EP3976290B1 - Verfahren zum herstellen eines verlorenen giesskerns - Google Patents

Verfahren zum herstellen eines verlorenen giesskerns Download PDF

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Publication number
EP3976290B1
EP3976290B1 EP20729191.5A EP20729191A EP3976290B1 EP 3976290 B1 EP3976290 B1 EP 3976290B1 EP 20729191 A EP20729191 A EP 20729191A EP 3976290 B1 EP3976290 B1 EP 3976290B1
Authority
EP
European Patent Office
Prior art keywords
casting core
core
casting
insert
box
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.)
Active
Application number
EP20729191.5A
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German (de)
English (en)
French (fr)
Other versions
EP3976290C0 (de
EP3976290A1 (de
Inventor
Andre Gröschel
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 EP3976290A1 publication Critical patent/EP3976290A1/de
Application granted granted Critical
Publication of EP3976290B1 publication Critical patent/EP3976290B1/de
Publication of EP3976290C0 publication Critical patent/EP3976290C0/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C13/00—Moulding machines for making moulds or cores of particular shapes
    • B22C13/12—Moulding machines for making moulds or cores of particular shapes for cores
    • B22C13/16—Moulding machines for making moulds or cores of particular shapes for cores by pressing through a die
    • 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

Definitions

  • the invention relates to a method for producing a lost casting core, which has a side surface, in a core box, which is composed of at least two core box parts, between which a parting plane runs when the core box is closed, and which delimits a mold cavity that determines the shape of the casting core to be produced and in which an inner surface forming the side surface of the casting core is provided, through which the parting plane of the core box passes.
  • Casting cores of the type in question are used in casting molds for the production of cast parts from molten metal by casting in order to depict design elements such as recesses, cavities, passages, channels and the like in the respective cast part. They are called “lost parts” because they are destroyed when the casting is demolded from the particular mold. This makes it possible to use such casting cores to also depict design elements of the type mentioned that are located inside the cast part. In the case of casting molds that are put together as a so-called "core package”, however, they also form the outer contour of the cast part.
  • the casting cores are produced in so-called "core shooters". These include a core box designed as a permanent mold for repeated series use, which is divided, for example, horizontally into an upper and a lower core box part. In practice, however, there are also core boxes in the Inserts that are split vertically or that combine splits that run in the horizontal and vertical directions.
  • the core box delimits with its core box parts a mold cavity depicting the casting core to be produced.
  • a molding material is introduced into this mold cavity under pressure via openings made in the core box. This process is called "core shooting".
  • the casting core hardens in the core box.
  • the core box is opened by moving at least one of the core box parts to remove the core.
  • Molding materials used for the production of casting cores of the type in question are usually mixed from a basic molding material, for example an inorganic, refractory molding sand, and a binder.
  • a basic molding material for example an inorganic, refractory molding sand, and a binder.
  • inorganic or organic binders are used for this purpose.
  • the molding material hardens in the core box by adding heat and removing moisture (similar to the so-called “hot box process")
  • organic binders the cores in the mold are gassed with a reaction gas to cause a chemical reaction to effect solidification of the binder with the reaction gas (“cold box process").
  • Molding materials based on both inorganic and organic binder systems are available on the market in a wide variety of designs. If necessary, one or more additives can be added to the molding materials in order to optimize the processing and usage properties of the respective molding material itself or of the casting core molded from it.
  • the "partition plane” or “parting plane” of a core box is the plane in which the parting line between the adjacent core box parts runs when the core box is closed. Even the fact that the core box for removing the finished casting core must be opened, requires at least a two-part design of the casting core.
  • the parting plane between the core box parts must also necessarily run between the core box parts in order to be able to remove the finished casting core from the mold cavity after one core box part has been removed.
  • the production of complex shaped casting cores, in particular casting cores with undercuts also requires core boxes which are composed of more than two core branch parts in order to enable the finished casting core to be removed from the mold without being destroyed. In such multi-part core boxes, too, a dividing plane is required between the core box parts that lie against one another when the core box is closed, along which the separation between the respective core box parts runs and which cuts through the mold cavity.
  • the points at which the respective parting plane intersects the mold cavity i.e. where the parting plane in question meets the parting line between two box parts and the mold cavity, can be seen on the finished cast part by a so-called "core dividing ridge".
  • This is a projection that typically runs linearly along the side surfaces of the casting core and has a concisely formed, generally tapering, but in any case clearly pronounced, burr profile.
  • the core dividing burr is caused by molding material that inevitably penetrates into the joints between the box parts when the molding material is shot into the mold cavity of the core box.
  • the core dividing ridge present on the casting core is shaped as a notch-like depression which also runs linearly along the side surface of the design element represented by the casting core. Stress peaks can occur at such a notch-like indentation during practical use of the casting, which can lead to the formation of cracks and even failure of the casting can. For this reason, castings in the areas in which the core dividing burr of the respective casting core leaves an undesired but production-related inevitable indentation during production have to be designed in such a way that, despite the indentation in question, they can safely withstand the loads that occur in practice.
  • a multi-wall ceramic core for casting an airfoil with one or more internal cooling channels can be prepared by first preforming at least one fugitive core insert.
  • the core insert is then formed in-situ adjacent to and fused to the at least one preformed core insert by introducing liquid fugitive pattern material into a composite core insert mold, thereby integrally joining the fugitive core inserts as a single composite core insert.
  • the composite core insert is placed in a core mold cavity. Liquid ceramic material is then introduced into the mold cavity to form the ceramic core body comprising the fugitive composite core insert.
  • castings with internal cavities or channels can be made using a master core and one or more slave cores.
  • the secondary cores are bonded to the main core by coating the secondary cores with a material that will dissolve on contact with the metal of the mold.
  • the cores to be coated can also be formed by hollow inserts of refractory material filled with sand polymerized resin.
  • the invention has achieved this object in that at least the work steps specified in claim 1 are carried out in the production of a lost casting core.
  • the method according to the invention is thus based on the idea of first prefabricating a casting core insert (step (a)) which, like the casting core obtained at the end of the method, is formed from mold material and destroyed when the casting is removed from the mold. Due to its separate prefabrication, the casting core insert can easily be shaped in such a way that it is perfectly formed in accordance with the design specifications in the area of its side surface section, on which a casting core burr must never be present.
  • a casting core insert prefabricated according to the invention does not have any unwanted shape deviations, such as peaks or depressions, in the area of its side surface section to be kept free from such shape defects, which would leave such shape defects on the casting that are later cast using the casting core produced according to the invention, through which the casting would be weakened could become.
  • the casting core insert that was prefabricated in step (a) and perfectly meets the specifications in the area of its critical side surface section is positioned in step (b) at the point within the mold cavity of the core box where the burr-free side surface of the casting core should be located in the finished casting core.
  • the side surface section of the casting core insert is in close contact with the associated inner surface of the mold cavity and covers the mouth area present there because it perfectly corresponds to the design specifications of the construction of the casting core from where the parting line, which lies in the parting plane intersecting the mold cavity, meets the mold cavity.
  • the casting core insert blocks the way to the mouth area of the parting line in question. Instead, the casting core molding material hits the outer surfaces of the casting core insert, which face the mold cavity that was open until then. In this way, the casting core molding material flowing into the mold cavity envelops the casting core insert, with the side surface section of the casting core insert lying against the inner surface section delimiting the mold cavity remaining unwetted by the casting core molding material.
  • the casting core insert is embedded in the casting core molding material and there is intensive contact between the poured casting core molding material and the side surfaces of the casting core insert assigned to the mold cavity. This connection is supported by the fact that the casting core molding material is introduced into the mold cavity of the core box in a conventional manner with a high "shooting pressure" selected in an equally conventional manner.
  • the formation of a dividing burr on the casting core to be produced is avoided by preforming a casting core insert for the critical area, which contains a partial volume of the to be manufactured casting core occupies.
  • This casting core insert is fully hardened and then inserted into the mold cavity of the core box provided for the production of the casting core.
  • the casting core is then finished in the usual way by introducing casting core molding material into the mold cavity of the core box.
  • the casting core molding material flows around the casting core insert and an intensive form-fitting clamping of the casting core molding material with the surface of the casting core insert occurs.
  • binder parts of the casting core molding material lying against the casting core insert combine with the prefabricated casting core insert and thus contribute to the secure hold of the casting core insert in the finished casting core.
  • the mold materials selected for the casting core insert and for the remaining volume of the casting core to be produced can be selected individually so that they optimally meet the requirements placed on the casting core insert on the one hand and the remaining part of the casting core on the other. So can the molding material from which the casting core insert is formed differs from the casting core molding material from which the rest of the casting core is formed. It is conceivable, for example, to use a molding material suitable for reproducing particularly smooth, flawless surfaces on the casting for the casting core insert, while a lower-quality casting core molding material can be used for the rest of the casting core if the accuracy of the mold reproduction or the surface quality of the rest of the casting core less stringent requirements.
  • the molding material from which the casting core insert is formed is the same as the casting core molding material from which the rest of the casting core is formed.
  • connection of the casting core insert to the remaining part of the casting core that is subsequently formed onto the casting core insert can be achieved in that during its production (work step (a)) the casting core insert has a projections, recesses and /or surface structure having undercuts is imparted on which, when the casting mold material introduced into the core box in step (c) encounters the respective surface sections, a form-fitting coupling of the casting core insert with the molding material of the rest of the casting core occurs.
  • the method according to the invention can be used without further ado in conventional core shooters already on the market without having to change the design of the core boxes used in these machines.
  • the inventively provided Casting core insert can be produced in a separate operation on a separately provided manufacturing facility.
  • a particularly economical embodiment of the method according to the invention which is advantageous in series operation, can be implemented in that the work steps (a) - (d) are repeated in serial sequence and the core box, in addition to the mold cavity in which in the one pass of the work step sequence (a ) - (d) the casting core insert is positioned (step (b)) and then the casting core to be produced is fully molded by introducing the molding material into the mold cavity (step (c)), includes an additional mold cavity in which, at the same time as the molding material is poured into the mold cavity provided for the casting core (work step (c)) that new casting core insert that is required for the next completed run is molded (work step (a) of the next run of work steps (a) - (d)).
  • a casting core insert is prefabricated and a casting core is finished in the same core box, with the prefabricated casting core insert being intended for the subsequent run of the method according to the invention.
  • a casting core insert for the production of a casting core according to the invention is always available in a continuous mass operation with minimized effort and optimizes short cycle times.
  • the volume of casting core molding material that is used in the work step ( c) is introduced into the mold cavity of the core box, and an alarm signal is emitted if the volume introduced exceeds a limit value. If the limit value is exceeded, this indicates that the non-existent casting core insert in the The mold cavity of the core box has also been filled with empty volumes using casting core molding material, which is not permitted since the casting core produced in this way will inevitably have a casting core burr on the critical side wall surface.
  • a control mold element such as a recess, a projection or a foreign body
  • a control mold element such as a recess, a projection or a foreign body
  • an additional shaped element is provided in the mold cavity of the core box, which can be a recess, a projection, a foreign body, an accumulation of dye or the like. If the casting core insert is properly seated in the mold cavity, the casting core insert prevents the mold material introduced into the mold cavity to complete the casting core from reaching the control mold element. If, on the other hand, the casting core insert is missing or if the casting core insert is not correctly positioned in the mold cavity, the mold material penetrates as far as the relevant control mold element when the mold cavity is filled.
  • Core box 1 which comprises an upper core box part 2 and a lower core box part 3 .
  • Recesses 4,5,6,7 are formed in each of the upper and lower core boxes 1, of which the recess 4 of the upper core box part 2 and the recess 5 of the lower core box part 3 when the core box 1 ( 4 , 5 ) together form a mold cavity 8, the shape of which corresponds to a negative of the casting core G to be produced.
  • the recess 6 of the upper core box part 2 and the recess 7 of the lower core box part 3 form an additional mold cavity 9 that is independent of the first mold cavity 8 and represents a negative of a casting core insert E.
  • a parting line 10 runs between the core box parts 2,3 which are seated one on top of the other in a parting plane T which here extends horizontally and intersects the mold cavities 8,9.
  • the parting line 10 opens into the mold cavities 8,9 in each case.
  • Filling openings 11, 12, 13 are formed in the upper core box part 2 in a manner known per se.
  • shooting nozzles enter the filling openings 11-13 in a manner known per se, through which the casting core molding material F is injected.
  • ejectors are provided in a similarly known manner, which eject the respectively completed casting core G from the core box 1 which is then open.
  • the stipulation applies that it must not have a casting core grade K on the side surfaces S1, S2 of a wall W separating the recesses A1, A2 of the casting core G and arranged in the interior of the casting core G after demolding from the core box 1, even if the recesses 4.5, which mold the wall W on the casting core G to be manufactured, from which Parting plane T are cut through, so that the parting line 10 opens into the inner surfaces 14,15 of the mold cavity 8 of the core box 1 forming the side surfaces S1, S2 of the casting core G.
  • a casting core insert E has been produced in a separate operation in the mold cavity 9 of the core box 1 .
  • the shape of the mold cavity 9 corresponds to the shape of that section A of the mold cavity 8 in which the parting line 10 meets the inner surfaces 14,15 of the mold cavity 8, which form the side surfaces S1, S2 on the casting core G.
  • the section A extends, starting from a thickened foot area, in the vertical direction to about two-thirds of the height of the wall W of the casting core G to be produced, thereby covering the mouth area of the parting line 10.
  • the mold cavity 9 is aligned in such a way that the parting plane T and correspondingly the parting line 10 are aligned parallel to the inner surfaces 16,17 of the mold cavity 9, which are the flat side surface sections provided on opposite sides of the casting core insert E Show SF1, SF2 of the core insert E.
  • the parting plane T and the parting line 10 therefore do not intersect the mold cavity 8 , 9 in the area of its inner surfaces 16 , 17 , which are oriented here in the horizontal direction H, but in the area of its narrow sides 18 , 19 , which extend in the vertical V direction.
  • the thickened base of the casting core insert E in section A of the core box 1 is placed in the recess 4 formed in the lower core box part 3 ( 3 ).
  • the casting core insert E completely occupies the section A of the mold cavity 8 and lies with its side surface sections SF1, SF2 close to the respective associated inner surface 14,15 of the mold cavity 9 at.
  • the side surface sections SF1, SF2 of the casting core insert E cover the mouth areas of the parting line 10, so that these are shielded from the open residual area 20 of the mold cavity 8, which until then was still free of mold material.
  • Casting core molding material F is then shot into the mold cavity 8 via the filling openings 11 and 12 by means of the shot nozzles already mentioned above.
  • the casting core molding material F completely fills the mold cavity 8 and comes into contact with the narrow sides of the casting core insert E assigned to the open part of the mold cavity 8, so that after completion of the filling process, the casting core insert E is completely embedded in the casting core molding material F on its lateral narrow sides and its top .
  • casting core molding material F is also shot into the mold cavity 9 until it is completely filled ( figure 5 ).
  • the casting core molding material F filled into the mold cavities 8, 9 is cured, depending on the binder system used in each case, by the application of heat, the removal of moisture or gassing.
  • a form-fitting connection is formed between the casting core insert E and the casting core molding material F lying against it between the grains of the casting core insert E, which engage in one another on the side surfaces, and the remaining part of the casting core G forming the casting core molding material F, which is not occupied by the casting core insert E.
  • material connections are formed at least locally Connections between the casting core molding material F of the casting core insert E and the casting core molding material F filled into the mold cavity 8 as a result of the bonding of binder, which is present in the casting core molding material F filled into the mold cavity 8, with the molding material grains of the casting core insert E.
  • transition areas U where the side surface sections SF1, SF2 merge into the adjoining side surface sections SF1, SF2 of the casting core G, are free of cracks or other unevenness. Likewise, the side surface sections SF1, SF2 are completely free of burrs in accordance with the requirements placed on them. In contrast, on the remaining surfaces not occupied by the side surface sections SF1, SF2 of the casting core insert E, a casting core flash K forms where the parting line 10 opens into the mold cavity 8.
  • the casting core insert E' produced at the same time as the casting core G is available for a further run of the method described here, in which a further casting core G is produced using the relevant casting core insert E that has been pre-produced independently of it.
  • the same commercially available casting core molding material F was used for the production of the casting core G and the casting core insert E, which was mixed in a known manner from a molding sand, an organic or inorganic binder and additives. Due to the completely independent production, however, a different mold material could have been used to produce the casting core insert E, for example in order to achieve a special surface quality in the area of the side surface sections SF1, SF2.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP20729191.5A 2019-05-29 2020-05-19 Verfahren zum herstellen eines verlorenen giesskerns Active EP3976290B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102019114493.0A DE102019114493A1 (de) 2019-05-29 2019-05-29 Verfahren zum Herstellen eines verlorenen Gießkerns
PCT/IB2020/054721 WO2020240342A1 (de) 2019-05-29 2020-05-19 VERFAHREN ZUM HERSTELLEN EINES VERLORENEN GIEßKERNS

Publications (3)

Publication Number Publication Date
EP3976290A1 EP3976290A1 (de) 2022-04-06
EP3976290B1 true EP3976290B1 (de) 2023-07-05
EP3976290C0 EP3976290C0 (de) 2023-07-05

Family

ID=70918738

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20729191.5A Active EP3976290B1 (de) 2019-05-29 2020-05-19 Verfahren zum herstellen eines verlorenen giesskerns

Country Status (7)

Country Link
US (1) US11890669B2 (pl)
EP (1) EP3976290B1 (pl)
CN (1) CN114126781B (pl)
DE (1) DE102019114493A1 (pl)
MX (1) MX2021014511A (pl)
PL (1) PL3976290T3 (pl)
WO (1) WO2020240342A1 (pl)

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITVI980160A1 (it) * 1998-09-03 2000-03-03 Foundry Automation Sas Metodo per la realizzazione di anime composite per getti di fonderia ed anime composite ottenute con tale metodo.
DE10013124A1 (de) * 2000-03-17 2001-09-20 Olsberg Hermann Everken Gmbh Verfahren zum Herstellen von Hohlräume aufweisenden Gußstücken und Gießkern-Herstellungsform
ITBS20020088A1 (it) * 2002-10-04 2004-04-05 Meccanica Bassi Spa Procedimento di fusione, in particolare per testa cilindri di motori
WO2006044713A2 (en) * 2004-10-20 2006-04-27 Chipless Metals Llc Insert cladding technique for precision casting processes
EP1721688A1 (en) * 2005-05-13 2006-11-15 Processi Innovativi Tecnologici, S.r.L Foundry cores and method for manufacturing the same
US8899303B2 (en) 2011-05-10 2014-12-02 Howmet Corporation Ceramic core with composite insert for casting airfoils
CN202185556U (zh) * 2011-06-22 2012-04-11 海门市沪海有色铸造有限公司 一种细长型壳体芯壳模具
CN103121083B (zh) * 2011-11-18 2015-06-03 广西玉柴机器股份有限公司 V型气缸体铸造分芯工艺
CN107520412B (zh) * 2017-09-04 2019-02-22 芜湖市云峰铸造有限责任公司 一种汽车制动器铝制件成型装置

Also Published As

Publication number Publication date
WO2020240342A1 (de) 2020-12-03
CN114126781A (zh) 2022-03-01
US11890669B2 (en) 2024-02-06
DE102019114493A1 (de) 2020-12-03
CN114126781B (zh) 2024-03-29
PL3976290T3 (pl) 2023-10-09
EP3976290C0 (de) 2023-07-05
EP3976290A1 (de) 2022-04-06
MX2021014511A (es) 2022-01-06
US20220234096A1 (en) 2022-07-28

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