EP3827911A1 - Metallguss mit kernen - Google Patents

Metallguss mit kernen Download PDF

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Publication number
EP3827911A1
EP3827911A1 EP20208614.6A EP20208614A EP3827911A1 EP 3827911 A1 EP3827911 A1 EP 3827911A1 EP 20208614 A EP20208614 A EP 20208614A EP 3827911 A1 EP3827911 A1 EP 3827911A1
Authority
EP
European Patent Office
Prior art keywords
core
venting element
casting
metal component
venting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20208614.6A
Other languages
English (en)
French (fr)
Inventor
Cesar Benjamin Martinez Dominguez
Qingsong Zhao
Dongxu Fan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nemak SAB de CV
Original Assignee
Nemak SAB de CV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nemak SAB de CV filed Critical Nemak SAB de CV
Publication of EP3827911A1 publication Critical patent/EP3827911A1/de
Withdrawn legal-status Critical Current

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    • 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
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/06—Core boxes
    • B22C7/065—Venting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/106—Vented or reinforced cores
    • 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
    • B22C9/108—Installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles

Definitions

  • the present invention relates to a method for producing a core to be used in metal casting of a metal component having a cavity structure, wherein the core at least partially defines the cavity structure in the metal component.
  • the invention also relates to a corresponding core for metal casting of a metal component having a cavity structure.
  • the invention also relates to a method for metal casting of a metal component having a cavity structure.
  • the invention further relates to a casting mold arrangement for metal casting of a metal component having a cavity structure.
  • cores or casting cores are used to create cavities and other moulded elements in the cast component.
  • the casting cores have so-called core prints or core marks at which they are held in the respective casting mould.
  • Cores of the type mentioned above are usually made of a mixture of sand and a binder (e.g. resin-bonded moulding sand) in order to ensure the dimensional stability required for their handling during the preparation and set-up of the mould.
  • a binder e.g. resin-bonded moulding sand
  • the cores typically have a certain humidity which will evaporate.
  • gases and vapours are produced as a result of the heating of the core at contact with the melt. These gases are typically removed or discharged in the area of the core prints. Otherwise, there is a risk that cavities or surface defects are present in the finished cast component which are caused by gas or steam residues which have not escaped.
  • Another way of avoiding the generation of gas in the first place would be a change of the binder system of the core.
  • a core binder system with a lower level of gas generation could be used or an overall reduced amount of binder could be used in the core production.
  • other parameters e.g. core box, sand system, ambient conditions
  • the binder levels that need to be used often still generate a certain amount of core gas during filling and solidification at levels that in the end cause undesired defects in the cast components.
  • a further approach could be the provision of additional drillings in the core in order to provide a passage from the area where the gas is generated to the location where the gas can be evacuated.
  • the main problem with this approach is that for cores with critical geometries, in particular rather long (e.g. around 500mm) and thin (e.g. a minimum diameter less than 10mm) cores as for example needed for forming oil galleries in a motor block or cylinder head.
  • Such geometry makes it very difficult, if not impossible, to drill the core over sufficient length without damaging it.
  • the above problem is solved by a method for producing a core to be used in metal casting of a metal component having a cavity structure, the core at least partially defining the cavity structure in the metal component, wherein the method comprises:
  • the above problem is also solved by a core for metal casting of a metal component having a cavity structure, in particular produced by a method of the first aspect, wherein the core at least partially defines the cavity structure in the metal component, and wherein the core comprises a venting element integrated in the core and establishing a hollow passage in the core.
  • the above problem is also solved by a method for metal casting of a metal component having a cavity structure, wherein the method comprises:
  • the above problem is also solved by a casting mold arrangement for metal casting of a metal component having a cavity structure, wherein the casting mold arrangement comprises:
  • the core comprises an integrated venting element establishing a hollow passage in the core allows to reduce or even eliminate core gas related defects in cast metal components and thus reducing the scrap rate related to these defects.
  • the gas generated due to the cores during the metal filling and solidification process can effectively be evacuated or discharged from the core and surrounding area by the hollow passage formed by the venting element.
  • the generated gas can be guided to core print areas or venting areas of the used die through the core itself even over longer distances.
  • the venting element directly manufactured with the integrated venting element, which does not impair the stability of the core or can even provide additional stability to the core.
  • the inventive approach according to the different aspects avoids the drawbacks mentioned earlier.
  • the inventive approach can avoid the drilling process and consequently avoids the risk of damaging the core during the drilling process, in particular for long and thin cores.
  • the inventive approach of using a venting element integrated into the core is also advantageous over an approach, where the venting element is for example not integrated into the core, but rather the hollow cores are produced through the use of e.g. sliding inserts in the core box.
  • a pin shaped insert (with necessary draft angle) would be installed on the front and rear ends of the core box, with necessary hydraulic cylinders to move the inserts. This would require extremely thin inserts, which would result in easy and frequent tooling damage.
  • the draft angle required to withdraw the sliding inserts during core production would make the insert too large to maintain enough core thickness to guarantee acceptable core quality.
  • the hollow-unsupported core would make it more susceptible to deformation during the metal filling process.
  • the hydraulic system required to move the sliding inserts on the core box would make the core box too large to fit in the existing core machine.
  • the metal used in the casting process may in particular be a light metal, such as aluminum or an aluminum alloy for instance.
  • the metal component may in particular be a light metal component, such as an aluminum or aluminum alloy component.
  • a core may also comprise more than one venting element.
  • a core may also comprise more than one venting element.
  • using a single venting element for a core results in a simpler positioning of the single venting element during production of the core (since no relative positioning of multiple venting elements needs to be made) and the potential act of removal of a single venting element from the core (as will be described in more detail below) is particularly fast and simple.
  • venting element may establish multiple hollow passages in the core element.
  • a venting element may generally be understood as an element or structure for guiding or for supporting guiding gas or vapour generated due to the composition of the core element to predefined parts inside or outside the core element.
  • the venting element may in particular be a hollow structure (such as a tube, as will be explained in more detail below) so that the hollow inner area of the venting element establishes the hollow passage in the core.
  • the venting element is in particular integrated such into the core that it guides generated gas of the core to other sections of the core.
  • the venting element guides generated gas to one or more end sections of the core.
  • the venting element is integrated such into the core that gas generated from the decomposition of the core or evaporating humidity to vents provided by the casting mold arrangement.
  • a core box may be understood as a machine for manufacturing respective cores.
  • a core box may in particular comprise a first (e.g. upper) and a second (e.g. lower) mold or cavity.
  • the venting element can be arranged or positioned in such an upper or lower mold (as will be explained in more detail below).
  • the core box can be configured for forming multiple cores in one cycle.
  • the casting mold into which a respective core element may be inserted, may generally be realized in different ways depending on the metal and the casting process used.
  • the casting process uses "lost" molds, i.e. the molds are destroyed after casting in order to remove the cast metal component from the casting mold.
  • the method according to the first aspect further comprises:
  • a blocking of the venting element may comprise applying a seal to one or more opening of the venting element.
  • a blocking of the venting element may comprise the insertion of a blocking element into the venting element.
  • the blocking element may be a flexible element, such as a wire, for instance, which is inserted into the venting element.
  • the blocking element blocks or seals substantially the whole venting element.
  • the blocking of the venting element may comprise a blocking by means of the core box itself, e.g. by blocking the ends of the venting element by the upper and/or lower mold of the core box without the need for an additional element.
  • the blocking could then advantageously be removed automatically when the core box is opened.
  • placing the venting element in the core box comprises positioning the venting element in a support structure provided by the core box, in particular by a first and/or second mold of the core box.
  • the support structure may comprise one or more support regions.
  • a support structure may comprise or be realized by one or more support elements or inserts.
  • a support insert or element may be a defined recess (e.g. integrated in a mold of the core box) for receiving and thus supporting a part of the venting element.
  • the first and second mold of the core box may comprise a corresponding support elements or inserts.
  • a support structure comprises support regions at least at the ends of a (e.g. tube-like) venting element. Generally, it is preferred that the support structure is located and/or designed such that the cavity structure in the metal component defined by core is not affected.
  • the support structure of the core box for supporting the venting element is provided in the area of the core print.
  • the core prints are understood to be those section of the core supporting the core in the casting mold during casting. This allows providing a support structure without (or with only negligibly) affecting the geometry or formation of the cavity structure in the metal component.
  • the core is a sand core.
  • a sand core is typically made of sand and a binder or bonding agent.
  • the sand core may be made of sand and resin.
  • the sand core may be a green sand core or a dry-sand core.
  • sand cores typically generate gas or vapor when decomposing during casting. These gases or vapors can advantageously be discharged or evacuated via the hollow passage established by the venting element in the core.
  • the core may also be another type of lost or disposable core or a core with a porous structure generating gas or vapor generation during casting.
  • the venting element substantially extends from one end of the core to an opposing end of the core. Gases and vapors generated along the whole core can be effectively discharged and evacuated.
  • the core may be substantially elongate core.
  • the venting element may be run along the axial direction of the elongate core. Opening may be provided at the respective ends of the venting element functioning as discharge or outlet openings.
  • the venting element is a tube, in particular a metal tube, for instance a steel tube.
  • the tube has a substantially straight geometry.
  • the tube may have a cylindrical geometry.
  • the tube may also be conceivable, that the tube has a curved or bent geometry.
  • the venting element may also be made from other materials, such as a synthetic material (e.g. a plastic material) or a natural material.
  • the venting may be made from cardboard, which would be rigid enough and at the same time disposable resulting in a lower overall cost.
  • the venting element may also be at least partly dissolvable or decomposable so that the venting elements may be used even if further removal from the internal cavities of the casting is not possible (such as inside water jacket cores).
  • the venting element comprises venting holes along its surface.
  • the venting holes or perforations may allow the generated gas and vapor to easily enter the inner hollow passage of the venting element.
  • the venting holes may thus be considered as intake openings.
  • other intake structures such as slits, for instance, are possible as well.
  • the venting element has a length of at least 100mm, preferably at least 300mm and more preferably at least 500mm.
  • the venting element has an outer diameter at most 10mm, preferably at most 5mm and more preferably at most 2.5mm.
  • the inner diameter of the venting element is preferably in the range of 1mm to 3mm, for instance 1.5mm.
  • the venting element has at least 50, preferably at least 100, more preferably at least 300 venting holes.
  • the venting holes preferably have a diameter of at most 0.5mm, preferably at most 0.3mm, more preferably at most 0.15mm.
  • the cavity structure defined by the core is an oil channel (in particular a high pressure oil channel) or a water jacket of a motor block, a cylinder head or a part thereof.
  • An oil channel or oil distribution system comprises long, thin cavities. Particularly for high pressure oil channels, a strict control of defects is required.
  • Such a cavity structure can advantageously be formed in a motor block or cylinder head with the help of cores. Utilizing the inventive cores can drastically reduce the scrap rate of motor blocks and cylinder heads due to gas related defects, such as bubble formation on the surface.
  • the core may also define other cavities in a motor block or in other components.
  • the method of the third aspect further comprises:
  • a removal of the venting element in an intact (e.g. un-bent) state may advantageously allow re-using the venting element in order to increase economic benefits of the described approach.
  • the venting element may for instance be removed manually.
  • the venting element may be removed with a tool.
  • the venting element may be removed during the de-coring process of the cast metal component.
  • a venting element may also protrude from the core, it is integrated in facilitating a removal of the venting element from the core and cast component.
  • the core is method for metal casting, wherein the metal component is a motor block, a cylinder head or a part thereof and the cavity structure defined by the core is an (e.g. high pressure) oil channel or water jacket of the motor block, the cylinder head or a part thereof.
  • the metal component is a motor block, a cylinder head or a part thereof
  • the cavity structure defined by the core is an (e.g. high pressure) oil channel or water jacket of the motor block, the cylinder head or a part thereof.
  • the metal casting is a sand molded casting process (also called sand casting).
  • Sand casting is a well-known casting technique utilizing sand as the mold.
  • sand and binders can be used, as already explained with respect to the core.
  • the metal casting may utilize other lost molds than sand molds.
  • the method according to the third aspect comprises producing the core according to a method according to the first aspect.
  • Fig. 1 is a perspective view of an exemplary embodiment of a venting element 1.
  • the venting element 1 is a straight, cylindrical steel tube.
  • the venting element 1 has openings 2 and 4 at its opposing ends.
  • the venting element 1 has a plurality of venting holes 6 on its surface (around 300 holes in this case), so that the venting element 1 can be considered as a perforated pipe.
  • the venting element 1 has in this example a length of approximately 500mm and, an outer diameter of 2.5mm and an inner diameter of 1.5mm.
  • the diameter of the venting holes 6 is 0.15mm.
  • the venting element 1 may also have a different geometry.
  • the venting element may have different length and diameters.
  • the venting element 1 may also have different cross sections, e.g. an elliptical cross section.
  • the venting element 1 may also be curved, for example.
  • the venting element can be integrated in different cores, as will be explained in the following.
  • Fig. 2a is a side view of an exemplary embodiment of a core 10 defining a cavity structure of a high pressure oil channel or oil gallery of a motor block and defines a substantially straight channel.
  • the core 10 comprises core prints 12, which allow the core to be positioned and fixed in the casting mold (cf. Fig. 6 ).
  • the venting element 1 of Fig. 1 is integrated into the core 10, such that the venting element 1 established a hollow passage in the core 10.
  • the venting element 1 extends within the core 10 from end to end.
  • the openings 2 and 4 of the venting element are open and in communication with the environment.
  • the venting element 1 extends through the core 10, as shown in Fig. 2b , which is an enlarge cross sectional view of the core 10.
  • the venting element 1 protrudes on both sides of the core 10, in other embodiments the venting element 1 may also be flush on one or both sides of the core 10.
  • the core is a sand core comprising of a mixture of sand and a binder. It may occur that the core material does not cover the venting element at certain parts of the venting element. It may then be necessary to cover the venting element with additional paste work. The manufacturing of the core will be explained in more detail with respect to Fig. 5 and 6 .
  • Fig. 3a shows a side view of another exemplary embodiment of a core 10 defining a cavity structure of an oil channel of a motor block, similarly to the embodiment shown in Fig. 2 .
  • a blocking element 14 in this case a wire, is partially inserted into the venting element 1 integrated in the core 10.
  • the blocking element 14 may have substantially the same length as the venting element 1. However, it may be advantageous to have a slightly longer blocking element 14 in order to facilitate removal of the blocking element 14 from the venting element 1.
  • the opening 2 (and likewise opening 4) is closed or blocked by blocking element 14. This is advantageous in order to prevent sand form entering the venting element during the forming of the core around the venting element (cf. Fig. 5 and 6 ).
  • venting holes 6 are closed from the inside.
  • a blocking of the ends of the venting element could also be achieved through the design of the core box, e.g. where the core box (e.g. the upper and/or lower cavity) would block the ends of the venting element. This can reduce the operation time required to prepare the venting element by removing the blockage prior to casting. This can also reduce the overall costs as no additional blocking elements would be required.
  • the core box e.g. the upper and/or lower cavity
  • Fig. 4 is a perspective view of an exemplary embodiment of a casting mold arrangement 20 with a casting mold 22 and two cores 10 already inserted into the casting mold 22.
  • the casting mold 22 is a sand mold defining a part of the outer surface of the metal component to be cast, which is a motor block in this example.
  • the casting mold arrangement 20 further comprises dies 24 around the casting mold 22, which can be closed in order to support the casting mold 22 and/or establish a closed cavity.
  • the metal such as aluminum or an aluminum alloy, will be cast into the casting mold 22.
  • the molten metal will contact the cores 10.
  • the cores 10 will start to decompose and humidity will evaporate and gas and vapor will be generated.
  • the gases and vapors can be evacuated by entering the venting element thorough the venting holes 6, being guided along the venting element and exiting via the openings 2 and 4 and the ends of the core 10.
  • the cast component can be removed from the dies 24 and the casting mold can be removed from the cast component.
  • the venting elements 1 will be extracted from the cast component. For instance, a tool may be used in order to draw the venting elements 1 from the cast component. After successful extraction, the venting elements 1 may advantageously be reused for manufacturing new cores.
  • Fig. 5a , b are a top view of a lower mold 30 and a upper mold 40 of a core box for manufacturing cores, such as core 10 of Figs. 2 and 3 defining an oil channel of the exhaust side of a motor block.
  • core also called core shooting
  • venting elements 1 are placed in one of the molds 30, 40, as illustrated by venting elements 1 shown in both molds in this case in Figs. 5a and 5b .
  • venting elements 1 are placed in one of the molds 30, 40, as illustrated by venting elements 1 shown in both molds in this case in Figs. 5a and 5b .
  • venting elements 1 are placed in one of the molds 30, 40, as illustrated by venting elements 1 shown in both molds in this case in Figs. 5a and 5b .
  • a support structure comprising support regions 32, 34 in the lower mold and/or corresponding support regions 42, 44 in the upper mold, which may for instance be inserts or integral parts of the respective mold.
  • the openings of the venting element 1 are blocked by a blocking element, as was for instance illustrated in Fig. 3 with wire 14.
  • the molds 30, 40 are then closed and the core is formed around the venting element 1, without the risk of sand entering into the openings of the venting element.
  • Fig. 6 shows a cross sectional view of the venting element 1 positioned between the molds 30, 40 of a core box. Due to the venting element 1 supported between the molds 30, 40, the core 10 can be formed in the space between the molds and the venting element 1, so that the venting element 1 will be integrated into the core 1, as shown in Fig. 2 and 3 .
  • a corresponding procedure may be used for manufacturing cores to be used e.g. for defining an oil channel of the intake side of a motor block or for defining channels required in other metal components.
  • the core can then be placed in a casting mold, and the metal component can be cast, as already explained with respect to Fig. 4 . It has been found that the bubble formation on the surface of the cast component can be substantially reduced by using a core with an integrated venting element as described herein. Experiments have shown, that there is heavy bubble formation on the surface of the cast component in case a regular core without any an integrated venting element is used. Using a core with a venting element with only one opening (e.g. only opening 2 or 4) at one end of the core being available already showed an improvement with only minor bubble formation. In case both openings 2, 4 at both ends of the venting element integrated in the core were provided and in communication with the surrounding, practically no bubble formation due to gases and vapors from the core could be observed anymore.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP20208614.6A 2019-11-27 2020-11-19 Metallguss mit kernen Withdrawn EP3827911A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN201911178360.XA CN112846091A (zh) 2019-11-27 2019-11-27 利用型芯的金属铸造

Publications (1)

Publication Number Publication Date
EP3827911A1 true EP3827911A1 (de) 2021-06-02

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EP20208614.6A Withdrawn EP3827911A1 (de) 2019-11-27 2020-11-19 Metallguss mit kernen

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CN (1) CN112846091A (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114850399A (zh) * 2022-03-23 2022-08-05 中国第一汽车股份有限公司 一种发动机缸盖气道芯随型抽芯棒及排气工艺
CN116809865A (zh) * 2021-08-23 2023-09-29 大洺科技(海南)有限公司 一种铸造用覆膜砂砂芯薄片处的排气方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114406201B (zh) * 2022-01-26 2023-11-14 阜新力达钢铁铸造有限公司 导轨无孔立柱的铸造方法及系统
CN114850413B (zh) * 2022-07-07 2022-10-28 中国航发北京航空材料研究院 具有排气结构的细长管路状树脂砂型芯及其制备方法

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EP0154787A1 (de) * 1984-02-08 1985-09-18 G. Clancey Limited Verbesserungen in Bezug auf das Giessen
ES1001032U (es) * 1985-09-10 1988-04-16 J. Wizemann Gmbh & Co Arbol de leva
EP1291097A1 (de) 2001-09-10 2003-03-12 Hydro Aluminium Deutschland GmbH Verfahren und Vorrichtung zum Bestimmen des Gasdurchlässigkeitsvermögen von insbesondere aus Sand bestehenden Kernen
CN103624217A (zh) * 2013-12-11 2014-03-12 中船动力有限公司 柴油机前端箱体滑油腔砂芯成型工装及成型方法
CN109954838A (zh) * 2017-12-25 2019-07-02 科华控股股份有限公司 一种铸件细长孔成型砂芯结构

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JP2003025046A (ja) * 2001-07-09 2003-01-28 Kooee:Kk 鋳造用の棒状中子およびその製造方法
CN100518993C (zh) * 2007-12-19 2009-07-29 西安鑫龙机械铸造有限公司 一种热电偶保护管的生产工艺

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0154787A1 (de) * 1984-02-08 1985-09-18 G. Clancey Limited Verbesserungen in Bezug auf das Giessen
ES1001032U (es) * 1985-09-10 1988-04-16 J. Wizemann Gmbh & Co Arbol de leva
EP1291097A1 (de) 2001-09-10 2003-03-12 Hydro Aluminium Deutschland GmbH Verfahren und Vorrichtung zum Bestimmen des Gasdurchlässigkeitsvermögen von insbesondere aus Sand bestehenden Kernen
CN103624217A (zh) * 2013-12-11 2014-03-12 中船动力有限公司 柴油机前端箱体滑油腔砂芯成型工装及成型方法
CN109954838A (zh) * 2017-12-25 2019-07-02 科华控股股份有限公司 一种铸件细长孔成型砂芯结构

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116809865A (zh) * 2021-08-23 2023-09-29 大洺科技(海南)有限公司 一种铸造用覆膜砂砂芯薄片处的排气方法
CN114850399A (zh) * 2022-03-23 2022-08-05 中国第一汽车股份有限公司 一种发动机缸盖气道芯随型抽芯棒及排气工艺

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