WO2018044760A1

WO2018044760A1 - Mold apparatus having a first sliding core that moves a second sliding core

Info

Publication number: WO2018044760A1
Application number: PCT/US2017/048825
Authority: WO
Inventors: Zhiyou Xu; Chih-Hung Chung; Ravi Desai
Original assignee: American Axle & Manufacturing, Inc.
Priority date: 2016-09-01
Filing date: 2017-08-28
Publication date: 2018-03-08

Abstract

A mold tool includes a slider core, which is movable about a first axis, an auxiliary slider core, which is mounted in the slider core and movable about a second axis that isn't parallel to the first axis, and an auxiliary slider core transport that is movably coupled to both the slider core and the auxiliary slider core. Movement of the auxiliary slider core transport in a direction parallel to the second axis and toward the slider core extends a forming portion from the slider core. A method of forming a casting is also provided.

Description

MOLD APPARATUS HAVING A FIRST SLIDING CORE THAT MOVES A SECOND

SLIDING CORE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/382,315 filed September 1, 2016, the disclosure of which is incorporated by reference as if fully set forth in detail herein.

FIELD

[0002] The present disclosure relates to a moid apparatus having a first sliding core that moves a second sliding core. BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art

[0004] With the increasing complexity of the housings of driveline components such as power take-off units and rear drive modules, it has become increasingly necessary to employ metal die casting techniques that employ one or more loose cores to form the desired geometry. The use of loose cores, however, is considered to be a challenge not only in the facility that performs the die casting operation, but also in the design and construction of the die casting casting. In this regard, the use of loose cores typically dictates a specific die draw orientation and gating direction, which frequently limit the ability of the casting designer to optimize the casting design.

[0005] In lieu of loose cores, we have considered the use of multiple slider cores in which the several slider cores are each moved along a different slide axis. In a conventionally constructed mold for die-casting a housing of a driveline component, each of these slider cores would have an associated linear motor mat moves the slider core between a retracted position and an extended position. This solution is disadvantageous due to the cost of additional linear motors and the need to align each of the additional linear motors to an axis and location that are potentially unique to a given die casting moid. SUMMARY

[0006] This section provides a general summary of the disclosure, and; is not a comprehensive disclosure of its full scope or ait of its features.

[0007] In one form, the present disclosure provides a mold tool that includes first and second mold halves, a first slider core, an auxiliary slider core, and an auxiliary slider core transport The second moid half is movable relative to the first moid half along a first movement axis between an open position, in which the first and second moid halves are spaced apart from one another along the first movement axis, and a closed position in which the first and second mold halves are seated against one another. The first slider core is movable relative to the first and second moid halves along a second movement axis, between a first position, in which the first slider core is spaced apart from the first and second moid halves, and a second position in which the first slider core is seated against at least one of the first and second mold halves. The second movement axis is not parallel to the first movement axis. The auxiliary slider core is mounted in the first slider core for sliding movement along a third movement axis that is not parallel to the first movement axis or the second movement axis. The auxiliary slider core is movable between a retracted position, in which a forming portion on the auxiliary slider core is retracted into the first slider core, and an extended position in which the forming portion on the auxiliary slider core extends from the first slider core. The auxiliary slider core transport is movabiy coupled to both the auxiliary slider core and the first slider core. The auxiliary slider core transport is movable relative to the first slider core in directions that are parallel to the second movement axis. Movement of the auxiliary slider core transport in a direction away from the first slider core moves the auxiliary slider core toward the retracted positon. Movement of the auxiliary slider core transport in a direction toward the first slider core moves the auxiliary slider core toward the extended position.

[0008] in another form, the present disclosure provides a method for forming a casting. The method includes: providing an auxiliary slider core having a forming portion; positioning the auxiliary slider core into a first slider core such that the forming portion of the auxiliary slider core is retracted into the first slider core; moving a first mold half relative to a second mold half along a first movement axis to seat the first and second mold halves against one another, with the auxiliary slider core retracted into the first slider core, moving the first slider core relative to the seated first and second mold halves along a second movement axis to seat the first slider core against at least one of the first mold half and the second mold half, the second movement axis not being parallel to the first movement axis; moving an auxiliary slider core transport toward the first slider core in a direction parallel to the second movement axis to extend the forming portion from the first slider core; and directing a liquid material into a moid cavity that is at least partly defined by the first moid half, the second mold half, the first slider core and the forming portion of the auxiliary slider core.

[0009] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. DRAWINGS

[0010] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0011] Figure 1 is a longitudinal section view of a casting formed with a die cast mold tool that is depicted in Figure 2;

[0012] Figure 2 is a longitudinal section view of an exemplary die cast mold tool formed in accordance with the teachings of the present disclosure, the view depicting first and second mold halves, a first slider core, a second slider core and an auxiliary slider core in their first or retracted positions;

[0013] Figure 3 is a view similar to that of Figure 2 except that the first and second mold halves and the first and second slider cores are shown in their second or extended positions; and

[0014] Figure 4 is a view similar to that of Figure 3 except that the auxiliary slider core is also shown in its second or extended position.

[0015] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0016] With reference to Figure 1, an exemplary housing mat is formed via die casting with a die casting mold constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10. The casting 10 can be formed of a suitable material, such as aluminum, and can have a first flange 12, a second flange 14, and a circumferential wall 16 that can be coupled at its opposite axial ends to the first and second flanges 12 and 14. The casting 10 can have an interior surface 20, a first axial end surface 22 and a second axial end surface 24.

[0017] The circumferential wall 16 can define an annular mount 30, a recess 32, a transverse boss 34 and a casting undercut 36. The annular mount 30 can be formed along a first axis 40 and can define a first bore 42 and a second bore 44 that is concentric with and intersects the first bore 42. The first bore 42 is larger in diameter than the second bore 44. The recess 32 can be formed in the annular mount 30 on an axial side of the annular mount 30 in which the first bore 42 is formed, in the example provided, the recess 32 does not extend about the circumference of the first bore 42. The transverse boss 34 can be configured to have a through-bore 48 formed therethrough and can be disposed about a second axis 50 that is transverse to the first axis 40. In the particular example provided, the first and second axes 40 and 50 are perpendicular to one another, but are offset from one another so that they do not intersect one another, in this regard, the first and second axes 40 and 50 are contained in respective planes that are parallel to one another. The casting undercut 36 can be disposed axially between the annular mount 30 and the first flange 12 and can define a portion of the interior surface 20 that can project radially outwardly from the first axis 40 by a distance d1 that is greater than a distance d2 by which a portion 52 of the interior surface 20 that is located axially between the casting undercut 36 and the first axial end surface 22.

[0018] With reference to Figure 2, an exemplary die cast mold tool 70 constructed in accordance with the teachings of the present disclosure is illustrated to include a first moid half 72, a second mold half 74, a first slider core 76, a second slider core 78, a core or auxiliary slider core 80 and an auxiliary slider core transport 82. The first and second moid halves 72 and 74 can be constructed in a conventional and well known manner and can be moved relative to one another along a first movement axis 86 that is shown in a vertical orientation in Figure 2. The first and second moid halves 72 and 74 are movable along the first movement axis 86 between a first or open position (Fig. 2) in which the first and second mold halves 72 and 74 are spaced apart from one another along the first movement axis 86 to permit the casting 10 (Fig. 1) to be removed from the die cast mold tool 70, and a second or closed position (Fig. 3), in which the first and second mold halves 72 and 74 are seated against one another.

[0019] The first slider core 76 is movable along a second movement axis 90 that is parallel to the first axis 40 (Fig. 1 ) of the casting 10 (Fig. 1 ). The first slider core 76 is movable between a first position (Fig. 2) in which the first slider core 76 is spaced apart from the first and second mold halves 72 and 74, and a second position (Fig. 3) in which the first slider com 76 is seated against the first and second moid halves 72 and 74. In the example provided, the first slider core 76 has an exterior surface that is configured to form the portion of the circumferential wall 16 that defines the first bore 42 as well as the portion of the interior surface 20 (Fig. 1 ) of the casting 10 (Fig. 1 ) that is disposed axially between the first axial end surface 22 and the annular mount 30 (including the recess 32), with the exception of the casting undercut 36. Those of skill in the art will appreciate that because the first slider core 76 must be capable of being moved from its second position to its first position after the casting 10 (Fig. 1 ) has been formed in the die cast moid tool 70, first slider core 76 cannot be shaped and sized in a manner that would cause the casting 10 (Fig. 1) to lock the first slider core 76 to the first mold half 72. Consequently, the first slider core 76 is not configured to form any portion of the interior surface 20 (Fig. 1) that projects radially outwardly from the first axis 40 (Fig. 1) by a distance that is greater than the amount by which any portion of the interior surface 20 (Fig. 1 ) that is axially closer to the first axial end surface 22 (Fig. 1 ) projects radially outward from the first axis 40 (Fig. 1). In the example provided, the exterior surface of the first slider core 76 does not form the portion of the interior surface 20 that is defined by the casting undercut 36.

[0020] The second slider core 78 can be disposed on a side of the first and second mold halves 72 and 74 opposite the first slider core 76 and can be moved along a third movement axis 96 that can be parallel to (or coincident with) the second movement axis 90. The second slider core 78 is movable between a first position (Fig. 2) in which the second slider core 78 is spaced apart from the first and second mold halves 72 and 74, and a second position (Fig. 3) in which the second slider core 78 is seated against the first and second mold halves 72 and 74. In the example provided, the second slider core 78 has an exterior surface that is configured to form the portion of the circumferential wall 16 that defines the second bore 44 as well as the portion of the interior surface 20 (Fig. 1) of the casting 10 (Fig. 1) that is disposed axially between the second axial end surface 24 and the annular mount 30.

[D021] The auxiliary slider core 80 can be housed in the first slider core 76 and can be movable along a fourth movement axis 100 that is skewed or slanted relative to the second movement axis 90. In the example provided, the auxiliary slider core 80 is received into a slider core bore 102 formed through the first slider core 76 along the fourth movement axis 100. The auxiliary slider core 80 is movable between a first positon (Fig. 2), in which a forming portion 108 of the auxiliary slider core 80 is retracted Into the first slider core 76, and second position {Fig. 4), in which the forming portion 108 of the auxiliary slider core 80 extends from ihe first slider cone 76. The forming portion 108 is configured to form the portion of the interior surface 20 (Fig. 1) that is defined by the casting undercut 36 (Fig. 1).

[0022] The auxiliary slider core transport 82 is configured to move the auxiliary slider core 80 along the fourth movement axis 100 based on movement mat is directed along the second movement axis 90. In the particular example provided, the auxiliary slider core transport 82 is slidably received in a bore 120 formed into the first slider core 76 along the first movement axis 86 and includes a cam (not shown) that engaged to a cam follower (not shown} coupled to the auxiliary slider core 80. The cam and cam follower are configured to convert the motion of the auxiliary slider core transport 82 along the second movement axis 90 (relative to the first slider core 76) into corresponding motion of the auxiliary slider core 80 along the fourth movement axis 100.

[0023] A die casting operation that employs the die cast mold tool 70 can begin with each of the first and second mold halves 72 and 74, the first slider core 76, the second slider core 78, and the auxiliary slider core 80 in their respective first positions. Thereafter, the first and second mold halves 72 and 74 can be dosed against one another and the first and second slider cores 76 and 78 can be moved along the second and third movement axes 90 and 96 into their second positions as shown in Figure 3. Thereafter, movement of the auxiliary slider core transport 82 along the second movement axis 90 can cause corresponding movement of the auxiliary slider core 80 along the fourth movement axis 100 to its second position as shown in Figure 4. In the condition depicted in Figure 4, the die cast mold tool 70 defines a mold cavity 150 that is configured to form the interior surface 20 (Fig. 1 ) of the casting 10 (Fig. 1 ).

[0024] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

CLAIMS What is claimed is:

1. A moid tool (70) comprising:

a first mold half (72);

a second mold half (74) that is movable relative to the first mold half (72) along a first movement axis (86) between an open position, in which tine first and second mold halves (72, 74) are spaced apart from one another along the first movement axis (86), and a closed position in which the first and second mold halves (72, 74) are seated against one another;

a first slider core (76) that is movable relative to the first and second mold halves

(72, 74) along a second movement axis (90), between a first position, in which the first slider core (76) is spaced apart from the first and second mold halves (72, 74) and a second position in which the first slider core (76) is seated against at least one of the first and second mold halves (72, 74), wherein the second movement axis (90) is not parallel to the first movement axis (66);

an auxiliary slider core (80) that is mounted in the first slider core (76) for sliding movement along a third movement axis (100) that is hot parallel to the first movement axis (66) or the second movement axis (90), the auxiliary slider core (80) being movable between a retracted position, in which a forming portion (108) on the auxiliary slider core (80) is retracted into the first slider core (76), and an extended position in which the forming portion (108) on the auxiliary slider core (80) extends from the first slider core (76); and

an auxiliary slider core transport (82) movably coupled to both the auxiliary slider core (80) and the first slider core (76), the auxiliary slider core transport (82) being movable relative to the first slider core (76) in directions that are parallel to the second movement axis (90), wherein movement of the auxiliary slider core transport (82) in a direction away from the first slider core (76) moves the auxiliary slider core (80) toward the retracted position, and wherein movement of the auxiliary slider core transport (82) in a direction toward the first slider core (76) moves the auxiliary slider core (80) toward the extended position.

2. The mold tool (70) of Claim 1, wherein the mold tool (70) defines a mold cavity (150) and wherein the forming portion (108) on the auxiliary slider core (80) forms a portion of the mold cavity (150) that is configured to form a casting undercut (36).

3. A method for forming a casting (10), the method comprising:

providing an auxiliary slider core (80) having a forming portion (108);

positioning the auxiliary slider core (80) into a first slider core (76) such that the forming portion (108) of the auxiliary slider core (80) is retracted into the first slider core (76);

moving a first mold half (72) relative to a second moid half (74) along a first movement axis (86) to seat the first and second mold halves (72, 74) against one another,

with the auxiliary slider core (80) retracted into the first slider core (76), moving the first slider core (76) relative to the seated first and second mold halves (72, 74) along a second movement axis (90) to seat the first slider core (76) against at least one of the first mold half (72) and the second mold half (74), the second movement axis (90) not being parallel to the first movement axis (86);

moving an auxiliary slider core transport (82) toward the first slider core (76) in a direction parallel to the second movement axis (90) to extend the forming portion (108) from the first slider core (76); and

directing a liquid material into a moid cavity (150) that is at least partly defined by the first mold half (72), the second mold half (74), the first slider core (76) and the forming portion (108) of the auxiliary slider core (80).

4. The method of Claim 3, wherein the liquid is a molten metal.

5. The method of Claim 3, wherein the forming portion (108) on the auxiliary slider core (80) forms a portion of the mold cavity (150) mat is configured to form a casting undercut (36).