JPH0699247A - Casting method using special core - Google Patents

Abstract

PURPOSE:To efficiently form cast products having the wide range of shapes without any restriction of the shape by using a special core except a sand core generally used as the core. CONSTITUTION:After forming the non-sand core 1 by using a material except the sand, the non-sand core 1 is arranged between a punch 2 and a die 3 to form a mold 4. Successively, molten metal, such as molten aluminum, is poured into a cavity part 5 formed in the mold 4 according to the cast product. Then, after forming the cast product 6 having the shape according to the shape of the cavity part 5, the cast product 6 is taken out from the mold 4 and the unnecessary part of burrs, etc., in the cast product 6 is removed to obtain the aimed finish product. In this casting method using the special core in which the non-sand core is used as the core to form the mold and this mold is used to produce the cast product, the improvement of the productivity and enlargement of application range can be obtd., and the cost for cast product can drastically be reduced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a casting method using a special core, and in particular, by using a special core without using a sand core which has been conventionally generally used as a core, The present invention relates to a casting method using a special core capable of efficiently forming a wide variety of cast products without being restricted by the above.

[0002]

2. Description of the Related Art In casting employed as a part of machining, a non-disintegrating core or a disintegrating core is used to form a hollow portion and an undercut portion.

As the former (non-disintegrating core), there is a metal core, but it cannot be used except for those that can be directly punched or deformed, and the range of use is limited to that of a specific shape.

As the latter (disintegrating core), a sand core is generally used, but it is difficult to mold and
Not only is it easy to disintegrate and is difficult to handle, but it is also difficult to meet the conflicting conditions of pressure resistance during casting and disintegration after casting.

Therefore, in recent years, it has been proposed to apply a special coating to the surface of the sand core, but the following problems have not been solved. (1) The coating is difficult because it is difficult to form not only one layer but also a plurality of layers. Therefore, not only the coating is time-consuming and labor-intensive, but also time and cost are required. It is difficult to achieve the initial purpose. (2) Since it is difficult to completely remove the binder which is a component of the coating layer and the sand core after casting, it is necessary to perform a sand baking treatment for removing the coating layer and the binder. It is time-consuming and costly. (3) Since the sand core is difficult to mold, it requires not only equipment and man-hours, but also the molded sand core is fragile and difficult to handle, and it requires man-hours and yield is poor.
It takes time and money. (4) Sand core requires complicated pressure adjustment to prevent collapse during casting, and complete collapse after casting is difficult. Therefore, heat treatment step, sand drop step, and sand drop inspection are necessary. Therefore, it requires man-hours, time and cost. (5) It is easy to generate defective products such as a molten metal being inserted between sand particles of a core during casting, and a component of the sand core penetrating into a cast product to cause a cavity in the cast product, Casting yield is poor and productivity is poor. (6) It is difficult to completely remove the core sand after casting, and it adheres to the cast product, causing problems such as wear and damage of the product. (7) Casting of complicated shapes and large castings are difficult or virtually impossible to cast, so the range of application is limited,
There is a problem in design and production. (8) When the sand of the sand core is reused after casting, it is difficult to completely remove the coating layer and the binder because the coating layer and the binder are contained in the sand core, which requires man-hours. Then
It takes time and money. (9) The sand core has many defects such as difficulty in molding, easy to collapse, and difficult to handle, and it is difficult to satisfy the conflicting conditions of pressure resistance during casting and disintegration after casting. It requires many steps as described below, the yield is low, and it takes time and cost.

That is, the conventional casting method using a sand core requires the following steps. (1) Core molding → (2) Core coating mold → (3) Core drying → (4) Mold formation → (5) Casting by pouring molten metal →
(6) Casting sand removal → (7) Casting sand heat treatment (sand baking) → (8) Casting sand removal inspection → (9) Casting deburring → (10) Finished product.

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems by adopting the following constitution. That is, (1) By using a special core that is difficult to break as the core,
The core is easy to mold and handle, reducing man-hours and time and cost. (2) By using a special core that does not use a penetrating component such as a binder, it is possible to prevent the core component from penetrating into a cast product, thereby preventing the occurrence of defects such as porosity. , Preventing the occurrence of defective cast products, contributing to improved yield and improved productivity. (3) The use of a special core that has the conflicting conditions of pressure resistance during casting and collapsibility after casting prevents the occurrence of molten metal injection during casting and avoids pressure adjustment (pressure resistance (non-collapse)). Property), and facilitates complete collapse of the core after casting (disintegration property) and complete removal of core components,
Prevents adhesion to castings and prevents casting defects such as wear and damage of castings. (4) The use of a special core facilitates the formation of hollow parts and undercut parts, and improves core strength,
Expanding the range of application by enabling casting of all shapes and sizes without being bound by shapes and sizes. (5) The special core does not contain binders and other difficult-to-remove components, which facilitates complete collapse and removal of the core after casting, facilitates reuse, prevents pollution, and reduces man-hours. Save time and money.

[0008]

According to the present invention, such an object is characterized in that a non-sand core is used as a core to form a mold, and a casting is manufactured using the mold. It is achieved by providing a casting method using a special core.

[0009]

According to the present invention as described above, there are the following actions.

That is, according to the present invention, a casting method using a special core is used, in which a special core is used as a core to form a mold, and a casting is produced using the mold. The idea is to improve the property and expand the scope of application. (1) By using a special core that is difficult to break as the core,
Molding of the core is facilitated, molding equipment is simplified, the number of steps is reduced, and time and cost can be reduced. (2) Since a special core that is hard to break is used as the core, it will not break even if dropped or thrown, making it easy to handle, easy to transport and store, and no need to adjust the pressure during casting. Can be reduced, and time and cost can be reduced. (3) Since the special core used does not contain a permeation component such as a binder, the core component is prevented from permeating into the cast product, which prevents defects such as porosity from occurring The generation of defective products can be prevented, and the yield and productivity can be improved. (4) By using a special core as the core, it becomes easy to form the hollow part and the undercut part, and the core strength is improved. It is possible to cast the sword and expand the range of application. (5) By using a special core that has the conflicting conditions of pressure resistance during casting and disintegration after casting,
It avoids the occurrence of molten metal insertion during casting, avoids pressure adjustment, maintains pressure resistance (non-disintegration), and completely disintegrates the core after casting (disintegration) and completely removes core components. It is easy to prevent the adhesion to the cast product and prevent the occurrence of the cast product defect such as wear and damage of the cast product. (6) Since the special core used as the core does not contain components that are difficult to remove, such as a binder, it is easy to completely disintegrate and remove the core, and it is easy to reuse, resulting in pollution. Can be prevented, the man-hours can be reduced, and the time and cost can be reduced.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings.

1 to 4 show a first embodiment of a casting method using the special core of the present invention.

That is, the present invention does not use a sand core that is generally widely used as a core, but does not use a sand core made of a material other than the sand core that is usually considered to be difficult or unusable. A casting method using a special core, characterized in that a mold is formed using the core, and a cast product is manufactured using the mold.

The non-sand core used in the present invention is
It is required to satisfy the conflicting conditions of pressure resistance (non-disintegration) during casting and complete disintegration (disintegration) after casting.

Further, the non-sand core is required to have a condition that does not exert an adverse effect on a cast product such as generation of a large amount of gas during casting.

In the present embodiment, a case will be described in which a die made of synthetic resin (plastic) is used as the non-sand core, and die casting is performed as one of the casting methods.

That is, in this embodiment, casting is performed in the following steps.

First Step First, although not shown, a hollow portion as well shown in FIG. 4 is formed by using a synthetic resin (plastic) by a synthetic resin molding method (plastic molding method) such as injection molding. A synthetic resin core (plastic core) (hereinafter referred to as “resin core”) 1 having S is molded.

Second Step Subsequently, as shown in FIG. 1, the resin core 1 is disposed between the upper mold 2 and the lower mold 3 to form a mold 4 having a cavity 5. Form.

Third Step Next, as best shown in FIGS. 1 and 2, a molten metal such as an aluminum molten metal is poured into the cavity 5 formed in the mold 4 depending on the material of the cast product. To do.

As a result, a cast product 6 having a shape corresponding to the shape of the hollow portion 5 is formed.

The resin core 1 contributes to the formation of a desired casting 6 by maintaining its shape during casting, and is melted by residual heat of the casting 6 after casting. Since it is removed by removing it, no residue remains.

In this case, the temperature of the molten metal is considerably lower than the initial temperature (for example, in the case of aluminum molten metal, about 660 ° C.) by the time it reaches the cavity 5 of the mold 4.

Further, the resin core 1 retains its initial shape without being immediately melted by the reflecting action and the temperature action even if the molten metal acts due to the temperature and latent heat of the resin core itself. The resin core 1 is melted and removed by the residual heat of the cast product 6 after the molten metal has been poured into the cavity 5 and a predetermined time has passed and the molten metal has cooled and solidified.

Subsequently, as well shown in FIGS. 2 and 3, the casting 6 formed as described above is taken out from the mold 4, thereby completing the casting.

Fourth Step Further, although not shown, unnecessary parts such as burrs of the cast product 6 can be removed to obtain a finished product.

Therefore, in comparison with the conventional method which required the following 10 steps, only 4 steps are required and 6 steps are omitted.

That is, the conventional method using the sand core is as follows.
It looks like this: (1) Core molding → (2) Core coating mold → (3) Core drying → (4) Mold formation → (5) Casting by pouring molten metal →
(6) Casting sand removal → (7) Casting sand heat treatment (sand baking) → (8) Casting sand removal inspection → (9) Casting deburring → (10) Finished product.

Next, FIG. 5 shows a second embodiment of the special core used in the present invention. The resin core 1 as the non-sand core which is the special core has its surface (outer surface). A protective layer 7 is formed on the surface of the substrate.

The protective layer is a heat resistant coating layer made of a heat resistant resin or the like.

Materials for forming the heat resistant coating layer include heat resistant resins such as silicon rubber and silicon resin, low melting point metals, new ceramics (fine ceramics) and other heat resistant materials.

The special core used in the present invention is not limited to that of the above-mentioned embodiment, but can be applied to various shapes using various special cores to improve the quality of cast products. However, the present invention is not limited to the above-described embodiment, and many modifications can be considered.

For example, the special core of the above-mentioned embodiment has a hollow shape from the viewpoints of weight reduction, cost reduction, and ease of collapse / removal after casting, but is not limited to this. Needless to say, it can be a solid shape in terms of non-disintegration during casting.

Further, the casting method using the special core of the present invention is not limited to the casting method of the above-mentioned embodiment, and it is possible to further improve the quality of the cast product by adding specific steps. It is not limited to the casting method of the above-mentioned embodiment, and many modifications can be considered.

Further, the core made of synthetic resin (plastic) as the non-sand core, which is the special core of this embodiment, has both conflicting conditions of pressure resistance during casting and disintegration after casting. However, it is required that it does not adversely affect the cast product such as generating a large amount of gas during casting. The synthetic resin (plastic) as the core material that satisfies this condition is as follows. is there.

That is, as a synthetic resin (plastic) as a core material having the above respective conditions, for example,
There is a thermoplastic synthetic resin, which satisfies all of the above conditions, and a cast product that sufficiently satisfies the initial purpose can be obtained.

The most suitable of these thermoplastic synthetic resins are fluororesins (polyfluorethylene resins) such as tetrafluorinated ethylene resins, polyimide resins, polyamideimide resins and polysulfone resins, and any of the above conditions is used. Also, it is possible to obtain a cast product that satisfies the initial purpose.

Next to this, there are polyamide resin (nylon resin) and polypropylene resin, which meet all of the above conditions, and a cast product satisfying the initial purpose can be obtained.

Other examples include polyethylene resin, polyester resin (tetron resin), and polysulfone sun resin, which meet all of the above conditions and obtain a cast product satisfying the initial purpose. be able to.

The core made of synthetic resin (plastic) used for the casting special core of this embodiment is not limited to the above synthetic resin (plastic), and the pressure resistance during casting and the pressure after casting As long as it has a reciprocal condition with disintegration and does not give a bad influence to the cast product such as generating a large amount of gas during casting,
It goes without saying that thermosetting resins such as silicone resin and other synthetic resins (plastics) other than those in the above-mentioned examples can be used, and the same effects as those in the above-mentioned examples can be obtained.

Further, the casting method using the non-sand core as the special core of the present invention is not limited to the casting method using the core made of the synthetic resin (plastic) of the above embodiment, Needless to say, a casting method using a non-sand core made of a material other than the synthetic resin (plastic) can be used as a non-sand core as a special core other than the synthetic resin (plastic). , There is the next one.

That is, for example, there are low melting point metals, new ceramics (fine ceramics) and other materials,
A non-sand core can be formed by using these materials, a mold can be formed by using the non-sand core, and a cast product can be manufactured using the mold, and the same effect as that of the above-mentioned embodiment can be obtained. be able to.

In the above-mentioned embodiment, the case of performing die casting as one of the casting methods using the core made of synthetic resin (plastic) as the non-sand core as the special core has been described. The special core for casting of the present invention is
The present invention is not limited to the die casting, but can be applied to the sand type gravity casting method, the die gravity casting method, the low pressure casting method and the precision casting method, and other casting methods, and the same effect as the above-mentioned embodiment. Can be obtained.

The casting method using the special core of the present invention is not limited to the above casting method, and it is possible to further improve the quality of the cast product by adding specific steps.
The present invention is not limited to the above casting method, and many modifications can be considered.

Next, the operation of the casting method using the special core according to this embodiment will be described.

As described above, the present invention provides a casting method using a special core, in which a non-sand core is used as a core to form a mold, and a casting is produced using the mold. The idea is to improve productivity and expand the scope of application, and has the following effects. (1) By using a non-breakable non-sand core as the core,
Molding of the core is facilitated, molding equipment is simplified, the number of steps is reduced, and time and cost can be reduced. (2) Since a non-sand core that is hard to break is used as the core, it will not break even if dropped or thrown, making it easy to handle, easy to transport and store, and no need to adjust the pressure during casting. Man-hours can be reduced, and time and cost can be reduced. (3) Since no infiltration component such as a binder is used, penetration of core components into the cast product is prevented, so that defects such as cavities are prevented, and defective products of the cast product are prevented. It is possible to improve yield and productivity. (4) By using a non-sand core, the hollow part and the undercut part can be easily formed, and the core strength is improved. Casting becomes possible and the range of application can be expanded. (5) By using a special core that has the conflicting conditions of pressure resistance during casting and disintegration after casting,
It avoids the occurrence of molten metal insertion during casting, maintains pressure resistance (non-disintegration) by avoiding pressure adjustment, and completely disintegrates the core after casting (disintegration) and completely removes core components. It is easy to prevent the adhesion to the cast product and prevent the occurrence of the cast product defect such as wear and damage of the cast product. (6) Since the non-sand core does not contain components that are difficult to remove, such as a binder, it is easy to completely disintegrate and remove the core, and it is easy and easy to reuse to prevent the occurrence of pollution. In addition, the man-hours can be reduced, and the time and cost can be reduced.

Incidentally, the casting method using the special core of the present invention is not limited to the above-mentioned embodiments, and many modifications can be considered.

[0048]

As described above, the present invention provides a casting method using a special core for forming a mold using a non-sand core as the core and producing a casting using the mold. The idea is to improve productivity and expand the scope of application, and has the following excellent effects. (1) By using a non-breakable non-sand core as the core,
There are advantages that the molding of the core becomes easy, the molding equipment is simplified, the process is reduced, and the time and cost can be reduced. (2) Since a non-sand core that is hard to break is used as the core, it will not break even if dropped or thrown, making it easy to handle, easy to transport and store, and no need to adjust the pressure during casting. This has the advantage of reducing man-hours and time and cost. (3) Since no infiltration component such as a binder is used, penetration of core components into the cast product is prevented, so that defects such as cavities are prevented, and defective products of the cast product are prevented. The yield is improved, and the productivity is improved. (4) By using a non-sand core, it is easy to form hollow parts and undercut parts, and the core strength is improved. There is an advantage that casting is possible and the range of application can be expanded. (5) By using a special core that has the conflicting conditions of pressure resistance during casting and disintegration after casting,
It avoids the occurrence of molten metal insertion during casting, avoids pressure adjustment, maintains pressure resistance (non-disintegration), and completely disintegrates the core after casting (disintegration) and completely removes core components. There is an advantage that it can be made easy, and adhesion to the cast product can be prevented, and occurrence of cast product defects such as wear and damage of the cast product can be prevented. (6) Since the non-sand core does not contain components that are difficult to remove, such as a binder, it is easy to completely disintegrate and remove the core, and it is easy and easy to reuse, thus preventing pollution. In addition to the above, there is a great advantage that man-hours can be reduced and time and cost can be reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a method of forming a mold using a resin core that is a non-sand core in a casting method using a special core according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a method of forming a cast product by pouring a molten metal in a casting method using a special core according to an embodiment of the present invention.

FIG. 3 is a cross-sectional view showing a cast product taken out from a mold in a casting method using a special core according to an embodiment of the present invention.

FIG. 4 is a cross-sectional view showing a resin core which is a non-sand core used in a casting method using a special core according to an embodiment of the present invention.

FIG. 5 is a sectional view showing a second embodiment of the resin core. 1 Resin core (synthetic resin core: plastic core)
(Non-sand core which is a special core) 2 Upper mold 3 Lower mold 4 Mold 5 Cavity 6 Cast product 7 Protective layer S Hollow

Claims (3)

[Claims] 1. A casting method using a special core, wherein a mold is formed by using a non-sand core as the core, and a casting is manufactured using the mold. 2. A non-sand core having a reciprocal condition of pressure resistance during casting and disintegration after casting,
The casting method using the special core according to claim 1, which is used. 3. A casting method using a special core according to claim 1 or 2, wherein a core made of synthetic resin (plastic) is used as the non-sand core.