US20060272791A1 - Casting of metals - Google Patents
Casting of metals Download PDFInfo
- Publication number
- US20060272791A1 US20060272791A1 US10/547,951 US54795104A US2006272791A1 US 20060272791 A1 US20060272791 A1 US 20060272791A1 US 54795104 A US54795104 A US 54795104A US 2006272791 A1 US2006272791 A1 US 2006272791A1
- Authority
- US
- United States
- Prior art keywords
- casting
- chill
- die assembly
- segment
- die
- 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.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
- B22D15/04—Machines or apparatus for chill casting
Definitions
- This invention relates to the sand casting of metals, particularly aluminium and more particularly to the casting of aluminium products requiring desired mechanical properties.
- the rapid cooling of a casting results in increased hardness and other properties in the casting, or selected areas of the casting.
- the rapid cooling can be achieved by oil and/or water and/or air-cooling of the mould, particularly in the use of metal moulds.
- the cooling can be achieved by a metal insert or chill in the mould, the chill having the capacity of conducting the heat into itself, thus cooling the molten metal and solidifying the casting.
- a further object of the invention is to provide for the rapid cooling of the bulkhead section of a casting thereby producing the desired mechanical properties in the sand cast aluminium alloy.
- a still further object of the invention is to provide movable die portions or segments, with each segment containing the chill.
- a still further object of the invention is to maintain the chill in contact with the casting as it shrinks during solidification.
- a still further object of the invention is to allow the chill to move with the bulkhead section thus reducing residual stresses and potential cracking of the casting as it shrinks during solidification.
- a segmented die assembly for the casting of a metal object, the die assembly incorporating chill segments to be retained in contact with the molten metal during solidification of the casting, characterised in that the one or more of the segmented die segments are movable to maintain the chill in contact with the surface of the casting as it solidifies.
- the die segments are interconnected, and movable by an actuator.
- the chills are cooled, using oil and/or water and/or air.
- each actuator is controlled by a Fuzzy logic module.
- the Fuzzy logic module controls the actuators independently in response to inputs from devices measuring casting solidification parameters.
- FIG. 1 is an end view of a segmented die cope
- FIG. 2 is a top view of the segmented die cope in FIG. 1 ;
- FIG. 3 is a detail view of two segments illustrating the degree of contraction of the cylinder block.
- the figures show a design for a segmented die assembly having an interconnected chill segment 2 and outer segment 4 on each side of the cylinder block 1 .
- the chill segment 2 and outer segment 4 are interconnected by a coupling 6 , the coupling ensures that the chill returns with the outer segment when it is retracted by the actuator (not shown).
- the coupling comprises a ‘T’ shaped projection stemming from the chill segment 2 , the head 8 of the coupling being received in a recess in the outer segment that is shaped and adapted to receive the male portion of the coupling.
- This assembly produces the bulkhead section of the cylinder block, and can form a part of the clamping system of the chill machine.
- the design shown cools the half round and sides of the bulkhead resulting in a faster and more uniform cooling of the bulkhead section.
- the contraction of the block from the solidus is a problem with any chill that is produced as a one-piece assembly. Tightening on the inside surfaces of the chill 2 will result in the casting 1 locking onto the chill.
- the total movement required by the actuator is increased as the segments follow the casting, and any clearance C between the couplings 6 that interconnect the segments can be used to control at what point and how much the chill 2 moves.
- An actuator under the control of a controller moves each die assembly, the actuators pushing the respective die to the centre section, which is fixed.
- Each chill 2 is cooled by cool water, air or oil passing through the chill.
- Sensors such as thermocouples monitor the temperature of the cooling medium entering the chill and the outgoing cooling medium from the chill. Also the temperature of the molten metal is monitored and together with the difference in temperature between the ingoing and outgoing water these parameters are fed to a Fuzzy logic module whereby the amount of actuator movement required is calculated.
- the Fuzzy logic module controls the actuators independently in order to ensure that the chills are in contact with the casting as it cools and contracts.
- the actuators pull the chills back to their default position and the casting is removed from the casting machine.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
Abstract
A segmented die assembly for the casting of a metal object, the die assembly incorporating chill segments that are cooled using oil and/or water and/or air, the segments being interconnected and moved by actuators under the control of a Fuzzy logic module, wherein in use the assembly ensures that the chill maintains contact with the surface of the casting as it solidifies.
Description
- This invention relates to the sand casting of metals, particularly aluminium and more particularly to the casting of aluminium products requiring desired mechanical properties.
- This is particularly so in the casting of aluminium cylinder blocks for automotive engines. Recent developments in aluminium cylinder block design have resulted in a requirement for high mechanical properties in the bulkhead sections of the casting. The rapid cooling of a casting results in increased hardness and other properties in the casting, or selected areas of the casting. The rapid cooling can be achieved by oil and/or water and/or air-cooling of the mould, particularly in the use of metal moulds. However in sand cast moulds, the cooling can be achieved by a metal insert or chill in the mould, the chill having the capacity of conducting the heat into itself, thus cooling the molten metal and solidifying the casting.
- While chilling processes have been used in the area of the bulkheads of the cylinder block, they have caused many production related problems in existing facilities using moulds made from sand.
- It is an object of this invention to provide for the rapid cooling of a cast metal object to produce the desired mechanical properties of the object.
- A further object of the invention is to provide for the rapid cooling of the bulkhead section of a casting thereby producing the desired mechanical properties in the sand cast aluminium alloy.
- A still further object of the invention is to provide movable die portions or segments, with each segment containing the chill.
- A still further object of the invention is to maintain the chill in contact with the casting as it shrinks during solidification.
- A still further object of the invention is to allow the chill to move with the bulkhead section thus reducing residual stresses and potential cracking of the casting as it shrinks during solidification.
- Thus there is provided according to the invention a segmented die assembly for the casting of a metal object, the die assembly incorporating chill segments to be retained in contact with the molten metal during solidification of the casting, characterised in that the one or more of the segmented die segments are movable to maintain the chill in contact with the surface of the casting as it solidifies.
- Preferably, there is a central chill segment and an outer die segment on opposite sides of the casting.
- Preferably, the die segments are interconnected, and movable by an actuator.
- Preferably, the chills are cooled, using oil and/or water and/or air.
- Preferably, each actuator is controlled by a Fuzzy logic module.
- Preferably, the Fuzzy logic module controls the actuators independently in response to inputs from devices measuring casting solidification parameters.
- Reference is now made to the accompanying drawings in which:
-
FIG. 1 is an end view of a segmented die cope; -
FIG. 2 is a top view of the segmented die cope inFIG. 1 ; and -
FIG. 3 is a detail view of two segments illustrating the degree of contraction of the cylinder block. - In the following description the invention is described as casting a
cylinder block 1 of an internal combustion engine, but it is to be realized by a person skilled in the relevant art however, that the invention can be applied to the casting of any article whether it is cast in aluminium or another metal. - The figures show a design for a segmented die assembly having an interconnected
chill segment 2 andouter segment 4 on each side of thecylinder block 1. Thechill segment 2 andouter segment 4 are interconnected by acoupling 6, the coupling ensures that the chill returns with the outer segment when it is retracted by the actuator (not shown). The coupling comprises a ‘T’ shaped projection stemming from thechill segment 2, thehead 8 of the coupling being received in a recess in the outer segment that is shaped and adapted to receive the male portion of the coupling. This assembly produces the bulkhead section of the cylinder block, and can form a part of the clamping system of the chill machine. The design shown cools the half round and sides of the bulkhead resulting in a faster and more uniform cooling of the bulkhead section. - As discussed above, the contraction of the block from the solidus is a problem with any chill that is produced as a one-piece assembly. Tightening on the inside surfaces of the
chill 2 will result in thecasting 1 locking onto the chill. The total movement required by the actuator is increased as the segments follow the casting, and any clearance C between thecouplings 6 that interconnect the segments can be used to control at what point and how much thechill 2 moves. An actuator under the control of a controller moves each die assembly, the actuators pushing the respective die to the centre section, which is fixed. - Each
chill 2 is cooled by cool water, air or oil passing through the chill. Sensors such as thermocouples monitor the temperature of the cooling medium entering the chill and the outgoing cooling medium from the chill. Also the temperature of the molten metal is monitored and together with the difference in temperature between the ingoing and outgoing water these parameters are fed to a Fuzzy logic module whereby the amount of actuator movement required is calculated. The Fuzzy logic module controls the actuators independently in order to ensure that the chills are in contact with the casting as it cools and contracts. - At the end of the casting cycle the actuators pull the chills back to their default position and the casting is removed from the casting machine.
- The development of the segmented die assembly will result in a cost effective method of producing the mechanical properties required in modem engine block design.
- Although one form of the invention has been described it is to be noted that variations and modifications can be made falling within the spirit and scope of the invention.
Claims (12)
1. A segmented die assembly for the casting of a metal object, the die assembly incorporating chill segments to be retained in contact with the molten metal during solidification of the casting, characterised in that the one or more of the segmented die segments are movable to maintain the chill in contact with the surface of the casting as it solidifies.
2. The segmented die assembly as set forth in claim 1 , further characterized in that there is a central chill segment and an outer die segment on opposite sides of the casting.
3. The segmented die assembly as set forth in claim 1 , further characterized in that the die segments are interconnected, and movable by an actuator.
4. The segmented die assembly as set forth in claim 1 , further characterized in that the chills are cooled, using oil and/or water and/or air.
5. The segmented die assembly as set forth in claim 3 , further characterized in that each actuator is controlled by a Fuzzy logic module.
6. The segmented die assembly as set forth in claim 5 , further characterized in that the Fuzzy logic module controls the actuators independently in response to inputs from devices measuring casting solidification parameters.
7. (canceled)
8. A die assembly for casting of a metal object, comprising a center section in which molten metal solidifies to form a casting of the metal object, and die segments on opposite sides of the casting;
wherein each die segment comprising an outer segment and chill segment interconnected with the outer segment;
wherein the chill segments are each positioned for contact with the surface of the casting and the outer segment are each positioned radially outward from its interconnected chill segment; and
wherein one or more of the die segments are movable to maintain the chill segments in contact with the surface of the casting as it solidifies.
9. A die assembly as set forth in claim 8 , wherein the center section is fixed.
10. A die assembly as set forth in claim 8 , wherein the center section has a shape corresponding to a cylinder block.
11. A die assembly as set forth in claim 8 , wherein the chill sections cool bulkhead sections of the cylinder block.
12. A method of casting a metal object with the die assembly of claim 8 , said method comprising the steps of:
moving each die segment inward to the center section;
contacting the chill segment with the casting
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003901028A AU2003901028A0 (en) | 2003-03-07 | 2003-03-07 | Improvements in and relating to the casting of metals |
AU2003901028 | 2003-03-07 | ||
PCT/AU2004/000275 WO2004078382A1 (en) | 2003-03-07 | 2004-03-05 | Improvements in and relating to the casting of metals |
Publications (1)
Publication Number | Publication Date |
---|---|
US20060272791A1 true US20060272791A1 (en) | 2006-12-07 |
Family
ID=31500073
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/547,951 Abandoned US20060272791A1 (en) | 2003-03-07 | 2004-03-05 | Casting of metals |
Country Status (3)
Country | Link |
---|---|
US (1) | US20060272791A1 (en) |
AU (1) | AU2003901028A0 (en) |
WO (1) | WO2004078382A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113084116A (en) * | 2021-04-16 | 2021-07-09 | 杭州汽轮铸锻有限公司 | Auxiliary positioning method for dark chill in core box |
CN113145799A (en) * | 2021-05-12 | 2021-07-23 | 北京航星机器制造有限公司 | Sand mould with prevent swashing slot structure |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN114603120B (en) * | 2022-03-21 | 2023-07-14 | 山东鑫典精密铸造有限公司 | Rapid cooling casting device for high-strength casting machining |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS523530A (en) * | 1975-06-27 | 1977-01-12 | Hitachi Ltd | Method of making steel ingot and casting |
GB2106021A (en) * | 1981-10-02 | 1983-04-07 | Gen Electric | Apparatus and method for producing a metal casting which contains a recess |
US6056040A (en) * | 1997-10-10 | 2000-05-02 | Alcan International Limited | Mould device with adjustable walls |
-
2003
- 2003-03-07 AU AU2003901028A patent/AU2003901028A0/en not_active Abandoned
-
2004
- 2004-03-05 WO PCT/AU2004/000275 patent/WO2004078382A1/en active Application Filing
- 2004-03-05 US US10/547,951 patent/US20060272791A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113084116A (en) * | 2021-04-16 | 2021-07-09 | 杭州汽轮铸锻有限公司 | Auxiliary positioning method for dark chill in core box |
CN113145799A (en) * | 2021-05-12 | 2021-07-23 | 北京航星机器制造有限公司 | Sand mould with prevent swashing slot structure |
Also Published As
Publication number | Publication date |
---|---|
WO2004078382A1 (en) | 2004-09-16 |
AU2003901028A0 (en) | 2003-03-20 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: EQUIPMENT MERCHANTS INTERNATIONAL INC., OHIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CASTALLOY MANUFACTURING PTY LTD.;REEL/FRAME:017572/0518 Effective date: 20050906 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |