US20160361759A1 - Creation of slots on the surface of a core - Google Patents

Creation of slots on the surface of a core Download PDF

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Publication number
US20160361759A1
US20160361759A1 US15/121,359 US201515121359A US2016361759A1 US 20160361759 A1 US20160361759 A1 US 20160361759A1 US 201515121359 A US201515121359 A US 201515121359A US 2016361759 A1 US2016361759 A1 US 2016361759A1
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US
United States
Prior art keywords
core
slots
molding part
aluminium alloy
foundry
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
US15/121,359
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English (en)
Inventor
Vincent MORLOT
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.)
Montupet SA
Original Assignee
Montupet SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Montupet SA filed Critical Montupet SA
Assigned to MONTUPET S.A. reassignment MONTUPET S.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MORLOT, Vincent
Publication of US20160361759A1 publication Critical patent/US20160361759A1/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B22C9/106—Vented or reinforced cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B22C9/067—Venting means for moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/24—Cylinder heads
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00—Casings, e.g. crankcases or frames
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F2200/00—Manufacturing
    • F02F2200/06—Casting

Definitions

  • the present invention relates to the field of foundry and casting of foundry pieces in aluminium alloy.
  • the invention relates more particularly to a foundry core for casting pieces in aluminium alloy in a mold.
  • the relevant cores especially include a mixture of sand and binder.
  • the foundry core constitutes part of the mold serving to produce a piece made of metal and in particular aluminium alloy.
  • the core is generally composed of a mixture of grains of sand and binder.
  • the foundry core enables creation of internal recesses of a piece. It is therefore immersed fully or partly in the molten metal.
  • Another known attempt consists of adding contact forms between the core immersed in the liquid metal and the exterior of the mold. Evacuation of gases generated in the core can occur by these forms which serve as discharge chimneys.
  • This technique is widely used but requires different added operations restrictive on the cast pieces to replug the vacuums left by these forms: machining of the piece, adding one or more plugs to reclose the shape which enabled discharge and placing of a sealing control system.
  • This configuration is delicate to carry out and its configuration needs permanent control which constitutes a disadvantage per se.
  • this type of system must suction enough to avoid the problem of gas discharges but not suction too strongly to prevent suction of metal in the core.
  • the shape of the cores is often poorly adapted to their use. Their management and their maintenance represent complications of a technical and economic order.
  • the aim of the invention is to eliminate these limitations.
  • the invention proposes a foundry core for casting pieces of aluminium alloy in a mold, the core comprising a molding part, intended to be in contact with the molten metal, and at least one non-molding part, intended to be located outside the molten metal, the core comprising at least one slot on the surface of the core and the slot extending from the molding part to at least one non-molding part for discharge of the gases generated in the molding part of the core during casting outside the molding part.
  • the invention proposes a simplified alternative to techniques of the prior art by making slots on the surface of the cores. These slots create a space which discharges the gases generated in the core, and at the same time the slots are fine enough to prevent the aluminium alloy from entering within them. By drawing a preferred gas discharge path to the non-molding parts of the core, outside the molten metal (typically the core prints), these slots discharge gases which can be generated in the core without involving the disadvantages mentioned hereinabove.
  • the invention also proposes a mold adapted for casting foundry pieces, comprising a core such as described previously.
  • the mold can further comprise a suction system adapted to suction in the slots the generated gases, with suction occurring at the non-molding zones.
  • the invention also proposes a method for manufacturing a core such as described previously, characterized in that it comprises an etching step of said slots on the surface of the core by means of a laser.
  • the invention also proposes a method for manufacturing a piece of aluminium alloy by casting molten metal by means of a mold previously described.
  • the invention proposes a cylinder head for an automobile obtained by a method for manufacturing a piece previously described, as well as an engine block for an automobile.
  • FIG. 1 a shows a core as per the invention immersed in a molten aluminium alloy.
  • FIG. 1 b shows an enlargement of the core of FIG. 1 a.
  • FIG. 2 a illustrates a drawing in side elevation in section of a mold and a core such as defined in the invention, whereof the molding part is immersed in the molten metal.
  • FIG. 2 b illustrates the core of FIG. 2 a viewed from above, without the mold.
  • FIG. 3 a illustrates a more exact representation of a core as per the invention.
  • FIG. 3 b illustrates a sectional view along plane [AA′] of FIG. 3 a of the core such as defined in the invention.
  • FIG. 4 a illustrates different profiles of slots (not necessarily to scale).
  • FIG. 4 b illustrates different types of slots with the flashes of molten metal entering inside these slots (not necessarily to scale).
  • FIG. 5 illustrates a simplified drawing of a plan view of the surface of the core immersed in the molten metal, within a mold, with possible circulation (arrows) in the slots of the gases generated in the core.
  • FIG. 6 illustrates the evolution of gaseous discharge as a function of the number of slots.
  • FIGS. 1 a , 1 b , 2 a, 2 b, 3 a, 3 b a core 10 as per the invention is described.
  • the core 10 is adapted for casting foundry pieces in a mold 20 .
  • These cast foundry pieces are made of aluminium alloy and are typically intended for the automobile industry. These cast pieces are typically intended to be engine blocks or cylinder heads.
  • the core 10 comprises a molding part 11 which is intended to be in contact with the molten aluminium alloy 30 .
  • the core 10 also comprises a non-molding part 12 a, intended to be located outside the molten aluminium alloy 30 .
  • a core 10 comprises several non-molding parts 12 a separated especially by the molding part 11 .
  • the core 10 is placed inside the mold 20 and held there immobile by the core prints 12 b, which are generally non-molding parts 12 a (see FIG. 2 a ).
  • the mold 20 comprises a sole 21 which constitutes the bottom of the mold 20 , and at least one movable guillotine 22 which constitutes a side wall of the mold 20 when said guillotine 22 is closed.
  • the sole 21 and the guillotines 22 create the external shapes of the cast pieces.
  • the guillotines 22 are also adapted to immobilize the core 10 .
  • the core prints 12 b are in contact with said guillotines 22 for this purpose.
  • the core 10 comprises at least one slot 13 located on the surface of the core 10 .
  • the slot 13 extends from the molding part 11 to at least one non-molding part 12 a and produces a preferred discharge path of the generated gases to discharge the gases generated in the molding part 11 out of said molding part 11 and preferably then out of the non-molding parts 12 a (see FIGS. 2 a , 2 b , 3 a , 3 b ).
  • the main function of the slot 13 located on the surface of the core 10 , and which extends from the molding part 11 to at least one non-molding part 12 a, is to create a preferred discharge path of the gases generated to discharge the gases generated in the molding part 11 out of said molding part 11 .
  • These gases could be evacuated to a distance from the part of the core 10 which will effectively mold the piece to be made. They could accumulate at the non-molding parts 12 , or be evacuated out of these parts 12 if the slot 13 is put in contact with free air.
  • Each slot 13 consists of a groove which connects the molding part 11 to a non-molding part 12 a.
  • the slot 13 preferably connects the two non-molding parts 12 a by passing through the molding part 11 .
  • the profile of the slots 13 is preferably rectangular, in U-shape or V-shape. These forms offer a good compromise between the simplicity of manufacture and efficacy, i.e., the capacity of the generated gases to circulate and be drained.
  • a profile enlarging as it moves away from the surface of the core 10 of trapezoidal type, for example, makes easier circulation and drainage of the generated gases and prevents the molten aluminium alloy 30 from entering inside the slot 13 .
  • Other profiles are also possible.
  • the dimensions of the slots respond to restrictions linked to the molten metal and the generated gases.
  • the volume of the slot 13 has to be optimized.
  • the slots 13 have a width 13 a such that the molten aluminium alloy 30 does not produce any visible flashes 31 on the surface of the piece after cooling (see FIG. 4 b ).
  • the molten aluminium alloy 3 must not enter inside the slots 13 or it must enter by a given distance less than a quality criterion defined by a specification.
  • the impact on the surface state of the aluminium alloy has to be zero or the value of the roughness of the cast piece unchanged with and without slots 13 .
  • Optimizing of this width 13 a makes easier optimization of the volume of the slot 13 , particularly in the case of fairly simple geometric profiles.
  • the width 13 a is a useful width, i.e., it is measured at the surface (see the widths 13 a in FIG. 4 b ).
  • the width 13 a is especially a function of the types of aluminium alloy used.
  • the width of the slots 13 a is less than 1 mm and preferably less than or equal to 0.2 mm.
  • FIG. 4 b illustrates different profiles of flashes 31 obtained for different widths 13 a of the slot 13 .
  • the slots 13 have an average depth 13 b such that the generated gases can circulate inside the slots 13 .
  • the depth 13 b of the slots 13 theoretically has no influence for the flashes 31 but the complexity, cost and fragility of the core, inter alia, increase with depth 13 b.
  • this volume optimization will optimize the average depth 13 b.
  • a depth value 13 b greater than 0.2 mm in practice means that the gases generated in the molding part 12 a can circulate inside said slots 13 .
  • the depth 13 b is greater than 0.2 mm and less than 2 mm.
  • the path of the slots 13 is traced so as to drain as much generated gases as possible by offering a preferred circulation path of the generated gases.
  • the tracing plan is optimized so as to favour circulation and drainage of the generated gases to limit the pressure due to said gases to a maximum.
  • An advantageous tracing plan can for example consist of having the fewest zones of the molding part 11 without slots 13 , i.e., ensure that no point of the surface of the molding part 11 of the core 13 is at a distance greater than a given limit value, relative to the closest slot 13 .
  • the minimal and/or maximal spacing between the slots 13 can be determined.
  • the slots 13 are preferably traced by maximizing the radii of curvature and limiting the angles, even more so acute angles, to facilitate circulation and drainage of the generated gases ( FIG. 3 a ).
  • said slots 13 do not cross each other to maximize the surface covered for a total given length of slots 13 .
  • said slots 13 cross each other to offer a circulation alternative and better drainage of the generated gases ( FIG. 2 b ).
  • the non-molding parts 12 a are advantageously core prints 12 b since the core prints 12 b are already acting as non-molding parts 12 a.
  • the non-molding parts 12 a which receive the slots 13 comprise means 40 adapted to enable discharge of the gases generated in the molding part 11 ( FIG. 2 a ).
  • These means 40 can be made in different ways.
  • the means 40 can simply consist of a fluid connection 41 between slots 13 of the non-molding parts 12 a and a certain volume of pressurized air less than the pressure of the generated gases to be discharged (this pressure is typically atmospheric pressure), said volume being typically far greater than the volume of generated gases.
  • a bore or an opening 42 in the guillotine 22 allows said connection 41 between slots 13 of the non-molding parts 12 a (here typically core prints 12 b ) with the volume of air.
  • the devices 40 further comprise a suction system 43 for favouring circulation and drainage of the gases generated in the slots 13 ( FIG. 5 ).
  • the slots 13 are preferably produced by a laser 50 . This technique is minimally invasive and enables fine precision in manufacture despite the complex forms of cores 10 .
  • slots 13 by means of specialized tooling which can consist of an apparatus with reliefs in the shape of blades (the slots 13 whereof the profile is V-shaped are typically obtained this way).
  • the core 10 is installed in the mold 20 and fixed to the guillotines 22 of the mold 20 by the core prints 12 b.
  • the molten aluminium alloy 30 is poured into the mold 20 and encloses the molding part 11 of the core 10 .
  • the heat causes generation of gases inside the core 10 . These gases preferably circulate via the slots 13 and are drained to the non-molding parts 12 a ( FIG. 4 ) to then be discharged by the discharge means 40 . There are no traces of gas discharges in the piece. Selecting the width 13 a of the slots as adapted further avoids the flashes 31 on the cooled piece.
  • Use of the slots 13 on the core 10 helps reduce pressure due to the gases generated inside the core 10 by allowing the gases generated to circulate and be drained outside the molding part 11 via a preferred circulation route.
  • FIG. 6 illustrates results obtained.
  • test piece test piece without slot 13 on the surface
  • test pieces test pieces
  • test pieces (including the reference test piece) have the same general geometry outside the possible slots 13 and consist of the same material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Induction Machinery (AREA)
US15/121,359 2014-02-25 2015-02-23 Creation of slots on the surface of a core Abandoned US20160361759A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1451514A FR3017811B1 (fr) 2014-02-25 2014-02-25 Realisation de fentes en surface de noyau
FR1451514 2014-02-25
PCT/EP2015/053722 WO2015128286A1 (fr) 2014-02-25 2015-02-23 Réalisation de fentes en surface de noyau

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US20160361759A1 true US20160361759A1 (en) 2016-12-15

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US15/121,359 Abandoned US20160361759A1 (en) 2014-02-25 2015-02-23 Creation of slots on the surface of a core

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US (1) US20160361759A1 (zh)
EP (1) EP3110582A1 (zh)
JP (1) JP2017506585A (zh)
KR (1) KR20160132872A (zh)
CN (1) CN106170352B (zh)
CA (1) CA2940314A1 (zh)
FR (1) FR3017811B1 (zh)
MX (1) MX2016011031A (zh)
WO (1) WO2015128286A1 (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114147183A (zh) * 2021-11-26 2022-03-08 中国航发北京航空材料研究院 一种铝合金机匣铸件3d打印型芯自排气系统

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US20170355933A1 (en) * 2016-06-09 2017-12-14 The Procter & Gamble Company Cleaning compositions including nuclease enzyme and malodor reduction materials

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DE3804801A1 (de) * 1988-02-16 1989-08-24 Audi Ag Verfahren zur herstellung von leichtmetall-gussteilen
JP2005205412A (ja) * 2004-01-20 2005-08-04 Sintokogio Ltd 中子および金型
CN101337261B (zh) * 2008-08-08 2011-04-27 佛山市峰华自动成形装备有限公司 可提高砂芯排气能力的无模成形工艺及砂芯
CN101435378B (zh) * 2008-12-22 2010-12-22 奇瑞汽车股份有限公司 一种汽车发动机气缸体
DE102009023329A1 (de) * 2009-05-29 2010-12-02 Daimler Ag Gusskern zur Anordnung in einer Gussform
CN201794676U (zh) * 2010-09-07 2011-04-13 浙江信阳实业有限公司 一种全地形汽车单体汽缸盖
CN203170908U (zh) * 2012-11-23 2013-09-04 珠海市润星泰电器有限公司 一种ht-1铝合金的型芯模具

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114147183A (zh) * 2021-11-26 2022-03-08 中国航发北京航空材料研究院 一种铝合金机匣铸件3d打印型芯自排气系统

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Publication number Publication date
CN106170352A (zh) 2016-11-30
MX2016011031A (es) 2017-03-09
EP3110582A1 (fr) 2017-01-04
JP2017506585A (ja) 2017-03-09
CN106170352B (zh) 2018-04-06
FR3017811B1 (fr) 2016-03-04
FR3017811A1 (fr) 2015-08-28
CA2940314A1 (fr) 2015-09-03
KR20160132872A (ko) 2016-11-21
WO2015128286A1 (fr) 2015-09-03

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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:MORLOT, VINCENT;REEL/FRAME:039986/0827

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