WO2006104149A1 - Procede de production de moules en sable par moulage par injection et son programme d’analyse - Google Patents

Procede de production de moules en sable par moulage par injection et son programme d’analyse Download PDF

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Publication number
WO2006104149A1
WO2006104149A1 PCT/JP2006/306305 JP2006306305W WO2006104149A1 WO 2006104149 A1 WO2006104149 A1 WO 2006104149A1 JP 2006306305 W JP2006306305 W JP 2006306305W WO 2006104149 A1 WO2006104149 A1 WO 2006104149A1
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WIPO (PCT)
Prior art keywords
molding
injection molding
analysis
slurry
sand
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Application number
PCT/JP2006/306305
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English (en)
Japanese (ja)
Inventor
Hiroyasu Makino
Original Assignee
Sintokogio, Ltd.
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 Sintokogio, Ltd. filed Critical Sintokogio, Ltd.
Priority to JP2007510528A priority Critical patent/JP4569629B2/ja
Publication of WO2006104149A1 publication Critical patent/WO2006104149A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C19/00—Components or accessories for moulding machines
    • B22C19/04—Controlling devices specially designed for moulding machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes

Definitions

  • the present invention relates to a method for predicting a filling failure of sand mold molding by injection and performing molding with improved filling properties. More specifically, the present invention relates to an injection molding method in which a foamed mixture obtained by stirring particulate aggregate, a water-soluble binder and water is press-fitted into a heated mold cavity to mold a mold. It relates to the analysis program.
  • the core system is mainly a shell core or a cold box. Since both core systems are binders developed for pig iron, there is a problem with disintegration, especially in the case of low melting aluminum casting.
  • the shell core is a blow mold in which dry core sand coated with rosin is blown together with compressed air into a heated mold, while the cold box is wet core sand coated with rosin at room temperature. Blow mold into mold, then solidify by gassing.
  • protein-based binders and inorganic-based binder core systems have been developed and attracted attention for aluminum objects.
  • Non-patent Documents 1 and 2 The present applicants have developed a core system for aluminum products using a binder based on natural polysaccharides (Non-patent Documents 1 and 2).
  • this binder system water and a polysaccharide-based binder are added to silica sand, and the mixture is stirred to form a whip containing bubbles, then injection molded into a heated mold, and dried and solidified.
  • the decomposition temperature of the binder is low, so it has excellent disintegration, and since it is a binder based on natural polysaccharides, there is almost no odor.
  • the conventional core system is blow-molded, whereas the binder system is injection-molded in a whip shape with good fluidity, so the molding process is different and the filling into details is good.
  • Non-Patent Document 1 Zengo, Kato, Asano, Nagasaka, Japan Society for Engineering Engineering 144th Annual Lecture Meeting Summary (2004) 151
  • Non-Patent Document 2 Kato, Asano, Yoshitsugu, Nagasaka, Japan Society for Engineering Engineering 144th National Lecture Meeting Summary of Performance (2004) 152
  • the mold design including the mold design such as the mold temperature and the injection speed, it is necessary to grasp the filling phenomenon of the core mold in detail.
  • the present invention is a vertical injection capable of stably filling a slurry material containing a binder into a mold cavity based on optimized molding conditions.
  • a method for predicting a filling failure in a filling space of a sand molding by injection and performing molding with improved filling property is adopted by an injection molding machine.
  • a step of inputting molding data including molding conditions, the shape of the filling space and the physical properties of the sand, into the calculation means; based on the input data regarding the molding before the molding is actually performed A step of calculating the filling property of the sand sand by a sand molding analysis method; a step of repeating the calculation by the sand molding analysis method by changing molding conditions of the injection molding as necessary; and by the injection molding machine
  • the injection molding machine used in the above aspect is configured by filling a whip-like foam mixture obtained by stirring particulate aggregate, a water-soluble binder, and water into a heated mold cavity by a press-fitting method.
  • a saddle type can be formed.
  • the injection molding machine can be provided with at least one of temperature measuring means for the particulate aggregate or the foamed mixture, viscosity measuring means for the foamed mixture, and moisture measuring means for the foamed mixture.
  • the vertical injection molding method is a vertical injection molding method in which a slurry-like material containing a binder is filled in a filling space inside a mold by injection to perform vertical molding. Based on the judgment of the analysis results of the injection molding analysis method! The method includes a step of performing vertical molding under the molding conditions.
  • the vertical injection molding method of the present invention is a vertical injection molding method in which vertical molding is performed by filling a slurry-like material containing a binder into a filling space inside a mold by injection. Analyzing the injection molding analysis method based on data related to molding, including molding conditions and physical properties that are the physical properties of the slurry-like material. And a step of determining whether or not the molding condition is to be changed, and a step of performing an actual mold molding executed by the mold injection molding apparatus under the molding condition based on the determination! /
  • the vertical injection molding method is a vertical injection molding method in which a slurry-like material containing a binder is filled in a filling space inside a mold by injection to perform vertical molding.
  • the calculation by the injection molding analysis method is repeated by changing the molding conditions and determining the parameters, and the actual process executed by the injection molding apparatus. And a step of performing molding under modified molding conditions so as to match the analysis result of the injection molding analysis method using the determined parameters.
  • the program for injection molding according to the present invention is based on the molding conditions set for molding and data relating to molding including physical property values that are physical properties of the slurry-like material.
  • the computer calculates the equation of motion of the slurry material numerically so as to satisfy the continuity equation, and analyzes the equation of motion to obtain the velocity distribution of the slurry material after a minute time And a function of repeating the temperature distribution analysis for calculating the temperature distribution of the slurry-like material at the time.
  • the present invention configured as described above makes it possible to clarify the molding process of the Noinder system and optimize the mold design and molding conditions.
  • the present invention also performs molding under molding conditions optimized by the injection molding analysis method so as to eliminate the filling failure of the slurry-like material into the filling space by injection. Obtainable.
  • the present invention is based on the continuum model, and among the parameters necessary for the analysis of the injection-type analysis method mathematically modeled as a Newtonian fluid considering the shear rate dependence of the viscosity, a specific parameter is preliminarily subjected to preliminary experiments. Estimate / identify the force such as the physical property value that is the physical property of the slurry-like material and set it temporarily. Then, based on the temporarily set parameters, molding computer simulation by the injection molding analysis method is performed.
  • the parameters are data relating to molding including molding conditions set during molding and physical properties that are physical properties of the slurry-like material, and are data necessary for an injection molding analysis method.
  • the specific parameters are parameters that particularly contribute to the filling property, such as viscosity, heat transfer coefficient filling property, and packing density.
  • the injection molding analysis method for example, the equation of motion of the slurry-like material is calculated numerically so as to satisfy the continuous equation, and the velocity distribution of the slurry-like material after a minute time is obtained. It is possible to use an analysis method that repeats the above analysis and the temperature distribution analysis for calculating the temperature distribution of the slurry-like material at the time. This injection molding analysis method is stored in advance in a computer.
  • the molding is analyzed by the injection molding analysis method, and the quality of the molding using the temporarily set parameters is determined. If the result of this determination is a negative determination (underfill condition), the molding conditions are changed and the molding is analyzed by the injection molding analysis method. In the case of a good judgment (good filling state), the actual molding performed by the injection molding apparatus is performed under the modified molding conditions so as to match the analysis result of the injection molding analysis method. Yes.
  • the molding conditions are conditions executed by the injection molding apparatus. For example, the injection speed of the slurry-like material, the injection pressure, the injection flow rate (determining the shape force of the filling space), the initial temperature of the slurry-like material, Mold temperature, molding completion time (filling time and holding time in the mold after filling).
  • the physical property values which are physical properties of the slurry-like material include, for example, viscosity (depending on shear rate and water temperature), moisture, density, specific heat, thermal conductivity, porosity, mold and slurry. Such as heat transfer coefficient between materials.
  • the slurry material in the present invention is not particularly limited as long as it can be injected, and examples thereof include a particulate aggregate, a water-soluble binder, and a material obtained by stirring water. .
  • the slurry-like material contains the foamed mixture thus produced and whipped. In the present embodiment, core molding using the slurry-like material will be described.
  • At least one of the temperature measuring means for the particulate aggregate or slurry material, the viscosity measuring means for the slurry material, and the moisture measuring means for the slurry material may be omitted. it can.
  • the present invention is characterized in that the mold is at a temperature higher than the curing temperature of the binder, and the temperature of the slurry-like material is close to / from the mold temperature.
  • the equation (1) is a continuous equation
  • the equation (2) is a viscous fluid equation of motion.
  • Equation (3) represents the energy equation.
  • p is the density
  • v is the velocity vector
  • g is the gravity vector
  • Cp is the specific heat
  • T is the temperature
  • ⁇ is the thermal conductivity
  • y Shear rate. Since the slurry-like material is highly viscous, the time term (left side), inertia term (first term on the right side) and gravity term (fourth term on the right side) in Equation (2) may be zero.
  • numerical analysis is performed by the finite element method.
  • Table 1 shows the physical properties, which are the physical properties of the core material, which has been agitated into a slurry, and Table 2 shows the analysis conditions such as the mold temperature.
  • the moisture content of the core material is determined by weighing a predetermined amount of the core material in a 120 ° C drying oven for 1 hour or more. Above, it is measured by reduced weight after being sufficiently dried.
  • the core material used in this analysis is a slurry-like material, it is considered that the core material has thixotropy whose viscosity depends on the shear rate. Therefore, the fluidity is investigated using the apparatus shown in Fig. 1 as a means for measuring the viscosity of the core material that is the slurry-like material in this analysis.
  • Fill the cylinder 1 with the core material 2 pressurize it with the piston 3, and let it flow out of the pilot hole 4.
  • the flow rate from the pilot hole 4 is changed, and the viscosity is calculated using equation (4) and the shear rate is calculated using equation (5).
  • Figure 2 shows the results obtained. Both Plotting with a logarithmic graph shows a linear relationship, so it is approximated by the Arrhenius equation. From Fig. 2, it was confirmed that the viscosity decreased with increasing shear rate, indicating thixotropy. That is, in the actual molding process, the higher the injection speed, the better the fluidity. In this case, the moisture value was 4.2% and 4.7% for 1S. It was considered that there was almost no influence of the moisture value within this condition, and Equation (6) was obtained.
  • Mold core The heat transfer between the materials is a very important factor in the present invention.
  • the amount of heat transferred from the mold to the core material is measured by a simple apparatus shown in FIG.
  • the mold 5 is heated to 523 K (about 250 ° C.), and then the molding core material 6 stirred in a slurry state is applied at a predetermined pressure so as to be in close contact with the mold 5.
  • the temperature gradient is calculated from the measured temperature and the heat transfer coefficient h (W / m2K) is obtained by equation (7).
  • Fig. 4 shows the obtained temperature measurement results and the calculated heat transfer coefficient.
  • the core shape is a rectangular ring shape, the outer dimensions are 100mm x 100mm, and the cross section is a square of 10mm x 10mm.
  • the core cavity volume is 40 x 10-6m3. In this basic experiment type, we will also check the condition of the weld where the core material joins.
  • Fig. 6 shows the analysis results when the injection flow rate Qi during molding was 79 X 10-6 m3Zs.
  • the core material flows left and right symmetrically, and molding is completed after 0.5 seconds.
  • the front line of the core material in the filling process had a smooth convex shape.
  • FIG. 1 The molding behavior observed in this example is shown in FIG.
  • a core material is filled in a sleeve of ⁇ ⁇ m, and injection molding is performed by an electric servo cylinder.
  • the cylinder speed was set to 0. OlmZs—constant, and the recorder speed was confirmed by the recorder during the molding process.
  • the forging time for filling almost symmetrically is 0.7 sec, which is slightly longer than the analysis result. This is considered to be because, in the initial stage of molding, the air existing between the cylinder and the core material is compressed and gradually flows out immediately before the cylinder contacts the core material in the sleeve.
  • the front line of the core material in the filling process had a smooth convex shape, which was very close to the shape obtained by the analysis.
  • Fig. 8 shows the temperature distribution immediately after the completion of molding when the injection flow rate Qi during molding is 79 X 10-6m3Zs and 393 X 10-6m3Zs. It is clear that the tip part is gradually heated during the molding process where the temperature of the final filling part is the highest. In addition, the one with a low ejection flow rate has a high temperature because it takes a long time to complete molding.
  • thermocouple ( ⁇ 0. lmm) was inserted into the cavity of the final filling portion, and the temperature during molding was measured. The obtained results are shown in FIG. Prior to the start of molding, the air temperature rose to about 493K (about 220 ° C) due to radiant heat from the mold even within the cavity. For this reason, since the thermocouple measures the temperature of the core material at the time of molding, the temperature is lowered gradually, and then the temperature of the core material is increased by being heated by the mold. Table 3 shows the temperature of the final filling part immediately after molding.
  • FIG. 10 shows the shape of the core of the target water jacket. Figure 10 also shows six injection ports.
  • the injection flow rate was set to flow 330 X 10-6 m3Zs from each injection port.
  • Figure 11 shows the filling behavior obtained from the analysis.
  • the core material is filled in order from the vicinity of the six injection ports. Since the skirting board part at the back left is relatively small, the filling force in about 0.2 seconds The skirting board part on the right front side is large, so it is the final filling part. In this core, there are 6 injection ports, but filling is completed smoothly without any weld lines.
  • the filling time was 0.6 seconds.
  • FIG. 12 shows the temperature distribution immediately after completion of filling obtained by analysis. Filled at a relatively early stage, and the thin-walled part has the highest temperature, but since it is about 310K (about 37 ° C), no water vaporization has occurred and it has solidified. It is not considered.
  • Figure 13 shows the core that was actually molded under these conditions. No weld line was observed in the unfilled part, and a very good core was obtained. In other words, it is considered that the core material did not solidify during the filling process, and the core material temperature solidified beyond 373K (about 100 ° C) after filling. In addition, aluminum was actually fabricated, and a good aluminum product was obtained.
  • the molding conditions in the injection molding analysis method by limiting the temperature so that the temperature of the slurry-like material does not exceed 100 ° C before the filling of the slurry-like material is completed. You can see this. Also, in the injection molding analysis method, before the completion of the filling of the slurry-like material, the temperature of the slurry-like material does not exceed 100 ° C and the limit is set so that the slurry can be filled in the shortest time. It can also be seen that it is preferable to obtain.
  • the temperature of the filled slurry-like material is a predetermined temperature at which filling is completed at least before the binder is completely cured, for example, 200 to 250 ° C, preferably 100 ° C or less. . Therefore, it is preferable that the injection molding analysis method obtains the molding conditions by limiting the temperature so that the temperature of the filled slurry-like material is at least a predetermined temperature at which the filling is completed before the curing is completed. .
  • the present analysis model and the parameter can express the molding phenomenon of the core system. Therefore, in the present invention, since the influence of the parameters on the moldability (fillability) is confirmed in advance and molded, it is possible to prevent filling failure.
  • FIG. 1 is a schematic view of an apparatus for investigating the fluidity of a core material.
  • FIG. 2 is a graph showing the relationship between the shear rate and viscosity of the core material.
  • FIG. 3 is a schematic view of an apparatus for measuring the heat transfer coefficient between mold and core material.
  • FIG. 4 is a graph showing the results of measurement temperature and heat transfer coefficient in the measurement of the heat transfer coefficient between mold and core material.
  • FIG. 5 shows an analysis model of the present invention and a basic experiment type for evaluating the validity of various parameters.
  • FIG. 6 shows the analysis results of the molding behavior obtained using the basic experimental mold shown in FIG.
  • FIG. 7 shows experimental results of molding behavior obtained using the basic experimental mold shown in FIG.
  • FIG. 8 shows the temperature distribution result immediately after completion of molding, obtained using the basic experimental model shown in FIG. [9]
  • Figure 9 shows the temperature measurement results in the cavity during molding, obtained using the basic experimental model shown in Figure 5.
  • FIG. 10 shows the shape of the water jacket core used in the example of the present invention.
  • FIG. 11 shows an analysis result of the filling behavior obtained by using the water jacket core shown in FIG.
  • FIG. 12 shows the analysis result of the temperature distribution immediately after completion of filling, obtained using the water jacket core shown in FIG.
  • FIG. 13 shows a water jacket core actually formed using the analysis result of the present invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

L’invention décrit un procédé pour la production de moules par moulage par injection qui permet de charger stablement une cavité du moule avec un liant contenant un matériau boueux dans des conditions de moulage optimisées, à savoir, un procédé pour la production de moules par le chargement par injection d’une cavité de moule avec un liant contenant le matériau boueux et par moulage du matériau, qui comprend l’étape qui consiste à réaliser le moulage dans des conditions basées sur l’évaluation des résultats d’une analyse de moulage par injection. L’analyse de moulage par injection comprend le calcul numérique de l’équation du déplacement du matériau boueux de sorte à satisfaire l’équation de continuité et la répétition de l’analyse de l’équation du déplacement afin de déterminer la distribution de la vitesse du matériau après un laps d’une minute et l'analyse de la distribution des températures pour calculer la distribution des température du matériau en un instant précis.
PCT/JP2006/306305 2005-03-28 2006-03-28 Procede de production de moules en sable par moulage par injection et son programme d’analyse WO2006104149A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104968452A (zh) * 2013-02-26 2015-10-07 迪帕克·乔杜里 砂优化以减少铸造废品的计算机实施系统和方法
JP2019072768A (ja) * 2017-10-17 2019-05-16 マグマ ギエッセレイテクノロジ ゲーエムベーハーＭＡＧＭＡ Ｇｉｅｓｓｅｒｅｉｔｅｃｈｎｏｌｏｇｉｅ ＧｍｂＨ 中子造型装置および中子造型装置の制御方法
JP2019188426A (ja) * 2018-04-23 2019-10-31 三菱重工業株式会社 中子一体型鋳型製造方法、鋳物の製造方法、及び中子一体型鋳型

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JPH10202344A (ja) * 1997-01-17 1998-08-04 Sintokogio Ltd 生砂造型の充填不良の予測方法
JP2000015396A (ja) * 1998-07-01 2000-01-18 Sintokogio Ltd 生型造型方法およびそのシステム
WO2005023457A1 (fr) * 2003-09-02 2005-03-17 Sintokogio, Ltd. Procede de formation de moule et noyau destine au coulage metallique

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JPH08230007A (ja) * 1995-02-27 1996-09-10 Canon Inc 射出成形プロセスのシミュレーション方法及びその装置
JPH11291313A (ja) * 1998-04-07 1999-10-26 Mitsubishi Plastics Ind Ltd 熱可塑性樹脂射出成形品のフローマーク予測方法
JP3396837B2 (ja) * 1999-03-29 2003-04-14 日立協和エンジニアリング株式会社 流動凝固解析方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH10202344A (ja) * 1997-01-17 1998-08-04 Sintokogio Ltd 生砂造型の充填不良の予測方法
JP2000015396A (ja) * 1998-07-01 2000-01-18 Sintokogio Ltd 生型造型方法およびそのシステム
WO2005023457A1 (fr) * 2003-09-02 2005-03-17 Sintokogio, Ltd. Procede de formation de moule et noyau destine au coulage metallique

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104968452A (zh) * 2013-02-26 2015-10-07 迪帕克·乔杜里 砂优化以减少铸造废品的计算机实施系统和方法
JP2016508882A (ja) * 2013-02-26 2016-03-24 チョウダハリ， ディーパックＣＨＯＷＤＨＡＲＹ， Ｄｅｅｐａｋ 鋳造棄却品を削減することを目的とする砂最適化用コンピュータ利用システムおよび方法
JP2019072768A (ja) * 2017-10-17 2019-05-16 マグマ ギエッセレイテクノロジ ゲーエムベーハーＭＡＧＭＡ Ｇｉｅｓｓｅｒｅｉｔｅｃｈｎｏｌｏｇｉｅ ＧｍｂＨ 中子造型装置および中子造型装置の制御方法
JP7408276B2 (ja) 2017-10-17 2024-01-05 マグマ ギエッセレイテクノロジ ゲーエムベーハー 中子造型装置および中子造型装置の制御方法
JP2019188426A (ja) * 2018-04-23 2019-10-31 三菱重工業株式会社 中子一体型鋳型製造方法、鋳物の製造方法、及び中子一体型鋳型

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