US20100139884A1 - Casting mould for casting a cast part and use of such a casting mould - Google Patents

Casting mould for casting a cast part and use of such a casting mould Download PDF

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Publication number
US20100139884A1
US20100139884A1 US12/513,757 US51375707A US2010139884A1 US 20100139884 A1 US20100139884 A1 US 20100139884A1 US 51375707 A US51375707 A US 51375707A US 2010139884 A1 US2010139884 A1 US 2010139884A1
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US
United States
Prior art keywords
casting
mould
chill
core
thermal conductivity
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
Application number
US12/513,757
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English (en)
Inventor
Detlef Kube
Marcus Speicher
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.)
Nemak Dillingen GmbH
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Nemak Dillingen GmbH
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Filing date
Publication date
Application filed by Nemak Dillingen GmbH filed Critical Nemak Dillingen GmbH
Assigned to NEMAK DILLINGEN GMBH reassignment NEMAK DILLINGEN GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUBE, DETLEF, SPEICHER, MARCUS
Publication of US20100139884A1 publication Critical patent/US20100139884A1/en
Abandoned legal-status Critical Current

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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
    • B22D15/02—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 of cylinders, pistons, bearing shells or like thin-walled objects
    • 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
    • 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
    • B22C9/101—Permanent cores
    • 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
    • B22C9/103—Multipart cores

Definitions

  • the invention relates to a casting mould for casting a casting, comprising mould parts produced from moulding sand and casting cores and having at least one casting core for the formation of a space in the casting.
  • Casting moulds of this type are used in particular for the casting of engine blocks for combustion engines.
  • the casting core in the engine block casting forms the individual combustion chamber, while the other mould part forms the head surface of the engine block, on which, during assembly, the cylinder head of the individual combustion engine is placed and secured, as necessary, as an add-on part.
  • the cylinder cavities of the engine block are formed by dies inserted into the sand mould, these consisting of a brass material.
  • the aluminum solidifies on the surface of the brass die as a consequence of the higher thermal conductivity of the metal of the die more rapidly than on the surface of the sand mould.
  • a microstructure is produced there to an adequate depth, such that it possesses a higher resistance to the loads incurred in practical operation on the running surfaces of the cylinders.
  • the object of the invention was to provide a casting mould which makes it possible, in a simple manner, for castings to be produced in which at least one locally closely confined section is formed with a microstructure which differs from the remainder of the casting. In addition to this, it should also specify an advantageous use of such a casting mould.
  • the casting core forming the space in the casting in each case is divided into at least two sections.
  • the first section in this situation is formed by a chill, while the other section usually consists of mould sand placed in the area of the sand casting.
  • Such mould sand is formed in a known manner from mixtures of basic mould material, as a rule free-flowing, and a binder.
  • This mould sand mixture is shaped in a core mould to the individual mould part or casting core and then secured by a suitable mechanical, chemical, and/or thermal treatment in such a way that the part or core obtained has adequate shape stability for the casting process.
  • the chill used according to the invention as a part of the casting core forming the space has according to the invention a thermal conductivity many times higher than the mould sand from which the other section of the casting core is produced. Accordingly, in the area of the casting mould in which the melt poured into the mould comes in contact with the die locally delimited accelerated cooling takes place. By the selection of the material and the volume of the chill it is possible, in this situation, for the speed at which the locally delimited cooling takes place to be directly influenced, as well as the quantity of heat drawn off the casting metal in each case.
  • the extent of the area over which the specifically accelerated drawing off of heat should take place can be adjusted in a simple manner by the overall design of the chill. If it is intended, for example, when casting an engine block, that the casting material surrounding the cylinder space to be formed in the engine block should be specifically and massively cooled for the purpose of forming a particularly stress-resistant casting microstructure over a specific part length of the cylinder space, then for this purpose the casting core forming the individual cylinder space is provided with a ring-shaped chill, the height of which corresponds to the specifically cooled part length of the cylinder chamber, taking account of the heat migration.
  • a further advantage of the invention which is of importance in actual practice lies in the fact that the chill used according to the invention does not need to be subjected before its use to either a special surface treatment or be pre-heated. It has been shown, for example, that with a suitable choice of material and shaping, the chill can be removed in a simple manner from the finished solidified casting.
  • a chill used according to the invention produces, in the area of the casting material coming in contact with it, such a good surface quality that the chill can be inserted into the casting mould without a coating. Accordingly, with a casting mould according to the invention, the casting material comes in direct contact with the chill, such that a particularly rapid heat removal takes place, not impeded by any intermediate layer functioning as an insulator.
  • the invention in this way makes the economical manufacture of castings possible in which, in the area of a space to be formed in the castings, locally closely confined zones are present with a casting microstructure created by accelerated cooling.
  • the properties achieved by the embodiment according to the invention make casting moulds according to the invention particularly well-suited for the casting in large-scale series of engine blocks for combustion engines, wherein their advantages come to the fore in particular in the casting of such engine components made of light metal or light metal alloys, in particular of aluminum or aluminum alloys. It is particularly with the casting of engine blocks that the possibility created by the invention, of specific and massive cooling in a closely confined part area of the individual cylinder chamber has a particularly favorable effect. This becomes particularly noticeable if the zone of the engine block which is to be specifically cooled is the area at which the individual cylinder chamber merges into the assembly surface on which the cylinder head of the engine is mounted. With the aid of the invention, it is possible at that point specifically for the casting material to be cooled in a specific manner in the course of its solidification such that material properties which are always in keeping with the requirements arising in practical operation are present to optimum effect.
  • One variant of the invention which is particularly advantageous with regard to mass production makes provision for the chill to be manufactured from cast iron Chills consisting of cast iron can be economically manufactured and have a thermal conductivity which is favorable with regard to the processing aim being striven for in this situation.
  • a casting mould according to the invention is particularly well-suited for the manufacture of such castings in which a microstructure is to be created in the area of a transition between the space to be created in the casting and an assembly surface, which is capable of supporting the loads occurring during operation.
  • One embodiment of the invention which is of importance in practice therefore makes provision for at least one of the mould parts of a casting mould according to the invention to form an assembly surface on the casting, on which an add-on part can be mounted on the casting after its solidification, and for the mould core, in particular with the chill, to border on this mould part.
  • the thermal conductivity of the chill should likewise be many times higher than the thermal conductivity of the mould part forming the assembly surface.
  • the arrangement of the chill and of the other section of the casting core forming the space in the casting in the correct position can be assured by a simple procedure, in that elements are formed on the chill and the other section of the casting core, by means of which the chill and the other section of the casting core are connected to one another in positive fit.
  • the chill is used in such a way that it cools a zone of the casting which is to be produced at the transition into the assembly surface, it is advantageous if at least one element is formed on the chill which engages in positive fit into a correspondingly shaped cut-out aperture of the mould part.
  • this element is preferably formed as a projection engaging into the mould part.
  • the chill which engages in this way into the mould part concerned extends in this case over the assembly surface to be produced on the casting, such that the occurrence of burrs or comparable mould defects in the area of the aperture of the individual cylinder chamber is reliably prevented.
  • the inner surface of the projection is inclined at an oblique angle in relation to the longitudinal axis of the chill, in such a way that the diameter of the aperture of the casting core widens in the direction of the mould part, in this situation the removal of the chill from the finished casting can be made additionally easier.
  • the casting core with the chill is held by a ram extending into the casting core.
  • This ram can, on the one hand, be used for the precisely positioned holding of the casting core.
  • such a ram also allows, when coupled to an appropriate adjustment device, automatic installing of the casting core itself.
  • liners are, for example, prefabricated tubular structural elements made of grey cast iron, of which the inner diameter corresponds to the inner diameter of the cylinder chamber to be formed in the engine block and the inner surfaces of which form the running surfaces in the finished engine block, along which, in operation, the piston of the combustion engine moves.
  • liners can also be cast into the casting which is to be produced, with the simultaneous exploitation of the advantages of the invention, if the casting core carries on its outer surface a liner which is to be cast into the casting.
  • the single FIGURE shows in diagrammatic form a casting mould G for casting an engine block for a straight-4 combustion engine.
  • the casting mould 1 is composed of different mould parts 1 , 2 , 3 and casting cores 4 , 5 , 6 , 7 produced in each case from moulding sand, which are formed in each case from a section 8 prefabricated from moulding sand and a chill 9 .
  • the mould part 1 represented at the top in the FIGURE is what is referred to as a “bottom core”, which forms the assembly surface 10 on the engine block which is to be cast, also referred to as the “top-deck surface”, on which, in the course of the assembly of the combustion engine a cylinder head is secured, not represented here.
  • the mould part 2 arranged opposite the mould part 1 , represents what is referred to as the “crank chamber core”, which forms the crank chamber in the engine block to be cast.
  • the casting cores 4 , 5 , 6 , 7 are in each case retained by a ram 11 , 12 , 13 , 14 .
  • the rams 11 - 14 are coupled to an actuator device, not shown here, which moves them out of a mounting position, in which the casting cores 4 , 5 , 6 , 7 are mounted on them, into the position represented in the FIGURE.
  • the front section 15 of the rams 11 - 14 projecting into the individual casting core 4 - 7 is in this case formed such as to taper conically over the entire height of the casting cores 4 - 7 in the direction of the free end of the ram, in order to be able to draw the rams 11 - 14 unimpeded out of the casting cores 4 - 7 after the conclusion of the casting process.
  • the section 8 of the casting cores 4 - 7 has a beaker shape, wherein the interior which it surrounds is adapted to the shape of the front section 15 of the rams 11 - 14 in such a way that the section 15 concerned is located in positive fit in the interior.
  • a projection 16 is formed at the front free end of the section 15 , in each case arranged centrically on the face side of the casting cores 47 , which engages into a correspondingly shaped cut-out aperture 17 of the mould part 2 and is likewise held in this in positive fit.
  • the section 8 of the casting cores 4 - 7 On its opposite edge, facing the chill 9 which is produced as a monolithic block made of grey cast iron, the section 8 of the casting cores 4 - 7 has in each case a circumferential shoulder 18 , into which a ring-shaped circumferential projection 19 engages, formed at the face-side edge of the chill 9 facing the section 8 .
  • the chills 9 of the casting cores 4 - 7 are linked in positive fit to the section 8 , made of moulding sand, of the individual casting core 4 - 7 .
  • the chills 9 in this situation themselves have a ring-shaped design.
  • the interior surrounded by them is in this situation adapted to the shape of the front section 15 of the rams 11 - 14 facing them in each case, such that the chills 9 are likewise retained in positive fit and essentially free of play on the rams 11 - 14 allocated to them.
  • a circumferential projection 20 is likewise formed in each case on the chills 9 , the outer circumferential surface of which, as with the projection 19 , merges smoothly into the circumferential surface 21 of the main section of the individual chill 9 .
  • the chills 9 in this situation have a slightly conical shape, tapering in the direction of the free end of their projection 19 .
  • the common circumferential surface 21 of the chills 9 is inclined by an angle of at least 2° in relation to their longitudinal axes L, congruent with the longitudinal axes of the rams 11 - 14 .
  • the inner surfaces of the chills 9 are also inclined.
  • the conical outer shape of the chills 9 facilitates the removal of the chills 9 from a liner 22 , which is held in positive fit by the individual casting core 4 - 7 in each case, and, after solidification, remains in the engine block which is to be cast in the casting mould G.
  • the liners 22 surround the cylinder chambers which are to be formed by the casting cores 4 - 7 in the engine block.
  • the height of the projections 20 of the chills 9 is dimensioned in such a way that in each case, with the casting cores 4 - 7 and mould parts 1 - 3 positioned ready in the casting mould G, they engage over the assembly surface 10 into a correspondingly shaped cut-out aperture 23 of the mould part 1 . In this way, burr formation can be reliably prevented in the area of the opening of the cylinder chambers of the engine block which is to be cast.
  • feeders and filling channels are formed, not shown here, by means of which the aluminum melt poured into the casting mould G flows into the mould cavity 24 surrounded by the casting mould G. Heat is drawn off in an accelerated fashion, via the liners 22 and the individual chill 9 , from the melt which in this situation passes into the areas 25 of the mould cavity 24 adjacent to the chills 9 , such that it solidifies more rapidly than the melt present in the other zones of the mould cavity 24 .
  • an aligned finer-grain microstructure is formed, such that the section of the engine block adjacent to the assembly surface 10 , which in this area is subjected to particular heavy loading, will reliably resist the thermal and mechanical loads occurring in practical operation.
US12/513,757 2006-11-10 2007-11-09 Casting mould for casting a cast part and use of such a casting mould Abandoned US20100139884A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102006053404.2 2006-11-10
DE102006053404A DE102006053404A1 (de) 2006-11-10 2006-11-10 Gießform zum Gießen eines Gussteils und Verwendung einer solchen Gießform
PCT/EP2007/062131 WO2008055973A1 (de) 2006-11-10 2007-11-09 Giessform zum giessen eines gussteils und verwendung einer solchen giessform

Publications (1)

Publication Number Publication Date
US20100139884A1 true US20100139884A1 (en) 2010-06-10

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Application Number Title Priority Date Filing Date
US12/513,757 Abandoned US20100139884A1 (en) 2006-11-10 2007-11-09 Casting mould for casting a cast part and use of such a casting mould

Country Status (10)

Country Link
US (1) US20100139884A1 (de)
EP (1) EP2091678B1 (de)
JP (1) JP2010509070A (de)
KR (1) KR20090077949A (de)
CN (1) CN101547760B (de)
DE (2) DE102006053404A1 (de)
MX (1) MX2009004733A (de)
PL (1) PL2091678T3 (de)
RU (1) RU2432223C2 (de)
WO (1) WO2008055973A1 (de)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014048066A1 (en) * 2012-09-27 2014-04-03 He Bingxiang New pouring process for a core/mold package of automobile engine castings
CN104826986A (zh) * 2015-04-20 2015-08-12 鞍山千钢机械制造有限公司 防止砂型铸造铸件粘砂的方法及砂型预制件
CN108262449A (zh) * 2018-03-06 2018-07-10 溧阳市联华机械制造有限公司 一种热芯盒制作石墨成型冷铁的方法
CN108326264A (zh) * 2018-03-06 2018-07-27 溧阳市联华机械制造有限公司 一种冷芯盒制作石墨成型冷铁的方法
US10850321B2 (en) 2014-07-09 2020-12-01 Nemak, S.A.B. De C.V. Foundry core, use of a foundry core, and method for producing a foundry core
CN114833311A (zh) * 2021-02-01 2022-08-02 通用汽车环球科技运作有限责任公司 用于铸铝缸体的具有金属冷铁的混合凸轮孔砂芯

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DE102011079356A1 (de) * 2011-07-18 2013-01-24 Mahle International Gmbh Gießkern einer Gussform zur Herstellung eines Zylinders
KR101224988B1 (ko) * 2011-07-29 2013-01-22 현대제철 주식회사 열간압연롤 주조용 몰드
KR101224990B1 (ko) * 2011-08-30 2013-01-22 현대제철 주식회사 열간압연롤 주조용 몰드의 제조방법
CN102380581B (zh) * 2011-10-28 2013-04-24 刘天平 一种壳体铸件芯撑间隔层叠多组芯工艺方法
KR101340890B1 (ko) * 2013-07-02 2013-12-13 (주) 캐스텍코리아 주형 및 이를 이용한 주조방법
DE102015225588A1 (de) 2015-12-17 2017-06-22 Volkswagen Aktiengesellschaft Gießverfahren und Kühleinsatz zur Herstellung eines Gussteiles
DE102019110580A1 (de) * 2019-04-24 2020-10-29 Nemak, S.A.B. De C.V. Vorrichtung und Verfahren zur Entnahme mindestens eines Kühlelementes aus einem wenigstens teilweise entformten Gussteil, Verfahren zur Einbringung mindestens eines Kühlelementes in einen Formkern einer Gussteilform, Kühlelement sowie Gussteil
US11654476B2 (en) * 2020-09-28 2023-05-23 GM Global Technology Operations LLC Hybrid core for manufacturing of castings
US20220241847A1 (en) * 2021-02-01 2022-08-04 GM Global Technology Operations LLC Profile chill for forming a cast device
KR102609755B1 (ko) 2023-02-06 2023-12-05 주식회사 한국귀금속보석 중량 조절이 가능한 주물틀

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US1833128A (en) * 1928-11-19 1931-11-24 Walten B Robe Chill for sand molds
US1999511A (en) * 1931-05-28 1935-04-30 Continental Motors Corp Method and apparatus for casting engine blocks
US2831225A (en) * 1954-10-04 1958-04-22 Gen Motors Corp Method of making cylinder blocks
US4981168A (en) * 1989-07-11 1991-01-01 Farley, Inc. Mandrel holds expendable core in casting die
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US5954113A (en) * 1995-08-28 1999-09-21 Eisenwerk Bruehl Gmbh Method for producing light metal castings and casting mold for carrying out the method
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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014048066A1 (en) * 2012-09-27 2014-04-03 He Bingxiang New pouring process for a core/mold package of automobile engine castings
US10850321B2 (en) 2014-07-09 2020-12-01 Nemak, S.A.B. De C.V. Foundry core, use of a foundry core, and method for producing a foundry core
CN104826986A (zh) * 2015-04-20 2015-08-12 鞍山千钢机械制造有限公司 防止砂型铸造铸件粘砂的方法及砂型预制件
CN108262449A (zh) * 2018-03-06 2018-07-10 溧阳市联华机械制造有限公司 一种热芯盒制作石墨成型冷铁的方法
CN108326264A (zh) * 2018-03-06 2018-07-27 溧阳市联华机械制造有限公司 一种冷芯盒制作石墨成型冷铁的方法
CN114833311A (zh) * 2021-02-01 2022-08-02 通用汽车环球科技运作有限责任公司 用于铸铝缸体的具有金属冷铁的混合凸轮孔砂芯

Also Published As

Publication number Publication date
EP2091678B1 (de) 2015-05-13
RU2432223C2 (ru) 2011-10-27
RU2009122220A (ru) 2010-12-20
JP2010509070A (ja) 2010-03-25
WO2008055973A1 (de) 2008-05-15
DE102006053404A1 (de) 2008-05-15
CN101547760A (zh) 2009-09-30
MX2009004733A (es) 2009-06-22
PL2091678T3 (pl) 2015-10-30
DE202007018797U1 (de) 2009-04-23
EP2091678A1 (de) 2009-08-26
CN101547760B (zh) 2013-04-10
KR20090077949A (ko) 2009-07-16

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