US3613768A - Liquid metal forging process - Google Patents

Liquid metal forging process Download PDF

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Publication number
US3613768A
US3613768A US793757*A US3613768DA US3613768A US 3613768 A US3613768 A US 3613768A US 3613768D A US3613768D A US 3613768DA US 3613768 A US3613768 A US 3613768A
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US
United States
Prior art keywords
liquid metal
punch
mold
sealing member
pressure
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.)
Expired - Lifetime
Application number
US793757*A
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English (en)
Inventor
Taikichi Awano
Yoshihiro Oishi
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Toyota Central R&D Labs Inc
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Toyota Central R&D Labs Inc
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Filing date
Publication date
Application filed by Toyota Central R&D Labs Inc filed Critical Toyota Central R&D Labs Inc
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Publication of US3613768A publication Critical patent/US3613768A/en
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Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
    • Y10S425/806—Flash removal

Definitions

  • the present invention relates to an improvement in liquid metal forging in which molten or half-molten metal in a metal mold is pressed by a punch, or a plunger and solidified under high pressure to produce products in various desired shapes.
  • the apparatus used in the present invention utilizes a sealing member, interposed between said punch and said liquid metal which prevents leakage of the liquid metal into the clearance space between the mold and the punch, and thus, applies pressure from the punch to the liquid metal more effectively and prolongs the life of the mold and punch.
  • liquid metal is defined to include molten, half-molten, and partially molten metal to be forged.
  • liquid metal is poured into a metal mold, and a punch of a size having a predetermined clearance with the wall surface of the pressure portion of the mold is inserted therein. High hydraulic pressure is then applied to the liquid metal by the punch until solidification of the liquid metal is completed.
  • the resultant product evidences fine grain, compact internal structure.
  • the clearance between the punch and the wall surface of the pressure portion of the metal mold is made as small as possible (from 0.01 to 0.05 mm.), and the liquid metal, which is squeezed into the punch clearance space when pressure is applied, is quickly cooled and is made to work as a packing, hereinafter termed "self-metal packing.
  • self-metal packing there is a strong tendency for the packing to freeze the punch and mold together and when the punch clearance is too small, the wall surface of the mold and the punch come in contact with each other causing galling, and damage increases until the mold is broken by the tremendous friction between the self-metal packing, or flash, and the mold.
  • Another disadvantage is that the pressure-effect of the punch is reduced, and it becomes impossible to exert sufficient pressure to the central portion of the liquid metal because the surrounding portion of the liquid metal is quickly solidified, producing a resistance to pressure which the ram cannot overcome.
  • the wear and damage to the mold is relatively small, but when the liquid metal is one of the metals of the iron group, the hardness of the self-metal packing is remarkably high as it becomes iron oxide, or the like, and, therefore, the mold and the punch are greatly damaged when pressure is applied, and often to an extent that they are usable only once and cannot be further employed.
  • a mold reinforcement be used in the form of an antiabrasive alloy such as a molybdenum alloy placed at the portion of the mold most subject to abrasion, but this has been found to be almost useless.
  • the above mentioned disadvantages and drawbacks have led to poor results and no progress in the art of liquid metal forging.
  • the pressure is applied by the ram, or plunger, as in the conventional method, but a sealing member in the form of a metal plate is interposed between the liquid metal and the pressure applying surface of the punch, and pressure is applied by the punch to the liquid metal through sealing member.
  • the sealing member is plastically deformed by the resultant high temperature and high pressure, and the rim of the sealing member is thereby deformed to closely fit to the wall surface of the pressure portion of the mold, and acts as a seal to prevent entrance of the liquid metal to the clearance space between the mold and the punch.
  • the rim of the sealing member has its hardness lowered by the high temperature, and moves smoothly in contact with the wall surface of the metal mold during the entire time the punch is being lowered.
  • a primary object of the present invention is to provide an improvement in liquid metal forging which will overcome the defects and disadvantages of the previously outlined conventional method of liquid metal forging.
  • Another important object of the present invention is to provide an improvement in liquid metal forging which permits the forging of metals of the iron group without breakdown, or rupture, of the mold or the punch except after repeated use, in contrast with conventional liquid metal forging wherein the mold and associated parts can be used only once.
  • FIG. 1 is a cross-sectional view of an apparatus used in an embodiment of the present invention
  • FIGS. 2 and 3 are fragmentary sections similar to FIG. 1 showing apparatuses used in other embodiments.
  • FIGS. 4 to 6 are sectional views of the FIG. 3 apparatus with the punch in successively lowered positions during the forging operation.
  • FIG. 1 illustrates the apparatus used in an embodiment of the invention differing from conventional liquid metal forging apparatus in the addition of a thin metal plate 12 to the punch 3.
  • Plate 12 is temporarily adhered by means of an adhesive, such as a resin, on the pressure applying end surface 4 of the punch 3.
  • the remainder of the apparatus which is conventional includes a metal mold 1 having a cylindrical molding space inside thereof, the upper portion of the cylinder being the pressure portion 2 and the bottom portion thereof being the casting shaping portion or cavity 6.
  • the molding space may have other and even irregularly shaped cross sections.
  • the mold l is fixed on the base 8 by means of bolts 9.
  • liquid metal 11 is poured into said mold and pressed with the punch, or plunger 3, capable of moving longitudinally within the pressure portion 2 by fluid, hydraulic, or any other pressure means, (not shown) until the metal is solidified into a dense, fine grain, round bar.
  • Nearly uniform clearance space 5 exists between the punch 3 and the wall surface of the pressure portion 2 and the liquid metal passes into this space to form flash, as explained above.
  • the knockout pin 10 is movable through an aperture in the base 8 to lift the forged casting out of the mold 1 upon completion of the process of forging.
  • the thin metal plate 12 is made of a material whose melting point is almost the same as, or higher than, that of the liquid metal 11 to be forged, and is shaped as a disk whose diameter is nearly the same as, or slightly larger than, that of the pressure portion 2.
  • the rim 121 of plate 12 is preferably inturned, or bent, in one direction. The thin metal plate 12 is placed against and afiixed to the end surface 4 of the punch in such a manner that the inwardly bent rim 121 faces toward the surface of the liquid metal 1 l to be forged.
  • the disk 12 can be easily attached coaxially to the pressure applying end surface 4 of the punch by fitting a central projection 31 of the punch into a central hole 122 in the disk 12, as shown, for example, in FIG. 2.
  • the disk 12 can be attached on the end surface 4 of the punch by inserting therebetween a thin plate 13 of compressed glass fiber, or ceramic fiber, of virtually the same disklike form as the metal disk, as shown in FIG. 3.
  • the disk 12, with or without disk 13, must be temporarily attached coaxially to the end surface of the punch 4 by any suitable adherent means including the means mentioned above, and or glue, adhesive, pins, bolts, or the like.
  • the punch 3 when the punch 3 is pushed into the pressure portion 2 of the mold to press the liquid metal, the gas at the surface of the liquid metal 11 escapes through the clearance space 5 past the bent rim 121 of the metal plate 12.
  • the punch 3 is further lowered and the plate 12 touches the upper surface of the liquid metal 11, the temperature of the plate 12 is quickly raised to the heat of the liquid metal and the plate 12 is plastically deformed.
  • the bent rim 121 of the plate is pushed upwardly and spread outwardly by pressure of the molten metal 11 so that its outer edge fits closely against the cylindrical wall surface of the pressure portion 2 of the mold.
  • FlGS. 4 to 6 show successive positions of the punch in the mold and the resultant deformation of the thin plate 12 as the punch is lowered.
  • plate 12 is of stainless steel of 0.3 mm., thickness and is attached to the end surface of the punch 3 by a thin glass fiber plate 13 inserted therebetween.
  • the liquid metal 12 to be forged is molten cast iron and the diameter of the cylindrical pressure portion 2 of the mold is 45 mm.
  • the stainless steel plate 12 is softened by the high temperature, and its movement against the metal mold l is smoothly carried out, because the glass fiber disk 13 is melted and works as a lubricant to reduce the friction between stainless plate 12 and the metal mold 1. After the pressing operation is completed, the stainless steel plate 12 is adhered to the upper surface of the product, but it can be easily removed by simple mechanical processing, such as grinding, after the product is removed from the mold.
  • the present invention improves the conventional liquid metal forging process by use of a sealing member in the form of a thin metal plate attached to the pressure applying surface of the pressure punch for contacting the surface of the liquid metal.
  • the added plate prevents the fonnation of flash in the clearance space between the punch and the mold, and as a result the friction between the flash and the metal mold is entirely eliminated.
  • the life of the metal mold is greatly prolonged.
  • the pressure of the punch is retained without undue loss in overcoming flash-friction and is effectively applied to the liquid metal.
  • the operation is very easily carried out as described, and can be effectively applied to all kinds of metals.
  • a liquid metal forging process of the type including the steps of pouring liquid metal into the cavity of a mold, applying high pressure to said liquid metal by a punch which is inserted into said cavity with clearance space, and compressing said liquid metal until it solidifies, the improvement comprising the step of inserting between the surface of said liquid metal and a pressure applying surface of said punch a first sealing member made of a metal plate having a surface area to fit the cross-sectional area of the mold and interposing between the first sealing member and the pressure applying surface of said punch a second sealing member made of a thin plate of a glassy substance having a melting temperature below that of the first-named sealing member and below the temperature of the metal to be forged, whereby said high pressure is applied through both said sealing members to said liquid metal, while simultaneously sealing the clearance space between said punch and the walls of said mold against entrance of liquid metal by deformation of the first sealing member to closely fit the mold, and the movement of said first sealing member along the wall of the mold is lubricated by melting of said second sealing member.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)
US793757*A 1968-01-31 1969-01-24 Liquid metal forging process Expired - Lifetime US3613768A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP612968 1968-01-31

Publications (1)

Publication Number Publication Date
US3613768A true US3613768A (en) 1971-10-19

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ID=11629876

Family Applications (1)

Application Number Title Priority Date Filing Date
US793757*A Expired - Lifetime US3613768A (en) 1968-01-31 1969-01-24 Liquid metal forging process

Country Status (3)

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US (1) US3613768A (de)
DE (1) DE1904910A1 (de)
GB (1) GB1257963A (de)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3802063A (en) * 1972-07-21 1974-04-09 Connor J O Process for casting material under pressure
US3815663A (en) * 1972-02-18 1974-06-11 Connor J O Die casting apparatus
US3901306A (en) * 1972-08-17 1975-08-26 Nippon Light Metal Co Molten metal injector for an injection die casting machine
US4049041A (en) * 1974-08-30 1977-09-20 Institute Po Metalosnanie I Technologia Na Metalite Pri Ban Method of and apparatus for fluid die stamping
US4659002A (en) * 1985-08-08 1987-04-21 Pace, Incorporated Apparatus for replacement of through-hole mounted PCB components
US4886107A (en) * 1986-02-28 1989-12-12 Zecman Kenneth P Piston for cold chamber
US4899804A (en) * 1989-02-21 1990-02-13 Hammerer Norman L Plunger tip for cold chamber die cast machine
DE4002263A1 (de) * 1990-01-26 1991-08-08 Audi Ag Kolben-zylindereinheit und deren verwendung
WO2008085134A1 (en) * 2007-01-12 2008-07-17 Agency For Science, Technology And Research Magnetically permeable liquid forged articles
WO2008085136A1 (en) * 2007-01-12 2008-07-17 Agency For Science, Technology And Research Liquid forged article
WO2010110742A1 (en) * 2009-03-27 2010-09-30 Agency For Science, Technology And Research Method and apparatus for forming a liquid-forged article
CN109249002A (zh) * 2018-11-28 2019-01-22 吴江伟 一种灯壳铝合金压铸模具
CN112846679A (zh) * 2019-11-28 2021-05-28 世佳工业股份有限公司 一体式中央锁固的自行车刹车碟盘的制造方法

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* Cited by examiner, † Cited by third party
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US6701998B2 (en) 2002-03-29 2004-03-09 Water Gremlin Company Multiple casting apparatus and method
US6997234B2 (en) 2003-09-29 2006-02-14 Water Gremlin Company Enhanced gravity casting
US7338539B2 (en) 2004-01-02 2008-03-04 Water Gremlin Company Die cast battery terminal and a method of making
US8701743B2 (en) 2004-01-02 2014-04-22 Water Gremlin Company Battery parts and associated systems and methods
EP2425478B1 (de) 2009-04-30 2018-10-31 Water Gremlin Company Batterieteile mit halte- und abdichtungselementen sowie verfahren zu ihrer herstellung und verwendung
US9748551B2 (en) 2011-06-29 2017-08-29 Water Gremlin Company Battery parts having retaining and sealing features and associated methods of manufacture and use
US9954214B2 (en) 2013-03-15 2018-04-24 Water Gremlin Company Systems and methods for manufacturing battery parts
BR112020021221A2 (pt) 2018-12-07 2021-07-27 Water Gremlin Company peça de bateria, método para fabricar uma peça de bateria, e, sistema para fabricar peça de bateria

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR908322A (fr) * 1944-12-20 1946-04-05 Dispositif de moulage sous pression
US2804666A (en) * 1952-08-28 1957-09-03 Renault Pressure casting piston machines
US2810942A (en) * 1952-08-28 1957-10-29 Renault Pressure die casting machines
US2932865A (en) * 1957-01-23 1960-04-19 Nat Lead Co Cold chamber shot end with loose piece arrangement
US3133843A (en) * 1961-06-14 1964-05-19 Beryllium Corp Method of liquid forming a copperberyllium alloy
CH379702A (fr) * 1959-03-17 1964-07-15 Nat Lead Co Procédé de fabrication d'une pièce en fonte injectée au moyen d'une machine à mouler par injection, à chambre froide, et machine pour la mise en oeuvre de ce procédé
GB965652A (en) * 1962-02-07 1964-08-06 Volkswagenwerk Ag Injection means for pressure casting machines

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR908322A (fr) * 1944-12-20 1946-04-05 Dispositif de moulage sous pression
US2804666A (en) * 1952-08-28 1957-09-03 Renault Pressure casting piston machines
US2810942A (en) * 1952-08-28 1957-10-29 Renault Pressure die casting machines
US2932865A (en) * 1957-01-23 1960-04-19 Nat Lead Co Cold chamber shot end with loose piece arrangement
CH379702A (fr) * 1959-03-17 1964-07-15 Nat Lead Co Procédé de fabrication d'une pièce en fonte injectée au moyen d'une machine à mouler par injection, à chambre froide, et machine pour la mise en oeuvre de ce procédé
US3133843A (en) * 1961-06-14 1964-05-19 Beryllium Corp Method of liquid forming a copperberyllium alloy
GB965652A (en) * 1962-02-07 1964-08-06 Volkswagenwerk Ag Injection means for pressure casting machines

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3815663A (en) * 1972-02-18 1974-06-11 Connor J O Die casting apparatus
US3802063A (en) * 1972-07-21 1974-04-09 Connor J O Process for casting material under pressure
US3901306A (en) * 1972-08-17 1975-08-26 Nippon Light Metal Co Molten metal injector for an injection die casting machine
US4049041A (en) * 1974-08-30 1977-09-20 Institute Po Metalosnanie I Technologia Na Metalite Pri Ban Method of and apparatus for fluid die stamping
US4659002A (en) * 1985-08-08 1987-04-21 Pace, Incorporated Apparatus for replacement of through-hole mounted PCB components
US4886107A (en) * 1986-02-28 1989-12-12 Zecman Kenneth P Piston for cold chamber
US4899804A (en) * 1989-02-21 1990-02-13 Hammerer Norman L Plunger tip for cold chamber die cast machine
DE4002263A1 (de) * 1990-01-26 1991-08-08 Audi Ag Kolben-zylindereinheit und deren verwendung
WO2008085134A1 (en) * 2007-01-12 2008-07-17 Agency For Science, Technology And Research Magnetically permeable liquid forged articles
WO2008085136A1 (en) * 2007-01-12 2008-07-17 Agency For Science, Technology And Research Liquid forged article
WO2010110742A1 (en) * 2009-03-27 2010-09-30 Agency For Science, Technology And Research Method and apparatus for forming a liquid-forged article
CN102438772A (zh) * 2009-03-27 2012-05-02 新加坡科技研究局 形成液锻物品的方法和装置
CN102438772B (zh) * 2009-03-27 2014-05-28 新加坡科技研究局 形成液锻物品的方法和装置
CN109249002A (zh) * 2018-11-28 2019-01-22 吴江伟 一种灯壳铝合金压铸模具
CN112846679A (zh) * 2019-11-28 2021-05-28 世佳工业股份有限公司 一体式中央锁固的自行车刹车碟盘的制造方法
CN112846679B (zh) * 2019-11-28 2022-06-17 世佳工业股份有限公司 一体式中央锁固的自行车刹车碟盘的制造方法

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Publication number Publication date
GB1257963A (de) 1971-12-22
DE1904910A1 (de) 1969-09-11

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