JPS6357146B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for casting metal objects, and more particularly to a method for continuously casting sheet metal articles.

Thin plate cores for laminated iron cores in transformers and magnetic heads are extremely thin articles with a thickness of, for example, 0.1 to 0.5 mm. Conventionally, when manufacturing such a thin plate core, when permalloy is used as the material, it is manufactured through the steps of melting → forging → rolling → punching → annealing.
When using an Al-based alloy (trademark: Sendust) as a material, it does not have stretchability, so it is manufactured through the steps of slicing an ingot, cutting it into bars, grinding it, slicing it, finishing it, and annealing it.

The above-mentioned conventional methods all involve a large number of steps, and each step is independent, so they are unsuitable for continuous mass production, and therefore have the disadvantage of high costs. Furthermore, when Fe-Si-Al alloy is used as a material, it is a very brittle material, so
Cracks and chips occur during machining such as grinding and cutting, resulting in poor yield and productivity.

In view of the above points, it is a particular object of the present invention to provide a method by which thin plate cores can be produced easily and continuously.

A general object of the present invention is to provide a method for continuously casting sheet metal articles.

To summarize the present invention, mold holes corresponding to the shape of the target article are continuously provided on a metal or fire-resistant tape at equal intervals in the length direction, and while the tape is running at a constant speed, the mold is molded. This is a continuous casting method in which the hole is filled with molten metal, followed by another tape that is pressed from above, and is cooled and solidified while running to obtain a cast product.

Hereinafter, the present invention will be explained in detail with reference to embodiments shown in the drawings.

FIG. 1 is a perspective view showing an example of a thin plate article to be manufactured by the method of the present invention, this example being a core for a magnetic head.

FIGS. 2 to 4 are views showing an embodiment of the present invention for casting the core shown in FIG. run along a fixed path. This tape 1 has a first
Mold holes 2 matching the shape of the core shown in the figure are successively provided at intervals in the length direction. For example, 0.1~ made of iron, stainless steel, aluminum, etc.
Apply embossing to a tape approximately 0.5mm thick,
A mold hole 2 is formed. The height of the embossing, that is, the depth h of the mold hole is set to be the same or almost the same as the thickness of the target core. Note that it is preferable to apply a mold release agent to the bottom surface of the mold hole 2. Hereinafter, this tape 1 will be referred to as a mold tape.

This mold tape 1 is wound on a roll 3 to form a wound body 4, and is pulled out from the roll 3 to form backing rolls 5a, 5b, pressure rolls 6a, 6b.
(The roll 6b is a cushion roll wrapped with cotton or the like), passes through a pulley 7, backing rolls 8a and 8b, and is wound onto a winding roll 9 to form a rolled body 10. The tape is run by rotating the take-up roll 9. That is, by being wound onto the winding roll 9, the mold tape runs along the above-mentioned rolls and pulleys between the roll 3 and the winding roll 9. Bucking rolls 5a, 5b and 8a, 8
The mold tape is given appropriate tension by the action of b.

On the other hand, the other metallic flat tape 11 is roll 1.
It is unwound from the winding body 13 on 2 and passed through bucking rolls 14a, 14b to pressure rolls 6a, 6
It is superimposed on the mold tape 1 at step b, and thereafter runs in a state overlapping with the mold tape 1 and is wound onto the roll 9. Therefore, the wound body 10 is wound not only with the mold tape 1 but also with the flat tape 11. In addition, bucking rolls 14a, 14b and 8a, 8b
Appropriate tension is also given to the flat tape 11 by this.

Pressure rolls 6a and 6b on the running path of the mold tape 1
A pouring port 16 from the vacuum melting furnace 15 is arranged closer to the bucking rolls 5a, 5b, and the molten metal is poured into the mold hole 2 from the pouring port 16. Note that at least the pressure rolls 6a, 6b and the pouring port 16 of the vacuum melting furnace 15 are in the non-oxidizing atmosphere chamber 1.
7. Therefore both tapes 1 and 11
passes through this non-oxidizing atmosphere chamber 17.

In addition, it is preferable to provide a controller for controlling the traveling speed of the mold tape 1, the pouring time, and the pouring speed so that a predetermined amount of molten metal is reliably poured into each mold hole 2.

Molten metal is poured into the mold hole 2 on the mold tape 1 from the pouring port 16 while the mold tape 1 and the flat tape 11 are running. After the mold tape 1 passes through the spout, it is pressed into a flat tape 11 by pressure rolls 6a and 6b.
The mold hole into which the molten metal has been poured advances to pressure rolls 6a and 6b, where it is covered with flat tape 11 and pressurized. This state is shown enlarged in FIG. Note that the poured molten metal is indicated by 18.

The molten metal in the mold hole is rapidly cooled and solidified until the mold tape 1 and the flat tape 11 are wound onto the take-up roll 9 in the pressed state. A core having the shape shown in FIG. 1 is thus cast.

Here, the cast product is held between the wound tapes 1 and 11, so by carrying the wound body 10, it is possible to carry a large number of cores at once. Easy to handle. Of course, when taking out the tape, it is sufficient to peel it off while feeding out the crimped tape.

As mentioned above, mold tape 1 and flat tape 11
By pouring the molten metal from the pouring port 16 into the mold holes 2 that are successively traveling while the molds are running, it is possible to continuously manufacture cast products.

In addition, when heat treatment such as annealing treatment is required like the above-mentioned core, both the pressurized tapes 1 and 11 are heat treated in an annealing furnace or the like before being wound onto the take-up roll 9. All you have to do is let it pass through the furnace. In FIG. 2, the annealing furnace is indicated at 19. In this case, since the product is hermetically surrounded by both tapes 1 and 11, an air atmosphere annealing furnace is sufficient as the annealing furnace.

Figures 5 and 6 show a modification of the above embodiment in which the mold tape 1' is composed of two tapes 1'a and 1'b, and everything else is the same as the previous embodiment. . That is, here, the mold tape 1' is a metal tape 1'a having a thickness similar to the thickness of the object, and holes 2' that match the shape of the object are continuously punched out at equal intervals in the length direction. , another flat metal tape 1'b is superimposed on the lower side of this metal tape 1'a.

FIG. 7 shows another embodiment of the present invention, which is basically the same as the embodiment shown in FIG. 2, but uses the same mold tape as the embodiment shown in FIG. This allows the product to be wrapped in a packaging tape rather than a casting tape, and the cast product can be ground if necessary.

Referring to FIG. 7, the punched tape 1'a and the flat tape 1'b constituting the mold tape 1' are rolled into wound bodies 4'a on their respective feed rolls 3'a and 3'b.
and 4'b, are overlapped and guided between pressure rolls 6a and 6b. On the other hand, the other flat tape 11 is also unwound from the winding body 13 on the unwinding roll 12 and guided between the pressure rolls 6a and 6b.
It is pressed onto the mold tape 1'. At this time, the flat tape 11 is pressed onto the punched tape 1'a on the side opposite to the flat tape 1'b.

The molten metal 18 in the melting furnace 15 is poured from the pouring port 16 into the mold hole 2' (see FIG. 5) of the mold tape 1' at a position immediately before being introduced between the pressure rolls 6a and 6b. The molten metal confined by the tapes 1'a, 1'b and 11 pressed by the pressure rolls 6a and 6b is rapidly cooled and solidified during subsequent movement of the tapes, and is then cast.

As the tape progresses, it passes through the annealing furnace 19,
The casting is annealed here. After the annealing treatment, the flat tapes 11 and 1'b are peeled off from the punched tape 1'a and wound onto respective winding rolls 21 and 22. On the other hand, the punching tape 1'a advances while holding the casting in the punching hole 2' (the casting is attached to the inner wall of the hole), and
It is wound onto a take-up roll 25 while being sandwiched from both sides by packaging tapes 24a and 24b made of paper, cloth, anticorrosion paper, etc., which are fed out from a and 23b.

In addition, if the tolerance of the thickness dimension of the target product is small and grinding is required, as shown in FIG. A double-sided grinder 26 and a cleaning machine 27 are arranged on the running path so that while the punching tape 1'a is passing therethrough, both sides of the cast product held by the punching tape are ground and cleaned. That's good.

In the explanation of the above embodiment, metal tapes were used as the mold tape 1, punching tape 1'a flat tape 11, 1'b. A tape coated with ceramic or the like can be used.

As described above, the present invention enables the casting of thin plate articles through a series of continuous processes from melting to annealing, and furthermore, from grinding to packaging operations. Thin cores can be easily manufactured without wasting material.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing a core for a magnetic head as an example of a thin plate article manufactured by the method of the present invention;
Fig. 2 is a system diagram of a production line showing an embodiment of the present invention, Fig. 3 is a diagram showing the mold tape in Fig. 2, where a is a plan view, b is a sectional view, and Fig.
5 is a sectional view showing a casting state using a mold tape and a flat tape in the embodiment shown in the figure; FIG. 5 is a perspective view showing a main part of a modification of the embodiment shown in FIG. 2;
A sectional view similar to FIG. 4 according to a modification of the figure, and FIG. 7 show a system diagram of another embodiment of the invention. 1, 1'... Mold tape, 1'a... Punching tape, 1'b, 11... Flat tape, 2, 2'... Mold hole, 6a, 6b... Pressure roll, 16... Note Sprue, 18...molten metal, 19...annealing furnace.

Claims (1)

[Scope of Claims] 1. A mold tape, which is a metal or fire-resistant tape and has a plurality of mold holes formed at intervals in the length direction, is run at a constant speed along a predetermined running path. The molten metal is poured into the mold hole at the starting end position of the path, and at a position adjacent to the molten metal supply position, a flat tape for the lid body for closing the mold hole is supplied onto the mold tape, and both tapes are crimped to form the mold. A continuous casting method characterized in that the molten metal in the hole is pressurized, and thereafter, the molten metal in the mold is cooled and solidified while the tape runs along the tape running path, thereby continuously producing cast products. 2. A mold tape, which is a metal or fire-resistant tape and has a plurality of mold holes punched out at intervals in the length direction, is run at a constant speed along a predetermined running path, and near the starting end of the running path. , first and second flat tapes made of metal or refractory material are supplied and crimped to both sides of the mold tape, and the mold is placed at a position where at least one of the first and second flat tapes is supplied. A molten metal is supplied into the mold cavity of the tape, and after the supplied molten metal is pressurized by pressing the first and second flat tapes, it is cooled and solidified while the tape runs along the running path. A continuous casting method characterized by continuous production of cast products by 3. The continuous casting method according to claim 1 or 2, characterized in that an annealing furnace is provided in the middle of the running path, and the cast metal is heat-treated while it is in the mold. Continuous casting method.