EP3322547B1 - Procédé de fabrication d'un noyau de coulée et noyau de coulée - Google Patents

Procédé de fabrication d'un noyau de coulée et noyau de coulée Download PDF

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Publication number
EP3322547B1
EP3322547B1 EP16744851.3A EP16744851A EP3322547B1 EP 3322547 B1 EP3322547 B1 EP 3322547B1 EP 16744851 A EP16744851 A EP 16744851A EP 3322547 B1 EP3322547 B1 EP 3322547B1
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EP
European Patent Office
Prior art keywords
foundry core
core
deformation
foundry
casting
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Active
Application number
EP16744851.3A
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German (de)
English (en)
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EP3322547A1 (fr
Inventor
Sebastian TEWES
Franz-Josef Feikus
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Nemak SAB de CV
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Nemak SAB de CV
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
    • B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
    • B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • B22C1/2273—Polyurethanes; Polyisocyanates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening

Definitions

  • the invention relates to a method for producing a casting core for the casting production of a casting and a casting core as such.
  • the casting core in each case consists of a molding material which is mixed from a binder and a foundry sand and optionally added additives.
  • Cast cores of the type in question are typically used for the casting production of castings from a molten metal. They are referred to as "lost parts" because they are destroyed when the casting is removed from the mold.
  • a casting mold comprises several casting cores. These form cavities, channels and other recesses within the casting. For molds that are so However, they also form the outer contour of the casting from.
  • the cores are made in molds called “core shooters” which comprise a core box divided into upper and lower core box halves.
  • the core box delimits with its core box halves a mold cavity which depicts the casting core to be produced.
  • a molding material is shot with the core box closed with pressure. This process is called “core shooting”.
  • the casting core is cured in the core box.
  • the core box is opened by moving at least one of the core box halves to remove the casting core. If their size permits, in industrial mass production usually several casting cores are molded simultaneously in a core box.
  • Molded materials used for the production of casting cores of the type in question are usually mixed from a molding base material, for example an inorganic refractory molding sand, and a binder.
  • a molding base material for example an inorganic refractory molding sand, and a binder.
  • inorganic or organic binders are used for this purpose.
  • hot box process heat and moisture removal
  • organic binder the cores are gassed in the mold with a reaction gas to a chemical reaction of the binder with the Reaction gas to cause the solidification
  • hot box process heat and moisture removal
  • organic binder the cores are gassed in the mold with a reaction gas to a chemical reaction of the binder with the Reaction gas to cause the solidification
  • Both based on inorganic and on organic binder systems molding materials are available in the market in a variety of designs. If necessary, such molding materials contain additives in order to adjust their properties, in particular with regard to storability, flow behavior, etc.
  • the strength of filigree casting cores can also be increased by applying a foil to the circumference of the cores.
  • the object has arisen to give a method that allows the production of complex shaped or optimized in terms of their quality cores in a simple manner.
  • the invention has achieved this object by carrying out at least the steps specified in claim 1 during the production of casting cores.
  • a casting core which dissolves the abovementioned object is accordingly distinguished by the fact that it is made of a molding material which consists of a mixture of a binder and a foundry sand and optionally added additives, wherein the casting core is deformed by a deformation caused by an external force finished shape is brought.
  • a casting core can be produced in particular by using the method according to the invention.
  • the invention is based on the surprising finding, contrary to the previous estimates of the experts, that casting cores produced in a conventional manner can also be deformed at a suitable temperature if they have already been given their basic shape in a conventional core shooter. Deformation may be caused by bending, compression, tension, shear, torsional deformation, or any other deformation due to external forces applied to the respective core.
  • the deformation according to the invention allows casting cores produced from commercially available molding materials to subsequently obtain a shape which can not be produced with conventional core shooting machines at all, only with limited quality or only with a particularly high outlay.
  • the invention thus provides a high degree of design freedom and complexity in casting development. This makes it possible to implement novel casting core designs in a technically simple way. In particular, the production of undercuts is possible by the inventive subsequent forming of the cores without the need for complex core boxes with loose parts are used.
  • the process according to the invention can also be used for the subsequent optimization of properties of the core cores obtained after core shooting.
  • casting cores can be subsequently densified in the manner according to the invention with the result that they have a higher dimensional stability and improved surface properties.
  • the deformation according to the invention should be carried out at a slow deformation rate.
  • the respectively suitable maximum deformation rate can be determined experimentally in a simple manner. By means of practical tests it could be shown here that even filigree casting cores can be reliably deformed according to the invention if the deformation speed is limited to 2 mm / s at the most, in practice deformation rates of at least 0.01 mm / s are the rule should.
  • Optimal deformation speeds are in the range of 0.1 to 1.0 mm / s, in particular 0.3 to 0.7 mm / s.
  • casting cores which have an elongated, filigree shape can be safely bent, twisted, pulled or compressed when these deformation rates are selected.
  • the deformation forces to be applied in the deformation according to the invention and acting on the respective casting core from the outside can also be determined by simple experiments. Practical tests have shown here that with deformation forces which are 8 mm in diameter of a sample which is circular in cross-section in the range of 5-100 N or correspond to specific strengths of the cores of 0.2-0.6 N / mm 2 , Also filigree shaped cores can subsequently deform in accordance with the invention. This applies in particular if the deformation takes place at deformation speeds which are in the ranges mentioned in the preceding paragraph. Deformation forces of 20-80 N (corresponding to specific strengths of 0.1-0.4 N / mm 2 ), in particular 30-70 N (corresponding to specific strengths of 0.15-0.35 N / mm 2 ), have here proved to be particularly effective.
  • the invention can be applied to any type of foundry cores made of molded materials of the type in question. This applies both to mold materials containing an inorganic binder and to mold materials based on an organic binder. Practical experiments have shown here that the invention can be used particularly well in casting cores in which an organic binder is used. In this case, it is assumed that, in particular, such organic binders act in the manner of an adhesive as a result of the heating of the casting cores according to the invention and thus bond together the grains of the molding material from which the casting cores are formed.
  • the optimum deformation temperature to which the cores are heated before the deformation according to the invention can also be determined by simple experiments. Practical experiments have shown here that deformation temperatures which are in the range of 150-320 ° C, in particular 180-300 ° C, are practical. The upper limit of 300 ° C proves to be particularly important for mold materials with organic binders because otherwise there is a risk of premature deterioration of the binder.
  • the deformation temperature should be kept within the above range during the subsequent deformation, optimally maintaining a constant temperature level.
  • the heating rate when heating the cores should be 1 - 15 ° C / s, especially 4 - 8 ° C / s.
  • a heated tool for example, a convection oven or an infrared lamp can serve as the heat source for the heating according to the invention.
  • a general or local heating of the casting core by means of a concentrated hot air jet or the like.
  • the method according to the invention is also suitable for optimizing the shape of a casting core in the sense of a calibration.
  • the casting core is heated in accordance with the invention after removal from the core shooting machine and deformed by external force so that it corresponds exactly to the respective specifications of its geometry.
  • a first casting core can be produced, which has a recess.
  • a second casting core is provided, which has a projection, which is adapted to the shape of the recess of the first casting core. The second casting core can now be joined to the first casting core such that the projection of the second casting core engages in the recess of the first casting core to form a joining zone.
  • At least one of the casting cores passes through the work steps d) - f) and is thereby deformed in step e) such that in the region of the joining zone a dense positive connection is formed, by which the two casting cores are connected to each other.
  • two or more cores can be interconnected by connections, which are formed for example in the manner of plug-in or snap-in connections.
  • a first casting core with a recess (A) and a second casting core are provided, which is then positioned on the first casting core in a predetermined position, said after Positioning at least the second casting core the steps d) - f) passes through and is deformed in step e) by applying an external force such that material of the second casting core, which is arranged in the region of the recess of the first casting core, into the recess of the first casting core enters and fills this recess, so that a tight positive connection is formed, by which the two casting cores are interconnected.
  • FIGS. 1 and 3a - 4b illustrated casting cores G1, G3 are exemplary of elongated, delicate caster cores, for example, when filing cylinder heads for internal combustion engines filigree shaped ⁇ llays- or coolant channels. Cylinder heads of this type are usually cast today from cast aluminum materials.
  • the in Fig. 2 illustrated cylindrical casting core G2 is intended to mold a cavity, for example, when casting a cylinder crankcase for an internal combustion engine.
  • FIGS. 5a-5d illustrated cores G4, G5 stand for such cores, which are connected together to form a G intelligentkernkombination GK to complex shapes of cavities or channels in one of a Imagine any molten cast casting.
  • the casting cores G1 - G5 have each been produced in the so-called "PU cold box process".
  • the binder used in the PU cold box process comprises two components, namely phenol-formaldehyde resin as the first component and isocyanate as the second component. Fumigation with a tertiary amine causes a polyaddition of these two components to form polyurethane.
  • the foundry sand is in a suitable mixing unit, e.g. a vibratory mixer or blade mixer, the phenol-formaldehyde resin and the isocyanate for two to five minutes, especially three minutes, mixed.
  • a suitable mixing unit e.g. a vibratory mixer or blade mixer
  • the phenol-formaldehyde resin and the isocyanate for two to five minutes, especially three minutes, mixed.
  • the added amount of the two components of the binder may vary depending on the application and foundry sand. Typically, they are based on the added amount of molding material between 0.4 and 1.2% per part. A ratio of 0.7% per part has proved particularly favorable.
  • the ready-mixed molding material has been formed into the casting cores G1-G5 in a conventional core shooter.
  • the molding material with a shooting pressure of about 2 - 6 bar, in particular 3 bar, shot in a core box and compacted there.
  • the gassing cores G1-G5 in the core box were gassed with the gaseous catalyst, the tertiary amine, in order to effect the hardening of the cores.
  • Curing was carried out until cores G1-G5 reached a strength of 150-300 N / cm 2 typical for PU cold box cores.
  • the target was an optimal value of 220 N / cm 2 .
  • the rod-shaped casting core G1 thus produced had, for example, a circular cross-section of 10 mm and a length of 200 mm.
  • the casting core G3 was dimensioned accordingly.
  • the casting cores G1-G3 obtained in each case have now been heated to a preheating temperature of 220 ° C. in a circulating-air oven at a heating rate of 5 ° C./s.
  • the casting core G1 has been positioned with its end portions on two mutually spaced blocks B1, B2 with rounded supports. Subsequently, a force was applied by a force acting in the direction of force K.
  • This external force K has been applied by means of a stamp not shown here in detail, the center is aligned with the longitudinal extent of the G confusekerns G1 and is rounded at its coming into contact with the casting core G1 face to avoid pressure load peaks of the G confusekerns G1 in the deformation.
  • the load by the force K was quasi-static with a forming speed of 0.5 mm / s.
  • the initiated force K was 40 N.
  • the forming process was terminated after the desired deformation angle ⁇ of about 20-30 degrees was reached.
  • the casting core G1 was kept constant in a range around the deformation temperature of 220 ° C ⁇ 30 ° C.
  • the casting core G1 plastically deformed in this way has been cooled to room temperature in still air. Subsequently, it could be used in the casting process like a conventionally shaped casting core.
  • the casting core G2 like the casting core G1, has been heated in the manner described above and subsequently deformed by external force application KA with the aid of a punch-like tool, likewise not shown here, in such a way that it has the shape of an hourglass. There was a compression of the molding material, which had a positive effect on its dimensional stability and its surface texture. At the same time, the casting core has been calibrated so that its shape optimally met the geometric specifications.
  • the casting core G3 has also been heated to the deformation temperature in the manner described above for the casting core G1. Subsequently, the heated casting core G3 has been clamped with its one end in a holder and acted upon at its other end as an external force with a force acting about its longitudinal axis L torque M. In this way, the casting core G3 could be twisted about its longitudinal axis L by an angle of 90 °.
  • the two casting cores G4, G5 have also been produced in the manner described above for the casting cores G1-G3.
  • the casting core G4 has on its one end face a projection V, whereas in the associated end face of the casting core G5 a recess A has been formed, whose shape represents with a certain excess a negative of the shape of the projection V of the casting core G4.
  • the casting core G4 could be introduced with its projection V into the recess A of the casting core G5, so that the casting cores G4, G5 were joined in the region of a joining zone F delimited by the recess A.
  • the casting core G5 has been brought to a deformation temperature lying in the range of 180-300 ° C. by concentrated heating, for example in the hot air jet. Then, the casting core G5 has been acted upon by means of a suitable tool, not shown here, with an external force KX such that the material of the casting core G5 surrounding the recess A has been compressed. The material of the casting core G5 surrounding the recess A has been pressed against this projection against the projection V until the projection V is tightly enclosed by the material of the casting core G5 and a dense form-fitting connection is formed by which the casting core G4 is related in every degree of freedom fixed undetachably on the casting core G5 and the G deviskernkombination GK is formed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (11)

  1. Procédé de fabrication d'un noyau de coulée (G1 - G5) pour la fabrication par technique de fonderie d'une pièce coulée, le noyau de coulée (G1- G5) étant constitué d'une matière de moulage obtenue par mélange d'un liant et d'un sable de moulage ainsi que d'additifs ajoutés optionnellement, comprenant les étapes suivantes :
    a) moulage du noyau de coulée (G1 - G5) par introduction de la matière de moulage dans un moule à noyau de coulée ;
    b) solidification de la matière de moulage ;
    c) retrait du noyau de coulée (G1 - G5) du moule à noyau de coulée ;
    d) chauffage du noyau de coulée (G1 - G5) à une température de déformation ;
    e) déformation du noyau de coulée (G1 - G5) chauffé par application d'une force de déformation (K, KA, KX, M) au noyau de coulée (G1 - G5) ;
    f) refroidissement du noyau de coulée (G1 - G5).
  2. Procédé selon la revendication 1, caractérisé en ce que la force de déformation (K, KA, KX, M) suscite une déformation par flexion, pression, traction, poussée ou torsion du noyau de coulée (G1- G5).
  3. Procédé selon l'une des revendications précédentes, caractérisé en ce que la déformation est effectuée à une vitesse de déformation maximale de 2 mm/s.
  4. Procédé selon l'une des revendications précédentes, caractérisé en ce que la force de déformation est de 5 à 100 N.
  5. Procédé selon l'une des revendications précédentes, caractérisé en ce que le noyau de coulée (G1 - G5) est entièrement durci à l'étape b).
  6. Procédé selon l'une des revendications précédentes, caractérisé en ce que le liant de la matière de moulage est un liant organique.
  7. Procédé selon l'une des revendications précédentes, caractérisé en ce que la température de déformation est de 180 à 300 °C.
  8. Procédé selon l'une des revendications précédentes, caractérisé en ce que le taux de montée en température lors du chauffage du noyau de coulée à la température de déformation est de 1 à 15 °C/s.
  9. Procédé selon l'une des revendications précédentes, caractérisé en ce qu'un premier noyau de coulée (G5) pourvu d'une cavité (A) est produit par l'exécution des étapes a) à c), en ce qu'un deuxième noyau de coulée (G4) est fourni, lequel présente une partie saillante (V) adaptée à la forme de la cavité (A) du premier noyau de coulée (G4), en ce que le deuxième noyau de coulée (G5) est assemblé avec le premier noyau de coulée (G4) de telle sorte que la partie saillante (V) du deuxième noyau de coulée (G5) vienne en prise dans la cavité (A) du premier noyau de coulée (G5) en formant une zone d'assemblage (F), et en ce qu'au moins l'un des noyaux de coulée (G4, G5) est ensuite soumis aux étapes d) à f) et, à l'étape e), est déformé de telle sorte qu'une liaison étanche par complémentarité de formes, par laquelle les deux noyaux de fonderie (G4, G5) sont assemblés l'un à l'autre, soit formée dans la région de la zone d'assemblage (F).
  10. Procédé selon l'une des revendications 1 à 9, caractérisé en ce qu'un premier noyau de coulée pourvu d'une cavité (A) est produit lors de l'exécution des étapes a) à c), en ce qu'un deuxième noyau de coulée est fourni et ce deuxième noyau est positionné au niveau du premier noyau dans une position prédéterminée, en ce qu'au moins le deuxième noyau de coulée est soumis aux étapes d) à f) et, à l'étape e), est déformé par application d'une force externe de telle sorte que le matériau du deuxième noyau de coulée, qui est disposée dans la région de la cavité du premier noyau de coulée, pénètre dans la cavité du premier noyau de coulée et remplisse ladite cavité, de manière à former une liaison étanche par complémentarité de formes, par laquelle liaison les deux noyaux de fonderie sont liés l'un à l'autre.
  11. Noyau de coulée fabriqué à partir d'une matière de moulage, laquelle se compose d'un liant et d'un sable de moulage ainsi que d'additifs ajoutés optionnellement, caractérisé en ce que le noyau de coulée (G1 - G5) est amené dans sa forme finie par déformation par application d'une force de déformation (K, KA, KX, M) externe.
EP16744851.3A 2015-07-14 2016-07-14 Procédé de fabrication d'un noyau de coulée et noyau de coulée Active EP3322547B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102015111418.6A DE102015111418A1 (de) 2015-07-14 2015-07-14 Verfahren zum Herstellen eines Gießkerns und Gießkern
PCT/IB2016/000999 WO2017009708A1 (fr) 2015-07-14 2016-07-14 Procédé de fabrication d'un noyau de coulée et noyau de coulée

Publications (2)

Publication Number Publication Date
EP3322547A1 EP3322547A1 (fr) 2018-05-23
EP3322547B1 true EP3322547B1 (fr) 2019-01-30

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EP16744851.3A Active EP3322547B1 (fr) 2015-07-14 2016-07-14 Procédé de fabrication d'un noyau de coulée et noyau de coulée

Country Status (5)

Country Link
US (1) US10710150B2 (fr)
EP (1) EP3322547B1 (fr)
CN (1) CN107848021B (fr)
DE (1) DE102015111418A1 (fr)
WO (1) WO2017009708A1 (fr)

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Publication number Priority date Publication date Assignee Title
EP3946776B1 (fr) * 2019-03-25 2023-06-07 Safran Dispositif de moulage

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FR2785836B1 (fr) 1998-11-12 2000-12-15 Snecma Procede de fabrication de noyaux ceramiques minces pour fonderie
US6720028B1 (en) * 2001-03-27 2004-04-13 Howmet Research Corporation Impregnated ceramic core and method of making
US20060071364A1 (en) 2002-11-08 2006-04-06 Sintokogio, Ltd. Dry aggregate mixture, method of foundry molding using dry aggregate mixture and casting core
DE10341712B3 (de) * 2003-09-10 2005-03-24 Dieter Mack Verfahren und Vorrichtung zum Bearbeiten und Entgraten von Gießkernen
DE102008023336A1 (de) 2008-05-13 2008-11-06 Daimler Ag Gießkern zum Herstellen eines Gussbauteils
EP2163328A1 (fr) * 2008-09-05 2010-03-17 Minelco GmbH Sable de noyau ou de moule revêtu par et/ou mélangés avec des silicates de potassium ayant une teneur en eau comprise entre environ 0,25 poids -% jusqu'à environ 0,9 poids -%
US8813812B2 (en) 2010-02-25 2014-08-26 Siemens Energy, Inc. Turbine component casting core with high resolution region
CN102198487B (zh) * 2010-04-20 2013-01-09 机械科学研究总院先进制造技术研究中心 一种基于坎合结构的无模组装造型方法
CN102873276A (zh) 2012-10-24 2013-01-16 山东理工大学 铸造型芯制造工艺
CN103317102A (zh) 2013-06-27 2013-09-25 常州午阳柴油机水箱制造有限公司 一种射芯机制芯工艺及其装置

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Publication number Priority date Publication date Assignee Title
EP3946776B1 (fr) * 2019-03-25 2023-06-07 Safran Dispositif de moulage

Also Published As

Publication number Publication date
EP3322547A1 (fr) 2018-05-23
DE102015111418A1 (de) 2017-01-19
CN107848021B (zh) 2019-12-06
US20190030592A1 (en) 2019-01-31
US10710150B2 (en) 2020-07-14
WO2017009708A1 (fr) 2017-01-19
CN107848021A (zh) 2018-03-27

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