WO2018103789A1

WO2018103789A1 - Casting device, press and method for casting a component and component

Info

Publication number: WO2018103789A1
Application number: PCT/DE2017/101016
Authority: WO
Inventors: Martin Gaebges; Daniel Pietzka; Michael Richter; Michael Werbs; Tobias Schwarz
Original assignee: Schuler Pressen Gmbh
Priority date: 2016-12-05
Filing date: 2017-11-23
Publication date: 2018-06-14
Also published as: DE102016123491B4; DE102016123491A1

Abstract

The invention relates to a casting device for casting a component using a tool which comprises a mould for forming the component, said casting device comprises a tool receptacle for receiving the tool, having at least two metering cavities which is associated with a fluidic connection such that melts in the metering cavities can be transferred to the mould. The invention further relates to a press and to a method for casting a component.

Description

Casting device, press and method for casting a

Component and component

The invention relates to a casting device for casting a component by means of a tool, which has a mold for forming the component and the casting device has a tool holder for receiving the tool. Furthermore, the invention relates to a press and a method for casting a component and a component.

[02] In conventional die casting, the casting mold is filled with melt from a central casting unit by a movement of a driven casting piston. In this case, the casting unit is usually arranged outside of the casting tool, so that there is a long flow path of the melt up to the mold to be filled.

[03] For example, die casting devices and / or die casting processes are disclosed in DE 39 31 194 A1 and DE 102 56 834 A1.

[04] The disadvantage is that due to the temperature loss of the melt along the flow path, the casting time is limited because the melt already begins to solidify on the flow path. This requires a high flow rate of the melt, which in turn leads to abrasive wear of the tool and / or the mold. In addition, the fluidic resistance on the flow path leads to a high required drive energy and / or a high required casting pressure in the mold. [05] The above-mentioned disadvantages exist even if the melt is not supplied centrally at one point of the mold, but is divided by a sprue system with branches in partial streams and enters the mold at several points.

[06] Consequently, the known casting apparatuses and casting methods are limited for the above-mentioned reasons in terms of the manufactured wall thickness, strength and the production of large-area parts.

[07] In order to realize a method for producing cast components in several casting runs, DE 10 2013 101 962 B3 discloses an electromagnetic

Casting drive to adjust the speed of the melt in the casting runs by means of electromagnetic fields.

DE 39 31 194 AI discloses a hot chamber die casting machine with a Eingusssystem and several casting units, each casting unit consists of an oven, crucible, casting container and a press-in cylinder with pressure piston and the respective pressure piston of the plurality of casting units for the production of large-scale castings jointly controlled are.

[0001] DE 102 56 834 A1 claims a method and an apparatus for producing large-area workpieces in the die-casting method with a plurality of casting systems, which each have a casting cylinder and a driving hydraulic cylinder, wherein each casting cylinder is connected to the casting mold via a plurality of runners / sprues. In DE 196 06 806 AI has a device for thixoforming two mold halves and at least two runners, each run is fed by a separate filling chamber and the two runners are respectively arranged on the lower and the upper mold half.

[0001] EP 1 588 823 A1 relates to a device for producing injection-molded parts with a core part and a jacket part braced against one another, which form the mold, wherein a high-pressure feed line for the injection molding material opens into the cavity of the mold.

[12] The object of the invention is to improve the state of the art.

The object is achieved by a casting device for casting a component by means of a tool, which has a mold for molding the component, wherein the casting device has a tool holder for receiving the tool, with at least two Dosierkavitäten, each of which is assigned a fluid connection, so that located in the metering cavities melts are transferable into the mold.

[14] This eliminates or eliminates a central casting unit and / or a sprue system with branches.

[15] Because each dosing cavity is directly connected to the mold via a fluid connection, there is a shorter flow path to the mold. Consequently, the casting process can be performed much slower and / or with lower casting pressure than when using a central pouring unit. Consequently, the mold and / or tool wear is reduced.

[16] Since no complexly branched sprue system is used, but in each case a fluid connection which directly connects a dosing cavity as a local melt supply with the mold to be filled, the proportion of the solidified melt which remains in the fluid connection after the pouring operation is reduced by weight. Consequently, the waste to be disposed of and / or the circulation material are reduced.

[17] With regard to the projected tool surface, the locally arranged metering cavity with the short fluid connection leads to a smaller closing surface of the tool and thus to a lower required closing force of the casting device and / or press.

Furthermore, the casting tool can be designed and manufactured simpler due to the omission of the sprue knot and the omitted branched sprue system. In particular, the metering cavities in the tool can be manufactured together with the construction of the mold.

[19] An essential idea of the invention is based on the fact that several local metering cavities are arranged close to and / or within the mold cavity, so that the mold cavity is filled by these multiple local metering cavities via a very short fluid connection in each case.

[20] The following conceptual is explained In particular, a casting device has at least two dosing cavities as dosing container, at least two fluid connections and a shaping tool The casting device may be assigned a central melt container with liquid melt.

[22] "Casting" is, in particular, a manufacturing process in which a solid material of a certain shape is formed from a liquid material (melt) after solidification. or the continuous casting.

[23] A "component" is in particular an individual part of a technical complex, such as a machine or an apparatus, made of a workpiece, in particular, the component is created plastically due to a change in shape through targeted casting and / or reshaping finished or finished shapes or geometries.

[24] A "tool" is in particular an object in which a machining of a workpiece and / or a casting takes place for the manufacture of a component, wherein the tool is guided by a human and / or a machine In particular, the tool is used in a forming manufacturing process such as preforming, forming and / or master casting such as casting used in particular in a casting apparatus and / or a press. The tool may consist of a single tool part which directly has the shape of at least two tool parts, for example a lower and an upper tool, or a plurality of tool parts which form the mold in the case of closing the tool. Furthermore, the tool can also have other, not the form-forming tool parts. The tool may have an inner contour, which is applied as an outer contour of the component to be cast.

[25] A "mold" is understood to mean, in particular, a cavity of the tool whose inner contour is impressed on the workpiece as an outer contour and / or in which the cavity of the mold is poured with melt to produce the component " designated .

[26] A "tool holder" is a component which receives and / or holds the tool during casting and / or machining.The tool holder in particular allows rapid replacement of the tool and / or provides an interface between tool and drive.

[27] A "dosing cavity" is in particular a

Dosing container for melt, which is arranged locally in the vicinity of, on and / or in the form. In particular, the metering cavity absorbs only a portion of the melt, which is necessary for filling the mold. The various partial melts of each locally arranged In particular, metering cavities together produce at least the volume of melt which is necessary for completely filling the mold. The metering cavity may be a recess closed on three sides in the tool and / or in the mold for receiving the melt. Likewise, the metering cavity may be an open-topped container which is inserted into the tool and / or the mold.

[28] A "fluid connection" is, for example, a cavity which allows communication between a dosing cavity and the mold so that the melt can flow from the dosing cavity into the mold, The fluid connection may be a pipe or a channel However, fluid communication can also be a direct opening between the metering cavity and the mold, so that in this case the fluid connection has only a very short elongated extension of a few millimeters The melt flows through the fluid connection, in particular due to gravity and / or due to an applied casting pressure.

[29] A "melt" is in particular molten metal and / or metal alloys.

In a further embodiment, the casting device comprises the first metering cavity, the first fluid connection, the second metering cavity and the second fluid connection and / or a third metering cavity and a third fluid connection, a fourth metering cavity and a fourth fluid connection, a fifth metering cavity and a Fifth fluid connection and / or a further Dosierkavität and another fluid connection.

[31] Thus, several dosing cavities, each with a fluid connection, can be arranged locally according to the shape of the component to be cast and / or further requirements on the component. Here, the position, number and / or size of the metering cavities depends on the mass distribution of the component to be manufactured. Above all, the production of large-area components and / or a minimization of the wall thickness and / or an increase in the strength of the component is or will be made possible.

[32] The third, fourth, fifth and / or further dosing cavity corresponds in its design and function to the dosing cavity defined above.

[33] A third, fourth, fifth and / or further fluid connection corresponds in its design and function to the above-defined fluid connection.

[34] In order to cast complex and / or large-area components, the tool has a first tool part and a second tool part, which form the shape in the case of closing.

Of course, the tool may also have a third, fourth, fifth and / or further tool part, especially if special geometries and / or very large-area components to be cast. [36] In a further embodiment, the first tool part and the second tool part are aligned horizontally or vertically by means of the tool holder.

[37] Compared to the usual vertical alignment of the tool parts and mold in conventional casting, thus a horizontal arrangement of the tool parts and the shape is possible.

In order to transfer the melt from each metering cavity through the respective fluid connection into the respective mold with a corresponding pouring pressure and / or a corresponding flow rate, the pouring device has a first punch, a second punch, a third punch, a fourth punch, a fifth punch and / or a further punch, so that the melt is displaced in the respective Dosierkavitat by dipping the respective punch on the respective fluid connection in the mold.

[39] In the case of a horizontal alignment of the tool parts, a stamp preferably dips into the dosing cavity from above. In the case of a vertical alignment of the tool parts, the stamp is moved laterally into the dosing cavity and must therefore seal the dosing cavity with the melt before the dosing cavity is filled. In this case, filling of the dosing cavity takes place, for example, by means of an additional filling opening arranged at the top in the dosing cavity.

[40] A "stamp" (also called "metering bolt") is in particular a component which due to its movement displaces the melt in a Dosierkavität and thereby pressed by the associated fluid connection in the mold. For example, a punch may be a cylinder of solid material with or without venting. The shape of the punch is particularly matched to the inner shape of the metering cavity, so that the punch can dive flush into the associated Dosierkavität.

[41] In a further embodiment of the casting apparatus, the metering cavity is arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa.

[42] Thus, the plunger for immersion in the respective Dosierkavität not each need their own drive, but the immersion of the punch can be realized by a movement of the first tool part and / or the second tool part. For this purpose, the length of each stamp is matched to the corresponding end position of the movable first tool part and / or the second tool part. The punches and / or the dosing cavities can be arranged flush, protruding and / or recessed on the first tool part and / or on the second tool part.

[43] In order to keep the amount of solidified melt after casting and thus the accumulation of waste and / or circulation material and the explosive surface small, the metering cavities are arranged directly on and / or in the mold, so that the fluid connection or the fluid connections Length less than 50mm, in particular less than 20mm, preferably less than 5mm or have.

[44] Thus, a dosing cavity may also be part of the mold.

[45] It is particularly advantageous if the fluid connection is made only as a direct opening between the metering cavity and the mold.

[46] In addition, a very short fluid connection reduces the volume of air in the fluid connection, which is present before casting, so that less air is introduced into the mold during casting. This will cast a more homogeneous component.

[47] In a further embodiment, the casting device has at least one casting robot and / or a melt container.

As a result, the metering cavities can be filled with melt by means of at least one casting robot from a melt container. Preferably, each dosing cavity is filled by its own casting robot, so that all dosing cavities can be filled at the same time.

[49] A "pouring robot" is in particular a robot with a mounted ladle for the automated pouring of melt from the melt container into a metering cavity Inclined positions of the ladle are accurately measured by a distance measurement.

[50] A "melt container" is a container into which a solid is melted to form a liquid melt, and in particular the melt for each dosing cavity to be filled is removed from the melt container by means of a casting robot or several casting robots.

[51] In a further aspect of the invention, the object is achieved by a press for casting a component, wherein the press has a drive for applying a pressing force, with a casting described above orrichtung.

[52] Thus, not only a pressing force can be applied via the drive of the press, but also the shape can be filled beforehand by a movement of a tool part by immersing the punches in the metering cavities. Thus, no separate drive and / or separate hydraulic cylinders are or are necessary for the punch movement.

[53] Consequently, the press can be made in a smaller size. In addition, with the press according to the invention also large-area components, in particular in a horizontal orientation, are manufactured, so that the overall height of the press is reduced compared to a vertical orientation.

[54] A "press" is in particular a forming machine with rectilinear relative movement of the tool Primary forming, casting, forming, deep-drawing, joining, coating, cutting, cutting and / or modification of material properties. In particular, a press is a bound, energy or force press.

[55] In a further embodiment of the press, the first tool part and / or the second tool part has or have a movable tool part and a fixed tool part, so that a movement of the stamp can be realized free of application of the pressing force via the movable tool part.

By dividing the first and / or the second tool part into a movable tool part and a fixed tool part can first on the movable tool part, the punch movement for filling the mold and then via a movement of the fixed tool part compaction and repressurization of the melt and Pressing of the molded component due to the application of the pressing force to the fixed tool part and the movable tool part done. Thus, both the filling of the mold and the actual pressing can be realized by means of a single tool with a movable and a fixed part.

[57] In an additional aspect of the invention, the object is achieved by a method for casting a component by means of a previously described casting device and / or a previously described press, comprising the following steps: Filling at least two metering cavities by means of at least one casting robot with melt,

Closing the first tool part and the second tool part to form the mold,

Immersing one stamp in the respective metering cavity by a movement of the first tool part or of the second tool part and displacing the melt out of the metering cavities through the fluid connections into the mold,

- Connecting the melts in the mold to form a homogeneous component.

[58] Thus, a simplified method for casting a component is provided in which over locally arranged metering cavities filling of the mold and thus casting of the component takes place. Above all, the method makes it possible to cast a homogeneous and / or large-area component.

[59] In a further aspect of the invention, the object is achieved by a component, wherein the component is manufactured according to a method described above.

[60] Due to the adaptation of the position, number and / or size of the dosing cavities to the mass distribution of the component to be manufactured a very homogeneous component is manufactured with increased strength. In addition, components with smaller wall thicknesses and / or larger components can be manufactured. [61] In the following, the invention will be explained in more detail with reference to exemplary embodiments. Show it

Figure 1 is a schematic sectional view of a press with a

Die casting and an open tool with Dosierkavitäten and dosing,

Figure 2a, the press of Figure 1 with open

Tool and filled dosing cavities,

Figure 2b shows the press of Figure 2a with closed

Tool and immersed dosing bolts,

Figure 2c, the press of Figure 2b with further

Dipping the dosing bolts and

Recompressing, and

FIG. 2d shows the press from FIG. 2c

Constant holding of the pressing force.

[62] A press 101 has a die casting apparatus 103 and a tool 105. The tool 105 consists of the upper tool base plate 111, the shaping upper tool 107 and the lower tool 109. The upper tool base plate 111 is fastened to a press ram 117 and has two dosing bolts 123. The upper tool base plate 111 is connected to the movable upper forming tool 107 via two springs 125. The upper tool 107 has two spacers 128 above the

Upper tool base plate 111 on. [63] The lower tool 109 is attached to a press table 119 and has two metering cavities 121. On both sides of the edge of the lower tool 109 two distance cylinder 127 are attached. Below the

Press table 119, a Tischauswerferplatte 129 is arranged.

[64] In the case of closing the tool 105, the upper die 107 and the lower die 109 form the mold cavity 113.

[65] The metering bolts 123 are matched in their length to a lower end position of the upper tool 107. The distance cylinder 127 of the lower tool 109 have an upper and a lower end position.

[66] The following operations are carried out with the press 101, the die casting apparatus 103 and the tool 105:

[67] With the tool 105 open, the press ram 117 is at top dead center. The movable upper tool 107 has been lowered and is held with a spring force of the springs 125 in its lower position. By means of two pouring robots, not shown, the two metering cavities 121 of the lower tool 109 are filled with a respective required melt volume from a central melt container, not shown. The distance cylinder 127 in the lower tool 109 are in this case in their upper end position.

[68] After filling the metering cavities 121 by a movement of the press ram 117 down in a Closing direction 131, the tool 105 is closed. In this case, on the one hand, the upper tool 107 continues to be pressed in addition to the weight by the acting springs 125 with a preselected force down and on the other now additionally pressed when closing the tool upwards against the closing direction 131 until the spacer elements 128 a path between the movable upper tool 107 and the upper tool base plate 111 limit. Only when the spacer elements 128 to the stop

Upper tool base plate 111 is a ram force greater than the spring force on the upper tool 107 transferable.

By placing the upper tool 107 on the distance cylinder 127 of the lower tool 109, the mold cavity 113 is closed. In this case, however, the mold cavity 113 is not yet closed to the extent that a wall thickness of a component to be manufactured is reached. The closing in the closing direction 131 is continued, with the dosing bolts 123 dipping into the dosing cavities 121 and displacing the melts from the dosing cavities 121 into the directly connected mold cavity 113. In this case, the closing force between upper tool 107 and lower tool 109 merely consists of a dead weight of the movable upper tool 107 and the springs 125, so that no higher casting pressure is produced in the tool 105.

[70] The filling of the mold cavity 113 is terminated when the spacer element 128 between the fixed

Upper tool base plate 111 and the movable upper tool 107 sit and transmit a force. Then the distance cylinder 127 in the lower tool 109 are relieved and the upper tool base plate 111 and the movable upper tool 107 are further moved in the closing direction 131 until the tool 105 is closed so far that the actual wall thickness of the component to be cast is reached. The metering bolts 123 continue to dip into the metering cavities 121 and compact the cast component. In this recompression at the same time the ram force is exerted on the cast component over an entire surface of the tool 105.

[71] The ram force is maintained and after solidification of the cast component, the tool 105 is opened. Subsequently, the component is lifted for removal via the Tischauswerferplatte 129 in the press table 119.

[72] Thus, a press with die casting and a tool with integrated Dosierkavitäten and dosing provided, which allow very short flow paths to the mold cavity, a low mold and tool wear and a low scrap material. In addition, a very homogeneous component with a complex, large-area geometry is manufactured.

REFERENCES 101 Press

103 die casting device

105 tool

107 upper tool

109 lower tool

111 upper tool base plate

113 mold cavity

117 press ram

119 Press table

121 dosing cavity

123 dosing bolts

125 spring

127 distance cylinder

128 spacer element

129 Table ejector plate 131 Closing direction

Claims

Claims:

A casting apparatus (103) for casting a component by means of a tool (105) having a mold (113) for molding the component, the casting apparatus having a tool holder (111, 119) for receiving the tool, characterized by at least two dosing cavities (121), which in each case a fluid connection is assigned, so that located in the metering cavities melts are transferable into the mold.

2. Casting apparatus according to claim 1, characterized in that the casting device, the first Dosierkavität, the first fluid connection, the second Dosierkavität and the second fluid connection and / or a third Dosierkavität and a third fluid connection, a fourth Dosierkavität and a fourth fluid connection, a fifth Dosierkavität and a fifth fluid connection and / or a further dosing cavity and a further fluid connection.

3. Casting device according to one of the preceding claims, characterized in that the tool has a first tool part (107) and a second tool part (109), which form the shape in the case of closing.

4. Casting device according to claim 3, characterized in that the first tool part and the second tool part are aligned horizontally or vertically by means of the tool holder.

5. Casting device according to one of the preceding claims, characterized in that the casting device, a first punch (123), a second punch, a

90 third punch, a fourth punch, a fifth punch and / or another punch, so that the melt is displaced in the respective Dosierkavität by dipping the respective punch on the respective fluid connection in the mold.

Casting device according to one of claims 3 to 5, characterized in that the metering cavities are arranged on and / or in the first tool part and the punches on and / or in the second tool part or vice versa.

Casting device according to one of the preceding claims, characterized in that the metering cavities are arranged directly on and / or in the mold, so that the fluid connection or the fluid connections has a length less than 50mm, in particular less than 20mm, preferably less than 5mm or have.

Casting device according to one of the preceding claims, characterized in that the casting device at least one casting robot and / or a

Has melt container.

Press for casting a component, wherein the press has a drive for applying a pressing force, characterized by a casting device according to one of claims 1 to 8.

Press according to claim 9, characterized in that the first tool part and / or the second tool part has a movable tool part (107) and a fixed tool part (111) or, so on the movable tool part, a movement of the stamp free from an application of the pressing force is feasible.

91

1. A method for casting a component by means of a casting apparatus according to one of claims 1 to 8 and / or a press according to claim 9 or 10, characterized by the following steps:

Filling at least two metering cavities by means of at least one casting robot with melt,

Closing the first tool part and the second tool part to form the mold,

Exchanging in each case one punch in the respective metering cavity by a movement of the first tool part or of the second tool part and displacing the melts out of the metering cavities via the fluid connections into the mold,

- Connecting the melts in the mold to form a homogeneous component.

2. Component, characterized in that the component is manufactured by a method according to claim 11.