JPH09314310A - Metal casting method - Google Patents
Metal casting methodInfo
- Publication number
- JPH09314310A JPH09314310A JP15293096A JP15293096A JPH09314310A JP H09314310 A JPH09314310 A JP H09314310A JP 15293096 A JP15293096 A JP 15293096A JP 15293096 A JP15293096 A JP 15293096A JP H09314310 A JPH09314310 A JP H09314310A
- Authority
- JP
- Japan
- Prior art keywords
- pipe
- mold
- refractory
- casting
- casting method
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- General Induction Heating (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、金属鋳造方法に係
わり、さらに詳しくは、鋳鉄,鋳鋼,非鉄金属の鋳物を
作る際の鋳造方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal casting method, and more particularly to a casting method for producing cast iron, cast steel and non-ferrous metal castings.
【0002】[0002]
【従来の技術】鉄,非鉄を問わず、金属鋳物の製造に際
して引け巣等の鋳造欠陥を防ぐために押湯は必須不可欠
なものである。普通鋳鉄で本来の鋳造品の20〜40%,ダ
クタイル鋳鉄で20〜60%,鋳鋼で30〜70%,純銅鋳物で
は30〜70%の押湯が必要となる。つまり重量1の鋳物を
作るのに、重量0.2〜0.7の無駄を作る必要があるわけで
あり、金属の溶解コスト,造型コスト,型ばらし,押湯
部の切り取り作業等、押湯の存在のために計り知れない
無駄な費用が費やされるわけである。とくに押湯部の切
取り作業は、ネック部の溶断,ノコ歯切断,グラインダ
切断,ハンマリングあるいはこれらの併用によって実施
されているが、これらはいずれも苛酷な作業環境の中で
の作業を強いられ、いわゆる3Kとして嫌われている代
表的な作業である。 いかに押湯を小さくするか、そし
て押湯部の切取り作業をいかに合理化するか、この問題
は鋳造業界では極めて重要な問題である。2. Description of the Related Art A feeder is indispensable to prevent casting defects such as shrinkage cavities in the production of metal castings regardless of whether they are ferrous or non-ferrous. For normal cast iron, 20-40% of the original casting, 20-60% for ductile cast iron, 30-70% for cast steel, and 30-70% for pure copper casting are required. In other words, in order to make a casting with a weight of 1, it is necessary to make a waste of 0.2 to 0.7, and because of the presence of the riser, such as metal melting cost, molding cost, mold release, cutting work of the riser part, etc. There is an immeasurable waste of money. Particularly, the cutting work of the feeder part is performed by fusing the neck part, saw-tooth cutting, grinder cutting, hammering or a combination thereof, but these are all forced to work in a harsh working environment. This is a typical work that is disliked as so-called 3K. How to make the feeder smaller and how to streamline the cutting operation of the feeder is a very important issue in the casting industry.
【0003】このような状況を背景にして、過去、誘導
加熱を使って押湯の軽減を計る試みもある。特開昭55−
64958号には鋳型上部に誘導コイルを埋設して溶湯を誘
導加熱することが記載されているが、この方法は誘導コ
イルが鋳型に埋め込まれているために、鋳造,造塊後、
鋳型を壊して鋳物を取り出す際、誘導コイルを埋め込ん
だ耐火物も一緒に壊されることとなる。つまり一回の造
塊ごとに耐火物で誘導コイルを埋設する作業と埋設した
耐火物を壊してコイルを取り出す作業が必須不可欠であ
り、手間と費用がかかり過ぎる。更には、鋳込時、溶湯
の飛散やライニング材の破損等により、溶湯がコイルに
直接接触した場合、コイルの溶損,層間短絡がおこり、
コイル冷却水による水蒸気爆発を起す危険性がある等の
欠点がある。又、この方法は鉄鋼の造塊のような、大
型,単純形状の鋳造品には適用できても、いろいろな形
状を有する通常の鋳造品には適用し難い。また造塊後の
押湯部の切り取りに関しても、この発明では何等問題と
して上げられていない。Against this background, there have been attempts in the past to reduce the amount of riser by using induction heating. JP 55-
No. 64958 describes that the induction coil is embedded in the upper part of the mold to induction-heat the molten metal, but this method is because the induction coil is embedded in the mold, so after casting and ingot formation,
When the mold is broken and the casting is taken out, the refractory having the induction coil embedded therein is also broken. In other words, it is indispensable to bury the induction coil with a refractory and take out the coil by breaking the buried refractory for each ingot, which is too time-consuming and expensive. Furthermore, when the molten metal comes into direct contact with the coil due to splashing of molten metal or damage to the lining material during casting, coil melting damage and interlayer short-circuiting occur,
There are drawbacks such as the risk of steam explosion due to coil cooling water. Further, this method can be applied to large-sized and simple-shaped castings such as steel ingots, but it is difficult to apply to ordinary castings having various shapes. Further, the cutting of the riser portion after the ingot is not raised as a problem in this invention.
【0004】[0004]
【発明が解決しようとする課題】本発明はかかる問題に
鑑みてなされたもので、あらゆる形状,大きさ,少量か
ら多量まで、そして広汎な生産形態に自在かつ経済的に
対応でき、同時に押湯部の切り取り作業の改善に顕著な
効果をもたらす新しい鋳造方法を提供せんとするもので
ある。SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and can freely and economically respond to any shape, size, small amount to large amount, and a wide range of production forms, and at the same time, the feeder It is an object of the present invention to provide a new casting method which has a remarkable effect in improving the cutting work of a part.
【0005】[0005]
【課題を解決するための手段】上記問題点は次の鋳造方
法によって解決される。すなわち、 1.鋳型キャビティ−に連通するように該鋳型に埋入,
立設した耐火性パイプの外側に誘導コイルを遊嵌し、金
属注湯時、該誘導コイルで該耐火性パイプ内の溶湯を誘
導加熱して該パイプ内の溶湯を最終凝固させることを特
徴とする金属鋳造方法。 2.上記耐火性パイプが内管と外管の二重構造からな
り、内管,外管の間に隙間が形成されてなる上記1に記
載の金属鋳造方法。 3.上記耐火性パイプの内管内面に逆V字型のテ−パ−
が形成されてなる上記2に記載の金属鋳造方法。 4.上記耐火性パイプとして導電性を有するものを用い
る上記1〜3のいずれかに記載の金属鋳造方法。 5.上記耐火性パイプが内管と外管の二重構造からな
り、外管が耐火材,内管が鋳造用鋳型材で形成され、内
管が外管の中に嵌入されてなる上記1に記載の金属鋳造
方法。 6.上記遊嵌した誘導コイルの鋳型に近接した部分はコ
イルを多層に巻回してなる上記1〜5のいずれかに記載
の金属鋳造方法。 7.上記耐火性パイプの鋳型埋入部の外周に誘導発熱性
材料を配置してなる上記1〜6のいずれかに記載の金属
鋳造方法。 8.上記耐火性パイプの鋳型埋入部の外周に注湯発熱性
材料又は断熱材料を配置してなる上記1〜6のいずれか
に記載の金属鋳造方法。 9.上記耐火性パイプの基底部に注湯発熱性材料製又は
断熱材料製のパッドを配置してなる上記1〜8のいずれ
かに記載の金属鋳造方法。 の中からいずれかの鋳造方法を用いればよい。The above problems can be solved by the following casting method. That is, 1. Embedded in the mold so as to communicate with the mold cavity,
An induction coil is loosely fitted on the outer side of a standing refractory pipe, and when pouring metal, the induction coil heats the molten metal in the refractory pipe to finally solidify the molten metal in the pipe. Metal casting method. 2. 2. The metal casting method according to 1 above, wherein the refractory pipe has a double structure of an inner pipe and an outer pipe, and a gap is formed between the inner pipe and the outer pipe. 3. An inverted V-shaped taper is provided on the inner surface of the inner pipe of the fire resistant pipe.
The metal casting method according to the above 2, wherein the metal is formed. 4. The metal casting method according to any one of 1 to 3 above, wherein a conductive pipe is used as the refractory pipe. 5. The fire resistant pipe has a double structure of an inner pipe and an outer pipe, the outer pipe is formed of a refractory material, the inner pipe is formed of a casting mold material, and the inner pipe is fitted into the outer pipe. Metal casting method. 6. The metal casting method according to any one of 1 to 5 above, wherein a portion of the loosely fitted induction coil close to the mold is formed by winding the coil in multiple layers. 7. 7. The metal casting method according to any one of 1 to 6 above, wherein an induction heating material is arranged on the outer periphery of the mold-embedded portion of the refractory pipe. 8. 7. The metal casting method according to any one of 1 to 6 above, wherein a heat-generating material for pouring molten metal or a heat insulating material is arranged on the outer periphery of the mold-embedded portion of the refractory pipe. 9. 9. The metal casting method according to any one of 1 to 8 above, wherein a pad made of a heat-generating material for pouring molten metal or a pad made of a heat insulating material is arranged at the base of the refractory pipe. Any of the above casting methods may be used.
【0006】[0006]
【発明の実施の形態】次に、本発明鋳造方法の実施の形
態例について、図により説明する。 <耐火性パイプ>図1の耐火性パイプ1は鋳型本体2の
押湯を設置する場所に該鋳型本体のキャビティ−3に連
通するように埋入,立設される。パイプ1の立設箇所
は、従来の鋳物の押湯設計と同じ考えに立って設置箇所
を決めればよい。つまり、引け巣の発生しやすい肉厚部
に優先的に配置するようにすればよい。パイプ1の材質
は少なくとも鋳造する溶湯に耐える耐火性材質であれば
よい。すなわち、シエルモ−ルド等の通常の鋳物の製造
に常用される鋳型材で耐火性パイプ1を形成し、これを
鋳型本体2に立設してもよい。あるいは通常の耐火物、
例えば、アルミナ,シリカ,ジルコニア,クロミア,マ
グネシア,ムライト,コ−ジライト,ジルコン,チタニ
ア,クロマイト,シャモット質耐火物、あるいは黒鉛系
耐火物等で形成したパイプ1、あるいは不定型耐火物を
使って形成したパイプ1、あるいは窒化物、炭化物セラ
ミック等の焼結体パイプ1など、種類を問わずすべて使
用できる。また、パイプ1の内面には耐火度を上げるた
めに必要に応じて高耐火性粉末を塗布(塗型)して使用
してもよい。黒鉛系耐火物等の導電性材料を用いた場合
には、パイプ1内の溶湯ばかりでなくパイプ1自体もそ
の導電性に応じて誘導発熱するので、押湯部の加熱効率
を上げ、あるいは、押湯内の加熱分布を有利に調整する
手段等として利用することができる。BEST MODE FOR CARRYING OUT THE INVENTION Next, an embodiment of the casting method of the present invention will be described with reference to the drawings. <Fireproof Pipe> The fireproof pipe 1 of FIG. 1 is embedded and erected at the place where the riser of the mold body 2 is installed so as to communicate with the cavity-3 of the mold body. The standing position of the pipe 1 may be determined based on the same idea as that of the conventional casting riser design. That is, it may be arranged preferentially in the thick portion where shrinkage cavities are likely to occur. The material of the pipe 1 may be at least a refractory material that can withstand the molten metal to be cast. That is, the refractory pipe 1 may be formed from a mold material that is commonly used in the production of ordinary castings such as shell mold, and this may be erected on the mold body 2. Or normal refractory,
For example, a pipe 1 made of alumina, silica, zirconia, chromia, magnesia, mullite, cordierite, zircon, titania, chromite, chamotte refractory, or graphite refractory, or an irregular refractory. The pipe 1 or the sintered pipe 1 made of nitride, carbide ceramic or the like can be used regardless of the type. In addition, high refractory powder may be applied (coating type) to the inner surface of the pipe 1 as needed to increase the fire resistance. When a conductive material such as a graphite-based refractory material is used, not only the molten metal in the pipe 1 but also the pipe 1 itself generates heat in accordance with its conductivity, so that the heating efficiency of the riser part is increased, or It can be used as a means for advantageously adjusting the heat distribution in the feeder.
【0007】パイプ1の外側には誘導コイル4が遊嵌さ
れるが、鋳造時にパイプ1が割れて溶湯が誘導コイル4
に接触するのを防ぐためには、パイプの外にさらにパ
イプを嵌めこんだ二重構造管とし、あるいは、少なく
とも誘導コイル4の内面,底面に耐火物をライニングす
るのが有効である。二重構造管の場合、内管1a,外管1b
は使用する材質に応じて、隙間なく、あるいは、隙間を
設けて嵌め込んでよいが、内管の膨脹代に相当する隙間
を設けたほうが好ましい。隙間の大きさは1〜2mm程度
以上あればよい。なお、二重管構造にて前記黒鉛系耐火
物等の導電性材料を使用する場合には、内管として用い
るのがよい。二重構造管の内管、外管の材質は、上記し
たように、通常の鋳鉄,鋳鋼,非鉄鋳物で常用される鋳
型材から通常の耐火物、あるいはセラミック焼結体まで
幅広く選択できる。また、パイプ内面には耐火度を上げ
るために必要に応じて高耐火性粉末を塗布(塗型)して
使用してもよい。An induction coil 4 is loosely fitted on the outside of the pipe 1, but the pipe 1 is cracked during casting and the molten metal becomes an induction coil 4.
In order to prevent contact with the pipe, it is effective to use a double structure pipe in which a pipe is further fitted outside the pipe, or to lining a refractory material on at least the inner surface and the bottom surface of the induction coil 4. In case of double structure pipe, inner pipe 1a, outer pipe 1b
Depending on the material used, may be fitted without a gap or with a gap, but it is preferable to provide a gap corresponding to the expansion margin of the inner pipe. The size of the gap may be about 1 to 2 mm or more. When a conductive material such as the graphite-based refractory material is used in a double pipe structure, it is preferable to use it as an inner pipe. As described above, the materials of the inner pipe and the outer pipe of the double-structured pipe can be widely selected from usual cast iron, cast steel, non-ferrous castings to commonly used casting materials, ordinary refractories, and ceramic sintered bodies. Further, in order to increase the fire resistance, a high refractory powder may be applied (coating type) on the inner surface of the pipe and used.
【0008】上記の材料は、安価な材料を用いて一回使
用して捨ててしまうようにしてもよいが、内管の材料を
繰り返し使用可能な高級材質、例えば、ホスタイト(商
品名),BMセラミック,黒鉛系セラミック等の高級材
質にし、内面に逆V字型テ−パ−を設けてやると、鋳造
凝固後、内管を損傷することなく抜き取ることができ、
繰り返し使用できる。[0008] The above materials may be made of inexpensive materials and used once, but may be discarded, but high-grade materials such as phostites (trade name) and BM that can repeatedly use the material of the inner tube. If high-grade materials such as ceramics and graphite-based ceramics are used and an inverted V-shaped taper is provided on the inner surface, it can be removed without damaging the inner tube after casting and solidification.
Can be used repeatedly.
【0009】耐火性パイプ1を鋳型本体2に埋入した部
分、とくにパイプ1の基底部(鋳型本体2との境目部
分)は、誘導コイル4からの距離が遠くなるために誘導
加熱の効果が小さくなり易いことと併せて、この部分は
鋳型に接触し、鋳型から抜熱を受けるために、この部分
の溶湯は早く固まりやすい傾向がある。これを防ぐため
には、次のような方法が有効である。 鋳型本体2に近い部分の誘導コイル4のコイル巻回数
を多層巻きにして鋳型埋入部の誘導加熱の入熱密度を上
げる。誘導コイル4を図1に示すような構造にすると、
2層巻きになった部分の誘導電流密度が大となって、鋳
型埋入部の溶湯の加熱が促進されるものである。 高透磁率材料の磁路を鋳型近傍に配置する。図2に示
すように、耐火性パイプ1の外周部あるいは鋳型本体2
の上にフェライトの様な高透磁率材料でできた磁束の磁
路5を形成して誘導加熱効果を高める。 図3に示すように、金属のような誘導発熱性の材料6
を耐火性パイプ1の外周部に配置しこれを誘導発熱させ
て耐火性パイプ1を補助的に加熱する。あるいは鋳造前
に耐火性パイプ1を予備加熱する。 図4に示すように、耐火性パイプ1の鋳型本体2への
埋入部を誘導発熱性の耐火物7で形成して補助的に誘導
加熱する。あるいは鋳造前に予備加熱する。 図5に示すように、注湯発熱性材料8を耐火性パイプ
1の外周部に配置し、注湯した溶湯の熱によって発熱反
応を生起させて耐火性パイプ1の鋳型本体2への埋入部
を加熱する。図5において、2aは耐火材である。ここ
で、注湯発熱性材料8とは、注湯した溶湯によって加熱
されて発熱反応が生起される材料である。通常テルミッ
ト反応等の発熱反応を利用したものが使用されている。 図6に示すように、注湯発熱性材料製のパッド8aを耐
火性パイプ1の基底部に配置し、注湯した溶湯の熱によ
って発熱反応を生起させて耐火性パイプ1の基底部を加
熱する。なお、上記8又は8aには断熱性材料を使用して
もよい。The portion where the refractory pipe 1 is embedded in the mold body 2, especially the base portion of the pipe 1 (the boundary portion with the mold body 2) is far from the induction coil 4, so that the effect of induction heating is obtained. In addition to the tendency to become small, this portion comes into contact with the mold and receives heat removal from the mold, so that the molten metal in this portion tends to solidify quickly. In order to prevent this, the following method is effective. The induction coil 4 near the mold body 2 is wound in multiple layers to increase the heat input density of induction heating in the mold embedded portion. When the induction coil 4 has the structure shown in FIG. 1,
The induced current density in the two-layer wound portion becomes large, and heating of the molten metal in the mold-embedded portion is promoted. A magnetic path of high permeability material is placed near the mold. As shown in FIG. 2, the outer peripheral portion of the refractory pipe 1 or the mold body 2
A magnetic flux magnetic path 5 made of a high-permeability material such as ferrite is formed on the upper part to enhance the induction heating effect. As shown in FIG. 3, an inductive heat generating material 6 such as a metal
Is arranged on the outer peripheral portion of the refractory pipe 1, and this is induced to generate heat to supplementally heat the refractory pipe 1. Alternatively, the refractory pipe 1 is preheated before casting. As shown in FIG. 4, the embedded portion of the refractory pipe 1 in the mold body 2 is formed of a refractory 7 having an inductive heat generation property and auxiliary induction heating is performed. Alternatively, it is preheated before casting. As shown in FIG. 5, the pouring exothermic material 8 is arranged on the outer peripheral portion of the refractory pipe 1, and an exothermic reaction is caused by the heat of the poured molten metal to embed the refractory pipe 1 in the mold body 2. To heat. In FIG. 5, 2a is a refractory material. Here, the pouring exothermic material 8 is a material that is heated by the poured molten metal to cause an exothermic reaction. Usually, the one utilizing an exothermic reaction such as the thermite reaction is used. As shown in FIG. 6, a pad 8a made of an exothermic material for pouring molten metal is placed at the base of the refractory pipe 1, and an exothermic reaction is caused by the heat of the poured molten metal to heat the base of the refractory pipe 1. To do. A heat insulating material may be used for the above 8 or 8a.
【0010】<誘導コイル>誘導コイル4は耐火性パイ
プ1に遊嵌、固定してもよいし、嵌脱自在に遊嵌できる
ようにしてもよい。溶湯による誘導コイル4の損傷を少
なくするためには、鋳造時、誘導コイル4は抜いた状態
にしておき、鋳造後、素早く前記コイル4を嵌め込み、
スイッチをいれて急速加熱するようにしたほうがよい。
誘導加熱の出力は、注入された溶湯をただ保温するだけ
であるので、小さな出力で十分である。たとえば内径20
mm程度の耐火性パイプ1で、溶湯注湯時、5〜10kW程
度で十分である。したがって20〜30kW程度の電源が一
台あれば、同時に3〜5個前後の押湯を加熱できる。誘
導コイル4の内面は、耐火性パイプ1が割れて溶湯が飛
散する場合、あるいは溶湯の火玉が飛び散って接触する
場合に備えて、少なくともコイル内面、コイル底面は耐
火物でライニングしておくほうがよい。<Induction Coil> The induction coil 4 may be loosely fitted and fixed to the refractory pipe 1, or may be loosely fitted and detachable. In order to reduce the damage to the induction coil 4 due to the molten metal, the induction coil 4 should be removed during casting, and the coil 4 should be quickly fitted after casting.
It is better to turn on the switch and heat quickly.
The output of induction heating is sufficient to keep the injected molten metal warm, so a small output is sufficient. For example, inner diameter 20
With the refractory pipe 1 of about mm, about 5 to 10 kW is sufficient when pouring molten metal. Therefore, one power supply of 20 to 30 kW can heat about 3 to 5 feeders at the same time. The inner surface of the induction coil 4 should be lined with a refractory material at least on the inner surface of the coil and the bottom surface of the coil in case the molten metal splashes due to cracking of the refractory pipe 1 or when the molten metal splashes and contacts. Good.
【0011】誘導コイル4の周波数には特に制限はな
く、高周波〜低周波まで幅広い範囲で適宜選択して使用
できる。The frequency of the induction coil 4 is not particularly limited and can be appropriately selected and used in a wide range from high frequency to low frequency.
【0012】<鋳型本体>鋳型本体2は、通常の鋳鉄,
鋳鋼,非鉄鋳物に使用する鋳型材料はすべて使用でき
る。例えば、シェルモ−ド砂,シャモット質耐火材,黒
鉛基質耐火材,ジルコン基質耐火材,クロマイト基質耐
火材等、すべての鋳型材料を適用できる。<Mold body> The mold body 2 is made of normal cast iron,
All casting materials used for cast steel and non-ferrous castings can be used. For example, all mold materials such as shell mode sand, chamotte refractory material, graphite matrix refractory material, zircon matrix refractory material, and chromite matrix refractory material can be applied.
【0013】<誘導加熱>本発明では、誘導加熱をコン
ピュ−タ−制御することによって、耐火性パイプ1内の
溶湯温度をプログラム制御できる。プログラム制御する
ときのプログラムパタ−ンは、実操業で使用されている
最適な押湯方案の凝固パタ−ンを実測し、このパタ−ン
をプログラムパタ−ンとして使用するようにすればよ
い。<Induction heating> In the present invention, the temperature of the molten metal in the refractory pipe 1 can be program-controlled by controlling the induction heating by a computer. As the program pattern for program control, the solidification pattern of the optimum feeder method used in actual operation is actually measured, and this pattern may be used as the program pattern.
【0014】[0014]
実施例1 従来方法の鋳型と本発明方法の鋳型について比較した。
本発明方法は図7に示す鋳型を、従来方法は図8に示す
押湯なし鋳型と図9に示す発熱押湯鋳型を、それぞれ使
用した。 〔本発明方法(図7)〕 <鋳型> 鋳型キャビティ−寸法:131×131×131mm 鋳型寸法 :200×200×250mm 鋳型の製法 :鋳型キャビティ−部はCO2プロセスで造型した。 耐火性パイプ :内管,外管二重管方式を採用 内管の寸法 :内径20mm,外径30mm,長さ200mm 内管の材質 :シャモット質 外管の寸法 :内径60mm,外径75mm,長さ200mm 外管の材質 :内管と同質のシャモット質 内管,外管は図1のように鋳型の上から差し込んで立設
した。 〔従来方法(図8,図9)〕図8の押湯なし鋳型、図9
の発熱押湯鋳型とも、図7の鋳型と同じ。 鋳型の製法 :図7の鋳型と同じCO2プロセスで造型。 図9の鋳型には、鋳型本体2の上部に内面9aが図示した
ような釣鐘形状の発熱保温材9(フォセコ・ジャパン社
製)を載置した。発熱保温材9の釣鐘状部の体積は鋳型
キャビティ−3の体積の約10%。 <溶湯組成>FCD−450材質で、引けの発生が高い
下記組成のダクタイル鋳鉄を使用した。その成分組成
(%)は以下の通りである。 <鋳造条件> 溶解温度 :1510℃ 球状化処理温度 :1480℃ 鋳込み温度 :1400℃ 球状化処理 :球状化剤OGRC3を1.4%添加
取鍋置注法による。 <誘導加熱>本発明方法では、鋳造後、高周波コイル
(タ−ン数30)を耐火性パイプ1に嵌入し、周波数20kH
z、出力9kWで7〜10分間加熱した。なお、従来方法の
鋳造では、鋳型内でそのまま冷却した。 <結果>冷却後、鋳型から鋳造品を取り出し、切断して
引けの状況を調べた。 〔本発明方法〕耐火性パイプ1内部の金属、および鋳型
キャビティ−2、内金属、いずれも引けはまったく認め
られなかった。耐火性パイプ1の内部の金属は、わず
か、2分で切除できた。 〔従来方法〕 押湯なし鋳型 :鋳物上面部表面に引けが発生。湯口
下にも引け発生。 発熱押湯鋳型 :鋳物鋳型キャビティ−内金属,押湯
部,いずれも引けはなかった。ただし、押湯部の切断除
去に12分必要とした。 以上のテストで、本発明方法を実施する鋳型によると、
従来の大きな押湯と同じような効果があることを確認で
きた。また、型ばらし後の押湯部(耐火性パイプ1内部
の金属)除去作業も極めて短時間で処理できることを確
認できた。Example 1 The mold of the conventional method and the mold of the method of the present invention were compared.
The method of the present invention used the mold shown in FIG. 7, and the conventional method used the mold without riser shown in FIG. 8 and the exothermic riser mold shown in FIG. [Invention Method (FIG. 7)] <Mold> Mold cavity-dimension: 131 x 131 x 131 mm Mold dimension: 200 x 200 x 250 mm Mold manufacturing method: Mold cavity-part was molded by CO 2 process. Fire-resistant pipe: Inner pipe, outer pipe double pipe method Inner pipe dimensions: Inner diameter 20 mm, outer diameter 30 mm, length 200 mm Inner pipe material: Chamotte outer pipe dimensions: Inner diameter 60 mm, outer diameter 75 mm, long 200mm Material of outer tube: Chamotte material of the same quality as the inner tube The inner tube and outer tube were set up by inserting them from above the mold as shown in Fig. 1. [Conventional method (FIGS. 8 and 9)] Mold without riser of FIG. 8, FIG.
The exothermic feeder mold is also the same as the mold of FIG. 7. Mold making method: Molded by the same CO 2 process as the mold shown in FIG. 7. In the mold of FIG. 9, a bell-shaped heat-generating heat insulating material 9 (manufactured by Foseco Japan Ltd.) having an inner surface 9a as shown in the figure was placed on the upper part of the mold body 2. The volume of the bell-shaped portion of the heat insulating material 9 is about 10% of the volume of the mold cavity-3. <Molten metal composition> As the FCD-450 material, ductile cast iron having the following composition, which is highly likely to cause shrinkage, was used. The component composition (%) is as follows. <Casting conditions> Melting temperature: 1510 ° C Spheroidizing temperature: 1480 ° C Casting temperature: 1400 ° C Spheroidizing treatment: Add 1.4% of spheroidizing agent OGRC3 by ladle pouring method. <Induction heating> In the method of the present invention, after casting, a high frequency coil (the number of turns is 30) is inserted into the refractory pipe 1 and the frequency is set to 20 kH.
It was heated at a power of 9 kW for 7 to 10 minutes. In the conventional casting method, it was cooled in the mold as it was. <Results> After cooling, the cast product was taken out from the mold and cut to examine the condition of shrinkage. [Invention Method] No shrinkage was observed in the metal inside the refractory pipe 1, the mold cavity-2, or the metal inside. The metal inside the refractory pipe 1 could be cut off in just 2 minutes. [Conventional method] Mold without riser: A shrinkage occurred on the surface of the upper surface of the casting. Closed under the sprue. Exothermic feeder mold: The metal in the cavity of the casting mold and the feeder part were not closed. However, it took 12 minutes to cut and remove the feeder. In the above test, according to the mold for carrying out the method of the present invention,
It was confirmed that it has the same effect as the conventional large feeder. It was also confirmed that the work of removing the riser (metal inside the refractory pipe 1) after removing the mold can be performed in an extremely short time.
【0015】実施例2 鋳鋼について従来方法の鋳型と本発明方法の鋳型につい
て比較した。本発明方法では図7に示す鋳型を、従来方
法は図8(押湯なし鋳型)と図9(発熱押湯鋳型)に示
す鋳型を、それぞれ使用した。 <鋳型> 〔本発明方法〕 鋳型キャビティ−寸法:131×131×131mm 鋳型寸法 :200×200×250mm 鋳型の製法 :フラン自硬性砂プロセスで造型 耐火性パイプ :内管,外管二重管方式を採用し、内管は逆テ−パ− 管を使用。 内管の寸法 :上部内径25mm,下部内径30mm,外形40mm, 長さ200mm 内管の材質 :シャモット質 内面にはジルコン系塗型材を0.1mm厚塗装した。 外管の寸法 :内径60mm,外径75mm,長さ200mm 外管の材質 :シャモット質 内管,外管は図4のように鋳型の上から差し込んで立設
した。 〔従来方法〕図8の押湯なし鋳型、図9の発熱押湯鋳型
とも、図7の鋳型と同じ。 鋳型の製法 :図7の鋳型と同じであるが、図
9の鋳型には、鋳型上部に図示したような形状の発熱保
温材(フォセコ・ジャパン社製)を載置した。発熱保温
材9の杯状部9aの体積は鋳型キャビティ−3の体積の約
10%。 <溶湯組成>引けの発生が高い下記組成の鋳鋼を使用し
た。その成分組成(%)は以下の通りである。 <鋳造条件> 出湯温度 :1580℃ 鋳込み温度 :1470℃ <誘導加熱>鋳造後、高周波コイル(タ−ン数30)を耐
火性パイプ1に嵌入し、周波数20kHz、出力9kWで7〜1
0分間加熱した。なお、従来鋳造のものについては鋳型
内でそのまま冷却した。 <結果> 〔本発明方法〕冷却後、テ−パ−のついた内管の耐火性
パイプは抜き取ることができた。割れは認められず、再
使用が可能であった。テ−パ−管の部分および鋳物部分
を切断して引けの状況を調べた。本発明のものについて
は、耐火性パイプ内部の金属、および鋳型キャビティ
−、内金属、いずれも引けはまったく認められなかっ
た。耐火性パイプ内部の金属は、わずか、3分で切除で
きた。 〔従来方法〕 押湯なし鋳型 :鋳物上面部表面に深い引けが発生。
湯口下にも引け発生。 発熱押湯鋳型 :鋳物鋳型キャビティ−内金属に引け
はなかったが、押湯部に引けが発生。押湯部の切断除去
に15分必要とした。 以上のテストで、本発明方法を使用する鋳型によると、
鋳鋼については従来の大きな押湯以上の押湯効果が得ら
れることが確認できた。また、型ばらし後の押湯(耐火
性パイプ内部の金属)除去作業も極めて短時間で行える
ことを確認できた。また、テ−パ−のついた内管を使用
すると、抜き取ることができるので、再使用できること
が確認できた。Example 2 A cast steel was compared between a conventional mold and a mold of the present invention. In the method of the present invention, the mold shown in Fig. 7 was used, and in the conventional method, the mold shown in Fig. 8 (mold without riser) and the mold shown in Fig. 9 (exothermic riser mold) were used. <Mold> [The method of the present invention] Mold cavity-Dimensions: 131 x 131 x 131 mm Mold dimensions: 200 x 200 x 250 mm Mold manufacturing method: Molding by furan self-hardening sand process Fire resistant pipe: Inner pipe, outer pipe double pipe system The inner pipe uses a reverse taper pipe. Inner tube dimensions: Upper inner diameter 25 mm, lower inner diameter 30 mm, outer diameter 40 mm, length 200 mm Inner tube material: chamotte material Zircon-based coating material 0.1 mm thick was applied on the inner surface. Outer tube dimensions: Inner diameter 60 mm, Outer diameter 75 mm, Length 200 mm Outer tube material: Chamotte material Inner tube and outer tube were inserted upright from the mold as shown in Fig. 4. [Conventional Method] The mold without riser of FIG. 8 and the heat-generating mold of FIG. 9 are the same as those of FIG. 7. Manufacturing method of mold: The same as the mold of FIG. 7, but the heat insulating material (manufactured by Foseco Japan Co., Ltd.) having the shape as shown in the figure was placed on the mold of FIG. The volume of the cup-shaped portion 9a of the heat insulation material 9 is about the volume of the mold cavity-3.
Ten%. <Molten metal composition> A cast steel having the following composition, which is highly likely to shrink, was used. The component composition (%) is as follows. <Casting conditions> Hot water temperature: 1580 ° C Casting temperature: 1470 ° C <Induction heating> After casting, a high frequency coil (number of turns 30) was inserted into the refractory pipe 1, and the frequency was 20kHz and the output was 9kW.
Heated for 0 minutes. The conventional casting was cooled in the mold as it was. <Results> [Invention Method] After cooling, the refractory pipe with the taper inside could be removed. No cracks were observed and it was possible to reuse. The taper part and the cast part were cut to examine the condition of shrinkage. Regarding the present invention, no shrinkage was observed in the metal inside the refractory pipe, the mold cavity, or the inner metal. The metal inside the refractory pipe could be removed in just 3 minutes. [Conventional method] Mold without feeder: Deep shrinkage occurs on the surface of the upper surface of the casting.
Closed under the sprue. Exothermic feeder mold: There was no shrinkage in the metal inside the casting mold cavity, but shrinkage occurred in the feeder part. It took 15 minutes to cut and remove the feeder part. In the above test, according to the mold using the method of the present invention,
It was confirmed that cast steel has a higher feeder effect than the conventional large feeder. It was also confirmed that the work of removing the riser (metal inside the refractory pipe) after removing the mold can be performed in an extremely short time. Also, it was confirmed that the tape can be reused because it can be removed by using an inner tube with a taper.
【0016】[0016]
【発明の効果】本発明鋳造方法は以上の通りであって、
次の固有の効果が得られる。 1.押湯部分を極小化でき、鋳物歩留まりの大巾な改善
ができる。 2.押湯部切り取りに要する作業時間を大巾に短縮でき
る。 3.引け巣等による鋳造欠陥が激減する。 4.押湯部分の耐火物の再生利用ができる。The casting method of the present invention is as described above,
The following unique effects are obtained. 1. The feeder part can be minimized and the casting yield can be greatly improved. 2. The working time required for cutting the feeder part can be greatly reduced. 3. Casting defects such as shrinkage cavities are drastically reduced. 4. The refractory can be reused in the feeder part.
【図1】本発明鋳造方法に使用する鋳型とそれに埋入さ
れた耐火性パイプとこのパイプ内の溶湯の加熱を促進す
るための誘導コイルの関係構造を説明するための断面
図。FIG. 1 is a cross-sectional view for explaining a relational structure of a mold used in a casting method of the present invention, a refractory pipe embedded therein, and an induction coil for promoting heating of molten metal in the pipe.
【図2】本発明鋳造方法に使用する鋳型,耐火性パイ
プ,誘導コイルの関係構造の別例を説明するための断面
図。FIG. 2 is a cross-sectional view for explaining another example of the related structure of the mold, the refractory pipe, and the induction coil used in the casting method of the present invention.
【図3】本発明鋳造方法に使用する鋳型,耐火性パイ
プ,誘導コイルの構造の第三例を説明するための断面
図。FIG. 3 is a sectional view for explaining a third example of the structures of a mold, a refractory pipe, and an induction coil used in the casting method of the present invention.
【図4】本発明鋳造方法に使用する鋳型,耐火性パイ
プ,誘導コイルの構造において、耐火性パイプの構造の
別例を示す断面図。FIG. 4 is a cross-sectional view showing another example of the structure of the refractory pipe in the structure of the mold, the refractory pipe, and the induction coil used in the casting method of the present invention.
【図5】本発明鋳造方法に使用する鋳型,耐火性パイ
プ,誘導コイルの構造において、鋳型構造の別例を示す
断面図。FIG. 5 is a cross-sectional view showing another example of the mold structure in the structure of the mold, the refractory pipe, and the induction coil used in the casting method of the present invention.
【図6】本発明鋳造方法に使用する鋳型,耐火性パイ
プ,誘導コイルの構造において、鋳型構造の他の例を示
す断面図。FIG. 6 is a sectional view showing another example of the mold structure in the structures of the mold, the refractory pipe, and the induction coil used in the casting method of the present invention.
【図7】本発明方法の実施例に用いた鋳型の構造を説明
するための断面図。FIG. 7 is a sectional view for explaining the structure of the mold used in the example of the method of the present invention.
【図8】本発明の比較例に用いた鋳型の構造を説明する
ための断面図。FIG. 8 is a sectional view for explaining a structure of a mold used in a comparative example of the present invention.
【図9】本発明の比較例に用いた鋳型の構造を説明する
ための断面図。FIG. 9 is a sectional view for explaining a structure of a mold used in a comparative example of the present invention.
1 耐火性パイプ 1a 内管 1b 外管 2 鋳型本体 3 キャビティ− 4 誘導コイル 5 磁路 6 誘導発熱性の材料 7 誘導発熱性の耐火物 8 注湯発熱性材料 8a パッド 1 Fire-resistant pipe 1a Inner tube 1b Outer tube 2 Mold body 3 Cavity-4 Induction coil 5 Magnetic path 6 Induction heating material 7 Induction heating refractory 8 Pouring heat generation material 8a Pad
フロントページの続き (72)発明者 杉 山 隆 博 島根県出雲市神西沖町2400番地 ダイハツ 金属工業株式会社内 (72)発明者 松 原 洋 一 神奈川県川崎市川崎区殿町2丁目17番8号 第一高周波工業株式会社技術部内 (72)発明者 平 山 鋼 太 郎 神奈川県川崎市川崎区殿町2丁目17番8号 第一高周波工業株式会社技術部内Front Page Continuation (72) Inventor Takahiro Sugiyama 2400 Kamisaioki-cho, Izumo, Shimane Prefecture Daihatsu Metal Industry Co., Ltd. (72) Inventor Yoichi Matsubara 2-17-8 Tonomachi, Kawasaki-ku, Kanagawa Prefecture Daiichi Kogaku Kogyo Co., Ltd. Engineering Department (72) Inventor Taro Hirayama 2-17-8 Tonomachi, Kawasaki-ku, Kawasaki-shi, Kanagawa Dai-ichi Kogyo Kogyo Co., Ltd.
Claims (9)
型に埋入,立設した耐火性パイプの外側に誘導コイルを
遊嵌し、金属注湯時、該誘導コイルで該耐火性パイプ内
の溶湯を誘導加熱して該パイプ内の溶湯を最終凝固させ
ることを特徴とする金属鋳造方法。1. An induction coil is loosely fitted to the outside of a refractory pipe embedded and erected in the mold so as to communicate with the mold cavity, and when the metal is poured, the induction coil allows the induction coil to be installed inside the refractory pipe. A metal casting method, which comprises inductively heating a molten metal to finally solidify the molten metal in the pipe.
造からなり、内管,外管の間に隙間が形成されてなる請
求項1に記載の金属鋳造方法。2. The metal casting method according to claim 1, wherein the refractory pipe has a double structure of an inner pipe and an outer pipe, and a gap is formed between the inner pipe and the outer pipe.
のテ−パ−が形成されてなる請求項2に記載の金属鋳造
方法。3. The metal casting method according to claim 2, wherein an inverted V-shaped taper is formed on the inner surface of the inner pipe of the refractory pipe.
ものを用いる請求項1〜3のいずれかに記載の金属鋳造
方法。4. The metal casting method according to claim 1, wherein a conductive pipe is used as the refractory pipe.
造からなり、外管が耐火材,内管が鋳造用鋳型材で形成
され、内管が外管の中に嵌入されてなる請求項1に記載
の金属鋳造方法。5. The refractory pipe has a double structure of an inner pipe and an outer pipe, the outer pipe is formed of a refractory material, the inner pipe is formed of a casting mold material, and the inner pipe is fitted into the outer pipe. The metal casting method according to claim 1, wherein
た部分はコイルを多層に巻回してなる請求項1〜5のい
ずれかに記載の金属鋳造方法。6. The metal casting method according to claim 1, wherein a portion of the loosely fitted induction coil close to the mold is formed by winding the coil in multiple layers.
誘導発熱性材料を配置してなる請求項1〜6のいずれか
に記載の金属鋳造方法。7. The metal casting method according to claim 1, wherein an induction heating material is arranged on the outer periphery of the mold-embedded portion of the refractory pipe.
注湯発熱性材料又は断熱材料を配置してなる請求項1〜
6のいずれかに記載の金属鋳造方法。8. A pouring heat-generating material or heat-insulating material is arranged on the outer periphery of the mold-embedded portion of the refractory pipe.
7. The metal casting method according to any one of 6 above.
材料製又は断熱材料製のパッドを配置してなる請求項1
〜8のいずれかに記載の金属鋳造方法。9. A pad made of a heat-generating material for pouring or a heat insulating material is arranged at the base of the refractory pipe.
The metal casting method according to any one of 1 to 8.
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