US20180369906A1 (en)
EP (1) EP3277451A1 (en)
JP (1) JP2018516761A (en)
KR (1) KR20170132771A (en)
CN (1) CN107427906A (en)
CA (1) CA2981374A1 (en)
FR (1) FR3034332A1 (en)
MA (1) MA41836A (en)
MX (1) MX2017012495A (en)
WO (1) WO2016156692A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11958105B2 (en) 2022-03-09 2024-04-16 Honda Motor Co., Ltd. Rapid solidification of molded products

Family Cites Families (10)

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US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
CH650430A5 (en) * 1980-08-29 1985-07-31 Fischer Georg Gmbh Method for casting of metals by phenolic bound sand shapes.
JPS57202943A (en) * 1981-06-05 1982-12-13 Kubota Ltd Manufacture of casting mold
DE3373281D1 (en) * 1983-03-14 1987-10-08 Serio Thomas Di Method of producing pieces of aluminium or aluminium alloy
JPH02280956A (en) * 1989-04-21 1990-11-16 Kobe Steel Ltd Lost wax casting method
JP3008759B2 (en) * 1992-12-18 2000-02-14 株式会社リケンキャステック Hollow camshaft with oil hole in chill surface and its manufacturing method
US6622774B2 (en) * 2001-12-06 2003-09-23 Hamilton Sundstrand Corporation Rapid solidification investment casting
FR2995235B1 (en) * 2012-09-11 2016-12-09 Snecma FOUNDRY MODEL
FR3000910B1 (en) * 2013-01-17 2015-05-01 Snecma PROCESS FOR MANUFACTURING A PIECE BY LOST WAX FOUNDRY AND DIRECTED COOLING
CN103286279B (en) * 2013-07-03 2015-02-11 韶关市富迪精密铸造有限公司 Novel casting technique of semitrailer brake drum

Also Published As

Publication number Publication date
CA2981374A1 (en) 2016-10-06
KR20170132771A (en) 2017-12-04
US20180369906A1 (en) 2018-12-27
CN107427906A (en) 2017-12-01
WO2016156692A1 (en) 2016-10-06
MA41836A (en) 2018-02-06
JP2018516761A (en) 2018-06-28
FR3034332A1 (en) 2016-10-07
MX2017012495A (en) 2018-07-06

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