US1599801A - Method and apparatus for casting metal - Google Patents

Description

` Sept. 14 1926.

A. P. VREELAND METHOD AND APPARATUS FOR CASTING METAL Filed .July 3, 1922 3 Sheets-Sheet 1 Sept. 14 1926` 1,559,801 A. P. VREELAND.

METHOD AND APPARATUS FOR CASTING METAL Filed July v5, 1922 3 Sheets-Sheet 2 FIG. 11.

@uvam/tof, /qL/exA/VDER P, VRML/Mw,

Sept. 14, 1926. A. P. VREELAND METHOD AND ABPARATUS Foa CASTING METAL Filed July 3, 1922 3 sheets-'sheet :s

Patented Sept. 14, 1926.

UNITED STATES 1,599,801 PATENT oFF-ICE.

ALEXANDER VREELAND, OF LANSING, MICHIGAN, ASSIGNOR, BY MESNE ASSlG-- IYIENTS, TO METAL & THERMIT CORPORATON, OF CARTERET, NEW JERSEY, AIGUE- PORATO'N OF NEW JERSEY.

METHOD AND APPARATUS FOR CASTING METAL.

Application filed July 3,

This invention relates to a method and apparatus for casting meta-l, and more particularly for casting a metallic part upon a metallic body.

An object of this invention is to provide a method ot casting metal around a metallic body clamped between the sections of a mold so that leakage of molten metal between the mold sections is prevented.

Another object of the invention is to pro-v sections permits the use oi' sand molds whenv desired and it is still possible to apply a relatively high pressure to clamp the mold sections together.

Another object of the invention is to provide a method and apparatus for casting a grey iron or semi-steel hub around the center of a centrally aperture-d metallic wheel structure such as a disc or an assembly of spokes in such a manner as to term therewith a substantially unitary construction.

Another object of the invention is to provide an improvedapparatus for clamping relatively tightly mold sections together with a steel disc between them so that variations in the thickness of the metal are compensated for to prevent leakage of the molten metal between the mold sections. Also clamping means is provided to clamp a corrugated disc between mold sections having corrugated rims to compensate for variations in the corrugations of the disc, as well as the thickness ot metal forming the disc, to prevent leakage of molten metal.

A further object of the invention is to provide a method and apparatus which may be worked with either permanent metallic molds or dry sand molds for clamping the metallic wheel structure between the mold sections.

Another object of the invention is to pro- 1922. Serial No. 572,385.

duce a simple and eiicient apparatus for the above purposes which can be quickly operated.

In the following description and annexed drawings the invention is described as applied to the formation of a grey iron or semisteel hub upon a corrugated sheet metal disc.

In the annex-ed drawings:

Figure l is a perspective view of the sand mold.

Fig. 2 is an axial .section through the mold showing the disc clamped between the mold sections and the hub as cast within the mold.

Fig. 3 is an axial section through the mold cope.

lis a bottom plan view of the cope. F 1g. 5 is an axial section through the mold core.

Fig. 6 is a top plan view of the core.

Fig. 7 is an axial section throughthe mold drag.

F 8 is a top plan viewof the drag.

Fig. 9 is a top plan view ot the drag with the core seated therein. Y

Fig. 10 is a sectional view similar to Fig. 2 taken as indicated by line 101O of Fig. 9.

Fig. ll is a plan view of the disc.

Fig. 12 is a plan view of the disc with the hub cast thereon.

Fig. 18 is a top plan view showing the mold press with the mold and disc therein. F 1g. 14C is a side elevation of the press.

Fig. l5 is a detail view showing the connection of one of the standards to the base of the press.

Referring to the annexed drawings, the mold employed for casting a hub upon the metallic wheel structure comprises a cope l, a drag 2 and a core 3. n the drawings is indicated by way otexampl-e a sand mold preferably a dry sand mold with a suitable binder, as is well-known, though a metallic or permanent mold may be used if desired.

The cope l is composed ot sand pressed into the form of a cylindrical block with a flat upper tace 4; and a kcentral recess or pouring gate 5, from the bottom of which are narrow passages 6 Jfor the molten metal extending outwardly and then downwardly into the h ub forming recess on the under side of the cope. The under face of the cope isprovided with a central projection 7 in the form of a truncated cone, the Hat lower face of which when the mold is assembled rests upon the upper surface oit' the core 3. Surrounding the central projection 7 on the under face of the cope 1 is an annular depression 8 which has a flat bottom to form the inner face of the hub and which is surrounded by a rim 9 shaped to lit the disc or wheel structure upon which the hub is to be cast. ln the case shown the rim is corrugated to lit corrugations upon the disc. Air vents 10 extend from the annular' depression 8 to the upper face of the cope to permit escape of gases from the interior of the mold during the casting operation.

The drag 2 is a cylindrical block of sand of the same diameter the cope 1, provided with a flat lower face 11 and having its upper side formed with a corrugated rim portion 12 within which is a iiat bottomed annular depressed portion 13 for forming the outer hub plate. A series of regularly spaced square bosses or projections 111 are formed upon the flat bottom of the portion 13, which serve to 'form countersinlrs in the outer 'tace plate tor the heads of attaching bolts. A Core centering recess 15 having a flat bottom and a conical wall is formed at the center of the drag 2. The upper portion of the recess 15 is enlarged, forming a shoulf er 1G intermediate the top and bottom of the recess 15, and the wall of the enlarged portion is rounded to correspond to the rounded outer face of the hub flange.

The core 3 is formed to provide at its lower end a supporting and centering body portion 17 in the form of a truncated cone adapted to lit within the lower portion of the recess 15 in the drag with its flat bottom face resting upon the flat bottom of the recess 1o. Projecting outwardly and inclined upwardly from the body portion 17 is a flange portion 13 having its lower 'l'ace curved to correspond to the curve-d upper portion of the wall of the recess 15 in the drag. The downwardly projecting portion of the body 17 of the core 3 .is of suflicient height to space. the flange 13 above the npper portion wall of the recess 15 when the core is placed therein at a distance corresponding to the thickness of the hub flange to be cast in the mold. Projecting radially outward from the edOe of the circular flange 13 are a series of regularly spaced longand short projections 19 and 20,- which .serve to `form recesses within the cast hub to lighten thejsame. A recess 21 is formed in the top of the core within the upwardly inclined flange 18 to receive the central projection 7 on the under side ot the cope. The diameter ot' the flat bottom ot' the recess 21 is somewhat greater than that of the bottom face of the projection 7 so that the upper tace of the flange 13 is spaced from the conical face of the projection 7 at a distance corresponding to the thickness of the inner flange of the hub to be cast. e series otl regularly spaced apertures 22 are lormed through the flange 18 for the purpose ot forming a series of rivet like integral stiftening members between the inner and outer flanges of the hub.

1n assembling the parts for casting the hub upon a corrugated disc ior example, the corrugated disc 23 is laid upon the drag 2 with its corrugations gated rim 12 thereof and with its central aperture 2li: centered with resp-ect thereto. The core 3 is then placed upon the drag 2 with its centering projection 17 ezztcndin'r through the aperture of the disc and reso ing upon the bottom of the recess 15 in the drag, and with its long radial projections 1Q positioned within alternate depressions in thc corrugated dise 2d and with its short projections 2O within intermediate depressions opposite the countersinlr, forming projections 14 in the depressed portion of the drag 2. The cope 1 is then placed upon the top of the disc 23 with its central projection 7 resting upon the bottom of the recess 21 of the core and with its corrugated rim portion 9 fitting upon the upper face of the disc. A suitable gas vent is provided in the bottom of the mold by a passage 10n extending from the interior of the core 3 through the bottom wall of the drag 2.

ln casting the molten metal is poured into the gate 5 and runs throughnthe passages 6 to the chamber formed by the compiemental recesses in the cope and drag. The circumterentially disposed passages G have their outlets into the mold chamber within the central aperture 24 of the disc so that the molten metal is free to flow betwezzn the edge of the aperture 211 and the projcce tion 7 to the recesses in the drag Metal from the passages 6 flows into the space between the upper face of the disc 23 and the fiat bottom of the depression 8 in the cope 1 and around the radial projections 19 and 2f) in the depressions of the disc, to forin thc inner face plate 25 oit the hub; between the centra-l projection 7 of the cope 1 and thc flange 13 ot the core to form the inner flange 2G of the huh; through the aperture 2st of Ithe disc 23 into the annular flat bottomed outer portion 13 and around the projections 14 therein toform the outer :tace plate 27 ot the hub with the countersinls 23 therein; between the liange 1S and wall ot recess 15 in the drag 2 to form the outer flange 29 of the hub; and through the apertures 22 in the flange 18 of the core to form the rivet like stif'fening connections 30 between the flanges 26 and 28 of the hub. The projections 19 and 2O serve to provide recesses within the casting in the depression on the inner side of the disc. The short recesses in the casting opposite the countersinlrs 23 leave the casting solid opposite the counterfitting in the corrulill sinks 28, so that the bolt holes can be drilled through solid metal and the bolts will draw upon solid portions of the casting. VAfter the hub is cast the cope 1 and drag 2 are removed and maybe4 used again. The cores 3, however, are broken up in removal from th-e casting.

When a wheel structure such as a disc is used between the parts of the moldthe mold must be forced together with suiiicient pressure to compensate for the variations in the thickness of the metallic stock of the disc to prevent leakage of molten metal between the rims of the mold sections and upon the disc. Also in case a corrugat-ed disc or relatively thin metal be used, it is somewhat flexible or yieldable laterally in the hills and valleys of the corrugations near the central aperture of the disc. In the molding operation, therefore, it is necessary that sufficient pressure be applied to compensate for relatively slight irregularities in the corrugations. 'Ihese may be due either to defects in the dies forming the corrugations or to the grain Ior physical condition of the metallic stock used, for it is well-known that in forming discs from sheets having a grain structure, even though the dies be perfect certain of the corrugations have a tendency to spring or distort slightly so that when the-disc is removed from the dies the corrugations are not all uniform in curvature. Also, the pressure must force the mold sections sufiiciently tightly together to clamp the discs between them to compensate for any differences in contour between the corrugations of the mold sections and corrugations of the discs. It will thus be seen that with the use of my molds and press herein disclosed according` to my method the mold sections will clamp between, them a metallic structure contacting with a relatively large portion of the opposing mold surfaces suficiently tightly to compensate for irregularities in such structure and prevent leakage of molten metal from the mold.

To secure means for forcing the mold sections together to clamp the wheel structure between them I have provided the mold press shown in Figs. 13, 14 and 15 for holding the molds during the casting of the hub. The mold press has a base 31 upon which is mounted a fluid cylinder' 32, preferably pneu matic, provided with suitable connections for admitting and relieving pressure beneath the piston 33 which has a rod 34 extending through the upper end of the cylinder. The piston rod 34 has a rounded upper end 35 upon which is supported the drag engaging plate 36 provided with a rounded socket 37 in the bottom thereof fitting upon the rounded end of the piston rod 34. Standards 38 are attached to collars 39 journaled upon pins 40 at the ends of the base 31. The collars 39 have'lateral lugs 41 in which are mounted set screws 42 engaging lugs 43 upon the ends of the base 31. l By adjusting th-e set screws 42 the inclination of the standards can be varied. A cross bar 44 connects the upper ends of the standards 38 and is adjustably supported at its ends by lower nuts 45 and held upon the nuts 42 by upper nuts 46 and 47. The central portion of the cross bar 44 is enlarged to provide a flat plate 48 to engage the upper face of the cope. After the mold sections are assembled upon the disc 23, the mold is placed upon the supporting plate 36 and pressure applied to the piston 33 to force the mold into engagement with the upper plate 48. By reason of the ball and socket connection between the piston rod 34 and the plate 36 a substantially uniformly distributed pressure is applied to the mold. By so distributing the pressure I am enabled to apply considerable pressure even to sand molds without injury thereto, and by applying pressure to the molds the joints between the contiguous faces of the mold sections and disc ar-e made tight, so that there is no leakage of metal between them.

By way of example I have found that good results may be obtained by applying a pressure of approximately eighty pounds per square inch to the surfaces of sand molds, for such pressure substantially prevents leakage between the mold sections. It

is to be understood, however, that the pressure may be varied for the various sizes of molds and material clamped between the mold sections.

Furthermore, it is to be understood that the particular forms 'of apparatus shown and described, and the particular procedure set forth, are presented for purposes of explanation and illustration and that various modifications of said apparatus and procedure can be made without departing from my invention as defined in the appended claims.

Having described my invention, what I claim is:

1. The process of molding which consists in applying a relatively high pressure to the parts of a sand meld, to clamp an intervening` metallic member therebetween and molding metal around such member.

2. The method of casting a metallic hub upon a metallic wheel which consists in forming complementary sand mold sections, having their opposed faces formed to receive between them the part of the wheel surrounding a central aperture, and having complemental recesses to receive the metal to form the hub, clamping the wheel between said mold sections, applying pressure to the mold sections, and pouring molten metal into the molds to form the hub.`

3. The method of casting a metallic hub uponv a metallic wheel having a central aper- Cil ture which consists in forming' sand mold sections having their opposed faces formed to receive between them the part ot the Wheel which surrounds s aid aperture, and provided with complemental recesses conforming' to the outer faces ot the hub to be cast, 'forming a sand core conforming'v to the interior portion oit the hub, assembling said mold sections with the wheel and coreV be tween them applying' pressure to the mold sections, pouring molten metal into the mold to form the hub, permitting said metal to cool and solidify, and removing said mold sections.

il. The method ot casting' a metallic hub upon a corrugated disc having' a central aperture which comprises forming' a sand mold drag with a peripheral rim portion corrugated to conform to the contour ot the disc, and with a depressed portion inside the rim, the outer portion ot which conforms to one side of the hub and the center oi" which forms a core receiving' and centering' portion, forming a core corresponding to the interior portion ot' the hub and a cope having` a rim portion corresponding to the contour of the disc, and a depressed portion corresponding to the oppo-site tace ot the disc, positioning the disc upon the dragu inserting the core through the aperture ot' the disc into engagement with the centering' portion of the drag, placing the cope upon the upper surface of the disc, applying pressure to the cope and drag to lirmly clamp them upon the disc, and pouring molten metal into the mold.

5. A sectional mold comprising' a drag having its upper tace formed to provide a rim portion, a Vdepression at its center, a core member seated in said depression and provided with a flange, a cope having' its lower tace provided with a rim corresponding' to the rim of the drag, said cope having a member to engage the center of the core, and said core having a flange spaced from both the cope and drag' to forni discs when the metal is poured. u

6. A sectional mold comprising a drag' and cope, each having complementary corrugated rim portions tor engaging with a corrugated metallic disc, one ot said mold sections having' a depression and the other a. projection, a core itting in the depression ot one, and receiving the projection ot the other, and 'having a iiang'e extending' between said sections, said sections of the core being shaped to mold a centrally apertured pair oi' hub plates around the'center'ot said metallic disc. y A

7. A sectional mold for hubs comprising' a drag' having its upper face formed to provide a rim portion, a depressed portion inside the rim and a deeper depression at its center, a core member seated in said depression and provided with a fiang'e overhang'ing and spaced trom said depressed portion, and a cope having its lower face provided with a rim portion corresponding in contour to the rim of the drag, an annular depressed ,portion inside the rim, and a central core engaging projection, said cope having' a pouring gate formed therein.

8. A sand mold for casting' a metallic hub upon a corrugated disc, comprising' a drag having its upper tace formed with a rim portion corrugated to conform tothe oontour ot the disc, a central core receiving and centering recess, and a shallow recess surrounding said centering recess, a core having' a projecting' portion adapted to tit in said centering' recess, a flange adapted to overhang' said shallow recess, and Aradial projections from the liang'e adapted to extend within corrugations of the disc, and a cope having' a central projection engageable with said core, a shallow recess surrounding said projection and a rim portio-n corrugated to conform to the contour of the disc, said cope being formed with a pouring' gate.

9. A sectional mold comprising' a` cope and drag having rim portions, depressions in said sections, a core member engaging the cope and drag, and having' an overhanging' flange spaced between said depressions, said core having' apertures therethrough connecting with said depressions to :form integral connecting members between the spaced discs formed in the depressions by the molten.metal.

10. The method oi casting' a metallic part upon a metallic body w lich consists in forming' complementary sand mold sections having' their opposed 'faces formed to receive betweenthem the metallic body and having complemental recesses to receive the metal to 'form the metallic part, clamping the metallic body between said mold sections, applying pressure to the mold section, and pouring metal into the molds to form the netallic part.

n testimony whereof' atlix my signature.

ALEXANDER P. VREELAND.

Images