EP3603851B1 - Procédé et appareil de moulage d'objets en aluminium, alliages d'aluminium, alliages légers, laiton et matières analogues - Google Patents

Procédé et appareil de moulage d'objets en aluminium, alliages d'aluminium, alliages légers, laiton et matières analogues Download PDF

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Publication number
EP3603851B1
EP3603851B1 EP19187763.8A EP19187763A EP3603851B1 EP 3603851 B1 EP3603851 B1 EP 3603851B1 EP 19187763 A EP19187763 A EP 19187763A EP 3603851 B1 EP3603851 B1 EP 3603851B1
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EP
European Patent Office
Prior art keywords
liquid metal
die
punch
compactor
duct
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Application number
EP19187763.8A
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German (de)
English (en)
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EP3603851A1 (fr
Inventor
Roberto Boni
Ruggero Ferri
Claudio Frulla
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Idra SRL
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Idra SRL
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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
    • B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • 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
    • 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
    • B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
    • B22D27/11—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of mechanical pressing devices

Definitions

  • the present invention relates to a method and an apparatus for casting objects made of aluminum, aluminum alloys, light alloys, brass and the like.
  • the patent application MI2003A002186 describes an apparatus that consists of a lower die and an upper die which delimit a region for containing a dosed quantity of liquid metal that comes from a duct which is connected to a furnace and originates from below.
  • the upper die is provided with a flow control element which acts on the connecting opening to the liquid metal delivery duct, and a compactor punch which defines a portion of the upper impression of the die.
  • the die is then overfilled with the liquid metal, with the drawback, however, of not knowing exactly how much metal is necessary to complete the piece.
  • the dosing of the metal may not be correct since in the initial step the die is not fully filled, and instead the liquid metal is brought flush with the overflow line; the die is fully filled only after the connecting opening to the liquid metal delivery duct is closed, and the compactor punch has descended, making the liquid metal rise back up to complete the casting cavity.
  • EP 3170582 discloses an apparatus for casting objects of aluminum and US 5562147 discloses a multi-stage casting plant and a method of forming castings.
  • the aim of the present invention is to provide a method and an apparatus for casting objects made of aluminum, aluminum alloys, light alloys, brass and the like, in which the filling of the die is done without overflow and without specific dosing of the liquid metal.
  • an object of the present invention is to provide a method and an apparatus that make it possible to obtain cast pieces that are free from gas or air impurities and with precision shape, and with all types of aluminum alloys including plastic deformation alloys.
  • Another object of the present invention is to provide a method and an apparatus for casting objects made of aluminum, aluminum alloys, light alloys, brass and the like, which can be used even if a sand core or the like is inserted into the casting cavity.
  • Another object of the present invention is to provide a method and an apparatus that are highly reliable, easily and practically implemented and of low cost.
  • the apparatus according to the invention generally designated by the reference numeral 100, comprises a lower platen 1 and an upper platen 2.
  • a lower die 3 is arranged on the lower platen 1 and defines one or more lower impressions.
  • the liquid metal 19 originates from below with a low pressure exerted in a furnace 13 which is arranged in a position below the apparatus 100; such furnace contains the liquid metal 19 at a temperature approximately 70-150C° higher than the temperature of initial solidification of the alloy used.
  • the metal then goes from the furnace 13 through the duct 10 and enters the casting cavity and an accumulation chamber 18 for forging metal.
  • the delivery duct 10 is typically provided with conventional heating means for maintaining the metal in the liquid phase, and in consideration of the fact that when the casting cavity and accumulation chamber 18 is filled the delivery duct 10, which has an upper opening 11, is closed mechanically by way of a flow control element 9, which is better described below.
  • This makes it possible to make the diameter of the duct considerably larger than in systems used at low pressure, and in particular the diameter of the opening 11 can vary from 40 to 100mm.
  • An upper die 4 is provided at the upper platen 2 and can be coupled with the lower die 3 so as to define a cast piece 15, and is provided with one or more upper impressions that can engage in the corresponding lower impressions of the lower die 3.
  • inserts 14 at the lower die 3 which are adapted to define the piece 15 to be provided.
  • the inserts 14 are conveniently provided with electrical resistance heaters 20 for their heating, which are paired with thermocouples 21.
  • the inserts 14 are kept in position by a containment ring 17, which is integral with a die holder 5, in order to prevent their opening during the forging step.
  • the upper die 4 in its central portion, has a flow control element 9 which is controlled by a piston 7 which is concentric to a compactor punch 8 which in turn is controlled by a forging piston 6.
  • At least one impression of the casting cavity is connected to an accumulation chamber 21 for liquid metal 19 in the compactor punch 8.
  • the upper die 4 is supported by the die holder 5 which is connected to the upper platen 2 where the vacuum is applied.
  • the method for casting using the apparatus described above is as follows.
  • Figure 1 shows the condition of the apparatus with the die open and heated by the electrical resistance heaters 20, the temperature of which is controlled by the thermocouples 21, and cooled with pressurized water, through channel systems 22 and proportional valves 40 (see Figure 8 ), the temperature of which is controlled by thermocouples 23.
  • the inserts 14 are closed and the containment ring 17 holds them clamped, being coupled with the inserts 14.
  • Figure 3 shows the third step of casting of the method according to the invention, in which the liquid metal 19 is injected, through the duct 10 and the opening 11, into the casting cavity defined by the lower die 3 and by the upper die 4 which were brought to close against each other in the previous step.
  • the compactor punch 8 As shown in Figure 3 , is in an upper region at a programmed height and the chamber 18 containing liquid metal 19 for the forging is filled at low pressure together with the casting cavity.
  • the chamber 18 which contains liquid metal 20 is filled with an amount of metal equal to 6-10% of the weight of the piece to be cast.
  • the pressure of the liquid metal varies for example from 300 mbar to 2,000 mbar while during the step of compaction/solidification the pressure in the casting cavity varies from 500 kg/cm 2 (490 bar) up to 1,500 kg/cm 2 (1470 bar).
  • the flow control element 9 is in the maximum raised condition, i.e. at the maximum upward stroke, and is flush with the compactor punch 8.
  • the flow control element 9 moves to close the opening 11 of the duct 10, after which the pressure is immediately cut in the supply duct 10, as illustrated, under the die; the liquid metal 19 that is in the duct 10 goes back down to the position 12, while a dosed quantity of metal remains in the casting cavity and in the compaction chamber 18.
  • liquid metal presence sensor for detecting the level of the metal inside the casting cavity and the chamber of the compactor punch 8.
  • the temperature of the die and the temperature of the metal are preset and the furnace is preset to a pressure level that varies as a function of the position of the liquid metal in the furnace and in the casting cavity.
  • the descent of the compactor punch 8 is actuated by the piston 6 at a variable pressure, for example from 500 kg/cm 2 up to 1500 kg/cm 2 and at a speed programmable for example from 3 mm/sec a 15 mm/sec.
  • This operation in practice carries out a forging of the material which is still in the semi-solid state, transferring the liquid metal 19 accumulated in the chamber 18 of the compactor punch 8 to the casting cavity through the connection between the chamber 18 and the casting cavity.
  • an inert gas is introduced with a specific weight that exceeds that of air, such as for example argon, in order to eliminate or reduce the oxides that could form during the rise of the liquid metal.
  • Figure 8 shows the control of temperatures on the shapes of the die, both with cooling using pressurized water and proportional valves and also with an electric heating system. In both cases, each region of the casting is controlled by a thermocouple and the temperatures of the die can vary from 250C° to 380C°.
  • the apparatus further comprises a vacuum system 50 (see Figure 3 ) which makes it possible to aspirate the air contained in the casting cavity through air vents which are created on the die and which are closed by the liquid metal during the step of filling under low pressure. In this manner, during the forging step it is not necessary to install a valve for closing the vacuum duct.
  • a vacuum system 50 see Figure 3
  • the material necessary for compaction during solidification is accumulated in the compactor punch at a preset height.
  • the method and the apparatus according to the invention make it possible to produce pieces that are free from gas or air impurities and with precision in shape.
  • the pieces obtained have high-performing mechanical characteristics and solidify faster than similar pieces obtained with conventional methods and apparatuses; furthermore, they are obtained with all the aluminum alloys available on the market, including those used with the plastic deformation process i.e. with a low percentage of silicon or without silicon and more precisely the alloys of the series 2000, 6000, 7000.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Claims (11)

  1. Procédé pour couler des objets en aluminium, alliages d'aluminium, alliages légers, laiton et analogue, au moyen d'un appareil de coulée (100) qui comporte un plateau inférieur (1) adapté pour supporter une matrice inférieure (3) qui est reliée à un chenal (10) pour transférer du métal liquide (20), un plateau supérieur (2) sur lequel une matrice supérieure (4) est agencée, un poinçon compacteur (8) qui est agencé de sorte qu'il peut se déplacer coaxialement par rapport à ladite matrice supérieure (4), et un élément de commande d'écoulement (9) qui est agencé de manière concentrique à l'intérieur dudit poinçon compacteur (8), le procédé étant caractérisé en ce qu'il comporte les étapes consistant à :
    - fermer ladite matrice supérieure (4) sur ladite matrice inférieure (3) afin de définir une cavité de coulée,
    - introduire du métal liquide (19) par ledit chenal (10) dans ladite cavité de coulée,
    - placer le poinçon compacteur (8) vers le haut à une hauteur préréglée par rapport au rebord inférieur de la matrice supérieure (4),
    - accumuler une quantité de métal liquide (19) qui est égale à 6 à 10 % du poids de la pièce à couler dans une chambre (18) pour accumuler le métal liquide en vue d'un forgeage,
    - fermer le chenal (10) pour fournir du métal liquide (19) en déplaçant ledit élément de commande d'écoulement (9) vers le bas et supprimer la pression dans le chenal d'alimentation en métal métallique (10), en entraînant ainsi le retour dudit métal liquide (19) dans ledit chenal (10),
    - forger ledit métal liquide à l'intérieur de ladite cavité de coulée en déplaçant ledit poinçon compacteur (8) vers le bas, la température de ladite matrice varie de 250 à 380 °C, avec une commande assurée au moyen de résistances électriques chauffantes (20) avec des thermocouples (21) et un système de refroidissement (22, 23).
  2. Procédé selon la revendication 1, caractérisé en ce qu'à l'étape pendant laquelle ladite matrice est ouverte, ledit poinçon compacteur (8) est affleurant à ladite matrice supérieure (4).
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que ladite étape de forgeage est réalisée avec ledit poinçon compacteur (8) agissant directement sur ledit métal liquide (20) contenu dans ladite cavité de coulée.
  4. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que ledit métal liquide (19) est transféré à basse pression dans ledit chenal d'alimentation (10).
  5. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que ledit métal liquide (19) est agencé dans un four d'alimentation (19) à basse pression, qui est agencé dans une position au-dessous dudit appareil, la température du métal dans ledit four (13) étant de 70 à 150 °C plus élevée que la température à laquelle la solidification du métal débute.
  6. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que la pression de forgeage sur ledit poinçon compacteur (8) varie de 500 kg/cm2 (490 bar) à 1 500 kg/cm2 (1470 bar) .
  7. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce qu'il comporte, lorsque ledit appareil est ouvert et que la pièce coulée (15) a été extraite, une étape consistant à introduire un gaz neutre dans ledit chenal d'alimentation (10), afin d'éliminer la formation d'oxydes.
  8. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que des inserts (14) sont prévus qui sont adaptés pour définir la pièce à couler, lesdits inserts étant adaptés pour être déplacés d'une position ouverte, lorsque ladite matrice est à l'état ouvert, à une position fermée, lorsque ladite matrice est à l'état fermé, un anneau de confinement (17) étant prévu afin de maintenir lesdits inserts à l'état fermé.
  9. Appareil (100) pour couler des objets en aluminium, alliages d'aluminium, alliages légers, laiton et analogue, qui comporte un plateau inférieur (1) adapté pour supporter une matrice inférieure (3) dans laquelle débouche un chenal (10) pour transférer du métal liquide (19), un plateau supérieur (2) sur lequel une matrice supérieure (4) est définie qui est supportée par un porte-matrice (5), et un poinçon compacteur (8) qui est agencé coaxialement à ladite matrice supérieure (4), ledit poinçon compacteur ayant, de manière interne et concentrique à celui-ci, un élément de commande d'écoulement (9) qui est adapté pour ouvrir et fermer une ouverture (11) dudit chenal (10) pour fournir du métal liquide (19), caractérisé en ce que ledit poinçon compacteur (8) peut se déplacer depuis une position dans laquelle ledit poinçon compacteur (8) est affleurant à ladite matrice supérieure (4) jusqu'à une position dans laquelle ledit poinçon compacteur (8) est déplacé vers le haut par rapport à ladite matrice supérieure (4), afin de définir une chambre (18) pour accumuler du métal liquide en vue d'un forgeage, et en ce que des résistances électriques chauffantes (20) avec des thermocouples (21) et un système de refroidissement (22, 23) sont prévus afin de commander la température de ladite matrice.
  10. Appareil selon la revendication 9, caractérisé en ce que ledit poinçon compacteur (8) est déplacé par un piston (6) et ledit élément de commande d'écoulement (9) est également déplacé par un piston (7) correspondant.
  11. Appareil selon une ou plusieurs des revendications 9 à 10, caractérisé en ce que ladite matrice inférieure (3) définit au moins une empreinte et ladite matrice supérieure (4) définit de façon analogue au moins une empreinte.
EP19187763.8A 2018-08-02 2019-07-23 Procédé et appareil de moulage d'objets en aluminium, alliages d'aluminium, alliages légers, laiton et matières analogues Active EP3603851B1 (fr)

Applications Claiming Priority (1)

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IT102018000007754A IT201800007754A1 (it) 2018-08-02 2018-08-02 Procedimento e apparecchiatura per lo stampaggio di oggetti in alluminio, leghe di alluminio, leghe leggere, ottone e simili.

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EP3603851A1 EP3603851A1 (fr) 2020-02-05
EP3603851B1 true EP3603851B1 (fr) 2022-06-15

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CN111804885A (zh) * 2020-07-09 2020-10-23 科曼车辆部件系统(苏州)有限公司 一种铝合金汽车轮毂液态模锻成型工艺
CN112355276B (zh) * 2020-10-30 2021-10-19 临沂市铸信机械有限公司 模具压铸设备及压铸方法
CN112846135A (zh) * 2021-01-29 2021-05-28 吉立群 一种合金钢锻造用成形装置

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IT1268996B1 (it) * 1994-09-05 1997-03-18 Borli Engineering Srl Impianto di fusione multi stadi
ITPD20020167A1 (it) * 2002-06-21 2003-12-22 Bbs Riva Spa Attrezzatura per realizzare oggetti in alluminio, leghe di alluminio,leghe leggere e simili, e procedimento attuato da detta attrezzatura
ITMI20032186A1 (it) 2003-11-12 2005-05-13 Claudio Frulla Apparecchiatuira per lo stampaggio di oggetti in alluminio,
WO2005110645A1 (fr) * 2004-05-18 2005-11-24 Kosei Aluminum Co., Ltd Appareil de coulage vertical et procede de coulage vertical
ITUB20155732A1 (it) * 2015-11-19 2017-05-19 Idra S R L Procedimento e apparecchiatura per lo stampaggio di oggetti in alluminio, leghe di alluminio, leghe leggere, ottone e simili

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EP3603851A1 (fr) 2020-02-05

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