US20160045951A1 - Sand-mold molding method and sand-mold molding apparatus - Google Patents
Sand-mold molding method and sand-mold molding apparatus Download PDFInfo
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- US20160045951A1 US20160045951A1 US14/780,116 US201414780116A US2016045951A1 US 20160045951 A1 US20160045951 A1 US 20160045951A1 US 201414780116 A US201414780116 A US 201414780116A US 2016045951 A1 US2016045951 A1 US 2016045951A1
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- Prior art keywords
- mold
- sand
- metallic
- metallic mold
- cavity
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- 238000000465 moulding Methods 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims description 10
- 239000004576 sand Substances 0.000 claims abstract description 90
- 238000010438 heat treatment Methods 0.000 claims abstract description 30
- 238000012856 packing Methods 0.000 claims abstract description 21
- 239000011230 binding agent Substances 0.000 claims abstract description 14
- 238000003756 stirring Methods 0.000 claims abstract description 7
- 238000004519 manufacturing process Methods 0.000 claims abstract 2
- 238000007599 discharging Methods 0.000 claims description 4
- 239000012530 fluid Substances 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 23
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 9
- 235000019353 potassium silicate Nutrition 0.000 description 8
- 239000004094 surface-active agent Substances 0.000 description 4
- 238000005266 casting Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 238000013022 venting Methods 0.000 description 3
- 239000003232 water-soluble binding agent Substances 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/06—Core boxes
- B22C7/065—Venting means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
- B22C15/02—Compacting by pressing devices only
- B22C15/08—Compacting by pressing devices only involving pneumatic or hydraulic mechanisms
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C19/00—Components or accessories for moulding machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
Definitions
- the present invention relates to a sand-mold molding method and a sand-mold molding apparatus in which a foamed sand is packed into a metallic mold and solidified to mold a sand mold such as a sand core.
- a collapsible sand core (sand mold) is used for forming a hollow part such as a water jacket, an intake and exhaust port, or the like.
- the sand core is formed into a predetermined shape by, for example, blowing a shell sand coated with a thermoplastic resin into a metallic mold by compressed air from a nozzle of a sand blowing device to pack the shell sand into a cavity and then heating and solidifying it.
- a sand mold such as a core using foamed sand that is foamed by stirring water and an water-soluble binder with an aggregate.
- foamed sand when the foamed sand is molded by packing it into a cavity of a metallic mold, the internal pressure of the cavity increases due to evaporation of moisture and thermal expansion of air bubbles during the course of heating and hardening (baking) of the foamed sand.
- the water-soluble binder and the aggregate accumulate to form a dense hardened layer with high strength in a surface layer part, while a fragile brittle part with low density is formed in an inner part. Therefore, a core molded by foamed sand can ensure sufficient strength as a core during casting, and exhibits excellent collapsibility such that it can be easily removed from the casted article after casting.
- JP 2002 - 192305 A discloses providing gas venting holes to a metallic mold so as to discharge from the cavity of the metallic mold any gas that is produced when baking shell sand in the cavity of the metallic mold.
- the following problems may occur when molding a sand mold using foamed sand.
- the present invention was created in consideration of the above-described problems, and an object thereof is to shorten a hardening time by smoothly discharging water vapor and gas from within the cavity when heating and hardening foamed sand within a cavity of a metallic mold.
- the present invention provides a sand-mold molding method in which a molded article is obtained by packing foamed sand, which has been foamed by stirring a binder with an aggregate, into a cavity of a metallic mold and then heating and solidifying the foamed sand, wherein, after forming the cavity by clamping the metallic mold and packing the foamed sand into the cavity, the metallic mold is opened slightly to provide a gap in the metallic mold while maintaining the cavity.
- a sand-mold molding method in which a molded article is obtained by packing foamed sand, which has been foamed by stirring a binder with an aggregate, into a cavity of a metallic mold and then heating and solidifying the foamed sand, wherein, after forming the cavity by clamping the metallic mold and packing the foamed sand into the cavity, the metallic mold is opened slightly to provide a gap in the metallic mold while maintaining the cavity.
- a sand-mold molding apparatus including: a metallic mold in which a cavity is formed by mold clamping; a mold clamping device that opens/closes the metallic mold; a packing device that packs a foamed sand, which has been foamed by stirring a binder with an aggregate, into the cavity; and a heating device that heats the foamed sand within the cavity, wherein the mold clamping device slightly opens the metallic mold after the foamed sand has been packed into the cavity so as to form a gap in the metallic mold while maintaining the cavity.
- the gap in the metallic mold can be adjusted according to a counterforce from the metallic mold.
- the gap can be optimized to carry out preferable molding.
- water vapor and gas can be smoothly discharged from within the cavity through a gap in the metallic mold during heating and hardening of foamed sand within a cavity of a metallic mold, and thereby the hardening time can be shortened.
- FIG. 1 is a schematic view illustrating a sand-mold molding apparatus according to an embodiment of the present invention
- FIGS. 2A to 2C illustrate the steps for molding foamed sand with the sand-mold molding apparatus shown in FIG. 1 ;
- FIG. 3 is a table illustrating the relationship between a mold clamping set pressure and a gap in a metallic mold in the sand-mold molding apparatus shown in FIG. 1 ;
- FIG. 4 is a graph illustrating the relationship between a mold clamping set pressure and a gap in a metallic mold in the sand-mold molding apparatus shown in FIG. 1 ;
- FIG. 5 is a table illustrating the relationship between a mold clamping set pressure and the quality of a molded article in the sand-mold molding apparatus shown in FIG. 1 ;
- FIGS. 6A and 6B are image views illustrating a composition of foamed sand.
- FIGS. 7A and 7B are explanatory views illustrating the course of heating and hardening of foamed sand within a cavity of a metallic mold.
- a sand-mold molding apparatus 1 solidifies foamed sand to mold a sand core (sand mold), and includes a metallic mold 2 that forms a cavity C, a packing device 3 for packing foamed sand S into the cavity C of the metallic mold 2 , and a mold clamping device 4 that opens and closes the metallic mold 2 .
- the foamed sand S used in the present embodiment is obtained by mixing and kneading sand, which serves as an aggregate, with an water-soluble inorganic binder including water glass (sodium silicate), water, and a surfactant to foam the sand.
- An image of the state of the particles that constitute the foamed sand S is shown in FIGS. 6A and 6B .
- FIG. 6A illustrates a state in which bubbles 8 are adsorbed to the surface of a sand particle 7
- FIG. 6B illustrates an enlarged portion of a bubble 8 .
- FIG. 6A illustrates a state in which bubbles 8 are adsorbed to the surface of a sand particle 7
- FIG. 6B illustrates an enlarged portion of a bubble 8 .
- the foamed sand S is foamed by coating the surface of a water glass aqueous solution ( 10 denotes water and 11 denotes water glass) with a surfactant 9 to form bubbles 8 and then adsorbing the bubbles 8 to the surface of a sand particle 7 via the surfactant 9 , and the foamed sand S has suitable viscosity.
- a water glass aqueous solution 10 denotes water and 11 denotes water glass
- the foamed sand S having suitable viscosity can be obtained by setting the molar ratio and weight ratio of the water glass relative to the sand to approximately 1.0 to 3.0 and 0.4 to 3.0% respectively, setting the weight ratio of the water relative to the sand to approximately 1.5 to 5.0%, and setting the weight ratio of the surfactant relative to the sand to approximately 0.003 to 2.0%.
- the metallic mold 2 includes a stationary mold 12 and a movable mold 13 that are divided by a parting line P.
- a cavity C is formed by clamping the stationary mold 12 and the movable mold 13 .
- the stationary mold 12 is fixed to a stationary base 14 .
- the movable mold 13 is fixed to a movable base 15 that is movable, and the movable mold 13 moves together with the movable base 15 to open and close the metallic mold 2 .
- the stationary mold 12 and the movable mold 13 are heated to approximately 150° C. to 300° C. by a heating device H such as a heater, and thereby moisture of the foamed sand S packed into the cavity C is evaporated to solidify the foamed sand S.
- discharge passages such as slits 16 for discharging gas and water vapor to the outside during heating and hardening of the foamed sand S may be provided within the cavity C.
- a releasing device 17 is provided to each of the stationary mold 12 and the movable mold 13 of the metallic mold 2 .
- Each releasing device 17 includes a plurality of extruding pins 18 provided such that they can move towards/away from the inside of the cavity C, an extruding plate 19 connected to the bases of the plurality of extruding pins 18 , and an extruding spring 20 provided between the fixed base 14 /movable base 15 and the extruding plate 19 .
- the plurality of extruding pins 18 are compressed via the extruding plate 19 by the spring force of the extruding spring 20 to make the distal ends of the extruding pins 18 protrude into the cavity C.
- Refracting pins 21 whose distal ends oppose each other are attached to the extruding plates 19 on both sides.
- the distal ends of the retracting pins 21 abut each other to move the extruding plates 19 counter to the spring force of the extruding springs 20 , which causes the extruding pins 18 to retract from the cavity C.
- the extruding pins 18 move together with the opening/closing of the metallic mold 2 , such that they retract from within the cavity C when the metallic mold 2 is closed, and protrude into the cavity C when the metallic mold 2 is opened to release the molded core.
- the packing device 3 includes a sand tank 22 in which the foamed sand S is kneaded and stored, a pressurization mechanism 23 that pressurizes the foamed sand S within the sand tank 22 , and a packing port 24 that connects the sand tank 22 to the cavity C of the metallic mold 2 .
- the sand tank 22 is set onto the metallic mold 2 upon closing and clamping the stationary mold 12 and the movable mold 13 , and by pressurizing the foamed sand S within the sand tank 22 by the pressurization mechanism 23 , the foamed sand S is packed into the cavity C of the metallic mold 2 through the packing port 24 .
- the mold clamping device 4 includes a double-acting air cylinder 26 that drives the movable base 15 , an air source 27 that supplies compressed air to the air cylinder 26 , a switching valve 28 that switches the supply of compressed air from the air source 27 to the air cylinder 26 to make the movable base 15 advance forward or retract backward, a pressure adjusting valve 29 that adjusts the pressure of the compressed air to be supplied to the air cylinder, a pressure gauge 30 that detects the pressure of the compressed air supplied to the air cylinder 26 , and a control device 31 that controls the operation of the switching valve 28 and the pressure adjusting valve 29 .
- the control device 31 controls the switching valve 28 to switch the supply of compressed air so as to elongate/retract an activation rod 26 A of the double-acting air cylinder 26 .
- the movable mold 13 is made to advance/retract together with the movable base 15 to open/close the metallic mold 2 .
- the pressure adjusting valve 29 is operated based on a detected pressure of the pressure gauge 30 during mold clamping to adjust the pressure of the compressed air to be supplied to the air cylinder 26 , and thereby the mold clamping force is adjusted.
- the movable mold 13 is driven by the mold clamping device 4 to close and clamp the metallic mold 2 to form the cavity C, and then the packing device 3 is set onto the metallic mold 2 .
- the extruding pins 18 of the releasing devices 17 move together with the mold clamping so as to retract from the cavity C as explained above.
- the pressurization mechanism 23 of the packing device 3 is operated to pack the foamed sand S within the sand tank 22 into the cavity C of the heated metallic mold 2 through the packing port 24 .
- FIG. 2B illustrates a state in which the packing of the foamed sand S into the cavity C has been completed. The foamed sand S that has been packed into the cavity C of the metallic mold 2 is then hardened by evaporating the moisture therein via heating.
- FIGS. 7A and 7B the course of heating and hardening the foamed sand S packed into the cavity C will now be explained referring to FIGS. 7A and 7B .
- FIG. 7A in the cavity C of the metallic mold 2 , the air bubbles 8 of the foamed sand S expand due to heating, leading to an increase in the internal pressure of the cavity C.
- FIG. 7B the air bubbles 8 move along the inner wall of the cavity C of the metallic mold 2 and are discharged to the outside via the passages formed by the slits 16 or the like that are provided on the parting line P.
- the pressure adjusting valve 29 is operated by the control device 31 of the mold clamping device 4 based on the detected pressure of the pressure gauge 30 to reduce the pressure of the compressed air supplied to the air cylinder 26 by a predetermined pressure so as to decrease the mold clamping force.
- the movable mold 13 retracts slightly due to the pressure within the cavity C that has increased due to heating and hardening of the foamed sand S, the spring force of the extruding springs 20 of the releasing devices 17 , and a counterforce by warping of the metallic mold 2 .
- a fine gap L is formed on the parting line P between the stationary mold 12 and the movable mold 13 .
- Gas and water vapor that are generated during heating and hardening of the foamed sand S within the cavity C of the metallic mold 2 is smoothly discharged to the outside through the fine gap L.
- solidification of the foamed sand S can be accelerated, and the baking time can be shortened.
- the fine gap L is a slight gap of a size such that gas and water vapor can be smoothly discharged, and the amount of movement of the movable mold 13 is also small.
- the shape and dimensions of the cavity C are maintained, and the shape and dimensional precision of the core that is molded is not affected.
- the movable mold 13 is moved slightly by the pressure within the cavity C, the spring force of the extruding springs 20 of the releasing devices 17 , and a counterforce by warping of the metallic mold 2 to form the fine gap L between the stationary mold 12 and the movable mold 13 , a constant fine gap L can be secured regardless of the amount of accumulation of binder on the parting line P or the slits 16 in the metallic mold 2 .
- gas and water vapor that are generated during heating and hardening of the foamed sand S can be reliably discharged to the outside, and thus the baking time can be shortened and a molded article of good quality can be obtained.
- the switching valve 28 is operated by the control device 31 to switch the supply of compressed air to the double-acting air cylinder 26 and make the movable mold 13 retract together with the movable base 15 so as to open the metallic mold 2 and remove the molded sand core.
- the distal ends of the retracting pins 21 of the releasing devices 17 separate from each other together with the mold opening, and thus the extruding plates 19 move by the spring force of the extruding springs 20 and the extruding pins 18 protrude into the cavity C to release the molded sand core.
- the pressure of compressed air supplied to the air cylinder 26 of the mold clamping device 4 (the mold clamping force) is reduced to form the gap L between the stationary mold 12 and the movable mold 13 by warping in the metallic mold 2 .
- a predetermined gap L can also be formed by directly controlling the amount of movement of the movable mold 13 .
Abstract
A sand-mold molding method for producing a molded article obtained by packing foamed sand may include stirring a binder with an aggregate to form foamed sand; forming a cavity via clamping a metallic mold closed; packing the foamed sand into the cavity of the metallic mold and then heating and solidifying the foamed sand; and opening the metallic mold partially to provide a gap in the metallic mold while maintaining the cavity.
Description
- This application claims priority to Japanese Patent Application No. 2013-066335, filed Mar. 27, 2013, and International Patent Application No. PCT/JP2014/051273, filed Jan. 22, 2014, both of which are hereby incorporated by reference in their entirety.
- The present invention relates to a sand-mold molding method and a sand-mold molding apparatus in which a foamed sand is packed into a metallic mold and solidified to mold a sand mold such as a sand core.
- When casting a cylinder block, a cylinder head, or the like of an engine, a collapsible sand core (sand mold) is used for forming a hollow part such as a water jacket, an intake and exhaust port, or the like. The sand core is formed into a predetermined shape by, for example, blowing a shell sand coated with a thermoplastic resin into a metallic mold by compressed air from a nozzle of a sand blowing device to pack the shell sand into a cavity and then heating and solidifying it.
- In contrast, there is a technology for molding a sand mold such as a core using foamed sand that is foamed by stirring water and an water-soluble binder with an aggregate. In this way, when the foamed sand is molded by packing it into a cavity of a metallic mold, the internal pressure of the cavity increases due to evaporation of moisture and thermal expansion of air bubbles during the course of heating and hardening (baking) of the foamed sand. Thus, in the molded article, the water-soluble binder and the aggregate accumulate to form a dense hardened layer with high strength in a surface layer part, while a fragile brittle part with low density is formed in an inner part. Therefore, a core molded by foamed sand can ensure sufficient strength as a core during casting, and exhibits excellent collapsibility such that it can be easily removed from the casted article after casting.
- When heating and hardening foamed sand within a metallic mold, water vapor and gas are produced, and thus it is necessary to smoothly discharge such water vapor and gas to the outside of the cavity of the metallic mold. Thus, slits or passages for discharging water vapor and gas are provided in metallic molds used for molding foamed sand. Also, although not in relation to foamed sand, JP 2002-192305 A discloses providing gas venting holes to a metallic mold so as to discharge from the cavity of the metallic mold any gas that is produced when baking shell sand in the cavity of the metallic mold.
- Literature 1: JP 2002-192305 A
- The following problems may occur when molding a sand mold using foamed sand.
- In order to shorten the heating and hardening time (baking time) of foamed sand, how quickly water vapor can be discharged from the cavity of the metallic mold is important. However, since the water-soluble binder flows out together with water vapor and gas from the slits or passages for gas venting during the course of heating and hardening the foamed sand, solidified binder may accumulate on the slits or passages for gas venting due to repeated moldings, and this may obstruct the discharge of water vapor and gas. Thus, there has been a problem in that the baking of the foamed sand may require more time if the smooth discharge of water vapor and gas becomes obstructed.
- The present invention was created in consideration of the above-described problems, and an object thereof is to shorten a hardening time by smoothly discharging water vapor and gas from within the cavity when heating and hardening foamed sand within a cavity of a metallic mold.
- To solve the above-described problems, the present invention provides a sand-mold molding method in which a molded article is obtained by packing foamed sand, which has been foamed by stirring a binder with an aggregate, into a cavity of a metallic mold and then heating and solidifying the foamed sand, wherein, after forming the cavity by clamping the metallic mold and packing the foamed sand into the cavity, the metallic mold is opened slightly to provide a gap in the metallic mold while maintaining the cavity.
- Hereinafter, several examples of embodiments of the invention for which it is recognized that a patent claim is possible in the present invention (may also be referred to as “claimable inventions” below) are described below. The embodiments below are divided into aspects similar to the claims, and each aspect is assigned a number and described in a format where other aspect numbers may be cited as necessary. This division into aspects is for facilitating the understanding of the claimable inventions, and the combinations of components that constitute the claimable inventions are not limited to those described below in the following aspects. In other words, the claimable inventions should be interpreted upon referring to the descriptions in each aspect below and the descriptions of any examples and the like. As long as it is in line with such interpretations, the claimable inventions may include embodiments in which further components are added to the embodiments of each aspect or components are deleted from the embodiments of each aspect. The contents of (1) to (6) below correspond to various aspects of the disclosure.
- (1) A sand-mold molding method in which a molded article is obtained by packing foamed sand, which has been foamed by stirring a binder with an aggregate, into a cavity of a metallic mold and then heating and solidifying the foamed sand, wherein, after forming the cavity by clamping the metallic mold and packing the foamed sand into the cavity, the metallic mold is opened slightly to provide a gap in the metallic mold while maintaining the cavity.
- (2) The sand-mold molding method according to (1), wherein a mold clamping force of the metallic mold is reduced so that the gap is provided in the metallic mold by a counterforce from the metallic mold.
- (3) The sand-mold molding method according to (1) or (2), wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
- (4) A sand-mold molding apparatus including: a metallic mold in which a cavity is formed by mold clamping; a mold clamping device that opens/closes the metallic mold; a packing device that packs a foamed sand, which has been foamed by stirring a binder with an aggregate, into the cavity; and a heating device that heats the foamed sand within the cavity, wherein the mold clamping device slightly opens the metallic mold after the foamed sand has been packed into the cavity so as to form a gap in the metallic mold while maintaining the cavity.
- (5) The sand-mold molding apparatus according to (4), wherein the mold clamping device reduces a mold clamping force so that the gap is provided in the metallic mold by a counterforce from the metallic mold.
- (6) The sand-mold molding apparatus according to (4) or (5), wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
- With the structure of (1) and (4), by providing a fine gap in the metallic mold, water vapor and gas are smoothly discharged to the outside from the gap in the metallic mold during heating and hardening of the foamed sand within the cavity of the metallic mold, and thus the hardening time can be shortened.
- Even if solidified binder accumulates in a passage through which water vapor and gas are discharged from the cavity of the metallic mold, the water vapor and gas can be reliably discharged to the outside from the cavity by the gap in the metallic mold.
- At this time, since the gap in the metallic mold is sufficiently small and the shape and dimensions of the cavity are maintained, the dimensional precision of the molded article is not affected.
- With the structure of (2) and (5), the gap in the metallic mold can be adjusted according to a counterforce from the metallic mold.
- With the structure of (3) and (6), the gap can be optimized to carry out preferable molding.
- (7) The sand-mold molding apparatus of (5) or (6), in which the mold clamping device clamps the metallic mold by an air cylinder and reduces a pressure of compressed air supplied to the air cylinder so as to reduce a mold clamping force.
- According to the present invention, water vapor and gas can be smoothly discharged from within the cavity through a gap in the metallic mold during heating and hardening of foamed sand within a cavity of a metallic mold, and thereby the hardening time can be shortened.
-
FIG. 1 is a schematic view illustrating a sand-mold molding apparatus according to an embodiment of the present invention; -
FIGS. 2A to 2C illustrate the steps for molding foamed sand with the sand-mold molding apparatus shown inFIG. 1 ; -
FIG. 3 is a table illustrating the relationship between a mold clamping set pressure and a gap in a metallic mold in the sand-mold molding apparatus shown inFIG. 1 ; -
FIG. 4 is a graph illustrating the relationship between a mold clamping set pressure and a gap in a metallic mold in the sand-mold molding apparatus shown inFIG. 1 ; -
FIG. 5 is a table illustrating the relationship between a mold clamping set pressure and the quality of a molded article in the sand-mold molding apparatus shown inFIG. 1 ; -
FIGS. 6A and 6B are image views illustrating a composition of foamed sand; and -
FIGS. 7A and 7B are explanatory views illustrating the course of heating and hardening of foamed sand within a cavity of a metallic mold. - An embodiment of the present invention will now be explained below in detail based on the drawings.
- As shown in
FIG. 1 , a sand-mold molding apparatus 1 according to the present embodiment solidifies foamed sand to mold a sand core (sand mold), and includes ametallic mold 2 that forms a cavity C, apacking device 3 for packing foamed sand S into the cavity C of themetallic mold 2, and amold clamping device 4 that opens and closes themetallic mold 2. - The foamed sand S used in the present embodiment is obtained by mixing and kneading sand, which serves as an aggregate, with an water-soluble inorganic binder including water glass (sodium silicate), water, and a surfactant to foam the sand. An image of the state of the particles that constitute the foamed sand S is shown in
FIGS. 6A and 6B .FIG. 6A illustrates a state in whichbubbles 8 are adsorbed to the surface of asand particle 7, andFIG. 6B illustrates an enlarged portion of abubble 8. As shown inFIG. 6B , the foamed sand S is foamed by coating the surface of a water glass aqueous solution (10 denotes water and 11 denotes water glass) with asurfactant 9 to formbubbles 8 and then adsorbing thebubbles 8 to the surface of asand particle 7 via thesurfactant 9, and the foamed sand S has suitable viscosity. Herein, the foamed sand S having suitable viscosity can be obtained by setting the molar ratio and weight ratio of the water glass relative to the sand to approximately 1.0 to 3.0 and 0.4 to 3.0% respectively, setting the weight ratio of the water relative to the sand to approximately 1.5 to 5.0%, and setting the weight ratio of the surfactant relative to the sand to approximately 0.003 to 2.0%. - Referring to
FIG. 1 , themetallic mold 2 includes astationary mold 12 and amovable mold 13 that are divided by a parting line P. A cavity C is formed by clamping thestationary mold 12 and themovable mold 13. Thestationary mold 12 is fixed to astationary base 14. Themovable mold 13 is fixed to amovable base 15 that is movable, and themovable mold 13 moves together with themovable base 15 to open and close themetallic mold 2. Thestationary mold 12 and themovable mold 13 are heated to approximately 150° C. to 300° C. by a heating device H such as a heater, and thereby moisture of the foamed sand S packed into the cavity C is evaporated to solidify the foamed sand S. In themetallic mold 2, discharge passages such asslits 16 for discharging gas and water vapor to the outside during heating and hardening of the foamed sand S may be provided within the cavity C. - A releasing
device 17 is provided to each of thestationary mold 12 and themovable mold 13 of themetallic mold 2. Each releasingdevice 17 includes a plurality of extrudingpins 18 provided such that they can move towards/away from the inside of the cavity C, an extrudingplate 19 connected to the bases of the plurality of extrudingpins 18, and an extrudingspring 20 provided between the fixedbase 14/movable base 15 and the extrudingplate 19. The plurality of extrudingpins 18 are compressed via the extrudingplate 19 by the spring force of the extrudingspring 20 to make the distal ends of the extruding pins 18 protrude into the cavity C. Refracting pins 21 whose distal ends oppose each other are attached to the extrudingplates 19 on both sides. When thestationary mold 12 and themovable mold 13 are closed, the distal ends of the retracting pins 21 abut each other to move the extrudingplates 19 counter to the spring force of the extruding springs 20, which causes the extruding pins 18 to retract from the cavity C. Thereby, the extruding pins 18 move together with the opening/closing of themetallic mold 2, such that they retract from within the cavity C when themetallic mold 2 is closed, and protrude into the cavity C when themetallic mold 2 is opened to release the molded core. - The
packing device 3 includes asand tank 22 in which the foamed sand S is kneaded and stored, apressurization mechanism 23 that pressurizes the foamed sand S within thesand tank 22, and a packingport 24 that connects thesand tank 22 to the cavity C of themetallic mold 2. Thesand tank 22 is set onto themetallic mold 2 upon closing and clamping thestationary mold 12 and themovable mold 13, and by pressurizing the foamed sand S within thesand tank 22 by thepressurization mechanism 23, the foamed sand S is packed into the cavity C of themetallic mold 2 through the packingport 24. - The
mold clamping device 4 includes a double-actingair cylinder 26 that drives themovable base 15, anair source 27 that supplies compressed air to theair cylinder 26, a switchingvalve 28 that switches the supply of compressed air from theair source 27 to theair cylinder 26 to make themovable base 15 advance forward or retract backward, apressure adjusting valve 29 that adjusts the pressure of the compressed air to be supplied to the air cylinder, apressure gauge 30 that detects the pressure of the compressed air supplied to theair cylinder 26, and acontrol device 31 that controls the operation of the switchingvalve 28 and thepressure adjusting valve 29. - The
control device 31 controls the switchingvalve 28 to switch the supply of compressed air so as to elongate/retract anactivation rod 26A of the double-actingair cylinder 26. Thereby, themovable mold 13 is made to advance/retract together with themovable base 15 to open/close themetallic mold 2. Thepressure adjusting valve 29 is operated based on a detected pressure of thepressure gauge 30 during mold clamping to adjust the pressure of the compressed air to be supplied to theair cylinder 26, and thereby the mold clamping force is adjusted. Thereby, when heating and hardening the foamed sand S within the cavity C of themetallic mold 2, if the mold clamping force by theair cylinder 26 is decreased, themovable mold 13 will retract slightly due to the pressure within the cavity C, the spring force of the extruding springs 20 of the releasingdevices 17, and a counterforce by warping of themetallic mold 2. Thus, a fine gap L (refer toFIG. 2C ) is formed on the parting line P between thestationary mold 12 and themovable mold 13, and this gap L can be adjusted. - Next, the steps for molding a sand core with the sand-mold molding apparatus 1 will be explained.
- As shown in
FIG. 2A , themovable mold 13 is driven by themold clamping device 4 to close and clamp themetallic mold 2 to form the cavity C, and then thepacking device 3 is set onto themetallic mold 2. At this time, the extruding pins 18 of the releasingdevices 17 move together with the mold clamping so as to retract from the cavity C as explained above. In a state in which themetallic mold 2 has been preheated by the heating device H, thepressurization mechanism 23 of thepacking device 3 is operated to pack the foamed sand S within thesand tank 22 into the cavity C of the heatedmetallic mold 2 through the packingport 24.FIG. 2B illustrates a state in which the packing of the foamed sand S into the cavity C has been completed. The foamed sand S that has been packed into the cavity C of themetallic mold 2 is then hardened by evaporating the moisture therein via heating. - Herein, the course of heating and hardening the foamed sand S packed into the cavity C will now be explained referring to
FIGS. 7A and 7B . As shown inFIG. 7A , in the cavity C of themetallic mold 2, the air bubbles 8 of the foamed sand S expand due to heating, leading to an increase in the internal pressure of the cavity C. As shown inFIG. 7B , the air bubbles 8 move along the inner wall of the cavity C of themetallic mold 2 and are discharged to the outside via the passages formed by theslits 16 or the like that are provided on the parting line P. At this time, the water glass (binder) and aggregate that constitute the foamed sand S are pushed towards the inner wall side of the cavity C, and thus the density of water glass and aggregate near the inner wall of the cavity C increases. As a result, in a sand core W that has solidified within the cavity C, a densehardened layer 33 in which the density of the water glass and the aggregate is high is formed in a surface layer part that is in contact with the inner wall of the cavity C, whereas the inner density is low such that an easily-collapsiblebrittle part 34 is formed in a center part. - The water glass (binder) that is pushed toward the inner wall side of the cavity C penetrates into the passages consisting of the
slits 16 or the like together with the water vapor and gas and is released to the outside. Binder that has penetrated into the passages may harden and adhere to the passages. If the passages become blocked due to accumulation of binder that adheres to the passages, the smooth discharge of water vapor and gas may become obstructed, leading to an increase in the baking time and poor molding. - In the present embodiment, after completion of packing of the foamed sand S into the cavity C of the
metallic mold 2, thepressure adjusting valve 29 is operated by thecontrol device 31 of themold clamping device 4 based on the detected pressure of thepressure gauge 30 to reduce the pressure of the compressed air supplied to theair cylinder 26 by a predetermined pressure so as to decrease the mold clamping force. Thereby, as shown inFIG. 2C , themovable mold 13 retracts slightly due to the pressure within the cavity C that has increased due to heating and hardening of the foamed sand S, the spring force of the extruding springs 20 of the releasingdevices 17, and a counterforce by warping of themetallic mold 2. Thus, a fine gap L is formed on the parting line P between thestationary mold 12 and themovable mold 13. Gas and water vapor that are generated during heating and hardening of the foamed sand S within the cavity C of themetallic mold 2 is smoothly discharged to the outside through the fine gap L. As a result, solidification of the foamed sand S can be accelerated, and the baking time can be shortened. - At this time, the fine gap L is a slight gap of a size such that gas and water vapor can be smoothly discharged, and the amount of movement of the
movable mold 13 is also small. Thus, the shape and dimensions of the cavity C are maintained, and the shape and dimensional precision of the core that is molded is not affected. Also, since themovable mold 13 is moved slightly by the pressure within the cavity C, the spring force of the extruding springs 20 of the releasingdevices 17, and a counterforce by warping of themetallic mold 2 to form the fine gap L between thestationary mold 12 and themovable mold 13, a constant fine gap L can be secured regardless of the amount of accumulation of binder on the parting line P or theslits 16 in themetallic mold 2. As a result, gas and water vapor that are generated during heating and hardening of the foamed sand S can be reliably discharged to the outside, and thus the baking time can be shortened and a molded article of good quality can be obtained. - After the foamed sand S within the cavity C of the
metallic mold 2 has solidified, the switchingvalve 28 is operated by thecontrol device 31 to switch the supply of compressed air to the double-actingair cylinder 26 and make themovable mold 13 retract together with themovable base 15 so as to open themetallic mold 2 and remove the molded sand core. At this time, the distal ends of the retracting pins 21 of the releasingdevices 17 separate from each other together with the mold opening, and thus the extrudingplates 19 move by the spring force of the extruding springs 20 and the extruding pins 18 protrude into the cavity C to release the molded sand core. - Next, in the above-described steps, the relationships between the pressure of the compressed air supplied to the
air cylinder 26 when forming the gap L on the parting line P in the metallic mold 2 (refer toFIG. 2C ) with the size of the gap L and with the quality of the sand core that is molded will be explained referring toFIGS. 3 to 5 . - As shown in
FIGS. 3 and 4 , by reducing the pressure of the compressed air supplied to theair cylinder 26 during mold clamping from a pressure of 0.35 MPa to a pressure of 0.15 MPa, 0.10 MPa, and 0.05 Mpa, the gap L became on average 0.22 mm, 0.25 mm, and 0.36 mm respectively. Thereby, as shown inFIG. 5 , when the pressure of the compressed air that is supplied was kept unchanged at 0.35 MPa during mold clamping so that no gap L is provided, 60% of the molded articles were of good quality and 40% were of poor quality, whereas when the pressure of the compressed air that is supplied was reduced to 0.10 MPa so that the gap L is provided, 80% of the molded articles were of good quality and 20% were of poor quality. When the pressure of the compressed air that is supplied was further reduced to 0.05 MPa so as to increase the gap L, 100% good quality could be obtained. - In the above-described embodiment, the pressure of compressed air supplied to the
air cylinder 26 of the mold clamping device 4 (the mold clamping force) is reduced to form the gap L between thestationary mold 12 and themovable mold 13 by warping in themetallic mold 2. However, a predetermined gap L can also be formed by directly controlling the amount of movement of themovable mold 13. - 1: Sand-mold Molding Apparatus 2: Metallic Mold C: Cavity H: Heating Device L: Gap S: Foamed Sand
Claims (20)
1. A sand-mold molding method for producing a molded article obtained by packing foamed sand, comprising:
stirring a binder with an aggregate to form foamed sand;
forming a cavity via clamping a metallic mold closed;
packing the foamed sand into the cavity of the metallic mold and then heating and solidifying the foamed sand; and
opening the metallic mold partially to provide a gap in the metallic mold while maintaining the cavity.
2. The sand-mold molding method according to claim 1 , wherein opening the metallic mold further includes reducing a mold clamping force of the metallic mold so that the gap is provided in the metallic mold by a counterforce from the metallic mold.
3. The sand-mold molding method according to claim 1 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
4. A sand-mold molding apparatus comprising:
a metallic mold defining a cavity via clamping the metallic mold closed;
a mold clamping device configured to open and close the metallic mold;
a packing device configured to pack a foamed sand into the cavity, wherein the foamed sand is foamed by stirring a binder with an aggregate; and
a heating device configured to heat the foamed sand within the cavity,
wherein the mold clamping device partially opens the metallic mold after the foamed sand has been packed into the cavity to define a gap in the metallic mold while maintaining the cavity.
5. The sand-mold molding apparatus according to claim 4 , wherein the mold clamping device reduces a mold clamping force so that the gap is provided in the metallic mold by a counterforce from the metallic mold.
6. The sand-mold molding apparatus according to claim 4 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
7. The sand-mold molding apparatus according to claim 5 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
8. The sand-mold molding apparatus according to claim 4 , wherein the metallic mold includes a stationary mold and a movable mold.
9. The sand-mold molding apparatus according to claim 8 , wherein the mold clamp device clamps and secures the stationary mold to the movable mold.
10. The sand-mold molding apparatus according to claim 8 , wherein the mold clamping device includes an air cylinder that drives the movable mold.
11. The sand-mold molding apparatus according to claim 10 , further comprising a switch valve configured to regulate a supply of air to the air cylinder.
12. The sand-mold molding apparatus according to claim 10 , wherein the air cylinder includes a reciprocating rod driven by an air supply.
13. The sand-mold molding apparatus according to claim 8 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
14. The sand-mold molding apparatus according to claim 8 , wherein the mold clamping device reduces a mold clamping force so that the gap is provided in the metallic mold by a counterforce from the metallic mold.
15. The sand-mold molding apparatus according to claim 14 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
16. The sand-mold molding apparatus according to claim 15 , wherein the heating device heats the metallic mold to a temperature ranging from 150° C. to 300° C.
17. The sand-mold molding apparatus according to claim 4 , wherein the metallic mold includes at least one discharge passage for discharging fluid from the cavity.
18. The sand-mold molding apparatus according to claim 4 , wherein the heating device heats the metallic mold to a temperature ranging from 150° C. to 300° C.
19. The sand-mold molding method according to claim 1 , wherein heating and solidifying the foamed sand includes heating the metallic mold to a temperature ranging from 150° C. to 300° C.
20. The sand-mold molding method according to claim 2 , wherein the gap in the metallic mold ranges from 0.22 mm to 0.36 mm.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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JP2013-066335 | 2013-03-27 | ||
JP2013066335A JP2014188551A (en) | 2013-03-27 | 2013-03-27 | Sand type molding method and sand type molding device |
PCT/JP2014/051273 WO2014156246A1 (en) | 2013-03-27 | 2014-01-22 | Sand-mold molding method and sand-mold molding apparatus |
Publications (1)
Publication Number | Publication Date |
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US20160045951A1 true US20160045951A1 (en) | 2016-02-18 |
Family
ID=51623249
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US14/780,116 Abandoned US20160045951A1 (en) | 2013-03-27 | 2014-01-22 | Sand-mold molding method and sand-mold molding apparatus |
Country Status (6)
Country | Link |
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US (1) | US20160045951A1 (en) |
EP (1) | EP2979776A4 (en) |
JP (1) | JP2014188551A (en) |
CN (1) | CN104884188A (en) |
TW (1) | TW201440921A (en) |
WO (1) | WO2014156246A1 (en) |
Cited By (2)
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CN114700468A (en) * | 2022-04-01 | 2022-07-05 | 朱兴丰 | Automatic manufacturing equipment for composite sand mold for cast iron |
US11712114B2 (en) | 2019-06-21 | 2023-08-01 | Segos Co., Ltd. | Fixing assembly |
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CN105014007A (en) * | 2015-08-21 | 2015-11-04 | 广东富华铸锻有限公司 | Application method of roughing sand calcination technology to casting and sand core |
KR101712575B1 (en) * | 2015-10-02 | 2017-03-13 | 강길남 | Sand castings automated molding device |
JP6378157B2 (en) * | 2015-11-06 | 2018-08-22 | トヨタ自動車株式会社 | Foam sand manufacturing method and manufacturing apparatus thereof |
JP6396876B2 (en) * | 2015-11-06 | 2018-09-26 | トヨタ自動車株式会社 | Kneading sand filling method and filling device |
JP6733564B2 (en) * | 2017-01-24 | 2020-08-05 | 新東工業株式会社 | Mold making equipment |
JP6897538B2 (en) * | 2017-12-14 | 2021-06-30 | トヨタ自動車株式会社 | Core molding method and molding equipment |
JP6631654B2 (en) * | 2018-05-21 | 2020-01-15 | トヨタ自動車株式会社 | Core molding equipment |
JP2020131269A (en) * | 2019-02-25 | 2020-08-31 | トヨタ自動車株式会社 | Casting mold molding device |
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Also Published As
Publication number | Publication date |
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JP2014188551A (en) | 2014-10-06 |
WO2014156246A1 (en) | 2014-10-02 |
EP2979776A4 (en) | 2016-11-09 |
EP2979776A1 (en) | 2016-02-03 |
TW201440921A (en) | 2014-11-01 |
CN104884188A (en) | 2015-09-02 |
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