EP3616806B1 - Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse - Google Patents

Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse Download PDF

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Publication number
EP3616806B1
EP3616806B1 EP18192272.5A EP18192272A EP3616806B1 EP 3616806 B1 EP3616806 B1 EP 3616806B1 EP 18192272 A EP18192272 A EP 18192272A EP 3616806 B1 EP3616806 B1 EP 3616806B1
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EP
European Patent Office
Prior art keywords
model
core
lost
blank
ceramic
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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EP18192272.5A
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German (de)
English (en)
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EP3616806A1 (fr
Inventor
Johannes Otto
Michael Otto
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Johannes and Michael Otto GbR Vertreten Durch Die Gesellschafter Johannes Otto und Michael Otto
Original Assignee
Johannes and Michael Otto GbR Vertreten Durch Die Gesellschafter Johannes Otto und Michael Otto
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Priority to EP18192272.5A priority Critical patent/EP3616806B1/fr
Application filed by Johannes and Michael Otto GbR Vertreten Durch Die Gesellschafter Johannes Otto und Michael Otto filed Critical Johannes and Michael Otto GbR Vertreten Durch Die Gesellschafter Johannes Otto und Michael Otto
Priority to PL18192272T priority patent/PL3616806T3/pl
Priority to ES18192272T priority patent/ES2891542T3/es
Priority to PT181922725T priority patent/PT3616806T/pt
Priority to US17/269,022 priority patent/US11607721B2/en
Priority to PCT/EP2019/072308 priority patent/WO2020048774A1/fr
Priority to JP2021512901A priority patent/JP7100399B2/ja
Publication of EP3616806A1 publication Critical patent/EP3616806A1/fr
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Publication of EP3616806B1 publication Critical patent/EP3616806B1/fr
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores

Definitions

  • the invention relates to a method for producing a model mold core blank according to claim 1, a method for producing an investment casting mold according to claim 2 and a casting method for producing a cast part with a cavity structure according to claim 14.
  • Casting methods for producing components are known from the prior art. In these, a casting mold is filled with a material and removed after it has solidified or solidified. Particular challenges arise in the formation of undercuts on and cavity structures in the component.
  • the model can be made from wax, for example, and used to create a casting mold from a ceramic.
  • the casting mold is designed in particular as a lost mold in the form of a single-use ceramic coating of the model. After the wax has been removed from the casting mold, a cavity remains that can be filled with the material of the component to be manufactured. After filling and hardening, the mold is destroyed and the component removed.
  • cores are used around which the wax model is manufactured. After the wax has been removed from the ceramic coating, these cores remain in the cavity of the ceramic coating and then correspondingly also form a cavity in the component. The core is later removed from the component using mechanical or chemical processes.
  • a method is described in which a core is first produced according to a 3D model in a first CNC method.
  • the core is then positioned in a processing holder in order to subsequently be coated with a wax body blank. It is, so to speak, a process for the production of a model core blank.
  • the wax body blank is then processed in a second CNC process in such a way that a lost wax model of the component is created around the core.
  • the process can be described as a process for producing a model mold core.
  • the model mold core produced in this way therefore has a lost core and the lost model.
  • the disadvantage of the method for producing the model mold core blank and the model mold core is that the position of the core relative to the lost model cannot be achieved reliably with sufficient precision. This creates scrap.
  • the disadvantage of this work step is that the processing holder is exposed to the casting temperatures of the metal.
  • the processing holder can be deformed here, so that the relative positioning between the ceramic mold and the core changes.
  • the processing holder must be made of high-temperature-resistant materials, which makes it expensive and means increased effort when accommodating it in processing machines.
  • FIG EP 3 251 790 A2 famous One method of providing a mold for turbine blades is disclosed in FIG EP 3 251 790 A2 famous.
  • a model core is first made by first gluing sleeves into parallel holes on one side of a ceramic block. With these sleeves, the ceramic block is then placed on an annular holder that engages with a pin in one of the sleeves.
  • the ceramic block can be removed from the ring-shaped holder at any time, or it can be placed in a machine tool with it. Alternatively, it is also disclosed that the ceramic block is glued to the ring-shaped holder. After machining the ceramic block to A model core is encapsulated with wax and then the wax is machined.
  • the object of the invention is therefore to develop process steps that contribute to reliable, reproducible and, above all, precise positioning of a lost core relative to a ceramic form of an investment casting mold, the process steps being as little complex as possible and quick and inexpensive to perform. In particular, this should also prevent rejects from the core production to the finished component.
  • the invention relates to a method for producing a model mold core blank, which is particularly suitable for producing a cast part with a cavity structure, using a 3D model (three-dimensional model) of digital geometry coordinates of the cast part.
  • a ceramic blank is positioned on a processing holder and a fixation is established between the ceramic blank and the processing holder.
  • the cubature of the ceramic blank is preferably larger than a core element to be produced from it.
  • a core element is then manufactured, a lost core being manufactured from the ceramic blank based on the 3D model in a first CNC manufacturing process while the fixation continues, the machining holder being fixed in a CNC machine for performing the first CNC manufacturing process .
  • the lost core is preferably a cavity model of the cavity structure.
  • the method is supplemented by the fact that a stabilization frame is produced from the ceramic blank during the first CNC production process and while the fixation continues, the stabilization frame supporting the lost core, in particular at at least one support point which is arranged at a distance from the machining holder.
  • a stabilization frame is produced from the ceramic blank during the first CNC production process and while the fixation continues, the stabilization frame supporting the lost core, in particular at at least one support point which is arranged at a distance from the machining holder.
  • a removal of one or more support points between the stabilizing frame and the lost core is provided after the production of the lost core and before the production of the model blank, this preferably in the first CNC production process.
  • the lost core is thus kept stable during machining in the first CNC manufacturing process and particularly fine contours can be formed on the lost core.
  • the support points are preferably connecting webs which are preferably narrower and / or thinner than the adjoining area of the lost core.
  • the method provides for making a model blank by casting model material around the lost core and allowing the model material to solidify while the fixation continues.
  • the cubature of the model blank is preferably larger than a lost model to be produced from it, the lost model preferably being a positive model of the cast part if the outer contour of the lost model is produced by a material-removing process such as turning, milling, laser cutting, etc.
  • the cubature of the model blank is preferably smaller than a lost model to be produced from it, the lost model preferably being a positive model of the casting if the outer contour of the lost model is produced on the model blank by a material application process such as 3D printing.
  • the stabilizing frame is removed after the production of the lost core and before the production of the model blank, preferably after the removal of one or more support points, and furthermore preferably in the first CNC production process. This is particularly suitable for lost cores that have sufficient inherent stability.
  • the stabilizing frame is not removed before the model blank is produced.
  • the stabilizing frame can then also support the lost core during the production of the model blank and optionally also during the production of the lost model.
  • the stabilizing frame can be arranged at least partially in the model blank. However, it should be outside the lost model. Support points of the stabilization frame can then extend through the lost model to the lost core. This also stabilizes lost cores of unstable design during the further process steps, prevents changes in shape and prevents damage.
  • the advantage of the method according to the invention is that the lost core has a defined position relative to the machining holder. This avoids positioning problems which could otherwise arise from a subsequent fixation of an already manufactured core element with a lost core on a machining holder. This is because each time a core element is clamped in a machining fixture, stress deformations of the core element can occur.
  • the alternative production of a fixation by gluing takes a long time, and curing tensions in the adhesive can also lead to positional deviations between the core element and the processing holder. Even small deviations in the area of the fixation can lead to larger position deviations away from the fixation. All of this is avoided according to the invention.
  • a ceramic form is applied to the outer contour of the lost model and a positioning connection of the ceramic form is formed with at least one connection point on the core element. Finally, the lost model is removed from the ceramic mold.
  • the advantage here is that the core element and the lost shape have a high degree of relative positional accuracy to one another by means of the positioning connection.
  • the processing holder has no direct connection to the ceramic mold. This allows it to be removed.
  • the positioning connection should be designed in such a way that the removal of the processing holder has no influence on the relative positioning between the ceramic mold and the lost core.
  • an inexpensive processing holder can be used that does not have to withstand baking or sintering temperatures or casting temperatures during component production.
  • reusable machining holders can be used, in particular also those which are made at least in part or completely from tool steel.
  • the method for manufacturing an investment casting mold can be supplemented by the fact that a stabilization frame is manufactured from the ceramic blank during the first CNC manufacturing process and while the fixation continues, the stabilization frame supporting the lost core, in particular at at least one support point that is spaced apart from the processing holder is arranged.
  • a stabilization frame is manufactured from the ceramic blank during the first CNC manufacturing process and while the fixation continues, the stabilization frame supporting the lost core, in particular at at least one support point that is spaced apart from the processing holder is arranged.
  • removal of one or more support points between the stabilization frame and the lost core is optionally provided after the production of the lost core and before the production of the model blank, this preferably in the first CNC production process.
  • the lost core is thus kept stable during machining in the first CNC manufacturing process and particularly fine contours can be formed on the lost core.
  • the support points are preferably connecting webs which are preferably narrower and / or thinner than the adjoining area of the lost core.
  • a machining process in particular a milling process, and / or a generative manufacturing process such as, for example, 3D printing, selective laser melting or laser sintering, can be used as the first CNC manufacturing process.
  • the preferred method is the milling method.
  • a 3D printing process can also be provided in which a model material, for example wax, on and / or is printed around the lost core while the fixation continues.
  • a model material for example wax
  • Such 3D printing processes allow particularly complex geometries.
  • the machining holder is positioned in the executing CNC machine before the first CNC manufacturing method is carried out and before the machining holder is fixed.
  • the advantage here is that the machining holders can be connected to the ceramic blank away from the CNC machine. This reduces machine downtimes, especially if several machining holders have a uniform geometry.
  • the machining holder has a coupling piece for receiving in a zero point fixing system, the coupling piece being received in a zero point fixing system of the performing CNC machine when the first CNC manufacturing process is carried out.
  • a zero point fixing system is characterized in particular by the fact that no exact positioning has to take place during the production of the fixation.
  • the coupling piece only has to be roughly positioned and the alignment of the coupling piece in the zero point fixing system then takes place automatically during fixing.
  • defined correlating positioning surfaces contribute to correct positioning in a zero point fixing system, in particular both on the part of the coupling piece and on the part of the zero point fixing system.
  • Zero point fixing systems in the context of this document are zero point clamping systems and other holding mechanisms (adhesion, gluing, negative pressure, etc.). Zero point clamping systems fix by means of clamping forces. Zero point clamping systems can also be combined with other holding mechanisms so that clamping and other holding forces are used for fixation.
  • a model wax is particularly suitable as the model material.
  • the model material should have a lower melting temperature than the core element.
  • a sprue model is formed when the model blank is produced.
  • Such a sprue model will later form a sprue in the ceramic investment casting mold during the production of a ceramic investment casting mold. At the same time, it can be used as an outlet for removing the lost model and / or the lost core.
  • the sprue model is optionally conical. A funnel-shaped sprue then results.
  • CNC computer-aided numerical control or manufacturing steps which, in particular, are computer-aided and automated.
  • the surfaces of the core element can optionally be coated after the first CNC manufacturing process. As a result, the surfaces can be made particularly smooth.
  • the lost core can for example be placed in a model molding tool and the model blank can be formed around the lost core by filling / injecting model material such as wax, thermoplastic or the like into the space between the lost core and the inner walls of the model molding tool.
  • model material such as wax, thermoplastic or the like
  • the ceramic blank can first be brought into the desired blank shape by injection molding, transfer molding or casting of a suitable liquid of ceramic material.
  • the starting material can comprise one or more ceramic powders, a binder and, optionally, additives that can be introduced into a correspondingly shaped blank molding tool.
  • the blank molding tool can be removed, for example opened, in order to remove the green compact.
  • the green compact After the green compact is removed from the blank mold, it should be fired at a high temperature in one or more steps to remove the volatile binder and to sinter and cure the ceramic blank. As a result, it achieves a strength and dimensional accuracy that are sufficient for use in the casting of metallic material such as a titanium, nickel or cobalt-based alloy.
  • the 3D model of the digital geometry coordinates of the cast part can be adapted in order to take into account a correction of manufacturing-related deviations in shape, for example shrinkage or material stresses.
  • the invention also includes a model mold core blank which is produced by a method for producing a model mold core blank, as described above and below.
  • the advantages of the process are also inherent in the model mold core blank. In particular, it can be manufactured with high precision, process reliability, and inexpensively.
  • the invention also relates to a method for producing a model mold core, in which the method for producing a model mold core blank, as described above and below, is carried out, and the production of an outer contour of a lost model from and / or based on the model blank comprises on the 3D model in a second CNC manufacturing process, while the fixation continues, wherein the machining holder is set in a CNC machine for performing the second CNC manufacturing process.
  • the lost core assumes a defined position on the machining holder and, as a result, the lost model is also correctly positioned relative to the machining holder and thus also to the lost core.
  • the machining holder is preferably positioned before the second CNC manufacturing method is carried out and before the machining holder is fixed in the CNC machine performing the process. Machining holders with defined geometry can be positioned particularly easily, quickly and precisely in the CNC machine (s) performing the work. During the execution of process steps for which a CNC machine is not required, this CNC machine can be released and used for other purposes.
  • the machining holder has a coupling piece for receiving in a zero point fixing system, the coupling piece being received in a zero point fixing system of the performing CNC machine when the second CNC manufacturing process is carried out. This enables the machining holder to be received particularly precisely and quickly in the CNC machine.
  • the first CNC manufacturing process is preferably a material-removing process, more preferably a cutting process, and particularly preferably a milling process.
  • the second CNC manufacturing process is preferably either a material-removing process, more preferably a cutting process, and particularly preferably a milling process, or an application process such as 3D printing.
  • the second CNC manufacturing process can also combine removing and depositing processes. This allows different areas of the lost model to be produced particularly efficiently.
  • the optional stabilizing frame can lie at least partially outside of the lost model. It then has at least partially no contouring influence on the component to be produced later, which in particular will be based on the positive body of the lost model.
  • the subject matter of the invention also includes a model mold core which is produced according to the method for producing a model mold core, as described above and below.
  • the advantages of the process are also inherent in the model mold core. In particular, it can be manufactured with high precision, process reliability, and inexpensively.
  • the method can optionally be supplemented by a step in which the fixation between the processing holder and the core element and the separation of the core element from the processing holder take place before or after removing the lost model from the ceramic mold, ie in particular after the application of the ceramic mold or after the lost model has been removed from the ceramic mold, and particularly preferably before the implementation of a casting process for producing the cast part in the investment casting mold.
  • the ceramic form can be applied to the outer contour of the lost model, for example, by repeated immersion in a ceramic slip, with excess slip flowing off after each immersion, sanding with ceramic stucco and air drying. In this way, several ceramic layers can be built up, which form the ceramic shape in the manner of a molded shell on the outer contour.
  • the resulting arrangement can then be fed to a steam autoclave in order to remove the lost model, so that the ceramic mold with the lost core arranged therein remains as an investment casting mold.
  • the method can be supplemented by the optional step of firing the arrangement comprising the core element and the ceramic mold before or after the core element is separated from the processing holder. This removes volatile binder and sintered and cured the assembly.
  • the investment casting mold produced in this way achieves a strength and dimensional accuracy that are sufficient for use in the casting of metallic material such as a titanium, nickel or cobalt-based alloy.
  • a sprue model is also formed, in particular from the model blank.
  • This step can include the complete elaboration of the sprue model from the model blank or, if provided, the post-processing of a coarser sprue model already formed on the model blank.
  • Such a sprue model will later form a sprue in the ceramic investment casting mold during the production of a ceramic investment casting mold.
  • the sprue can be used as an outlet for removing the lost model and / or the lost core.
  • the sprue model is optionally conical. A funnel-shaped sprue then results.
  • the subject matter of the invention also includes an investment casting mold which is produced by the method for producing an investment casting mold, as described above and below.
  • the advantages of the process are also inherent in the investment casting mold. In particular, it can be manufactured with high precision, process reliability and inexpensively, with the lost core in particular being correctly positioned and held in the ceramic mold. Sprue structures and ventilation structures for the casting process can then be attached to the investment mold. Alternatively, separate sprue structures can also be used on the lost model as well as ventilation structures for the later casting process are attached so that they are connected to the investment casting mold or are part of it.
  • the invention also relates to a casting method for producing a casting with a cavity structure, in which a method for producing an investment casting mold, as described above and below, is carried out, and in which molten metal is poured into the ceramic mold around the lost core , solidification of the molten metal to form a solid component, and removal of the ceramic mold and the lost core from the solid component take place.
  • the solid component has cavity structures that are positioned very precisely in the solid component so that, for example, there are no weak points that could render the solid component unusable.
  • the lost core is removed from the cavity structure of the component.
  • the lost core is preferably removed from the solid component by water-based or chemical washing or other techniques. If the core element also has an optional stabilizing frame, this is also removed from the fixed component.
  • the casting method preferably comprises the optional step of releasing the fixation between the processing holder and the core element and separating the core element from the processing holder at the latest before the molten metal is poured into the ceramic mold.
  • an inexpensive processing holder can be used, which at least does not have to withstand the casting temperatures of the molten metal.
  • the casting process is particularly suitable when the molten metal is a titanium, nickel or cobalt-based alloy. With such expensive components, high costs can be achieved by reducing rejects and component damage in accordance with the method.
  • the investment casting mold is preheated before the molten metal is poured. This can have a positive effect on crystal formation and avoid cracks in the investment mold due to thermal stresses due to sudden temperature changes.
  • the metal melt preferably solidifies polycrystalline, and particularly preferably monocrystalline. A high component strength is achieved in this way.
  • a ceramic core blank 10 which is fixed to a machining holder 50 via a two-sided fixation 51.
  • the fixation 51 can be formed, for example, by gluing or clamping.
  • the two sides of the fixation 51 are opposite one another and the ceramic core blank 10 is arranged between the two sides.
  • the processing holder 50 has a coupling piece 52 and a processing bridge 53.
  • the processing bridge 53 extends between the two sides of the fixation 51 and is connected to the coupling piece 52 or formed in one piece with it.
  • the coupling piece 52 is designed for inclusion in a zero point fixing system of CNC processing machines.
  • the cubature of the ceramic core blank 10 is preselected or prefabricated in such a way that a core element 11 to be produced from the ceramic core blank 10 by material removal or ablation with a lost core 12 lies within this cubature.
  • Fig. 2 is a possible consequence of the initial situation Fig. 1 after or during the production of the core element 11, the lost core 12 from the ceramic blank 10 (see Fig. 1 ) is manufactured according to a 3D model in a first CNC manufacturing process, for example a CNC milling process, while the fixation 51 continues.
  • a (temporary) stabilizing frame 15 is made from the ceramic blank 10 (see FIG Fig. 1 ) manufactured in the first CNC manufacturing process while the fixation 51 continues.
  • the (temporary) stabilization frame 15 supports the lost core 12 via support points 16.
  • the support points 16 are each arranged at a distance from the fixation 51.
  • the support points 16 are connecting webs or pins, each of which is narrower than the adjoining area of the lost core 12.
  • FIG. 3 the lost core 12 of the core element 11, which extends between the two sides of the fixture 51. It can be seen that the stabilizing frame 15 was removed after the production of the lost core 12, in particular after it was removed from the support points 16.
  • the ceramic core blank 10 In the area of the fixation 51, the ceramic core blank 10 (see Fig. 1 ) not processed in order not to weaken the fixation 51 and not to damage the processing holder 50.
  • This unprocessed area of the ceramic core blank 10 can also be referred to as the fusing area.
  • the core element 11 At this stage, the core element 11 also has two connection points 13, to which a ceramic mold 81 (see FIG Fig. 7 ) will connect.
  • Fig. 4 is the arrangement according to Fig. 3 It is further used in such a way that the lost core 12 continues to be fixed to the processing holder 50 via the fixation 51 and is stored in a model molding tool 30 for producing a model blank 20 (see FIG Fig. 5 ) is arranged.
  • the model molding tool 30 has a first and a second mold half 31, 32 and is supported by positioning surfaces 33 on the processing holder 50, in particular on the coupling piece 52 and on the processing bridge 53 Model molding tool 30 out. In this way, a tool cavity 35 is formed around the lost core 11.
  • a model sprue 34 which is formed by the model molding tool 30, opens into this tool cavity 35 from above.
  • the after Fig. 4 The initial situation shown is suitable for the production of a model blank 20 (see Fig. 5 ) by casting model material through the model sprue 34 into the tool cavity 35, that is to say in particular around the lost core 12 located in the tool cavity 35.
  • the model material can be a model wax, for example.
  • the model material should have a lower melting temperature than the core element 11.
  • the model material is then allowed to solidify.
  • the fixation 51 still exists.
  • the lost core 12 is positioned in a defined position relative to the model blank 20.
  • the cubatures of the model blank 20 and the tool cavity 35 are each larger than a lost model 21 to be produced from them (see Fig. 6 ).
  • Fig. 5 After removing the model molding tool 30 according to the method status after Fig. 4 the arrangement remains in accordance with Fig. 5 .
  • Fig. 5 it can be seen how the core element 11 with the lost core 12 is still fixed on the machining holder 50 via the fixation 51. However, the lost core 12 is now also arranged in the model blank 20 made of the model material. This results in a model mold core blank 1.
  • a production-related sprue point 24 also remains on the model blank 20.
  • a conical sprue model 23 is also recognizable through the model blank 20.
  • the machining holder 50 with the coupling piece 52 can again be fixed in a CNC machine for carrying out the second CNC manufacturing method after it has been positioned.
  • the lost core 12 still occupies a defined position on the machining holder 50 and, as a result, the lost model 21 is also correctly positioned relative to the machining holder 50 and thus also to the lost core 12.
  • the lost core 12, together with the lost model 21, forms a model mold core 2.
  • the second CNC manufacturing process is a material-removing process, preferably a cutting process and particularly preferably a milling process being used.
  • the outer contour 22 of the lost model 21 is to be produced in these areas by a material-applying process, for example in a (CNC) 3D printing process.
  • the model mold core 2, namely the lost model 21 and the lost core 12 arranged therein, can now be separated from the processing holder 50, because the goal of arranging the lost core 12 exactly in the lost model 21 has been achieved and will not be adversely affected in the next steps .
  • the fixation 51 is as shown in Fig. 7 can be recognized in particular by the fact that the lost core 12 is separated from the fixing area.
  • the fixing area can remain on the processing holder 50. The fixing area can be removed from this later if necessary.
  • Fig. 7 also shows how the lost model 21 and the lost core 12 are encased in a ceramic mold 81 of an investment casting mold 80. Only the ends of the lost core 12 look out of the ceramic mold 81.
  • the ceramic mold 81 was applied to the outer contour 22 of the lost model 21 in accordance with the method.
  • the ceramic form 81 can be applied to the outer contour 22 of the lost model 21, for example, by repeated immersion in a ceramic slip, with excess slip flowing off after each immersion, along with sand Ceramic stucco and air drying is done. In this way, several ceramic layers can be built up, which form the ceramic mold 81 in the manner of a molded shell on the outer contour 22.
  • a positioning connection 82 of the ceramic mold 81 with the two connection points 13 on the core element 11 is established so that the lost core 12 is firmly connected to the ceramic mold 81.
  • the lost core 12 with the connection points 13 protrudes from the lost model 21.
  • the model mold core 2 can be held at these overhangs during the production of the ceramic mold 81, the connection points 13 should be kept free.
  • casting and / or ventilation structure parts can be attached to the lost model 21 before the ceramic mold 81 is applied. These are then preferably connected to the ceramic mold 81 when it is applied.
  • a sprue 83 which is part of the ceramic mold 81, was also formed with the aid of the sprue model 23.
  • the lost model 21 can now be removed from the ceramic mold 81, for example by melting it out, with the molten model material being able to run off through the sprue 83.
  • the arrangement according to Fig. 7 for example, be fed to a steam autoclave in order to remove the lost model 21.
  • the ceramic mold 81 with the lost core 12 arranged therein remains as the investment casting mold 80.
  • the investment casting mold 80 is not yet sufficiently stable for the subsequent method steps, it can first be fired.
  • the casting process can be prepared and carried out.
  • the preparation usually includes a change of work location and positioning in a casting device.
  • the investment casting mold 80 is optionally preheated before casting.
  • molten metal is then poured through the sprue 83 into the ceramic mold 81 and around the lost core 12.
  • the molten metal can be, for example, a titanium, nickel or cobalt-based alloy.
  • the ceramic mold 81 and the lost core 12 can be removed from the fixed component 102, in particular in a destructive manner.
  • the ceramic shape is typically broken open and / or milled.
  • the lost core 12 can be, for example, by chemical reactions For example, dissolved in water or otherwise dissolved, dissolve and then run out of the remaining cavity structures 101 in the solid component 102.
  • the lost model 21 is therefore a positive model of the cast part 100 and the lost core 12 is a model of the cavity structure 101.
  • the geometries to be generated in the manufacturing process are based on the geometry data of the later cast part 100.
  • the geometries to be generated can be determined by using a 3D model of digital geometry coordinates of the cast part 100. If necessary, the geometries to be generated are adapted with respect to the digital geometry coordinates of the cast part 100. This allows shrinkage, component stress and the like to be taken into account in order to finally obtain a physical cast part 100, the shape of which corresponds to the 3D model of digital geometry coordinates of the cast part 100.
  • a stabilizing frame 15 with support points 16 based on the process status Fig. 2 to maintain.
  • the stabilizing frame 15 can then support the lost core 12 during the production of the model blank 20 and optionally also during the production of the lost model 21.
  • the stabilizing frame 15 can be arranged at least partially in the model blank 20. However, it can also be at least partially outside the model blank 20. However, the stabilizing frame 15 should be arranged outside the lost model 21. Support points 16 of the stabilization frame 15 can then protrude through the lost model 21 as far as the lost core 12. As a result, lost cores 12 of unstable design are also stabilized during the further process steps.

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

Claims (15)

  1. Procédé de fabrication d'un modèle d'ébauche de noyau de moule (1), particulièrement adapté à la fabrication d'une pièce moulée (100) ayant une structure de cavité (101), en utilisant un modèle 3D de coordonnées géométriques numériques de la pièce moulée (100) comprenant les étapes suivantes :
    a) Positionnement d'une ébauche en céramique (10) sur un support de traitement (50) et production d'une fixation (51) entre l'ébauche en céramique (10) et le support de traitement (50) ;
    b) Fabrication d'un élément de noyau (11), dans laquelle un noyau perdu (12) est fabriqué à partir de l'ébauche en céramique (10) sur la base du modèle 3D dans un premier processus de fabrication CNC tandis que la fixation (51) persiste, dans laquelle le support de traitement (50) est fixé dans une machine CNC pour effectuer le premier processus de fabrication CNC ;
    Fabrication d'un cadre de stabilisation (15) à partir de l'ébauche en céramique (10) pendant le premier processus de fabrication CNC et pendant que le dispositif de fixation (51) continue, le cadre de stabilisation (15) supportant le noyau perdu (12) ;
    Enlever un ou plusieurs points de support (16) entre le cadre de stabilisation (15) et le noyau perdu (12) après la fabrication du noyau perdu (12) et avant la fabrication de l'ébauche de modèle (20) ;
    c) Fabrication d'une ébauche de modèle (20) en coulant un matériau de modèle autour du noyau perdu (12) et en permettant au matériau de modèle de se solidifier tandis que la fixation (51) continue.
  2. Procédé de fabrication d'un moule de fonderie de précision (80) comprenant les étapes consistant à :
    A) Réalisation d'un procédé de fabrication d'un modèle noyau de moule (2), dans lequel les étapes suivantes sont réalisées :
    a. Réalisation du procédé de fabrication d'un modèle d'ébauche de noyau de moule (1), convenant en particulier à la fabrication d'une pièce moulée (100) avec une structure de cavité (101), en utilisant un modèle 3D de coordonnées géométriques numériques de la pièce moulée (100), comprenant les étapes suivantes :
    a) Positionnement d'une ébauche en céramique (10) sur un support de traitement (50) et production d'une fixation (51) entre l'ébauche en céramique (10) et le support de traitement (50) ;
    b) Fabrication d'un élément de noyau (11), dans laquelle un noyau perdu (12) est fabriqué à partir de l'ébauche en céramique (10) sur la base du modèle 3D dans un premier processus de fabrication CNC tandis que la fixation (51) persiste, dans laquelle le support de traitement (50) est fixé dans une machine CNC pour effectuer le premier processus de fabrication CNC ;
    c) Produire une ébauche de modèle (20) en coulant un matériau de modèle autour du noyau perdu (12) et en permettant au matériau de modèle de se solidifier tandis que la fixation (51) continue ;
    b. Produire un contour extérieur (22) d'un modèle perdu (21) à partir de et/ou sur l'ébauche de modèle (20) sur la base du modèle 3D dans un second processus de fabrication CNC tandis que la fixation (51) persiste, dans lequel le support de traitement (50) est fixé dans une machine CNC pour effectuer le second processus de fabrication CNC ;
    B) L'application d'un moule en céramique (81) sur le contour extérieur (22) du modèle perdu (21) et la formation d'une connexion de positionnement (82) du moule en céramique (81) à au moins un point de fixation (13) sur l'élément de noyau (11), dans lequel le support de traitement n'a pas de connexion directe avec le moule céramique ;
    C) Retirer le modèle perdu (21) du moule en céramique (81).
  3. Procédé de la revendication 2, comprenant l'étape consistant à :
    - Fabrication d'un cadre de stabilisation (15) à partir de l'ébauche en céramique (10) pendant le premier processus de fabrication CNC et pendant que la fixation (51) continue, le cadre de stabilisation (15) supportant le noyau perdu (12).
  4. Procédé de la revendication 3, comprenant l'étape consistant à :
    - Enlever un ou plusieurs points de support (16) entre le cadre de stabilisation (15) et le noyau perdu (12) après la fabrication du noyau perdu (12) et avant la fabrication de l'ébauche de modèle (20).
  5. Procédé de l'une quelconque des revendications 1 ou 3 ou 4, comprenant l'étape consistant à :
    - Retrait du cadre de stabilisation (15) après la fabrication du noyau perdu (12) et avant la fabrication de l'ébauche de modèle (20).
  6. Procédé selon l'une quelconque des revendications précédentes, comprenant l'étape consistant à :
    - Positionnement du support de traitement (50) avant d'exécuter le premier processus de fabrication CNC et avant de fixer le support de traitement (50) dans la machine CNC exécutante.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel le support de traitement (50) comprend une pièce d'accouplement (52) destinée à être reçue dans un système de fixation du point zéro, et dans lequel la pièce d'accouplement (52) est reçue dans un système de fixation du point zéro de la machine CNC d'exécution lors de la réalisation du premier processus de fabrication CNC.
  8. Procédé selon l'une quelconque des revendications précédentes, comprenant l'étape consistant à :
    - Formation d'un modèle de carotte (23) pendant la fabrication de l'ébauche de modèle (20).
  9. Procédé de la revendication 2 ou de la revendication 2 en combinaison avec l'une quelconque des revendications 3 à 8, comprenant l'étape consistant à :
    - Positionnement du support de traitement (50) avant d'effectuer le deuxième processus de fabrication CNC et avant de fixer le support de traitement (50) dans la machine CNC exécutante.
  10. Procédé de la revendication 2 ou de la revendication 2 en combinaison avec l'une quelconque des revendications 3 à 9, dans lequel le support de traitement (50) comprend une pièce d'accouplement (52) destinée à être reçue dans un système de fixation de point zéro, et dans lequel la pièce d'accouplement (52) est reçue dans un système de fixation de point zéro de la machine CNC d'exécution lors de l'exécution du deuxième procédé de fabrication CNC.
  11. Procédé selon la revendication 2 ou selon la revendication 2 en combinaison avec l'une quelconque des revendications 3 à 10, dans lequel un modèle de carotte (23) est formé à partir de l'ébauche de modèle (20) lors de la réalisation du contour extérieur (22) du modèle perdu (21).
  12. Procédé de la revendication 2 ou de la revendication 2 en combinaison avec l'une quelconque des revendications 3 à 11, dans lequel l'étape suivante est réalisée :
    - Libérer la fixation (51) entre le support d'usinage (50) et l'élément de noyau (11) et séparer l'élément de noyau (11) du support d'usinage (50) avant ou après avoir retiré le modèle perdu (21) du moule en céramique (81).
  13. Procédé de la revendication 12, dans lequel l'étape suivante est réalisée:
    - Cuire l'ensemble comprenant l'élément de noyau (11) et le moule en céramique (81) après avoir séparé l'élément de noyau (11) du support de traitement (50).
  14. Procédé de moulage pour produire une pièce moulée (100) ayant une structure de cavité (101), dans lequel les étapes suivantes sont réalisées :
    i) Mise en œuvre du procédé de fabrication d'un moule de fonderie de précision (80) selon l'une quelconque des revendications 2 à 13 ;
    ii) Verser du métal fondu dans le moule en céramique (81) autour du noyau perdu (12) ;
    iii) Solidification du métal fondu en un composant solide (102) ;
    iv) Retirer le moule en céramique (81) et le noyau perdu (12) du composant solide (102).
  15. Procédé de la revendication 14, dans lequel l'étape suivante est réalisée:
    i. b) Retirer la fixation (51) entre le support de traitement (50) et l'élément de noyau (11) et séparer l'élément de noyau (11) du support de traitement (50) au plus tard avant de verser le métal fondu dans le moule en céramique (81).
EP18192272.5A 2018-09-03 2018-09-03 Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse Active EP3616806B1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
PL18192272T PL3616806T3 (pl) 2018-09-03 2018-09-03 Sposób wytwarzania półfabrykatu na rdzeń formy modelu, rdzenia formy modelu oraz formy do odlewania precyzyjnego, jak również sposób odlewania służący do wytwarzania odlewu o strukturze drążonej
ES18192272T ES2891542T3 (es) 2018-09-03 2018-09-03 Procedimiento para la fabricación de una pieza en bruto de núcleo de molde de modelo, de un núcleo de molde de modelo y de un molde de fundición de precisión, así como un procedimiento de fundición para la fabricación de una pieza fundida con una estructura de cavidad
PT181922725T PT3616806T (pt) 2018-09-03 2018-09-03 Procedimentos para fabrico de uma pré-forma de núcleo de molde de maqueta, de um núcleo de molde de maqueta e de um molde de fundição de precisão, bem como um processo de fundição para fabrico de uma peça fundida com uma estrutura oca
EP18192272.5A EP3616806B1 (fr) 2018-09-03 2018-09-03 Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse
US17/269,022 US11607721B2 (en) 2018-09-03 2019-08-20 Method for producing a model mold core blank and a precision casting mold, and a casting method for producing a cast part having a void structure
PCT/EP2019/072308 WO2020048774A1 (fr) 2018-09-03 2019-08-20 Procédé destiné à la fabrication d'une ébauche de noyau de moule de modèle, d'un noyau de moule de modèle et d'un moule de précision ainsi que procédé de coulée destiné à la fabrication d'une pièce coulée à l'aide d'une structure creuse
JP2021512901A JP7100399B2 (ja) 2018-09-03 2019-08-20 モデルモールドコアブランク、モデルモールドコア、および精密鋳型を作製するための方法、ならびに空隙構造を有する鋳造部品を作製するための鋳造方法

Applications Claiming Priority (1)

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EP18192272.5A EP3616806B1 (fr) 2018-09-03 2018-09-03 Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse

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EP3616806A1 EP3616806A1 (fr) 2020-03-04
EP3616806B1 true EP3616806B1 (fr) 2021-07-28

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EP (1) EP3616806B1 (fr)
JP (1) JP7100399B2 (fr)
ES (1) ES2891542T3 (fr)
PL (1) PL3616806T3 (fr)
PT (1) PT3616806T (fr)
WO (1) WO2020048774A1 (fr)

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EP3616806B1 (fr) 2018-09-03 2021-07-28 Johannes + Michael Otto GbR vertreten durch die Gesellschafter Johannes Otto und Michael Otto Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse

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DE102013016868A1 (de) 2013-10-11 2015-04-16 Flc Flowcastings Gmbh Feingussverfahren hohler Bauteile
GB201608336D0 (en) * 2016-05-12 2016-06-29 Rolls Royce Plc A method of providing a fixture for a ceramic article, a method of machining a ceramic article and a method of investment casting using a ceramic article
CN105945220B (zh) * 2016-05-25 2017-11-17 东方电气集团东方汽轮机有限公司 一种带陶瓷型芯蜡模成型方法
JP6717736B2 (ja) 2016-11-28 2020-07-01 ファナック株式会社 レーザ加工システム
FR3059259B1 (fr) * 2016-11-29 2019-05-10 Jy'nove Procede de fabrication d'un noyau ceramique de fonderie
EP3616806B1 (fr) 2018-09-03 2021-07-28 Johannes + Michael Otto GbR vertreten durch die Gesellschafter Johannes Otto und Michael Otto Procédé de fabrication d'un lingot de noyau de moulage modèle, d'un noyau de moulage modèle et d'une moule de coulée fine ainsi qu'un procédé de coulée destiné à la fabrication d'une partie coulée dotée d'une structure creuse

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US11607721B2 (en) 2023-03-21
JP2021535840A (ja) 2021-12-23
WO2020048774A1 (fr) 2020-03-12
EP3616806A1 (fr) 2020-03-04
PL3616806T3 (pl) 2021-12-20
ES2891542T3 (es) 2022-01-28
PT3616806T (pt) 2021-09-29
US20210323049A1 (en) 2021-10-21
JP7100399B2 (ja) 2022-07-13

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