JP6509059B2 - Casting method and mold used therefor - Google Patents

Description

The present invention relates to a method of casting a lead for a modified drain consisting of a tubular portion and a thin plate-like flange portion, and a mold.

There are various types of lead products including sheet-like shapes. For example, there is a repair drain used for the repair of the deteriorated drainage drain.
A conventional repair drain will be described with reference to FIG.

FIG. 14 is a perspective view showing the configuration of a conventional repair drain.
As shown in FIG. 14, the conventional modified drain 22 is made of lead, and includes a cylindrical portion 23 and a thin plate-like flange portion 24 formed around one end of the cylindrical portion 23. The thin plate-shaped flange portion 24 has a circular hole punched out, and the cylindrical portion 23 is welded at the welding portion 25 to the thin plate-shaped flange portion 24 so that the tip thereof is along the periphery of the hole. The refurbished drain 22 is used, for example, in a state where the cylindrical portion 23 is directed horizontally. The cylindrical portion 23 serves as a drainage drain, and the thin plate-like flange portion 24 is embedded in the wall or floor to fix the cylindrical portion 23 to the wall or floor. The thin plate-like flange portion 24 is used by being bent along a wall or a floor according to the position of the drainage drain.

Unexamined-Japanese-Patent No. 2007-247295

  However, since the conventional lead-made repair drain 22 has the cylindrical portion 23 joined to the thin-plate shaped flange portion 24 by welding, it is difficult to bend the thin-plate shaped flange portion 24 in the vicinity of the cylindrical portion 23 . That is, the welded portion 25 is thick and it is difficult to bend at that portion. In addition, when the welding portion 25 is bent, a defect such as a crack is likely to occur in the welding portion 25. In particular, drainage drains are often provided near the floor of the wall, and are constructed so that the flange portion 24 follows both the wall in the vertical direction and the floor in the horizontal direction. The need to bend the flange 24 is high. Therefore, it is required to manufacture a refurbished drain by casting without joining the cylindrical portion 23 and the thin-plate shaped flange portion 24 by welding. However, it has been difficult to cast and manufacture an object including a thin portion such as a remodeled drain in which a thin plate-like large area flange portion 24 and a cylindrical portion 23 are integrally formed. Moreover, although it may be calculated | required by casting that the thing containing the thin-plate-like and thin-line-like thin-shaped part which is illustrated by the remodeling drain may be calculated | required, it was difficult to manufacture by casting.

In order to solve the above-mentioned problems, it is an object of the present invention to easily manufacture a modified drain as a structure including a thin plate portion or a thin line portion by casting.

In order to achieve the above purpose, the casting method is
Casting of a lead refurbished drain consisting of a cylindrical portion and a thin plate-like flange by casting using a mold provided at the end of the molten metal flow passage with an air vent formed around the formation region of the flange. There,
Applying in advance a lubricant containing cork powder and glue to the cavity surface of the mold ;
Clamping the mold;
Injecting molten lead into the molten metal flow path from the gate port located at the tip of the formation region of the cylindrical portion while maintaining the cavity temperature of the mold at 175 ° C. or higher and 185 ° C. or lower;
And opening the mold, characterized in that organic and the step of extracting the casting.

Further, the mold is a mold used for casting a modified drain consisting of a cylindrical portion and a thin plate-like flange portion, which is composed of a lower mold and an upper mold, and the lower mold is a hollow portion forming the formation region of the flange portion. And an air vent formed in at least a part of the mating surface of the projecting portion forming the inner diameter surface of the cylindrical portion and the upper mold around the recessed portion and having a depth of 0.01 mm or more and 0.05 mm or less includes a part, the first heater, the upper mold, to form a formation region of the tubular portion surrounds the projecting portion, and a lower surface forming the upper surface of the flange portion, the upper portion of the formation region And a second heater for supplying molten metal to the gate port, and a lubricant is applied to the surface of the recess and the lower surface of the upper mold, and the lubricant is It is characterized by including cork powder and glue.

As described above, an optimized lubricant based on cork powder is applied to the cavity surface of the mold, air is removed at the end of the mold cavity, and casting is performed while appropriately adjusting the mold temperature. It is possible to easily cast a modified drain as a structure including a thin plate shape or a thin line shape .

A perspective view illustrating the configuration of the repair drain Figure illustrating the configuration of the repair drain Figure illustrating the configuration of the repair drain Figure showing a table that illustrates the dimensions of the refurbished drain Figure illustrating the installation status of the repair drain Cross-sectional view for explaining the configuration of the mold A perspective view illustrating the configuration of the lower mold A perspective view illustrating the configuration of a mold Diagram for explaining the configuration of a lubricant-applied mold Figure showing the composition of lubricants Flow chart showing the casting method Cross section showing the molten metal injection process in the casting process Sectional drawing which shows the casting extraction process in a casting process The perspective view which shows the structure of the conventional repair drain

The casting method, mold and refurbished drain of the present invention will be described by using a refurbished lead made of lead as an example, with reference to FIGS.
1 is a perspective view illustrating the configuration of the repair drain, FIGS. 2 and 3 are diagrams illustrating the configuration of the repair drain, FIG. 4 is a table illustrating the dimensions of the repair drain, and FIG. 6 is a cross-sectional view illustrating the configuration of the mold, FIG. 7 is a perspective view illustrating the configuration of the lower mold, FIG. 8 is a perspective view illustrating the configuration of the mold, and FIG. Figure 10 illustrates the composition of the lubricant, Figure 11 is a flow chart showing the casting method, Figure 12 is a cross-sectional view showing the molten metal injection step in the casting process, and Figure 13 is a drawing in the casting process It is sectional drawing which shows a casting taking-out process.

First, the repair drain which is one of the embodiments of the present invention will be described using FIGS. 1 to 5.
The refurbished drain 1 is made of lead, and the cylindrical portion 2 and the thin plate-like flange portion 3 are integrally cast. Since it is integrally cast, no step due to solder is formed at the boundary between the cylindrical portion 2 and the flange portion 3 and the same thickness and smooth continuation from the cylindrical portion 2 to the flange portion 3 are achieved. .

  The modified drain 1 preferably has a thickness H of about 1.5 mm and an accuracy of +0 to 0.2. The outer diameter A and height D of the cylindrical portion 2 and the length W of one side of the flange portion 3 are arbitrary and can be, for example, the dimensions shown in FIG. The thickness H may be the same in all of the flange 3 and the cylinder 2. However, as shown in FIG. 3, the inner diameter of the cylinder 2 is inclined so that the tip of the cylinder 2 faces the flange 3 The thickness may be reduced so as to approach the thickness H of the flange 3. Thus, as described later, the gate opening is at the tip of the cylindrical portion 2, so that the inflow of the molten metal can be facilitated, and a removal gradient can be provided at the time of taking out the casting. For example, the inclination of the inner diameter of the cylindrical portion 2 can be about 1 ° with respect to the central axis of the cylindrical portion 2. Also, the thickness of the cylindrical portion 2 and the thickness of the flange portion 3 can be made different. The thickness H in this case refers to the thickness of the flange 3. Moreover, it is preferable to make the boundary part of the cylinder part 2 and the flange part 3 into a curved surface. Thereby, the molten metal can easily flow into the flange 3 at the time of casting. For example, the curvature of the curved surface can be about 10 mm in radius. The shape of the flange 3 may be square or rectangular, and is not limited to rectangular. Further, the corners of the outer shape may be curved. In addition, it may be circular or elliptical, and may have an outer shape combining a straight line and a curved line.

Next, the use aspect of the repair drain 1 is demonstrated using FIG.
The repair drain 1 is used to repair a drainage ditch 6 of a building or the like. For example, drainage grooves 6 are provided on the wall 4 and the floor 5 such as a veranda and a roof, and when the wall 4 and the floor 5 are cracked, a water leak occurs. When repairing this water leak, use the repair drain 1. At this time, the wall 4 and the floor 5 of the drainage groove 6 are cut, and the cylindrical portion 2 of the repaired drain 1 is inserted into the drainage groove 6. Then, the flange 3 is bent along the wall 4 and the floor 5. Thereafter, the wall 4 and the floor 5 are repaired so that the flange 3 and the wall 4 and the floor 5 are flush with each other. At this time, if the repair drain is made of resin or the like, the affinity with the concrete of the wall 4 and the floor 5 is low, but since it is made of lead, the construction is easy because the affinity between lead and concrete is high.

  Here, if the solder is placed around the cylindrical portion as in the case of the conventional repair drain, the flange portion can not be bent around the cylindrical portion. In that case, since the drain 6 is generally formed near the boundary between the wall 4 and the floor 5, the flange portion can not be bent along the wall 4 or the floor 5. On the other hand, in the refurbished drain 1, since the solder is not filled around the cylinder 2, the flange 3 can be bent even in the vicinity of the boundary between the cylinder 2 and the flange 3. The flange 3 can be folded along the floor 5. In addition, when the refurbished drain is manufactured by casting, the cost can be reduced as compared with the case of manufacturing the refurbished drain by manufacturing the refurbished drain by drawing or welding the cylindrical portion 2 and the flange portion 3 to manufacture the refurbished drain.

Next, the mold which is one of the embodiments of the present invention will be described using FIGS. 1 and 6 to 9.
A casting including a thin plate-like shape, for example, a mold 7 used when casting the modified drain 1 is composed of a lower mold 8 and an upper mold 9. In the description herein, the upper mold 9 is shown to be composed of two upper molds, and may be composed of one or more upper molds. By clamping the lower mold 8 and the upper mold 9, a cavity for casting a cast such as the modified drain 1 is formed. The mold 7 used for the casting of the modified drain 1 will be described below as an example. The cylindrical portion 2 of the refurbished drain 1 is cast by a cylindrical cavity 11 in the vertical direction surrounded by the projecting portion 10 protruding from the lower mold 8 and the plurality of upper molds 9. The outer diameter of the projecting portion 10 is a shape corresponding to the inner diameter of the cylindrical portion 2. The inner diameter formed when the upper mold 9 is clamped is a shape corresponding to the outer diameter of the cylindrical portion 2. The distance between the inner diameter surface of the upper mold 9 and the projecting portion 10 in the clamped state is a distance corresponding to the thickness of the cylindrical portion 2. When the inner diameter of the cylindrical portion 2 is inclined, the outer diameter surface of the protrusion 10 may be inclined. When the cylindrical portion 2 is cylindrical, the projecting portion 10 has a cylindrical shape, and the inner diameter surface of the upper mold 9 in a clamped state also has a cylindrical shape. Further, the gate port 12 of the mold 7 is provided on the upper portion of the upper mold 9, that is, on the opposite side to the lower mold 8 of the cavity 11 for the cylindrical portion. Furthermore, in the upper part of the gate port 12, a pool 13 is formed which stores the molten metal made of lead and injects it into the gate port 12. Further, a heater 14 is installed on the upper surface of the upper mold 9, and the heater 14 heats at least a cavity 15 for a flange to be described later, and holds the temperature at a constant temperature. When the molten metal is lead, the holding temperature can be, for example, 175 ° C. or more and 185 ° C. or less. It is preferable that a plurality of heaters 14 be provided at positions corresponding to the cavity 15 for the flange. The upper mold 9 is preferably configured to be able to open and close with respect to the lower mold 8. In this case, the upper mold 9 is closed, the mold is clamped and casting is performed, and the upper mold 9 is opened to take out the refurbished drain 1 which is a casting.

  The lower mold 9 is provided with a recess 16 for forming the flange 3 of the modified drain 1 on the upper surface of the lower mold 8 to be the mating surface 18 with the upper mold 9. The flange 3 is cast by a cavity 15 for flange in the horizontal direction formed by the recess 16 and the lower surface of the upper mold 9. The depth H of the recess 16 corresponds to the thickness H of the flange 3 of the drainage 1. For example, the depth of the recessed portion 16 = the thickness of the flange portion 3 = H is 1.4 mm or more and 1.6 mm or less, preferably 1.48 mm or more and 1.50 mm or less. The tubular portion cavity 11 and the flange portion cavity 15 are electrically connected, and the tubular portion cavity 11 and the flange portion cavity 15 form a cavity of the repairing drain 1. The molten metal flows through the cylindrical cavity 11 in the vertical direction, and then flows into the horizontal cavity 15 for the flange and flows to the end of the cavity 15 for the flange. Further, the lower mold 8 is provided with a groove-like air vent 17 extending from the recess 16 to the end of the lower mold 8 in at least a part of the mating surface 18 around the recess 16. When the upper mold 9 and the lower mold 8 are clamped, a gap from the cavity 15 for the flange portion to the outside of the mold 7 is formed in the mating surface 18 by the air vent 17. When the molten metal flows, the air pushed out of the molten metal can be extracted from the air vent 17 and the molten metal can be easily distributed even in the long thin ridge cavity 15 of the flow path of the molten metal. The depth h of the air vent 17 may be a depth at which the air is easily discharged and the molten lead is unlikely to leak out, and is, for example, 0.005 mm or more and 0.055 mm or less, preferably 0 It can be 0.20 mm or more and 0.05 mm or less. Although the formation area of the air vent 17 is optional, it is preferable to provide it on each piece around the lower mold 8. Also, a plurality of air vents 17 may be formed on each piece. Furthermore, the lower mold 8 is provided with a heater 19 along the lower surface of the recess 16. The heater 19 heats at least the flange cavity 15 and maintains it at a constant temperature. When the molten metal is lead, the holding temperature can be, for example, 175 ° C. or more and 185 ° C. or less. It is preferable that a plurality of heaters 14 be provided at positions corresponding to the cavity 15 for the flange.

  Further, as shown in FIG. 9, a lubricant 20 described later is applied to the cavity surface of the cavity formed by the upper mold 9 and the lower mold 8. In FIG. 9, one upper mold 9 is omitted. The lubricant 20 may be applied to the cavity surface of the cylinder cavity 11, but is preferably applied to at least the cavity cavity of the flange cavity 15. The cavity surface of the flange cavity 15 includes at least the bottom surface of the recess 16 and the mating surface 18 of the upper mold 9. For example, the lubricant 20 can be applied by spraying with a spray gun or the like. Thus, by applying the lubricant 20 at least to the cavity surface of the cavity 15 for the flange, the flowability of the molten metal is improved, and the molten metal can be easily circulated even in the long thin cavity for cavity 15 of the flow path of the molten metal. Can. The lubricant 20 may improve the fluidity of the molten metal by heating the temperature of the molten metal or the heater 14 and the heater 19. The lubricant 20 is applied before casting, and the used lubricant 20 is removed each time a predetermined number of castings are performed, and the lubricant 20 is applied again and then casting is performed.

Next, an example of a method of producing a lubricant will be described with reference to FIG.
The lubricant is produced, for example, by mixing cork powder, water and glue. Nikawa mainly plays the role of a binder of cork powder. Although the mixing ratio is arbitrary, it is preferable to set it as water: Nikawa: cork powder = 1000: 12: 36 by a weight ratio. Here, the cork powder is a powder of micron order. A process for producing a lubricant by mixing 10 liters (10000 g) of water, 120 g of glue and 360 g of cork powder will be described as an example. First, put 120 g of nikawa in a stirring vessel. Next, about 3.3 liters of water is put into a stirring vessel containing glue and kept for about 8 hours to 20 hours. After holding, about 6.7 liters of the remaining water is added, and the mixture is heated to 45 ° C. to 65 ° C., preferably 50 ° C. to 60 ° C. After the glue has softened sufficiently, the temperature is kept at 20 ° C. to 50 ° C., and about 360 g of cork powder is added while stirring. Thereafter, the temperature and agitation are maintained until the lubricant is applied, and in the case of application, the particles are filtered to a predetermined particle size and used.

Next, a method of casting the refurbished drain 1 with the mold 7 will be described with reference to FIGS. 1, 6 and 9 to 13.
A lubricant 20 is applied to the cavity surface of the mold 7 in advance. The application is performed by spraying using a spray gun or the like. The cavity surface to which the lubricant 20 is applied may include at least the cavity surface of the cavity 15 for the flange portion (steps 1 and 9 in FIG. 11).

  At the time of casting, first, a mold release agent is applied to the cavity surface of the mold 7. The mold release agent can easily remove the casting from the mold 7 (step 2 in FIG. 11). Next, the upper mold 9 and the lower mold 8 are clamped. At this time, the cavity surface is heated to a predetermined temperature, for example, about 180 ° C. by the heater 14 and the heater 19, and is controlled to maintain this temperature during casting. The temperature control is performed by a control device (not shown) connected to the heater 14 and the heater 19 and a temperature sensor (not shown) for measuring the cavity temperature (steps 3 and 6 in FIG. 11). Next, the molten metal 21 of lead is injected into the well 13. The molten metal 21 is heated to 460 ° C. or more and 490 ° C. or less, preferably 475 ° C. or more and 485 ° C. or less. The injected molten metal 21 is temporarily held and flows into the cavity from the gate port 12. The molten metal 21 larger than the volume of the cavity is injected into the well 13 so that the molten metal 21 remains in the well 13. The molten metal 21 circulates through the cavity 11 for the cylindrical portion, and is circulated inside the flange cavity 15 toward the end by the weight of the molten metal 21 remaining in the well 13. Further, since the air venting portion 17 is provided around the flange cavity 15, the air pushed out by the flowing molten metal 21 is discharged from the air venting portion 17 to the outside of the mold 7, and the flow of the molten metal 21 is compressed. Air inhibition is suppressed. Furthermore, since the lubricant 20 is applied to at least the cavity surface of the cavity 15 for the flange, the molten metal 21 can flow through the cavity 15 for the flange with low resistance. Therefore, the molten metal 21 can easily flow through the inside of the cavity 15 for the brim portion to the end portion, and even the thin plate-shaped and wide-area brim portion 3 can be easily cast. At this time, by setting the depth h of the air removal portion 17 to be 0.005 mm or more and 0.055 mm or less, it is possible to suppress the outflow of the molten metal 21 while the air is discharged (Step 4 of FIG. 11, Figure 12). Finally, after the molten metal 21 solidifies, mold opening is performed, and the completed casting, i.e., the repaired drain 1 is taken upward, and the excess pool 13 is cut off (step 5 in FIG. 11, FIG. 13). It is determined whether casting has been performed a predetermined number of times or for a predetermined period of time (step 6 in FIG. 11), and if casting is not performed a predetermined number of times or for a predetermined period of time When casting is performed a predetermined number of times or for a predetermined time, after the lubricant 20 is removed and a lubricant is applied again (Step 7 in FIG. 11), casting is continuously performed from application of the release agent.

  In the refurbished drain 1, the cylindrical portion 2 may have a cylindrical shape or a prismatic shape, and as long as it is cylindrical, the cross-sectional shape is arbitrary. The shape of the flange portion 3 is also arbitrary, and may be a square, a rectangle, a circle, an ellipse, a lattice shape, or a shape in which a plurality of strip plates are arranged.

As described above, when casting a modified drain casting having a thin portion such as thin plate shape or thin wire shape in which molten metal is difficult to flow, an optimum lubricant mainly composed of cork powder is applied to the cavity surface of the mold Of the molten metal in the cavity, air vents are provided at the end of the cavity of the mold to discharge the air pushed in the direction in which the molten metal flows, and the pressure of the air prevents the molten metal from flowing. Repair drain as a structure with a shape such as thin plate shape or thin wire shape that is difficult to circulate by casting while maintaining mold fluidity properly by controlling the mold temperature and maintaining the fluidity of the molten metal It can be easily cast. The application of a lubricant mainly composed of cork powder, the air venting part, and the temperature control improve the ease of casting by carrying out all of them, but they may be carried out by combining them appropriately depending on the shape of the casting. .

DESCRIPTION OF SYMBOLS 1 Renovation drain 2 Tubular part 3 Flange part 4 Wall 5 Floor 6 Drainage groove 7 Mold 8 Lower mold 9 Upper mold 10 Protrusive part 11 Cavity for cylinder part 12 Gate mouth 13 Water pool 14 Heater 15 Cavity for rib part 16 Hollow part 17 Air Extraction part 18 mating surface 19 heater 20 lubricant 21 molten metal 22 repair drain 23 cylindrical part 24 flange part 25 weld part

Claims (4)

Casting of a lead refurbished drain consisting of a cylindrical portion and a thin plate-like flange by casting using a mold provided at the end of the molten metal flow passage with an air vent formed around the formation region of the flange. There,
Applying in advance a lubricant containing cork powder and glue to the cavity surface of the mold ;
Clamping the mold;
Injecting molten lead into the molten metal flow path from the gate port located at the tip of the formation region of the cylindrical portion while maintaining the cavity temperature of the mold at 175 ° C. or higher and 185 ° C. or lower;
Casting method characterized by chromatic and a step of taking out the casting and the mold is opened.   The lubricant is characterized in that water, the glue and the cork powder are mixed by heating, stirring and mixing in a ratio by weight of water: glue: cork powder = 1000: 12: 36. Casting method described.   The mold is disposed such that the formation area of the cylindrical portion is in the vertical direction, the mold is disposed such that the formation area of the flange portion is in the horizontal direction, and the gate port is an upper portion of the formation area of the cylindrical portion The casting method according to claim 1 or 2, which is arranged in A mold used for casting a modified drain consisting of a tubular portion and a thin plate-like flange portion,
Consists of lower and upper molds,
The lower mold is
A recessed portion forming a formation region of the flange portion;
A projecting portion forming an inner diameter surface of the cylindrical portion;
An air vent portion formed in at least a part of a mating surface with the upper mold around the recessed portion and having a depth of 0.01 mm or more and 0.05 mm or less;
And a first heater,
The upper mold is
To form a formation region of the tubular portion surrounds the projecting portion,
A lower surface forming an upper surface of the flange portion;
A gate port provided above the formation region;
A pool for supplying molten metal to the gate port ;
And a second heater,
A lubricant is applied to the surface of the recess and the lower surface of the upper mold, and the lubricant includes cork powder and glue.

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