JP6748750B2 - Hot water system - Google Patents

Description

The present invention relates to a feeder system used in a metal casting operation using a mold, a feeder sleeve used in the feeder system, and a method of making a mold including the feeder system.

In a typical casting process, molten metal is poured into a preformed mold cavity that defines the shape of the casting. However, the metal shrinks during solidification, resulting in shrinkage cavities that result in unacceptable defects in the final casting. This is a well-known problem in the casting industry, during which the riser integrated into the mold either by attaching to the pattern plate or later by inserting the sleeve into the cavity of the formed mold. This is addressed by the use of sleeves or risers. Each feeder sleeve provides an additional (usually enclosed) volume or cavity in communication with the mold cavity so that molten metal also enters the feeder sleeve. During solidification, the molten metal in the feeder sleeve flows back into the mold cavity to compensate for shrinkage of the casting.

After solidification of the casting and removal of the mold material, undesired residual metal from within the feeder sleeve remains attached to the casting and must be removed. To facilitate removal of residual metal, the feeder sleeve cavity is located at its base (ie, the end of the feeder sleeve that will be closest to the mold cavity) in a design commonly referred to as a neck down sleeve. It may be tapered towards. When a strong blow is applied to the residual metal, it separates at the weakest parts near the mold (a process commonly known as "knock off"). A small footprint on the casting is also desirable to allow positioning of the feeder sleeve in areas of the casting where access may be limited by adjacent features.

Although the feeder sleeve may be mounted directly on the surface of the casting mold cavity, it is often used with feeder elements (also known as breaker cores). Breaker cores are discs of refractory material (typically resin-bonded sand cores, or ceramic cores, or feeder sleeve material) that are usually centered and located between the mold cavity and feeder sleeve material. Core). The diameter of the hole through the breaker core is designed to be smaller than the diameter of the internal cavity (not necessarily tapered) of the feeder sleeve, resulting in knock-off in the breaker core close to the casting.

Foundry sand can be divided into two main categories, chemical bonds (based on organic or inorganic binders) and clay bonds. Chemical Bonding Molding binders are typically self-curing systems in which the binder and chemical hardener are mixed with sand so that the binder and hardener immediately begin to react, but slowly enough. , Sand around the pattern plate and then harden sufficiently for removal and casting.

Clay-binding molding uses clay and water as a binder and can be used in a "raw" or undried state, commonly referred to as green sand. The green sand mixture does not immediately flow or move easily under compressive force only, so to pack the green sand around the pattern and to give the mold sufficient strength properties, a jolting, Various combinations of vibrating, squeezing and ramming are applied to produce molds of high productivity and uniform strength. Sand is typically compressed (packed) at high pressure, usually using one or more hydraulic rams.

To apply the sleeve to such a high pressure molding process, pins are typically provided on the molding pattern plate (defining the mold cavity) at predetermined locations as mounting points for the feeder sleeve. Once the required sleeve is installed on the pin (as the base of the feeder is on or above the pattern plate), the molding sand is placed on the pattern plate until the feeder sleeve is covered and the mold is filled. And by pouring around the feeder sleeve a mold is formed. The application of foundry sand and subsequent high pressure can result in damage and breakage of the feeder sleeve, which increases the complexity and productivity requirements of the casting, especially if the feeder sleeve is in direct contact with the pattern plate before compaction. As a result, more dimensionally stable molds are needed, which can result in a tendency to higher ramming pressures and consequent sleeve breakage.

Applicants have developed a variety of collapsible feeder elements for use in combination with feeder sleeves as described in WO2005/051568, WO2007141446, WO2012110753 and WO2013171439. The feeder element compresses under pressure during molding, thereby protecting the feeder sleeve from damage.

US 2008/0265129 describes a feeder insert for inserting into a mold used for cast metal, which comprises a feeder body having a feeder cavity therein. The bottom side of the feeder body communicates with the mold, and the energy absorbing device is provided on the top side of the feeder body.

EP1184104A1 (Chemex GmbH) is a two-part feeder sleeve (in which the outer wall of the first (lower) part and the inner wall of the second (upper) part are flush with each other when the molding sand is compressed, in order. It may be adiabatic or exothermic).

Figures 3a to 3d of EP 1184104A1 show the telescopic movement of the two part feeder sleeve (102). The feeder sleeve (102) is in direct contact with the pattern (122), which can result in inadequate surface finish, localized fouling of the casting surface, and secondary casting imperfections, which is exothermic. It causes harm when the sleeve is used. Also, even though the lower portion (104) is tapered, the lower portion (104) must still be relatively thick to withstand the forces it receives during compaction, so it is still on the pattern (122). There is a wide footprint in. This is insufficient in terms of knock-off and space occupied by the feeder system on the pattern. The lower inner portion (104) and the upper outer portion (106) are held in place by a retaining element (112). The holding element (112) breaks off and allows it to fall into the foundry sand in order to be able to perform a telescoping movement. The retaining element accumulates in the foundry sand over time and contaminates the foundry sand. This is especially troublesome if the holding element is made of a heat-generating material. This is because the retaining element can react and produce small explosive defects.

US 6904952 (AS Luengen GmbH & Co. KG) describes a feeder system in which a tubular body is temporarily glued to the inner wall of a feeder sleeve. There is relative movement between the feeder sleeve and the tubular body when the foundry sand is compressed.

Increasing demands are placed on feeder systems used in high pressure molding systems, partly due to advances in molding equipment, and partly due to new castings being manufactured. Certain grades of ductile cast iron and certain casting shapes can adversely affect the effectiveness of feeder performance through the neck of certain metal feeder elements. Also, some molding lines or casting shapes result in over-compression (crushing of the feeder element or expansion of the feeder system) that occurs at the base of the sleeve close to the casting surface separated by only a thin layer of sand. obtain. The present invention seeks to provide a feeder system for use in metal casting, which seeks to overcome one or more of the problems associated with prior art feeder systems, or to provide a useful alternative.

According to a first aspect of the present invention, including a feeder sleeve mounted on the tubular body,
The tubular body is provided with a first end, an opposite second end and a compression provided therebetween such that when a force is applied during use, the distance between the first end and the second end is reduced. Has a section,
The feeder sleeve includes a continuous side wall having a longitudinal axis and defining a cavity for receiving liquid metal during casting, the side wall extending substantially around the longitudinal axis, the side wall adjacent the second end of the tubular body. Have
The tubular body defines an open hole therethrough for connecting the cavity to the casting,
A feeder system for metal casting is provided in which at least one notch extends from the base into the side wall and a second end of the tubular body projects into the notch to a depth.

In use, the feeder system is mounted on the mold pattern and is typically mounted on a mold pin attached to a pattern plate to hold the system in place so that the tubular body is adjacent to the mold. .. The open hole defined by the tubular body provides a passageway from the feeder sleeve cavity to the mold cavity to raise the casting as it cools and contracts. During shaping and subsequent compaction, the feeder system will be subjected to forces in the direction of the longitudinal axis (hole axis) of the tubular body. When the second end of the tubular body is held at a certain depth in the notch of the feeder sleeve, this force causes the compression part to collapse, eliminating the possibility of relative movement between the tubular body and the sleeve. .. Therefore, the high compression pressure causes deformation of the tubular body rather than breakage of the feeder sleeve. Typically, the feeder system will be subject to a compaction pressure (when measured on the pattern plate) of at least 30, 60, 120 or 150 N/cm ² .

FIG. 3 of WO2005/051568 shows a feeder system including a compressible breaker core (10, which is a tubular body) and a feeder sleeve (20). The breaker core includes a radial sidewall region that is adhesively attached to the base of the feeder sleeve. FIG. 1 of WO2005/095020 shows a feeder system including a first compact (4, tubular body) and a second compact (5, feeder sleeve). The first shaped body (4) is in the form of a bellows and comprises a deformation element connected to the base of the feeder sleeve by means of an annular support surface. In the present invention, the tubular body fits within the notch in the feeder sleeve rather than being attached to the base of the feeder sleeve.

When a metal breaker core (folding or tubular expansion) is used, the metal, usually steel, is heated during casting to extract some energy from the liquid metal in the feeder. Metal breaker cores generally have a tubular mounting surface, thus reducing size or removing it altogether causes the core to heat up faster with less energy taken from the metal feeder. Reduce the amount of (cold) metal at. Furthermore, by partially embedding the breaker core in the exothermic sleeve, it receives additional energy and is overheated, which in turn improves the feeder performance through the neck of the core.

Tubular Body The tubular body has two functions: (i) the tubular body has an open hole therethrough that provides a passage from the feeder sleeve to the mold, and (ii) the deformation (due to the fold) of the tubular body Provide to act to absorb energy that could otherwise cause damage to the feeder sleeve.

The tubular body includes a compression section. In one embodiment, the compression section has a stepped shape. The stepped shape is known from WO 2005/051568. In one embodiment, the compression section includes a single step or "kink." In other embodiments, the compression section includes at least 2, 3, 4, 5 or 6 steps or twists. In one such embodiment, the compression section includes 4-6 steps or twists.

The diameter of the step or kink can be measured. In one embodiment, all steps have the same diameter. In another embodiment, the step diameter decreases toward the first end of the tubular body, ie the compression section is frustoconical.

The taper angle μ between the frustoconical compression part and the bore axis/longitudinal axis of the feeder sleeve can be measured. In one set of embodiments, the frustoconical section is inclined at an angle of 50, 40, 30, 20, 15, or 10° or less from the axis. In one set of embodiments, the frustoconical section is inclined at an angle of at least 3, 5, 10 or 15° from the axis. In one embodiment, the angle μ is 5-20°. A slight taper may be beneficial in providing additional compression.

The stepped shape may include a series of alternating first and second sidewall regions, and the angle formed between the pair of first and second sidewall regions is measurable. The internal angle (θ) is measured from the inside of the tubular body and the external angle (φ) is measured from the outside of the tubular body. It will be appreciated that when the compression portion collapses, the angles θ and φ decrease during compaction. In one set of embodiments, the angle between the pair of first and second sidewall regions is at least 30, 40, 50, 60 or 70°. In a set of embodiments, the angle between the pair of first and second sidewall regions is 120, 100, 90, 80, 70, 60 or 50° or less. In one embodiment, the angle between the pair of first and second sidewall regions is 60-90°.

The stepped shape may include a series of alternating first and second sidewall regions, the angle α formed between the first sidewall regions and the longitudinal axis (hole axis) of the tubular body being measurable. Similarly, the angle β formed between the second side wall region and the hole axis can be measured.

In one embodiment, the angles α and β are the same.

In one embodiment, α or β is about 90°, ie the first sidewall region or the second sidewall region is substantially perpendicular to the hole axis.

In one embodiment, α or β is about 0, that is, the first side wall region or the second side wall region is substantially parallel to the hole axis.

In one embodiment, each of α and β is 40-70°, 30-60° or 35°-55°.

The height of the tubular body can be measured in a direction parallel to the hole axis and may be compared to the height of the compression section (also measured in a direction parallel to the hole axis). In one set of embodiments, the height of the compression section corresponds to at least 20, 30, 40 or 50% of the height of the tubular body. In another set of embodiments, the height of the compression section corresponds to 90, 80, 70 or 60% or less of the height of the tubular body.

The size and mass of the tubular body depends on the application.

In general, it is preferable to reduce the mass of the tubular body when possible. This may also be beneficial by reducing material costs and, for example, by reducing the heat capacity of the tubular body during casting. In one embodiment, the tubular body has a mass of less than 50, 40, 30, 25 or 20 g.

It is understood that the tubular body has a longitudinal axis and a bore axis. Generally, the feeder sleeve and tubular body are shaped such that the bore axis and the longitudinal axis of the feeder sleeve are the same. However, this is not essential.

The height of the tubular body may be measured in a direction parallel to the hole axis and may be compared to the depth of the notch (first depth). In some embodiments, the ratio of height to first depth of the tubular body is from 1:1 to 5:1, 1.1:1 to 3:1 or 1.3:1 to 2:1. is there.

The tubular body has an inner diameter and an outer diameter, and a thickness that is the difference between the inner diameter and the outer diameter (all measured in a plane parallel to the hole axis). The thickness of the tubular body should allow the tubular body to project into the notch. In some embodiments, the tubular body has a thickness of at least 0.1, 0.3, 0.5, 0.8, 1, 2 or 3 mm. In some embodiments, the tubular body has a thickness of 5, 3, 2, 1.5, 0.8 or 0.5 mm or less. In one embodiment, the tubular body has a thickness of 0.3-1.5 mm. The small thickness makes it possible to reduce the material needed to manufacture the tubular body and to narrow the corresponding notches in the side wall, the heat capacity of the tubular body and thus the energy absorbed from the riser metal during casting. It is beneficial for several reasons such as reducing the amount. The notch extends from the base of the sidewall and the wider the notch, the wider the base must be to accommodate it.

In one embodiment, the tubular body has a circular cross section. However, the cross section may also be non-circular, for example oval, obround or elliptical. In one embodiment, the tubular body is narrow (tapered) away from the feeder sleeve (adjacent the casting in use). The constriction adjacent to the casting is known as the feeder neck and provides better knock off of the feeder. In one set of embodiments, the angle of the tapered neck with respect to the bore axis is no greater than 55, 50, 45, 40 or 35°.

To further improve knock-off, the base of the tubular body has an inwardly directed lip to provide a surface for attachment to the molding pattern and to make a cut in the resulting casting feeder neck to remove it ( Knock off).

The tubular body can be manufactured from a variety of suitable materials including metals (eg, steel, iron, aluminum, aluminum alloys, brass, copper, etc.) or plastics. In a particular embodiment, the tubular body is made of metal. The metal tubular body can have a small thickness while retaining sufficient strength to withstand the molding pressure. In one embodiment, the tubular body is not manufactured from riser sleeve material (whether heat insulating or exothermic). The feeder sleeve material is generally not strong enough to withstand the molding pressure with a small thickness, while the thicker tubular body requires a wider groove in the side wall, thus overall the feeder system Increases the size (and associated costs) of the. Tubular bodies made of feeder sleeve material can also give rise to poor surface finishes and imperfections when contacted with castings.

In some embodiments, where the tubular body is made of metal, it may be pressed from a single piece of metal of constant thickness. In one embodiment, the tubular body is manufactured by a drawing process whereby the metal sheet blank is drawn radially into the mold by the mechanical action of the punch. This process is considered deep drawing when the depth of the retracted portion exceeds its diameter and is achieved by redrawing the portion through a series of dies. In another embodiment, the tubular body is manufactured by a spatula or rotomolding process whereby a metal blank disc or tube is first mounted on a rotary lathe and rotated at high speed. Local pressure is then applied to a series of rollers or tool paths that cause metal to flow down on and around the mandrel having the required finished part internal dimension profile.

To be suitable for press forming or spatula drawing, the metal should be sufficiently malleable to prevent tearing or cracking during the forming process. In certain embodiments, the feeder element is a typical carbon ranging from a minimum of 0.02% (grade DC06, European standard EN10130-1999) to a maximum of 0.12% (grade DC01, European standard EN10130-1999). Manufactured from cold rolled steel having a content. In one embodiment, the tubular body consists of steel having a carbon content of less than 0.05, 0.04 or 0.03%.

Feeder Sleeve In one embodiment, the notch is a groove extending from the base of the sidewall. It will be appreciated that the side wall groove is separate from the feeder sleeve cavity. In one embodiment, the groove is located at least 5, 8 or 10 mm from the feeder sleeve cavity.

In another embodiment, the notch is adjacent to the feeder sleeve cavity. In one such embodiment, the end of the notch is defined by the sidewall ledge.

The notch is considered to have a first depth which is the distance the notch extends from the base into the sidewall. Typically, the notches have a uniform depth, i.e. the distance from the base into the sidewall is the same wherever measured. However, it will be appreciated that notches of variable depth can be used if desired and the first depth is the minimum depth. This is because it determines the extent to which the tubular body can project into the notch.

Prior to compaction, the tubular body is received in the notch to a second depth, and the tubular body projects at least partially into the notch. In one embodiment, the tubular body projects completely into the notch, ie the second depth is equal to the first depth.

In one embodiment, the compression section of the tubular body is remote from the notch. Alternatively, the compression section of the tubular body projects partially or completely into the notch of the feeder sleeve (prior to compaction). The size and shape of the compression section affects the placement of the compression section. It is more practical for the compression section to be located outside the feeder sleeve to allow for uniform and consistent crushing and to minimize the particles of the sleeve from being abraded by the movement of the compression section relative to the sleeve. Target.

The notch must be able to receive the tubular body. Thus, the cross section of the notch (in the plane perpendicular to the hole axis) corresponds to the cross section of the tubular body, for example the groove is a circular groove and the tubular body has a circular cross section. In one embodiment, the at least one notch is a single continuous groove. In another embodiment, the feeder sleeve has a series of slots and the tubular body has a corresponding shape, such as a castellated edge.

In one set of embodiments, the notch has a first depth of at least 20, 30, 40 or 50 mm. In one set of embodiments, the first depth is 100, 80, 60 or 40 mm or less. In one embodiment, the first depth is 25-50 mm. The first depth is comparable to the height of the feeder sleeve. In one embodiment, the first depth corresponds to 10-50% or 20-40% of the height of the feeder sleeve.

The notch is considered to have a maximum width (W) measured in a direction substantially perpendicular to the bore axis and/or feeder sleeve axis. It will be appreciated that the width of the notch must be sufficient to allow the tubular body to be received within the notch. In one set of embodiments, the notch has a maximum width of at least 0.5, 1, 2, 3, 5, 8 or 10 mm. In one set of embodiments, the notch has a maximum width of 15, 10, 5, 3 or 1.5 mm or less. In one embodiment, the notch has a maximum width of 1-3 mm. This is especially useful when the notch is a groove (away from the cavity). In one embodiment, the notch has a maximum width of 5-10 mm. This is especially useful when the notch is adjacent to the cavity.

The notches may have a uniform width, i.e. the width of the notches is the same wherever measured. Alternatively, the notches may have a non-uniform width. For example, when the notch is a groove, it may narrow away from the base of the sidewall. Therefore, the maximum width is measured at the base of the sidewall and then the width decreases to a minimum at the first depth.

In one set of embodiments, the second depth (D2, the depth in which the tubular body is received in the notch) is at least 30, 40 or 50% of the first depth. In one set of embodiments, the second depth is no more than 90, 80 or 70% of the first depth. In one embodiment, the second depth is 80-100% of the first depth.

Typically, the tubular body projects into the notch to a uniform depth, i.e. the distance from the base to the end of the tubular body is the same wherever measured. However, tubular bodies with non-uniform perimeters (eg castellated edges) can be used as needed to vary the distance, with the second depth being the maximum depth, to the foundry of foundry sand. It will be appreciated that it is ensured that there is no gap between the tubular body and the base of the side wall to avoid ingress of

The nature of the feeder sleeve material is not particularly limited and may be, for example, heat insulating, exothermic or a combination thereof. The exothermic feeder sleeve generates heat which helps keep the molten metal liquid for a longer period of time. The exothermic sleeve may be a fast ignition high exothermic high density sleeve, such as the FEEDEX® range of products sold by Foseco, or has a significantly lower density and is less exothermic than the FEEDEX range sleeve. It may be a heat insulating sleeve such as the KALMINEX® range of products sold by the company.

In one embodiment, the feeder sleeve is an exothermic feeder sleeve. As described above, according to the present invention, the tubular body (breaker core) is made of (cold) metal by embedding a part of the tubular body in the feeder sleeve and not using a mounting surface protruding to the outside of the feeder sleeve cavity. By avoiding cooling, which may adversely affect feeder performance by reducing the total amount of This advantage is more pronounced when using an exothermic sleeve rather than an insulating sleeve, as it appears to help overheat the metal tubular body (breaker core).

The manufacturing method is not particularly limited, and the sleeve may be manufactured using, for example, either a vacuum forming process or a core shot method. Typically, feeder sleeves combine low and high density refractory fillers (eg silica sand, olivine, aluminosilicate hollow microspheres and fibers, chamotte, alumina, pumice, perlite, vermiculite) with a binder. Consisting of a mixture of The exothermic sleeve contains a fuel (typically aluminum or aluminum alloy), an oxidizer (typically iron oxide, magnesium dioxide or potassium nitrate), and a normal initiator/sensitizer (typically cryolite). And need more.

In one embodiment, a conventional feeder sleeve is manufactured and then the feeder sleeve material is removed from the base to form a notch, for example by drilling or polishing. In another embodiment, a feeder sleeve is manufactured by a core shot method incorporating a tool defining the notch with a notch in place, for example the tool has a thin mandrel and has a thin mandrel around the mandrel. The sleeve is formed and then the sleeve is removed (stripped) from the tool and mandrel. In a further embodiment, the sleeve is formed around the tubular body.

In one set of embodiments, the feeder sleeve has a strength (crush strength) of at least 8 kN, 12 kN, 15 kN, 20 kN or 25 kN. In one set of embodiments, the sleeve strength is less than 25 kN, 20 kN, 18 kN, 15 kN or 10 kN. For ease of comparison, the strength of the feeder sleeve is defined as the compressive strength of a 50×50 mm cylindrical specimen made of feeder sleeve material. A 201/70EM compression tester (Form & Test Seidner, Germany) is used and operated according to the manufacturer's instructions. The test specimen is placed in the center of the lower steel plate, and ruptures as the lower plate moves towards the upper plate at a speed of 20 mm/min. The effective strength of the feeder sleeve depends not only on the exact composition, the binder used and the manufacturing method, but also on the size and design of the sleeve, which usually means that the strength of the specimen is of a standard flatness. It is indicated by the fact that it is higher than the strength measured for the upper sleeve.

In one set of embodiments, the feeder sleeve has a density of at least 0.5, 0.8, 1.0 or 1.3 g/cm ³ . In another set of embodiments, the feeder sleeve has a density of 2.0, 1.5 or 1.2 g/cm ³ or less. KALMIN S® is a commercial sleeve with a typical density of 0.45 g/cm ³ . Low density exothermic insulating feeder sleeves are available under the brand name KALMINEX® and typically have densities of 0.58 to 0.95 g/cm ³ . FEEDEX HD® is a commercially available high density, high exothermic sleeve with a density of 1.4 g/cm ³ . In general, increasing the density of the sleeve by adjusting the type of refractory filler and other components typically results in increased strength.

The parameters that can be considered when evaluating an exothermic feeder sleeve are ignition time, maximum temperature reached (Tmax), duration of exothermic reaction (burn time), and Modulus Extension Factor (MEF, coagulation). Time extension x coefficient of x).

In one embodiment, the feeder sleeve has a MEF of at least 1.40, 1.55 or 1.60. KALMINEX(R) feeder sleeves are exothermic insulating sleeves, typically having a MEF of 1.58-1.64, while FEEDEX(R) sleeves are exothermic and typically Specifically, it has a MEF of 1.6 to 1.7. KALMIN S® feeder sleeves are thermally insulating and typically have a MEF of 1.4-1.5.

In one embodiment, the feeder sleeve includes a top plate spaced from the base of the sidewall. The sidewalls and top plate together define a cavity for receiving liquid metal during casting. In one such embodiment, the top plate and sidewalls are integrally formed. Alternatively, the side wall and the top plate are separable, ie the top plate is a lid. In one embodiment, both the side wall and the top plate are made of feeder sleeve material.

Feeding sleeves are available in many shapes including cylinders, ellipses and domes. As such, the sidewalls are parallel to or angled from the longitudinal axis of the feeder sleeve. The top plate (if present) may be flat top, dome-shaped, flat top dome-shaped, or other suitable shape.

The top plate of the sleeve may be closed to enclose the feeder sleeve cavity and to assist in mounting the feeder system on the forming pins that are attached to the molding pattern, the top of the feeder (base and May also include a recess (blind hole) that extends partially through the other side. Alternatively, the feeder sleeve may have an opening (opening hole) extending through the entire feeder top plate with the feeder cavity opened. The openings must be wide enough to accommodate the support pins and narrow enough to avoid sand from entering the feeder sleeve cavity during molding. The diameter of the opening may be compared to the maximum diameter of the feeder sleeve cavity (both measured in a plane perpendicular to the longitudinal axis of the feeder sleeve). In one embodiment, the diameter of the opening is 40, 30, 20, 15 or 10% or less of the maximum diameter of the feeder sleeve cavity.

In use, the feeder system is typically installed on a support pin to hold the feeder system in the required position on the molding pattern plate before the sand is compressed and compacted. Upon compaction, the sleeve moves towards the molding pattern surface and, if fixed, the pin may pierce the top plate of the feeder sleeve, or simply an opening or recess as the sleeve moves downwards. You may cross. This movement and contact with the pins of the top plate can cause small pieces of the sleeve to break off and fall into the casting cavity, which can result in poor surface finish or localized contamination of the casting surface. This can be overcome by lining the openings or recesses in the top plate with hollow inserts or internal collars, which may be made of various suitable materials such as metal, plastic or ceramic. Therefore, in one embodiment, the feeder sleeve may be modified to include an internal collar that lines the opening or recess in the top plate of the feeder. This collar may be inserted into the opening or recess in the top plate of the sleeve after the sleeve has been manufactured, or alternatively incorporated during the manufacture of the sleeve, whereby the sleeve material is core-shot around the collar or Once molded, the sleeve is cured to hold the collar in place. Such a collar protects the sleeve from possible damage by the support pins during molding and stamping.

The invention also belongs to a feeder sleeve for use in the feeder system according to the embodiment of the first aspect.

According to a second aspect of the present invention, it includes a continuous side wall having a longitudinal axis and extending substantially around the longitudinal axis, and a top plate extending substantially intersecting the longitudinal axis, both the side wall and the top plate being cast. Defines a cavity for receiving liquid metal in
A feeder sleeve for use in metal casting is provided in which the side wall has a base spaced from the top plate and a groove extends from the base into the side wall.

The above description regarding the first aspect also applies to the second aspect, except that the feeder sleeve of the second aspect must include a top plate. It will be appreciated that the groove extends away from the base and extends towards the top plate.

In one embodiment, the openings (open holes) extend through the top plate of the feeder. In one such embodiment, the internal collar lines the opening. This embodiment is useful when the feeder sleeve is used with a support pin as described above.

In one embodiment, the top plate is closed, i.e. the opening does not extend through the top plate of the feeder.

According to a third aspect of the invention,
Installing the feeder system of the first aspect on a pattern, the feeder system comprising a feeder sleeve mounted on a tubular body,
The feeder sleeve includes a continuous side wall defining a cavity for receiving liquid metal during casting, the side wall having a base adjacent the tubular body,
The tubular body defines a through-opening hole for connecting the cavity to the casting, the tubular body having a first end, an opposite second end and a compression portion provided therebetween;
Installing a feeder system on the pattern, wherein the notch extends from the base into the side wall and the second end of the tubular body projects into the notch to a certain depth;
Enclosing the pattern with mold material,
Compressing the mold material,
Removing the pattern from the compressed mold material to form a mold,
Compressing the mold material comprises applying pressure to the feeder system such that the compression section is compressed and the distance between the first end and the second end is reduced. To be done.

The mold may be a horizontal dividing mold or a vertical dividing mold. When used in a vertical split molding machine (such as the DISAMATIC frameless molding machine manufactured by DISA Industries A/S), the feeder system typically swings in a horizontal position during a normal mold making cycle. (Pattern) Installed on the plate. The sleeve may be installed manually on a horizontal pattern or rocker plate or automatically by use of a robot.

The above description regarding the first and second aspects also applies to the third aspect. In particular, in one embodiment, the notch is a groove (away from the cavity). In other embodiments, the notch is adjacent to the casting.

In one set of embodiments, compressing the mold material comprises applying a compaction pressure of at least 30, 60, 90, 120 or 150 N/cm ² .

In one embodiment, the compression section has a stepped shape. In one such embodiment, the stepped shape comprises an alternating series of first and second sidewall regions, wherein compression of the compression portion reduces the angle between the pair of first and second sidewall regions.

In one embodiment, the mold material is clay-bound sand (commonly referred to as raw sand), typically clay such as sodium or calcium bentonite, water, and additives such as coal dust and flour binders. Including mixtures with. Alternatively, the mold material is mold sand containing a binder.

Embodiments of the present invention are described by way of example only with reference to the accompanying drawings.

1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention. 1 is a schematic diagram showing a feeder system according to an embodiment of the present invention.

Referring to FIG. 1a, a feeder system 10 before compression is shown. The feeder system includes an exothermic feeder sleeve 12 mounted on a tubular body 14. The feeder sleeve 12 has a longitudinal axis Z and a continuous sidewall 16 defines a cavity that extends generally radially about this axis to receive molten metal during casting. The upper part of the feeder sleeve 12 is not shown.

The tubular body 14 tapers inwardly at the first end 18 and contacts the pattern plate 20 to form a feeder neck. The tubular body 14 has a second end 22 that projects into a groove 24 that extends from the base 16a of the sidewall 16. The groove 24 is separated from the cavity. The second end 22 and groove 24 are sized and shaped to provide a friction fit that holds the tubular body 14 in place and at a constant depth.

The tubular body 14 defines a through-opening hole for connecting the cavity to the casting in use. In this example, the bore axis lies along the longitudinal axis Z.

The tubular body 14 includes two steps 26 between the first end 18 and the second end 22 to form a compression section. Step 26 can be viewed as an alternating series of first sidewall regions 26a and second sidewall regions 26b. The first side wall region 26a is perpendicular to the hole axis Z, and the second side wall region 26b is parallel to the hole axis Z. The angle between the pair of first sidewall region 26a and second sidewall region 26b is 90°. The diameter of the first and second side wall regions decreases in the direction away from the feeder sleeve and the compression section can be considered to be frustoconical. The distance between the first and second ends 18, 22 of the tubular body 14 is indicated as D1.

Referring to FIG. 1b, the feeder system 10 after compression is shown. Application of a force along the axis Z during compaction causes the tubular body 14 to collapse, thereby reducing the distance between the first end 18 and the second end 22 to D2. The feeder sleeve 12 approaches the pattern 20 during compaction.

Referring to FIG. 2a, the feeder system 28 before compression is shown. The feeder system includes an exothermic feeder sleeve 12 mounted on a tubular body 30 and a support pin 32. The tubular body 30 tapers inwardly at the first end 34 and contacts the pattern plate 20 to form a feeder neck. The tubular body 30 has a second end 36 that projects into the groove 24.

The upper portion of the molding pin 32 is disposed in a recess 38 that complements the top plate 40 of the sleeve 12, and when the sleeve 12 moves downward during compaction, the upper portion of the molding pin 32 is a thin portion at the upper portion of the top plate 40. Penetrate through. If desired, a collar could be fitted into the recess 38 to avoid the risk of broken pieces of the sleeve breaking off when the pin 32 pierces the top plate 40. Alternatively, a narrow opening could extend through the top plate 40 instead of the recess 38, thereby accommodating the support pin 32. In this case, the openings had a diameter corresponding to about 15% of the maximum diameter of the feeder sleeve cavity.

Tubular body 30 is shown in FIG. 2b without a feeder sleeve. The tubular body 30 includes a single outwardly facing kink 40 between the first end 34 and the second end 36 to form a compression section. The kink 40 is formed by the first sidewall region 40a and the second sidewall region 40b. The first sidewall region 40a makes an angle α with the longitudinal axis Z, and the second sidewall region 40b makes an angle β with the longitudinal axis Z. The angles α and β are the same (both about 50°). The angle θ formed between the first and second sidewall regions 40a, 40b is about 80°. It will be appreciated that α+β+θ=180°.

During compaction, a force is applied in the direction of the axis Z to collapse the tubular body, thereby reducing the distance between the first and second ends 34, 36 and reducing the angle θ.

Referring to FIG. 3a, the feeder system 42 before compression is shown. The feeder system 42 includes an exothermic feeder sleeve 12 mounted on a tubular body 44. The tubular body 42 is tapered at the first end 46 and contacts the pattern plate 20 to form a feeder neck. Tubular body 42 has an inwardly directed lip or flange 48 at the base that rests on the surface of pattern plate 20 in use, forming a notch in the resulting metal feeder neck to facilitate its removal (knock-off). The tubular body 42 has a second end 50 that projects into the groove 24 to the full depth of the groove 24. A tapered groove may be used, which does not allow the tubular body to project completely to the end of the groove where the groove becomes too narrow.

The tubular body 44 includes four inward kinks 52 between the first end 46 and the second end 50 to form a compression section. The kink 52 is formed by a series of alternating first sidewall regions 52a and second sidewall regions 52b. The first side wall region 52a forms an angle α with the longitudinal axis Z, and the second side wall region 52b forms an angle β with the longitudinal axis Z. The angles α and β are the same (both about 50°). The use of more than one kink 52 can be considered to provide a bellows type structure. The interior angle θ formed between the pair of first and second sidewall regions 52a, 52b is about 80°. It will be appreciated that α+β+θ=180°.

Referring to FIG. 3b, the feeder system 42 after compression is shown. Application of a force along the axis Z during compaction causes the tubular body 44' to collapse, thereby reducing the distance between the first end 46 and the second end 50 to D2. The feeder sleeve 12 comes closer to the pattern 20 during compaction.

Referring to FIG. 4a, the feeder system 54 before compression is shown. The feeder system includes an exothermic feeder sleeve 56 mounted on a tubular body 58. The feeder sleeve 56 has a longitudinal axis Z and a continuous sidewall 60 defines a cavity that extends generally radially about this axis to receive molten metal during casting. The continuous side wall 60 has a base 60a from which a notch 62 extends. The end of the notch 62 is defined by the ledge 60b of the sidewall 60. The notch 62 has a width W measured in a direction perpendicular to the hole axis Z.

The tubular body 58 tapers inwardly at the first end 64 and contacts the pattern plate 20 to form a feeder neck. The tubular body 58 has a second end 66 that projects into the notch 62 and abuts the ledge 60b. Tubular body 58 and notch 62 are sized and shaped so that tubular body 58 fits snugly into sidewall 60. The tubular body 58 defines a through-opening hole for connecting the cavity to the casting in use. In this example, the bore axis lies along the longitudinal axis Z.

The tubular body 58 includes three inward kinks 68 between the first end 64 and the second end 66 to form a bellows-like compression section. The kink 68 is a series of alternating first sidewall regions 68a and second sidewall regions 68b. Each first sidewall region 68a makes an angle α with the longitudinal axis Z, and each second sidewall region 68b makes an angle β with the longitudinal axis Z. The angles α and β are the same (both about 50°). The interior angle θ formed between the pair of first and second sidewall regions 68a and 68b is about 80°. It will be appreciated that α+β+θ=180°.

Figure 4b shows the feeder system 54 after compression. The tubular body 58 collapses to reduce the distance from the first end 64 to the second end 66 to D2. The kink is compressed to reduce the angle θ to about 5°.

FIG. 5 shows a tubular body 70 for use in combination with a feeder sleeve such as feeder sleeve 12 (FIG. 1) or feeder sleeve 56 (FIG. 4). The tubular body 70 has a first end 72 and a second end 74 and defines an open hole therethrough. The hole has a longitudinal axis Z (hole axis). The tubular body has a compression section consisting of an inward kink 76 having alternating series of first sidewall regions 76a and second sidewall regions 76b. The compression section is frustoconical and the diameter of the kink 76 decreases slightly from the second end 74 to the second end 72, i.e. the tubular body tapers inwardly towards the pattern plate 20. The taper angle μ is less than 10° (measured with respect to the hole axis Z).

The first side wall region 76a forms an internal angle α with the hole axis, and the second side wall region 76b forms an internal angle β with the hole axis. The angle α is slightly larger (about 60°) than the angle β (about 45°). The angle between the first and second sidewall regions is approximately 75° (whether measured inside or outside the tubular body).
The present invention is capable of the following embodiments.
(1) Including a feeder sleeve attached to a tubular body,
The tubular body is provided with a first end, an opposite second end and a compression provided therebetween such that when a force is applied during use, the distance between the first end and the second end is reduced. Has a section,
The feeder sleeve includes a continuous side wall having a longitudinal axis and defining a cavity for receiving liquid metal during casting, the side wall extending substantially around the longitudinal axis, the side wall adjacent the second end of the tubular body. Have
The tubular body defines an open hole therethrough for connecting the cavity to the casting,
A feeder system for metal casting wherein at least one notch extends from the base into the side wall and the second end of the tubular body projects into the notch to a certain depth.
(2) A feeder system in which the compression section includes a single step or kink formed by the first and second sidewall regions.
(3) A feeder system including a series of alternating first and second sidewall regions, thereby providing multiple steps/kinks.
(4) A feeder system in which a series of alternating first and second sidewall regions together form four steps or kinks.
(5) (i) The angle θ formed between the pair of first and second side wall regions is 60 to 90°, and (ii) is formed between the first side wall region and the longitudinal axis of the tubular body. The feeder system in which the angle α is 30-60° and/or (iii) the angle β formed between the second side wall region and the longitudinal axis of the tubular body is 30-60°.
(6) A feeder system in which each step/kink has a diameter measured in a direction perpendicular to the longitudinal axis, and all steps/kinks have the same diameter.
(7) Each step/kink has a diameter measured in a direction perpendicular to the longitudinal axis, the diameter of the step/kink decreasing towards the first end of the tubular body and a frustoconical compression section. Feeder system that forms the.
(8) A feeder system in which the truncated cone-shaped compression portion is inclined from the longitudinal axis at an angle of 15° or less.
(9) A feeder system in which the tubular body is metal.
(10) A feeder system in which the metal is steel with a carbon content of less than 0.05%.
(11) A feeder system in which the notch extends away from the base to a first depth, and the tubular body projects into the notch to the first depth.
(12) A feeder system in which the notch extends away from the base portion to a first depth, and the first depth corresponds to 5 to 30% of the height of the feeder sleeve.
(13) A feeder system in which the notch is a groove.
(14) The feeder system in which the notch is adjacent to the feeder sleeve cavity.
(15) The feeder system in which the compression part of the tubular body is separated from the notch.
(16) The feeder system in which the feeder sleeve is an exothermic feeder sleeve.
(17) A feeder system in which the feeder sleeve has a crush strength of at least 25 kN.
(18) A continuous side wall having a longitudinal axis and extending substantially around the longitudinal axis, and a top plate extending substantially intersecting the longitudinal axis, both of the side wall and the top plate receiving liquid metal during casting. Of a feeder sleeve for use in a feeder system, the cavity defining a cavity of which the sidewall has a base spaced from the top plate and a groove extending from the base into the sidewall.
(19) Installing a feeder system on a pattern, the feeder system including a feeder sleeve mounted on a tubular body,
The feeder sleeve includes a continuous side wall defining a cavity for receiving liquid metal during casting, the side wall having a base adjacent the tubular body,
The tubular body defines a through-opening hole for connecting the cavity to the casting, the tubular body having a first end, an opposite second end and a compression portion provided therebetween;
Installing a feeder system on the pattern, wherein the notch extends from the base into the side wall and the second end of the tubular body projects into the notch to a certain depth;
Enclosing the pattern with mold material,
Compressing the mold material,
Removing the pattern from the compressed mold material to form a mold,
Compressing the mold material comprises applying pressure to the feeder system such that the compression section is compressed and the distance between the first end and the second end is reduced.
(20) Compressing the mold material comprises applying a compaction pressure of at least 30 N/cm ² .
(21) The compression part has a stepped shape including a series of alternating first and second sidewall regions, and the compression of the compression part reduces the angle θ between the pair of first and second sidewall regions. ..

Claims (20)

Including a feeder sleeve attached to the tubular body,
The tubular body is a first end portion, a second end portion on the opposite side, and a compression portion therebetween, and when a force is applied during use, the first end portion and the second end portion are crushed by the compression portion. And a compression unit provided so that the distance between them becomes irreversibly small,
The feeder sleeve includes a continuous side wall having a longitudinal axis and defining a cavity for receiving liquid metal during casting, the side wall extending substantially around the longitudinal axis, the side wall adjacent the second end of the tubular body. Have
The tubular body defines an open hole therethrough for connecting the cavity to the casting,
Formed in at least one notch side walls, a groove or ledge extending to the side wall from the base, out collision to the second end portion is cut in the lack of the tubular body, it is held at a constant depth within the notch ,
Projecting cutout, part of the tubular body to have a second end, characterized in that it is substantially parallel to the longitudinal axis of the feeder sleeves, the feeder system for metal casting. 2. The feeder system according to claim 1, characterized in that the compression part consists of a single step or kink formed by the first and second side wall regions. 2. The feeder system according to claim 1, characterized in that the compression part consists of a series of alternating first and second side wall regions, thereby providing a plurality of steps/kinks. 4. The feeder system according to claim 3, characterized in that the alternating series of first and second side wall regions together form four steps or kinks. (I) The angle θ formed between the pair of first and second side wall regions is 60 to 90°, and (ii) the angle α formed between the first side wall region and the longitudinal axis of the tubular body is 30-60° and/or (iii) the angle β formed between the second side wall region and the longitudinal axis of the tubular body is 30-60°. The feeder system according to any one of 1. 6. A step/kink according to any one of claims 3-5, characterized in that each step/kink has a diameter measured in a direction perpendicular to the longitudinal axis, and all steps/kinks have the same diameter. Hot water system. Each step/kink has a diameter measured in a direction perpendicular to the longitudinal axis, and the diameter of the step/kink decreases toward the first end of the tubular body to form a frustoconical compression. The feeder system according to any one of claims 3 to 5, which is characterized in that. The feeder system according to claim 7, wherein the truncated cone-shaped compression portion is inclined from the longitudinal axis at an angle of 15° or less. The feeder system according to any one of claims 1 to 8, wherein the tubular body is made of metal. The feeder system according to claim 9, characterized in that the metal is steel with a carbon content of less than 0.05%. 11. The feeder system according to any one of claims 1 to 10, characterized in that the notch extends away from the base to a first depth and the tubular body projects into the notch to the first depth. 12. The notch extends away from the base to a first depth, the first depth corresponding to 10-40% of the height of the feeder sleeve, 12. Hot water supply system. The feeder system according to claim 1, wherein the notch is a groove. 13. The feeder system according to any one of the preceding claims, characterized in that the notch extends from the base to the side wall and forms a ledge adjacent to the feeder sleeve cavity. The feeder system according to any one of claims 1 to 14, characterized in that the compression part of the tubular body is separated from the notch. The feeder system according to claim 1, wherein the feeder sleeve is an exothermic feeder sleeve. 17. The feeder system according to any one of claims 1 to 16, characterized in that the feeder sleeve has a crush strength of at least 25 kN. Installing the feeder system according to any one of claims 1 to 17 on a pattern;
Enclosing the pattern with mold material,
Compressing the mold material,
Removing the pattern from the compressed mold material to form a mold,
Compressing the mold material comprises applying pressure to the feeder system such that the compression section is compressed and the distance between the first end and the second end is reduced. how to. Compressing the mold material is characterized in that it comprises applying a strike compaction pressure of at least 30 N / cm ^2, The method of claim 18. The compression section has a stepped shape including a series of alternating first and second sidewall areas, wherein compression of the compression section reduces an angle θ between the pair of first and second sidewall areas. 20. The method according to claim 18 or 19, wherein