US20100018664A1 - Casting process, upper mold assembly and method of securing core to upper mold - Google Patents

Casting process, upper mold assembly and method of securing core to upper mold Download PDF

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Publication number
US20100018664A1
US20100018664A1 US12/516,092 US51609207A US2010018664A1 US 20100018664 A1 US20100018664 A1 US 20100018664A1 US 51609207 A US51609207 A US 51609207A US 2010018664 A1 US2010018664 A1 US 2010018664A1
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US
United States
Prior art keywords
upper mold
core
mold
casting
mold assembly
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Abandoned
Application number
US12/516,092
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English (en)
Inventor
Kunihiro Hashimoto
Junichi Iwasaki
Yutaka Hagata
Takeshi Kamasaka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sintokogio Ltd
Aisin Takaoka Co Ltd
Original Assignee
Sintokogio Ltd
Aisin Takaoka Co Ltd
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Publication date
Application filed by Sintokogio Ltd, Aisin Takaoka Co Ltd filed Critical Sintokogio Ltd
Assigned to AISIN TAKAOKA CO., LTD., SINTOKOGIO LTD. reassignment AISIN TAKAOKA CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HAGATA, YUTAKA, HASHIMOTO, KUNIHIRO, IWASAKI, JUNICHI, KAMASAKA, TAKESHI
Publication of US20100018664A1 publication Critical patent/US20100018664A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—Installation of cores

Definitions

  • the present invention relates to a method of producing a casting (i.e. a casting method), an upper mold assembly used in the method, and a method of securing a core to an upper mold. More particularly the present invention relates to a sand mold press-casting process wherein an upper mold is put on a lower mold to define a cavity into which a molten metal is poured to produce a casting.
  • a mold cavity for casting is defined by putting an upper mold on a lower mold, and a molten metal is poured in the cavity for production of a casting.
  • the common casting process employs a gating system which necessarily needs flow channels of the pouring molten metal for controlling a flow of the pouring molten metal in order to obtain a high-quality casting free from inclusion of impurities and gasses, but the flow channels are irrelevant to shapes of a casting. In this sense, a yield of casting is degraded, and labor and time are required for separating additional metal pieces, e.g. risers and runners, from a casting after crushing sand molds, resulting in a decrease in productivity of casting and an increase in production costs.
  • JP-A-2005-52871 a sand mold press-casting process is proposed in JP-A-2005-52871.
  • the proposed process uses (1) a lower mold, which is prepared by a proper molding method so as to provide a cavity just for defining a profile of a casting itself without a cavity for the aforesaid gating system and (2) an upper mold, which is prepared by a proper molding method to a form with a projection for defining a mold cavity for a casting in combination with the cavity of the lower mold.
  • an amount of a molten metal necessary for producing the casting is poured in the cavity of the lower mold, and then the upper mold is put on the lower mold in the manner that the projection of the upper mold is fitted into the poured molten metal so as to define a mold cavity necessary for a profile of the casting.
  • the sand mold press-casting process has the advantage that a casting with an objective profile is produced with high yield of molten metals, but can not be simply applied to a casting method using cores due to flotation of the cores.
  • a recess with a shape similar to a core print of a core is generally formed as a part for receiving the core print in a lower mold, the core is placed in the receiving part and clamped between the upper and lower molds, and subsequently a molten metal is poured into the mold, as disclosed JP-A-9-57396.
  • the sand mold press-casting process involves a step of putting an upper mold on a lower mold after pouring a molten metal in the lower mold. If a core is simply placed in the lower mold before pouring, the core unfavorably floats due to buoyancy of the poured molten metal, resulting in defective a profile of a casting.
  • an object of the present invention resides in providing a new casting technique in the sand mold press-casting process with use of a core, which casting technique ensures a casting operation with a high yield while preventing occurrence of defective profiles of a cast product.
  • a casting process with use of a lower mold having a hollow corresponding to a partial profile of a casting, and an upper mold which supports a core and defines a mold cavity in cooperation with the lower mold, wherein the casting process comprises the steps of:
  • the status information of the upper mold assembly is of a pressure applied from the upper mold assembly to the molten metal in the hollow and/or the lower mold, or of a total descending movement distance of the assembled upper mold.
  • an upper mold assembly which comprises an upper mold and a core secured to the upper mold, and which defines a mold cavity in cooperation with the lower mold.
  • the core is preferably secured to the upper mold by a mechanical means.
  • the core is preferably secured to the upper mold by an adhesive.
  • the core is preferably secured to the upper mold by a frictional fitting relationship between a projection formed on the core and a recess formed in the upper mold.
  • the core is preferably secured to the upper mold by an engagement relationship between an engaging projection formed on the core and a stamped molding sand of the upper mold.
  • a plurality of cores may be secured to the upper mold, and a plurality of hollows corresponding to the plurality of cores may be formed in the lower mold, whereby making possible to produce simultaneously a plurality of castings by a single pair of the upper and lower molds.
  • a third aspect of the invention there is provided a method of securing a core to an upper mold with use of a frictional force
  • a casting mold consisting of the upper mold and a mating lower mold is used, which upper and lower molds are prepared by foundry molding, respectively, and which are superimposed on each other so as to define a mold cavity having a product profile for obtaining a casting,
  • the core has a partial profile of the casting
  • the core may have one or more projections
  • the upper mold also may have one or more recesses for receiving the one or more projections, wherein the projections and the recesses are so formed that at least a deep region of each of the recesses has an inner diameter smaller than an outer diameter of a complementary contact part of each of the projections.
  • the core supporter supporting the core model is moved relatively to the upper mold so as to bring the core model into contact with the upper mold, whereby preferably the information value of securing the core to the upper mold is a travel distance of the core supporter from an initial position when a pressure applied to the core model from the upper mold meets a predetermined information value.
  • a press controlling method which method comprises: preparing the upper mold assembly by securing the core to the upper mold; pouring a necessary minimum amount of a molten metal for obtaining a casting in the hollow of the lower mold; moving downwardly the upper mold assembly to the lower mold; detecting a status information of the upper mold assembly in a state when the upper mold assembly is superimposed on the lower mold, or arrived at the lower mold; and stopping the descending movement of the upper mold assembly after detecting that the status information comes at a predetermined state, whereby the press process is completed, it is possible to shorten a time length from the pouring step to the completion of the press process to be minimum.
  • a press process can be completed before a temperature of a molten metal poured in the mold cavity drops to occur a non-uniform temperature distribution in the molten metal, whereby it is possible to make a uniform metal structure of a casting.
  • FIG. 1 is a schematic vertical sectional view showing a relationship between an upper mold assembly and a lower mold as one embodiment of the invention
  • FIG. 2 is a schematic vertical sectional view of the upper mold assembly as one embodiment of the invention, which shows a mechanical connection relationship between the core and the upper mold;
  • FIG. 3 is a schematic vertical sectional view of an upper mold assembly as one embodiment of the invention, which shows an adhesive connection relationship between a core and an upper mold;
  • FIG. 4 is a schematic vertical sectional view of an upper mold assembly as one embodiment of the invention, which shows a frictional connection relationship between a core and an upper mold;
  • FIG. 5 is a schematic vertical sectional view of an upper mold assembly as one embodiment of the invention, which shows a connection relationship with use of molding sand between a core and an upper mold;
  • FIG. 6 is a schematic vertical sectional view illustrating a pouring operation with use of an upper mold assembly and a lower mold as one embodiment of the invention
  • FIG. 7 is a schematic vertical sectional view illustrating a descending movement state of the upper mold assembly at a first speed after the pouring operation shown in FIG. 6 ;
  • FIG. 8 is a schematic vertical sectional view illustrating a further descending movement state of the upper mold assembly at a second speed in succession to the state shown in FIG. 7 ;
  • FIG. 9 is a schematic vertical sectional view illustrating a state when the descending movement of the upper mold assembly is stopped after the upper mold assembly is superimposed on and pressed to the lower mold in succession to the state shown in FIG. 8 ;
  • FIG. 10 is a schematic vertical sectional view, as one embodiment of the invention, which illustrates a state when a core loaded on a core supporter of a core securing device is located at a position facing to an upper mold above the core;
  • FIG. 11 is a schematic view illustrating a state when the core is brought into close contact with the upper mold after the core supporter has been lifted;
  • FIG. 12 is a schematic sectional view illustrating a fitting engagement relationship between a core and an upper mold as one embodiment of the invention
  • FIG. 13 is a schematic view illustrating a core and an upper mold as another embodiment of the invention.
  • FIG. 14 is a schematic view illustrating an operation with use of a core model for pre-confirming a travel distance of a core for securing the core to an upper mold;
  • FIG. 15 is a schematic view illustrating the core model located at a lower position of the upper mold
  • FIG. 16 is a schematic view illustrating the core model brought into close contact with the upper mold.
  • FIG. 17 is a graph showing a relationship between a stroke (abscissa) of a piston rod and a pressure (ordinate) applied to the piston rod from the upper mold with respect to FIGS. 14 to 16 .
  • FIG. 1 is a schematic vertical sectional view illustrating a casting machine comprising a lower mold 10 and an upper mold assembly 20 as one embodiment of the invention.
  • the lower mold 10 has a hollow 12 corresponding to a partial profile of a casting.
  • the hollow 12 defines a mold cavity in combination with an upper mold 22 superimposed on the lower mold 10 .
  • the upper mold assembly 20 has a core 24 secured to a bottom of the upper mold 22 .
  • the core 24 serves as a projection 26 for shaping the profile of the casting in combination with the hollow 12 .
  • securing of the core 24 to the upper mold 22 is performed by mechanical connection, connection with an adhesive, connection with a frictional force or stamping molding sand.
  • a bolt 28 a and a nut 28 b are used as a mechanical connection means.
  • the bolt 28 a is previously implanted in the core 24 .
  • the upper mold 22 is designed in the manner that the bolt 28 a passes through the upper mold 22 along a vertical direction and the core 24 is held in contact with a bottom of the upper mold 22 .
  • a top of the bolt 28 a is screwed into the nut 28 b to prevent the core 24 to fall from the upper mold 22 .
  • the bolt 28 a may be alternatively inserted through the pre-formed upper mold 22 so as to secure the core 24 at a position facing to the bottom of the upper mold 22 .
  • Wires or wedges may be used as a mechanical connection means instead of the bolt and the nut.
  • FIG. 3 illustrates a core 24 A attached to an upper mold 22 with an adhesive.
  • a plurality of projections 24 a formed on a surface of the core 24 A, are fitted into respective recesses 22 a formed in a bottom of the upper mold 22 , and bonded to inner surfaces of the recesses 22 a with an adhesive B.
  • the adhesive B may be organic or inorganic without any restriction on its kind.
  • a quick drying strong adhesive based on a vinyl acetate resin was used as the adhesive B in this embodiment. If the core 24 A is weighty, a bonding strength can be increased by properly enlarging a bonded plane or properly designing a shape of the bonded plane.
  • FIG. 4 illustrates a core 24 B attached to an upper mold 22 with a frictional force.
  • Projections 24 b formed on a surface of the core 24 B are fitted into respective recesses 22 b formed in a bottom of the upper mold 22 .
  • the projections 24 b and the recesses 22 b are designed with substantially the same shapes and dimensions.
  • inner surfaces of the recesses 22 b are scraped, and a frictional force is generated by the scraped molding sand grains entrained in gaps between the inner surfaces and the projections 24 b whereby firmly holding the projections 24 b in the recesses 22 b , so that the core 24 B is secured to the upper mold 22 .
  • FIG. 5 illustrates a core 24 C attached to an upper mold 22 with use of molding sand.
  • the core 24 C which has projections 24 c each having a diameter enlarged toward the distal end thereof, is integrally incorporated with the upper mold 22 when foundry molding, so that the core 24 C is firmly secured in the upper mold 22 by the projections 24 c embedded in stamped molding sand.
  • the securing means for attaching the cores 24 , 24 A, 24 B and 24 C to the upper mold 22 are not limited to a single use of any one of them but also may be used in combination therewith for a single mold.
  • FIGS. 2 to 5 show one core 24 , 24 A, 24 B or 24 C attached to the respective upper mold 22 , but a plurality of cores may be attached to one upper mold 22 .
  • the upper mold assembly 22 shown in FIG. 1 is loaded on a lift 32 and vertically moved toward a lower mold 10 along guide rods 30 .
  • the lift 32 may be a proper means, e.g. an electric, hydraulics or pneumatic type
  • an electric servo cylinder is preferably used for controlling a height level and a descending speed of the upper mold assembly 20 with high accuracy.
  • the electric servo cylinder includes screws, a driving motor and a rotary encoder as a position transducer.
  • An electric servo cylinder for controlling a descending speed of the upper mold assembly 20 and a linear scale for detecting a position of the upper mold assembly 20 and controlling a height level of the upper mold assembly 20 in response to the detected value may be used in stead of the electric servo cylinder capable of controlling a height level and a descending speed of the upper mold assembly 20 .
  • a molten metal in a necessity minimum amount for shaping a casting is poured in a hollow 12 of a lower mold 10 , as shown in FIG. 6 .
  • An amount of the molten metal to be poured in the hollow 12 is properly determined in response to a demand.
  • the molten metal to be poured is preferably kept at a temperature higher by 100° C. or more than its liquidus temperature.
  • an upper mold assembly 20 is immediately put on the lower mold 10 before the molten metal is solidified in the lower mold 10 .
  • the upper mold assembly 20 is descended at a predetermined first speed quickly down to a predetermined height level just before coming into contact with a surface of the molten metal.
  • the descending speed is 375 mm/second for instance, but the value is not restrictive.
  • the descending speed is properly determined within a range whereat movement of the upper mold assembly 20 does not induce vibration of a casting machine as a whole.
  • the proper range of the first descending speed is 300 to 1000 mm/second.
  • the height level just before the upper mold assembly 20 comes into contact with the surface of the molten metal in the hollow 12 is 1 to 100 mm as a minimum distance from the surface of the molten metal to the upper mold 22 or the core 24 .
  • a descending speed of the upper mold assembly 20 including the upper mold 22 and the core 24 is changed to a predetermined second speed such that the upper mold assembly 20 slowly moves downwardly, as shown in FIG. 8 .
  • the second speed is too high, the molten metal is made turbulent so that gases are often included in a casting. If the second speed is too low on the contrary, solidification of the molten metal is completed before the upper mold assembly 20 arrives at a final position. Therefore, the second descending speed is properly determined in a range from 1 to 100 mm/second.
  • the core 24 is firmly secured to the upper mold 22 in a pouring step without any fear about floatation of the core 24 in the molten metal.
  • the upper mold assembly 20 is moved to downwards at the predetermined second speed in this way and put on the lower mold 10 , as shown in FIG. 9 , and a status information of affections provided to the lower mold 10 by the upper mold assembly 20 is detected.
  • the status information may be a pressure applied to the lower mold 10 from the upper mold assembly 20 or a total descending distance of the upper mold assembly 20 .
  • the pressure can be detected by a load cell attached to a distal end of a piston rod.
  • the descending movement of the upper mold assembly 20 is caused to stop.
  • the descending movement of the upper mold assembly 20 is caused to stop when a detected pressure reaches 1 kPa, and kept as such for a time length during which the molten metal is completely solidified, whereby a casting process is finished.
  • the upper mold assembly 20 with the core 24 secured to the upper mold 22 is moved downwardly to the lower mold 10 whereby effecting the casting operation, so that the core 24 is prevented from floating.
  • a movement time length of the core 24 in the molten metal can be adjusted to be minimum, so that it is possible to prevent deformation of the core 24 due to a heat or pressure of the molten metal and occurrence of casting defects such as misrun due to a temperature change of the molten metal. Consequently, according to the invention, when effecting casting operation by a sand mold press-casting process with use of a core, it is possible to carry out a casting operation without occurrence of shape defects of products.
  • the status information of the upper mold assembly may be given in a descending period other than the situation that the upper mold assembly is put on the lower mold.
  • the upper mold assembly may be prepared during or after a molten metal pouring step.
  • FIG. 10 illustrates a core 40 , which is loaded on a core supporter 58 of a core securing device 50 and located at a position facing to an upper mold 60 above the core 40 .
  • the core 40 has a rod-shaped projection 42 at a center of its top surface.
  • the rod-shaped projection 42 is fitted into a recess 62 formed at a center of a bottom of the upper mold 60 , so as to secure the core 40 to the upper mold 60 by frictional fitting engagement of the rod-shaped projection 42 with the recess 62 .
  • the core securing device 50 mainly comprises a frame 90 supported with a base (not shown), sliding guide rods 52 attached to the frame 90 , a pneumatically, hydraulically or electrically driving cylinder 54 having an upper part coupled to a frame 100 spanned over top ends of the guide rods 52 and a core supporter 58 secured to a top of a piston rod 56 of the driving cylinder 54 .
  • An axis of the driving cylinder 54 (i.e. an axis of the piston rod 56 ) is aligned with an axis of the rod-shaped projection 42 of the core 40 . These axes are also aligned with an axis of an upper mold 60 .
  • the driving cylinder 54 in a state of FIG. 10 is operated for ascending the core 40 , the rod-shaped projection 42 of the core 40 is fitted into the recess 62 of the upper mold 60 .
  • FIG. 11 shows a state that the core 40 is lifted to a position in close contact with the upper mold 60 by fitting the rod-shaped projection 42 into the recess 62 .
  • the rod-shaped projection 42 and the recess 62 are both formed to have a frustum conical shape, respectively.
  • the rod-shaped projection may be formed to be a round rod having a constant diameter.
  • the rod-shaped projection 42 has a length smaller than a depth of the recess 62 , so that some allowance remains at a part between a top of the rod-shaped projection 42 and a bottom (i.e. a deepest part) of the recess 62 when the rod-shaped projection 42 is completely fitted into the recess 62 .
  • a relationship of B ⁇ a ⁇ b ⁇ A is preferably maintained between the rod-shaped projection 42 and the recess 62 , wherein “a” is an outer diameter of a top of the rod-shaped projection 42 , “b” is an outer diameter of a root of the rod-shaped projection 42 , “A” is an inner diameter of an inlet of the recess 62 and “B” is an inner diameter of the recess 62 at a position near a deepest part at which the top of the rod-shaped projection 42 arrives.
  • the specified dimensional relationship assures smooth fitting motion of the rod-shaped projection 42 into the recess 62 .
  • the top of the rod-shaped projection 42 is pressed onto an inner wall of the recess 62 so that the distal end of the rod-shaped projection 42 bites the inner wall of the recess 62 .
  • resultant scraped chips are entrained in an allowance between a top of the rod-shaped projection 42 and a bottom (i.e. a deepest part) of the recess 62 .
  • the core 40 has one rod-shaped projection 42 as above-mentioned, but a plurality of rod-shaped projections may be formed in a core 40 A as another example shown in FIG. 13 .
  • the core 40 A has two rod-shaped projections 42 a and 42 b
  • an upper mold 60 A has two recesses 62 a and 62 b each corresponding to the rod-shaped projections 42 a and 42 b .
  • a dimensional relationship between the rod-shaped projections 42 a and 42 b and the recesses 62 a and 62 b is specified in the same way as the dimensional relationship between the rod-shaped projection 42 and the recess 62 .
  • FIG. 14 illustrates a core model 70 , which has the same profile and dimensions as those of the core 40 except for omission of the rod-shaped projection, loaded on the core supporter 58 of the core securing device 50 .
  • the core securing device 50 in FIG. 14 is illustrated in a core loading position offset from an axis of the upper mold 60 , at a fixed position, held by the upper mold holder 80 .
  • the core securing device 50 moves from the position of FIG. 14 to a position of FIG. 15 where an axis of the core model 70 coincides with an axis of the upper mold 60 held at the predetermined position.
  • the driving cylinder 54 is started to extend the piston rod 56 and to bring the core model 70 on the core supporter 58 in close contact with the upper mold 60 .
  • a pressure applied to the piston rod 56 from the upper mold 60 rises. Further extension of the piston rod 56 abruptly raises the pressure.
  • An upward motion of the core model 70 after coming into contact with the upper mold 60 leads to an increase in a contact pressure applied to the upper mold 60 .
  • FIG. 17 is a graph representing a relationship between a stroke (abscissas) of the piston rod 56 and a pressure (ordinate) applied to the piston rod 56 from the upper mold 60 when bringing the core model 70 into close contact with the upper mold 60 .
  • a proper contact pressure is estimated to a value near a point X (i.e. a value range of 0.008 to 0.009 MPa).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)
US12/516,092 2006-12-01 2007-09-27 Casting process, upper mold assembly and method of securing core to upper mold Abandoned US20100018664A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
JP2006325303 2006-12-01
JP2006-325303 2006-12-01
JP2007-152473 2007-06-08
JP2007152473 2007-06-08
PCT/JP2007/068855 WO2008068947A1 (ja) 2006-12-01 2007-09-27 鋳造方法、上鋳型組立体、および上鋳型に対する中子の固定方法

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US (1) US20100018664A1 (zh)
EP (1) EP1927415B1 (zh)
JP (1) JP4991755B2 (zh)
KR (1) KR20080050307A (zh)
CN (1) CN101573195B (zh)
BR (1) BRPI0705825A (zh)
EA (1) EA012717B1 (zh)
WO (1) WO2008068947A1 (zh)

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US20120118524A1 (en) * 2010-10-18 2012-05-17 Fathi Ahmad Core die with variable pins and process for producing a core
CN104859019A (zh) * 2015-06-05 2015-08-26 大连瑞丰达机械制造有限公司 横框加工机的内嵌固定件压入机构
US20150298202A1 (en) * 2014-04-16 2015-10-22 Mahle International Gmbh Apparatus for producing a piston
CN105710310A (zh) * 2016-04-29 2016-06-29 江苏锡华铸造有限公司 一种铸造泥芯下泥芯装置
WO2022093055A1 (en) * 2020-11-02 2022-05-05 Lothar Thoni A hybrid casting mould for metal alloy castings and its method of manufacture

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WO2008068947A1 (ja) 2008-06-12
EP1927415B1 (en) 2013-04-10
JP4991755B2 (ja) 2012-08-01
EA012717B1 (ru) 2009-12-30
CN101573195B (zh) 2012-11-21
JPWO2008068947A1 (ja) 2010-03-18
CN101573195A (zh) 2009-11-04

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