US3274652A - Method of constructing a casting mould by determination of isothermal pattern - Google Patents

Method of constructing a casting mould by determination of isothermal pattern Download PDF

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US3274652A
US3274652A US391808A US39180864A US3274652A US 3274652 A US3274652 A US 3274652A US 391808 A US391808 A US 391808A US 39180864 A US39180864 A US 39180864A US 3274652 A US3274652 A US 3274652A
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mould
cavity
wall
cross
casting
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US391808A
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Banks Allan Pearson
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Distington Engineering Co Ltd
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Distington Engineering Co Ltd
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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
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/06—Ingot moulds or their manufacture

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  • corner shelling a defect often encountered in the constructions of conventional moulds, (known as corner shelling).
  • An object of the invention is the provision of a method of casting metal whereby the walls surrounding the casting space are less likely to crack than when previously proposed methods are employed.
  • Another object of the present invention is the provision of a casting mould which is less prone to crack than moulds proposed hitherto.
  • a further object is the provision of a method of constructing a mould which reduces the incidence of corner shelling.
  • a method of casting metal in which molten metal is introduced into a moulding space bounded by a wall the thickness of different parts of which is such that the passage of heat through the thickness of the wall during cooling of the molten metal is at a substantially constant rate throughout the Wall.
  • a casting mould for carrying out the above method, the walls of which are shaped in cross-section so that on casting metal in the moulding space the crosssectional isothermal pattern during cooling consists of lines extending in the plane of said section substantially parallel to the sides of the moulding space.
  • a method of constructing a mould in accordance with the present invention comprising the steps of:
  • FIGURE 1 shows in more or less diagrammatic form a side view of a conventional square ingot mould
  • FIGURE 2 shows a cross-section of the mould of FIG- URE 1;
  • FIGURE 3 shows in more or less diagrammatic form a side view of an ingot mould embodying the present invention
  • FIGURE 4 shows a cross-section of the mould of FIGURE 3
  • FIGURE 5 shows a cross-section of a conventional rectangular ingot mould
  • FIGURE 6 shows a cross-section of another ingot mould embodying the present invention.
  • FIGURES 2, 4 and 5 Isothermal lines (i.e. lines joining points of equal temperature) are superimposed on FIGURES 2, 4 and 5. To avoid confusion, the usual hatching lines denoting a section have been omitted from these figures and also from FIGURE 6.
  • FIGURES 1 and 2 Such a conventional mould is shown in FIGURES 1 and 2, having a square-shaped moulding space or cavity 1 and an outer perimeter 2 which is also generally square, as seen in cross section.
  • the actual shape of the perimeter 2 is such that the thickness of the mould wall is substantially uniform.
  • Lines 3, 4 and 5 represent isotherms within the mould wall obtained during careful measurement of the temperature distribution ten minutes after steel had been cast in the mould to form an ingot.
  • These isotherms 3 to 5 are in decreasing order of temperature and it will be seen that the regions of highest temperature bounded by the isotherm 3 (parts of which extend through the cavity and are not shown) are located along the sides of the mould cavity while the corners of the cavity are cooler and at the next lower order of temperature indicated by the isotherm 4.
  • these isotherms indicate a pattern of heat flow which continues through the wall of the mould so that the corners of the mould are at an appreciably lower temperature than the sides and the temperature gradient is greatest at the corners.
  • the present invention takes account of the heat distribution pattern revealed by the above-described measurements and provides an ingot mould in which the wall thickness is not uniform but varies so that the outer perimeter of the mould cross-section follows to some degree the shape of the isotherms of a conventional mould.
  • One embodiment of the invention is shown in FIGURES 3 and 4 in which the cavity 11 is the same size andshape as that of cavity 1 but the outer perimeter 12 resembles the shape of the isotherm 5.
  • the mould wall is thickest at the centre of each cavity side and thinnest at each cavity corner.
  • the varying thickness compensates for the otherwise uneven heat flow from the cavity and an even heat distribution in the mould results. Consequently, the temperature differentials set up in the mould wall are considerably reduced relative to those set up in a conventional mould wall and susceptibility to cracking is reduced if not completely removed.
  • FIGURE 5 shows a cross-section of a conventional mould having a rectangular cavity surrounded by a wall 21 of substantially uniform thickness.
  • an isothermal pattern is created the shape of which is indicated by the isotherms 22 to 26.
  • one possible outer crosssectional shape of a mould embodying the invention is substantially that of the isotherm 26, as shown in FIG- URE 6 in which the cavity 27 is the same size and shape as the cavity 20.
  • the isothermal pattern which exists in a conventional mould is first determined.
  • One convenient method of doing this is to manufacture a conventional trial mould having walls of uniform thickness.
  • Metal is then cast in the mould and the isothermal pattern (as hereinbefore described) is determined during initial cooling of the metal.
  • a mould is then constructed having an outer shape, or outer cross-sectional periphery corresponding within practical limits to a chosen isotherm.
  • isotherm which defines said minimum thickness will normally be chosen. That is to say, referring again to FIGURE 1, the isothermal pattern shows that the thinnest part of the mould wall should be at the corners of the cavity. Thus, the minimum thickness is determined for the wall at those corners and the appropriate isotherm (in the aforedescribed embodiment, isotherm 5) determines the shape and dimensions of the wall periphery. It has been shown by experiment that, for moulds having the same cavity shape but of different sizes, the external shape remains the same with corresponding difference in the external dimensions. Thus, the isothermal pattern for a given cavity shape need only be determined once.
  • the present invention provides a novel method of constructing a mould; eg an ingot mould.
  • the casting sand or equivalent material in which the ingot mould is to be cast is formed into the usual central core.
  • the walls surrounding the core are formed into a cavity having a cross-sectional peripheral size and shape substantially the same as one of the isotherms of the aforedescribed isothermal pattern which exists in an equivalent conventional mould.
  • FIG- URES 1 and 3 are more or less diagrammatic and do not show any particular form of bottom or top constructions which may be employed in connection with the present invention. Such features are not illustrated or described since the present invention is concerned mainly with the body of the mould, which is sufficiently described to disclose the principle underlying the present invention.
  • a method of constructing .a casting mold for casting metal comprising the steps of:

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)

Description

Sept. 27, 1966 A. P. BANKS METHOD OF GONS'IRUCTING A CASTING MOULD BY DETERMINATION OF ISOTHERMAL PATTERN 2 Sheets-Sheet 1 Filed Aug. 24, 1964 FIG. 1.
F'IC5.2.
FIG.4.
.FIG. 3.
.ll ln-l-llllll'lllllulll-lnllllllll'll-Illl Sept. 27, 1966 A P. BANKS 3,274,652
METHOD OF CONSTRNCTING A CASTING MOULD BY DETERMINATION OF ISOTHERMAL PATTERN Flled Aug. 24, 1964 2 Sheets-Sheet 2 FIG. 5.
United States Patent 3,274 652 METHOD OF CGNSTRUC'I ING A CASTING MOULD BY DETERMINATION OF ISOTHERMAL PAT- TERN Allan Pearson Banks, Workington, Cumberland, England, assignor to Distington Engineering Company Limited Filed Aug. 24, 1964, Ser. No. 391,808 Claims priority, application Great Britain, Aug. 23, 1963, 33,444/ 63 4 Claims. (Cl. 22-493) This invention relates to the casting of metal and moulds therefore.
It has been a constant problem hitherto to reduce the susceptibility of such casting moulds to cracking during use, particularly cast iron moulds for casting steel ingots. Various expedients have been proposed for strengthening such moulds, for example steel bands encircling the mould cavity and incorporated in the mould during formation of the latter. Such expedients have not in general proved satisfactory for one reason or another.
Furthermore, during the construction of such moulds, there is an undesirable tendency to form thin films of high phosphorous metal at the internal corners of the mould, a defect often encountered in the constructions of conventional moulds, (known as corner shelling).
An object of the invention is the provision of a method of casting metal whereby the walls surrounding the casting space are less likely to crack than when previously proposed methods are employed.
Another object of the present invention is the provision of a casting mould which is less prone to crack than moulds proposed hitherto.
A further object is the provision of a method of constructing a mould which reduces the incidence of corner shelling.
According to one feature of the invention, there is provided a method of casting metal in which molten metal is introduced into a moulding space bounded by a wall the thickness of different parts of which is such that the passage of heat through the thickness of the wall during cooling of the molten metal is at a substantially constant rate throughout the Wall.
According to another feature of the invention, there is provided a casting mould for carrying out the above method, the walls of which are shaped in cross-section so that on casting metal in the moulding space the crosssectional isothermal pattern during cooling consists of lines extending in the plane of said section substantially parallel to the sides of the moulding space.
According to a further feature of the invention, there is provided a method of constructing a mould in accordance with the present invention, the mould having a moulding space or cavity of given cross-sectional shape and dimensions, comprising the steps of:
(a) Determining the cross-sectional isothermal pattern which exists in the Walls of a mould having walls of uniform thickness and having a moulding space or cavity of said given shape and dimensions during cooling of metal cast in such mould; and p (b) Constructing a final mould having a moulding space or cavity of said given shape and dimensions and having a wall the cross-sectional perimeter and peripheral shape of which conforms substantially to a selected one of the isotherms of said isothermal pattern.
3,274,652 Patented Sept. 27, 1966 According to yet a further feature of the invention, there is provided a method of constructing a mould having a moulding space of given cross-sectional shape and dimensions, comprising the steps of:
(a) Determining the cross-sectional isothermal pattern which exists in the walls of a mould having a moulding space or cavity of said given shape and dimensions and having walls of uniform thickness during cooling of metal cast in such mould;
(b) Arranging casting sand or equivalent material to form a cavity the cross-sectional peripheral size and shape of which is substantially the same as a selected one of the isotherms of said isothermal pattern;
(c) Erecting centrally within said cavity a core of moulding sand or equivalent material corresponding in size and shape to said moulding space; and
(d) Casting molten metal in said cavity and around said core; whereby during cooling of the metal heat passes at a substantially constant rate from the metal to said core.
The various features of the invention Will now be described, with reference to casting moulds in the form of ingot moulds and with reference to the accompanying drawings in which:
FIGURE 1 shows in more or less diagrammatic form a side view of a conventional square ingot mould;
FIGURE 2 shows a cross-section of the mould of FIG- URE 1;
FIGURE 3 shows in more or less diagrammatic form a side view of an ingot mould embodying the present invention;
FIGURE 4 shows a cross-section of the mould of FIGURE 3;
FIGURE 5 shows a cross-section of a conventional rectangular ingot mould; and
FIGURE 6 shows a cross-section of another ingot mould embodying the present invention.
Isothermal lines (i.e. lines joining points of equal temperature) are superimposed on FIGURES 2, 4 and 5. To avoid confusion, the usual hatching lines denoting a section have been omitted from these figures and also from FIGURE 6.
Conventional ingot moulds, that is to say moulds designed in accordance with the usual practice prevailing at the present time, have an external shape corresponding substantially to that of the mould cavity. In particular, a cross-section taken through the middle of a mould having a square cavity will have an outer perimeter which is generally square and symmetrical with the cavity.
Such a conventional mould is shown in FIGURES 1 and 2, having a square-shaped moulding space or cavity 1 and an outer perimeter 2 which is also generally square, as seen in cross section. The actual shape of the perimeter 2 is such that the thickness of the mould wall is substantially uniform. Lines 3, 4 and 5 represent isotherms within the mould wall obtained during careful measurement of the temperature distribution ten minutes after steel had been cast in the mould to form an ingot. These isotherms 3 to 5 are in decreasing order of temperature and it will be seen that the regions of highest temperature bounded by the isotherm 3 (parts of which extend through the cavity and are not shown) are located along the sides of the mould cavity while the corners of the cavity are cooler and at the next lower order of temperature indicated by the isotherm 4. Furthermore, these isotherms indicate a pattern of heat flow which continues through the wall of the mould so that the corners of the mould are at an appreciably lower temperature than the sides and the temperature gradient is greatest at the corners.
During experiments, temperature measurements were made after only five minutes from casting and the isotherms obtained followed a similar pattern to those above described. Thus, it has been discovered that the rate of heat transfer from the ingot to the mould is greatest at the corners and least through the side walls. It will be hoted that isothermal lines for temperatures below that of isotherm 5 will emerge through the mould outer surface at the corners of the mould. Thus, stresses due to temperature differentials are set up in the corner regions of the mould wall and these cause the cracks which are experienced in practice in these regions in conventional moulds.
The present invention takes account of the heat distribution pattern revealed by the above-described measurements and provides an ingot mould in which the wall thickness is not uniform but varies so that the outer perimeter of the mould cross-section follows to some degree the shape of the isotherms of a conventional mould. One embodiment of the invention is shown in FIGURES 3 and 4 in which the cavity 11 is the same size andshape as that of cavity 1 but the outer perimeter 12 resembles the shape of the isotherm 5. Thus, the mould wall is thickest at the centre of each cavity side and thinnest at each cavity corner. With this design of mould wall, the varying thickness compensates for the otherwise uneven heat flow from the cavity and an even heat distribution in the mould results. Consequently, the temperature differentials set up in the mould wall are considerably reduced relative to those set up in a conventional mould wall and susceptibility to cracking is reduced if not completely removed.
Temperature measurements were made in the mould shown in FIGURES 3 and 4 at different times after the casting of an ingot therein. Lines 13 to 15 represent isotherms obtained from measurements takenten minutes after casting. It will be noted that these isotherms are lines extending substantially parallel to the sides of the cavity and it will be apparent, without further explanation, that the heat flow is substantially uniform throughout the wall thickness.
Whilst the invention has been described with reference to moulds having a square cavity in section, it is to be understood that it applies to a mould of any shape or cavity. FIGURE 5 shows a cross-section of a conventional mould having a rectangular cavity surrounded by a wall 21 of substantially uniform thickness. During cooling of cast metal in the cavity, an isothermal pattern is created the shape of which is indicated by the isotherms 22 to 26. Accordingly, one possible outer crosssectional shape of a mould embodying the invention is substantially that of the isotherm 26, as shown in FIG- URE 6 in which the cavity 27 is the same size and shape as the cavity 20.
To determine the cross-sectional perimeter and peripheral shape of the wall of a mould in accordance with the invention, the shape and size of the cavity or moulding space having been chosen, the isothermal pattern which exists in a conventional mould is first determined. One convenient method of doing this is to manufacture a conventional trial mould having walls of uniform thickness. Metal is then cast in the mould and the isothermal pattern (as hereinbefore described) is determined during initial cooling of the metal. A mould is then constructed having an outer shape, or outer cross-sectional periphery corresponding within practical limits to a chosen isotherm.
Choice of isotherm will depend upon the structural strength requirements for the mould which will determine the minimum thickness of the thinnest part of the wall. Consequently, the isotherm which defines said minimum thickness will normally be chosen. That is to say, referring again to FIGURE 1, the isothermal pattern shows that the thinnest part of the mould wall should be at the corners of the cavity. Thus, the minimum thickness is determined for the wall at those corners and the appropriate isotherm (in the aforedescribed embodiment, isotherm 5) determines the shape and dimensions of the wall periphery. It has been shown by experiment that, for moulds having the same cavity shape but of different sizes, the external shape remains the same with corresponding difference in the external dimensions. Thus, the isothermal pattern for a given cavity shape need only be determined once.
As viewed from another of its aspects, the present invention provides a novel method of constructing a mould; eg an ingot mould. Thus, the casting sand or equivalent material in which the ingot mould is to be cast is formed into the usual central core. However, the walls surrounding the core are formed into a cavity having a cross-sectional peripheral size and shape substantially the same as one of the isotherms of the aforedescribed isothermal pattern which exists in an equivalent conventional mould. When the metal for forming the ingot mould is poured, heat flows from this cast metal to the core sand and at a substantially constant rate throughout the cast metal, during cooling thereof. Experiment has shown that this even distribution of heat flow results in a reduction, and in some cases the complete avoidance, of corner shelling.
Although reference has been made mainly to ingot moulds it is envisaged that the various features of the invention will be applicable to the casting of any metal, in any form of mould, and it is intended that the appended claims should be interpreted accordingly.
It is to be understood that the moulds shown in FIG- URES 1 and 3 are more or less diagrammatic and do not show any particular form of bottom or top constructions which may be employed in connection with the present invention. Such features are not illustrated or described since the present invention is concerned mainly with the body of the mould, which is sufficiently described to disclose the principle underlying the present invention.
I claim:
1. -A method of constructing a casting mold for casting metal, the mold having a cavity of given cross-sectional shape and dimensions, said method comprising the steps of:
(a) determining the cross-sectional isothermal pattern which exists in the wall of a trial mold having a wall of uniform thickness and a cavity of given shape and dimensions during cooling of metal cast in such mold; and
(b) constructing a final mold having a cavity of said given cross-sectional shape and dimensions and having a wall the outer crosssecti-onal periphery of which conforms substantially to a selected one of the isotherms of said isothermal pattern.
2. A method of constructing .a casting mold for casting metal, the mold having a cavity of given cross-sectional shape and dimensions, said method comprising the steps of:
(a) providing a trial mold having a cavity of said given cross-sectional shape and dimensions and a wall of uniform thickness bounding said cavity;
(b) casting metal in said trial mold and determining the cross-sectional isothermal pattern existing in the wall of the mold during the cooling of the casting metal; and
(c) constructing a final mold having a cavity of said given cross-sectional shape and dimensions and a boundary wall the outer cross-sectional outline of which con-forms substantially to a selected one of the isotherms of said isothermal pattern.
References Cited by the Examiner UNITED STATES PATENTS Gathnrann 249-174 Blage 249-174 Dockray et al 22-200 Larsen 22-200 Passemar 22-193 Petty 22-193 10 J. SPENCER OVERHOLSER, Primary Examiner.
E. MAR, Assistant Examiner.

Claims (1)

1. A METHOD OF CONSTRUCTING A CASTING MOLD FOR CASTING METAL, THE MOLD HAVING A CAVITY OF GIVEN CROSS-SECTIONAL SHAPE AND DIMENSIONS, SAID METHOD COMPRIING THE STEPS OF: (A) DETERMINING THE CROSS-SECTIONAL ISOTHERMAL PATTERN WHICH EXISTS IN THE WALL OF A TRIAL MOLD HAVING A WALL OF UNIFORM THICKNESS AND A CAVITY OF GIVEN SHAPE AND DIMENSION DURING COOLING OF METAL CAST IN SUCH MOLD; AND (B) CONSTRUCTING A FINAL MOLD HAVING A CAVITY OF SAID GIVEN CROSS-SECTIONAL SHAPE AND DIMENSION AND HAVING A WALL THE OUTER CROSS-SECTIONAL PERIPHERY OF WHICH CONFORMS SUBSTANTIALLY TO A SELECTED ONE OF THE ISOTHERMS OF SAID ISOTHERMAL PATTERN.
US391808A 1963-08-23 1964-08-24 Method of constructing a casting mould by determination of isothermal pattern Expired - Lifetime US3274652A (en)

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DE (1) DE1458029A1 (en)
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3349831A (en) * 1965-01-22 1967-10-31 William H Moore Process of producing a cast member having a varying graphite structure
US3552479A (en) * 1967-11-22 1971-01-05 Martin Metals Co Casting process involving cooling of a shell mold prior to casting metal therein
US4033401A (en) * 1974-05-29 1977-07-05 Sulzer Brothers Limited Precision casting process
US4785869A (en) * 1986-10-14 1988-11-22 Re-Top Usa, Inc. Method of sizing a hot top liner and assembling a hot top
US5129443A (en) * 1989-03-30 1992-07-14 Hitachi Metals, Ltd. Method of manufacturing a product by estimating thermal stress using a model of the product made of different material

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1440535A (en) * 1922-07-16 1923-01-02 Gathmann Emil Ingot mold
US1758823A (en) * 1928-01-20 1930-05-13 Blage Marcel Ingot mold
US2084247A (en) * 1935-07-10 1937-06-15 Charles J Dockray Method of making chilled metal mold castings
US2087347A (en) * 1934-12-21 1937-07-20 United States Steel Corp Method of solidifying molten metals
US2797458A (en) * 1954-06-28 1957-07-02 Passemar Felix Pierre Process for forming metallic moulds
US2848774A (en) * 1955-07-21 1958-08-26 Hudson Engineering Corp Sectional molds

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1440535A (en) * 1922-07-16 1923-01-02 Gathmann Emil Ingot mold
US1758823A (en) * 1928-01-20 1930-05-13 Blage Marcel Ingot mold
US2087347A (en) * 1934-12-21 1937-07-20 United States Steel Corp Method of solidifying molten metals
US2084247A (en) * 1935-07-10 1937-06-15 Charles J Dockray Method of making chilled metal mold castings
US2797458A (en) * 1954-06-28 1957-07-02 Passemar Felix Pierre Process for forming metallic moulds
US2848774A (en) * 1955-07-21 1958-08-26 Hudson Engineering Corp Sectional molds

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3349831A (en) * 1965-01-22 1967-10-31 William H Moore Process of producing a cast member having a varying graphite structure
US3552479A (en) * 1967-11-22 1971-01-05 Martin Metals Co Casting process involving cooling of a shell mold prior to casting metal therein
US4033401A (en) * 1974-05-29 1977-07-05 Sulzer Brothers Limited Precision casting process
US4785869A (en) * 1986-10-14 1988-11-22 Re-Top Usa, Inc. Method of sizing a hot top liner and assembling a hot top
US5129443A (en) * 1989-03-30 1992-07-14 Hitachi Metals, Ltd. Method of manufacturing a product by estimating thermal stress using a model of the product made of different material

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LU46821A1 (en) 1964-10-22
SE304815B (en) 1968-10-07
BE652166A (en) 1964-12-16
AT263236B (en) 1968-07-10
GB1086946A (en) 1967-10-11
NL6409760A (en) 1965-02-24

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