EP0941789B1 - Verfahren und Einrichtung zum Giessen von Teilen aus Leichtmetall-Legierungen - Google Patents

Verfahren und Einrichtung zum Giessen von Teilen aus Leichtmetall-Legierungen Download PDF

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Publication number
EP0941789B1
EP0941789B1 EP99400547A EP99400547A EP0941789B1 EP 0941789 B1 EP0941789 B1 EP 0941789B1 EP 99400547 A EP99400547 A EP 99400547A EP 99400547 A EP99400547 A EP 99400547A EP 0941789 B1 EP0941789 B1 EP 0941789B1
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Prior art keywords
mould
mold
sand
process according
casting
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EP99400547A
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English (en)
French (fr)
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EP0941789A1 (de
Inventor
Philippe Meyer
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Montupet SA
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Montupet SA
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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
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • 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
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D33/00—Equipment for handling moulds
    • B22D33/02—Turning or transposing moulds

Definitions

  • the present invention relates to a new process production of alloy casting parts aluminum, as well as an installation for the work of this process.
  • the quality of these parts relates so much to the aspects metallurgical (i.e. researching the most highest by a most foundry microstructure as fine and as healthy as possible in the areas requested) only on the dimensional aspects (in particular the maximum dimensional accuracy of all the room geometries that are critical for vehicle performance.
  • the metal mold foundry processes essentially the gravity process and the process by low pressure are certainly economically efficient and deliver a high level of metallurgical quality and dimensional. They are however unsuitable for production of parts with complex shapes.
  • the interior shapes are in this case produced by chemically bound sand cores, and these processes are only suitable if it is possible to insert all of these nuclei quickly after opening the mold and extracting the part previous.
  • the present invention aims to overcome the limitations of the state of the art and to propose a foundry process which better responds to needs of the market and in particular of the automobile market, while remaining economical implementation.
  • Another object of the present invention is to propose a foundry process using at least substantial part of the sand with physical setting, or sand green, not posing the particular problems of recycling and environment encountered with sands at chemical setting.
  • the invention offers a mold intended for the casting of a piece in light alloy such as aluminum alloy, the mold being provided with a molten alloy supply channel under pressure, the mold being characterized in that it is rotatably mounted on an essentially horizontal axis of so that it can be returned after filling, and what it includes a mechanical sealing means supply channel.
  • FIG. 1 we have shown a mold 10 whose imprints are formed by physically bound sand, i.e. not using no thermally or chemically cured resin, and preferably by sand to green.
  • the sand with green has a cost per unit of weight which is ten to fifteen times lower than that of a box type chemical sand Cold.
  • this type of sand does not pose the recycling and pollution problems posed so known by chemical setting sands.
  • This sand is used in chassis, most of the mold, produced in the form of two half-molds 10a and 10b, consisting of two metal half-frames 17a, 17b, each half-chassis carrying a half-cavity 11a, 11b carried out by the usual technologies of production of green sand molds, using a model.
  • each half-chassis Before closing the two half-frames, one on the other, each half-chassis is presented on a conveyor C in open position, indent side facing high, so as to facilitate remolding, that is to say the positioning of the different cores and inserts (together 13 primary and individual secondary nuclei 12) intended for obtaining interior shapes and certain external forms of the part to be produced, the example illustrated schematically here being that of a engine block.
  • These cores can be handled by hand in the case of small cores 12, or even by robots operating in successive work stations (case of the main set of cores 13).
  • These cores are preferably made of chemical setting sand (preferably of the cold box type or according to the “Isocet” type process.
  • silica sand (SiO 2 ) with a particle size equal to approximately 55 is preferably used. -60 AFS or more, the best surface states being obtained with the highest AFS particle size values).
  • nuclei 13 has in this example, besides different chemical sand nuclei 131 forming the desired geometry, metallic inserts 132 intended for form cylinder liners, as well as a block massive metallic cooling 16, as we will see further.
  • This cooling block can be incorporated into the set of cores 13 during the production of the nuclei 131, so as to produce a joining between cores and cooler.
  • the two half-chassis are assembled, the upper half-chassis, initially placed next to the lower half-chassis, imprint up, being turned 180 ° (see position of Figure 2a) to be assembled, with appropriate position indexing means, on the half-frame inferior.
  • FIG. 2b illustrates the position of the mold 10 during the filling phase, the example always being that of molding of an engine block.
  • Convenient filling at the bottom pressure is preferably achieved with the contacting of the sand mold 10 with a dip tube (not shown on Figure 2a) connected to a sealed oven type low oven pressure, classic in itself. After this docking, the metal rise and flow control are done by pressurization of the oven. Alternatively, use an electromagnetic pump.
  • An advantageous characteristic of the process according to the invention is the use of a mechanical obturation of the feeding system at the end of filling and before turning the mold 180 °.
  • Such a reversal has for the purpose of putting the flyweights 14 in the high position and achieve solidification under conditions identical to those of gravity feed.
  • reversal must be performed no later than 15 seconds, preferably 5 seconds later, after shutter.
  • the filling itself is performed the most as soon as possible after filling is complete not to waste time and not to be disturbed by a beginning of solidification in the supply duct.
  • the obturation is carried out at the latest 10 seconds after completion of filling, without that exceeding this limit poses a risk for the health of the room.
  • the sealing device allows the metal to remain in the mold, so that it contributes significantly entirely, to the process (increase in the volume of weights).
  • obturation can be achieved by the actuation of a metal hatch placed in the sand mold, as will be described in detail later (guillotine system), or by any other solution mechanical performing this function.
  • FIG. 2c illustrates the position of the mold 10 after 180 ° turning, the engine block produced being designated by BM.
  • the arrows F2 indicate the direction of propagation main cooling, this cooling mostly done from the cooler massive 16 now located in the lower part.
  • the method according to the invention puts advantageously in play one or more coolers placed opposite the weighting system and remoulded during the assembly sequences of the assembly principal of 13 nuclei in chemically bound sand.
  • coolers are preferably consisting of masses of cast iron or a other material with absorption capacity adequate heat. These masses can if necessary be in shape, that is to say serve to achieve partially the geometry of the part.
  • the coolers will preferably be monobloc. They can be placed in the core boxes used the production of chemically set and inserted cores in these at the time of their realization by spraying and polymerization of resin-coated sand in the core box.
  • the part is then subjected to the usual cycles of cleaning (removal of sand), deburring, heat treatment, machining and control.
  • FIGS 3a to 3e schematically illustrate the process of the invention, in which provision is made at the level passage 22 for supplying liquid metal, intended to be connected to the dip tube 20, sealing means, generally designated by the reference 30, which we will describe an example below.
  • the sealing means 30 are open and the supply tube 20 is docked on the mold 10 by movement of the mold according to arrow F3 ( Figure 3a). More precisely, thanks to an opening 21 practiced in the mold frame, the tube feed 20 then comes into contact with the sand to physical grip of the mold. Filling by bass pressure is then carried out ( Figure 3b). Ways shutter are then used to isolate the mold cavity, once filled, of the system feed (arrow F4 in Figure 3c), then we separate the dip tube 20 of the mold 10 according to arrow F5 (figure 3d). Finally the turning by rotation around a horizontal axis A is produced according to F6 in Figure 3e).
  • Figures 4a to 4d and Figure 5 illustrate a example of concrete implementation of the sealing means 30.
  • These include a metal plate 31, for example example in cast iron or steel, with a thickness of the order from 2 to 5 mm, inserted in one (here 11b) of the two footprints in sand to green of the mold during the realization thereof so as to be at the right of the metal supply channel 22.
  • the plate 31 At its free end facing the channel 22, the plate 31 has two lateral appendages 31a intended to allow a easy positioning of the plate 31 during the realization of the half-mold 11b, as well as to facilitate guiding the plate during its movement to shutter position.
  • the opposite imprint 11a has two substantially complementary cavities 33 in which said appendages can come engage when assembling the two half-chassis.
  • Figure 4a illustrates the making of the imprint 11b with a PM model plate, the imprint including the cover plate 31 and the two overhanging appendages 31a.
  • FIG. 4b illustrates the assembly of the two half-chassis, the ends of the appendages 31a, 31a engaging in the cavities 33 of the opposite impression.
  • FIG. 4c illustrates a cavity 34 formed in the imprint 11b and intended to receive the rod 216 and the head 216a of a jack intended to act on the plate 31 for close the channel 22 before closing.
  • the bottom of this cavity ends a short distance from the edge of the plate 31 opposite the channel.
  • Figure 4d illustrates the situation after the jack, via the rod 216 and its head 216a, pressed plate 31, after having driven out locally sand to green, to achieve the filling.
  • Figures 6a to 6c give an example of a mold handling EQ equipment which includes a main frame 100 comprising a frame part mobile 106 mounted on a base plate by through a tree 104 so that we can rotate around a vertical axis B under the action of a motor, like a carousel.
  • a secondary frame 200 intended to receive a mold 10 and to move it as we will see it later.
  • This secondary frame has a 202 mounted frame pivoting, for example on a toothed wheel 108, the rotation about the horizontal axis A is controlled by a suitable motor (not shown).
  • the mold 10 is mounted in this frame 202 with its feed channel 22 facing outward, and is held in place between a stressed pressure plate 204 by a jack 208 and a counter plate 210. Rollers of guide 206, 212 defining supports according to different directions allow the mold to be guided and wedged 10 in position in the equipment.
  • Figures 7a and 7b show the same equipment in side elevation, with the oven 300 fitted with its tube supply 20.
  • the secondary frame 200 is mounted via slides 110 on guide rails 220 integral with the main frame 106, to be able to slide, when the mold 10 is located with its supply channel 22 facing to the feed tube 20, in approach and at distance from this tube, under the action of a jack (not represented).
  • FIGS 8a to 8c illustrate for above the equipment described above, in cooperation with the conveyor C on which the molds are assembled, the low pressure oven 300 and a conveyor C 'for the start products after pouring and turning, to the cooling station.
  • the EQ equipment then rotates 90 ° around the vertical axis B, so that the mold 10 is facing the oven, and, simultaneously or dissociated, the mold is rotated 90 ° to adopt its position vertical molding ( Figures 6b and 8b).
  • the mold 10 is then moved in translation towards the oven 300 for bringing the supply tube 20 into waterproof communication with its supply channel 22 ( Figure 7a), and the low pressure casting is performed.
  • the channel 22 is closed and the pressure of the furnace 300 is released so as to bring the metal at a lower level than the tube feed 20, then the mold 10 is separated from the tube supply 20 and returned 180 ° around the axis horizontal A as described above ( Figure 6c and 7b).
  • the frame 200 is rotated 90 ° around the vertical axis B to bring the mold 10 facing an outlet conveyor C '(figure 8c) directing the mold to a cooling station.
  • a 4-cylinder in-line engine block weighing 18 kg is produced according to the low-pressure supply system shown in FIG. 2, but without coolers and with green sand of the zircon type with a particle size 113 AFS and of the following composition (in percentages by mass): bentonite 1.8%, water 1.5% the rest being zircon sand.
  • Interior and end cores are made with setting sand chemical.
  • the alloy used for casting has the following composition (in mass percentages): Yes 8.6% Cu 2.2% mg 0.3% Fe 0.4% mn 0.3% the rest being aluminum.
  • the temperature of the metal at the time of casting is 720 ° C.
  • Filling is carried out at low pressure and lasts 15 seconds.
  • the supply system is blocked performed 2 seconds after filling is completed.
  • the 180 ° turnaround is performed 30 seconds after filling.
  • the same engine block is made with a mold sand to siliceous green with a particle size of 55-65 AFS with the same bentonite and water concentrations as in example 1.
  • the inner cores and ends are made of chemical setting sand as in Example 1.
  • a cast iron cooler 16 is placed as shown in figure 2.
  • the conditions of pouring and filling are identical to those of Example 1.
  • the obturation is carried out 2 seconds after the end of filling.
  • 180 ° flipping begins a second after the shutter lasts 4 seconds. During this phase of reversal, it is advantageous to carry out the depressurization of the low pressure oven which is used to bring the liquid metal in the mold.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Mold Materials And Core Materials (AREA)
  • Forging (AREA)
  • Powder Metallurgy (AREA)
  • Casting Devices For Molds (AREA)
  • Dental Prosthetics (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Claims (20)

  1. Verfahren zum Gießen eines Teils aus einer Leichtmetalllegierung, wie einer Aluminiumlegierung, dadurch gekennzeichnet, dass es die aufeinanderfolgenden Schritte umfasst, bestehend aus:
    Herstellen einer Gießform (10) mit Formabdruck (11a, 11b) aus physikalisch abbindendem Sand,
    Einfügen eines verschiebbaren Verschlussmittels (31) in die Gießform in der Nähe einer Materialzufuhrleitung (22) der Gießform,
    Aufstellen der Gießform dergestalt, dass ihre Materialzufuhrleitung sich an der Unterseite befindet,
    Verbinden der Materialzufuhrleitung der Gießform mit einem Rohr für die Materialzufuhr (20) von geschmolzener, unter Druck gesetzter Legierung,
    Durchführen des Auffüllens der Form mit der Legierung,
    vor einer jeglichen substantiellen Verfestigung des Teils Verschieben des Verschlussmittels (31), um die Materialzufuhrleitung zu verschließen, dann Umkehren der Gießform um ungefähr 180°, um eine Verfestigung im Schwerkraftmodus sicherzustellen.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der Verschließschritt weniger als etwa zehn Sekunden nach dem Ende des Füllschritts beendet ist.
  3. Verfahren nach einem der Ansprüche 1 und 2, dadurch gekennzeichnet, dass der Umkehrschritt spätestens 25 Sekunden nach dem Ende des Verschließens beendet ist.
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass der Umkehrschritt spätestens 15 Sekunden nach dem Ende des Verschließens beendet ist.
  5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass man eine Gießform aus siliciumhaltigem Sand mit einer Korngrößenverteilung zwischen ungefähr 40 und ungefähr 55 AFS verwendet.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass man eine Gießform aus siliciumhaltigem Sand mit einer Korngrößenverteilung von wenigstens 80 AFS verwendet.
  7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass man eine Gießform mit zwei Halbrahmen (10a, 10b) verwendet und dass der Schritt der Herstellung der Gießform die Phasen umfasst, bestehend daraus, dass man in den zwei Halbrahmen zwei Halbformabdrücke formt, man Formkerne (12, 13) in den zwei Halbrahmen, die mit ihrem Halbformabdruck auf der Oberseite angeordnet sind, anordnet und man die zwei Halbrahmen zusammensetzt.
  8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass der Schritt des Zusammensetzens der zwei Halbrahmen zu einer Gießform in im allgemeinen horizontaler Position führt und dass es außerdem den Schritt umfasst, der darin besteht, die Gießform bis zu einer im allgemeinen vertikalen Füllposition umkippen zu lassen.
  9. Verfahren nach einem der Ansprüche 7 und 8, dadurch gekennzeichnet, dass die Kerne (12, 13) aus chemisch abbindendem Sand hergestellt sind.
  10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die Kerne aus siliciumhaltigem Sand mit einer Korngrößenverteilung von wenigstens 40 AFS hergestellt sind.
  11. Verfahren nach einem der Ansprüche 8 bis 10, dadurch gekennzeichnet, dass es nach Verfestigung des Teils einen Schritt einer Trennung des Teils und der Gießform umfasst, der es erlaubt, den Formabdrucksand und den Sand der Kerne getrennt zurückzugewinnen.
  12. Verfahren nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass es außerdem vor dem Schritt des Füllens der Gießform einen Schritt einer Anordnung von wenigstens einer massiven Kühlvorrichtung (16), die in einem Bereich der Gießform, der sich von dem Materialzufuhrbereich der Gießform entfernt befindet, plaziert wird, und nach der Verfestigung einen Schritt einer Rückgewinnung der Kühlvorrichtung oder Kühlvorrichtungen umfasst.
  13. Einrichtung zum Gießen eines Teils aus einer Leichtmetalllegierung, wie einer Aluminiumlegierung, dadurch gekennzeichnet, dass sie umfasst:
    eine Gießform (10), die in der Lage ist, durch Drehung um eine im wesentlichen horizontale Achse umgekehrt zu werden, die eine Rinne (22) für die Zufuhr von geschmolzener Legierung aufweist und ein Mittel (31) zum Verschließen dieser Rinne aufweist, und
    eine Vorrichtung (EQ) zur Bewegung der Gießform, die in der Lage ist, die Form durch Drehung um die horizontale Achse zu verschieben, und ein Mittel (214, 216) zur Betätigung des Verschlussmittels aufweist.
  14. Einrichtung nach Anspruch 13, dadurch gekennzeichnet, dass die Bewegungsvorrichtung (EQ) Mittel aufweist, um die Gießform in Form einer Parallelverschiebung in Richtung eines Rohrs (20) für die Materialzufuhr von geschmolzener Legierung zu verschieben.
  15. Einrichtung nach einem der Ansprüche 13 bis 14, dadurch gekennzeichnet, dass die Bewegungsvorrichtung gleichfalls in der Lage ist, die Gießform durch Drehung um die horizontale Achse zwischen einer Anfangsposition am Ausgang einer Station zum Zusammenbau der Gießform und einer Gießposition zu verschieben.
  16. Einrichtung nach einem der Ansprüche 13 bis 15, dadurch gekennzeichnet, dass die Bewegungsvorrichtung in der Lage ist, die Gießform um eine vertikale Achse herum zu verschieben, damit diese jeweils mit einer Zufuhrfördereinrichtung (C) der Gießform, einem Niederdruckgießofen (300), der mit dem Rohr für die Materialzufuhr (20) ausgerüstet ist, bzw. einer Ausgangsfördereinrichtung (C') der Gießform zusammenwirkt.
  17. Gießform (10), die für das Gießen eines Teils aus einer Leichtmetalllegierung, wie einer Aluminiumlegierung, bestimmt ist, wobei die Form mit einer Rinne (22) für die Zufuhr von geschmolzener, unter Druck stehender Legierung ausgestattet ist, wobei die Gießform dadurch gekennzeichnet ist, dass sie um eine im wesentlichen horizontale Achse (A) drehbar montiert ist dergestalt, dass sie nach dem Füllen umgekehrt werden kann, und dass sie ein mechanisches Verschlussmittel (30, 31) für die Zufuhrrinne umfasst.
  18. Gießform nach Anspruch 17, dadurch gekennzeichnet, dass sie wenigstens einen Formabdruck (11b) aus physikalisch abbindendem Sand aufweist und dass das mechanische Verschlussmittel eine Metallplatte (31) umfasst, die in den Formabdruck inkorporiert ist und direkt von jenem geführt wird.
  19. Gießform nach Anspruch 18, dadurch gekennzeichnet, dass sie eine Scheinaussparung (34) umfasst, die rechts von einem Rand der genannten Metallplatte endet und in der Lage ist, eine Stange (216) eines Betätigungsmittels der Platte aufzunehmen.
  20. Gießform nach einem der Ansprüche 18 und 19, dadurch gekennzeichnet, dass die Platte (31) wenigstens einen Führungsansatz (31a) aufweist, der in einer anfänglichen Position der Platte, in einen gegenüberliegenden Formabdruck (11a) der Gießform eindringt.
EP99400547A 1998-03-10 1999-03-08 Verfahren und Einrichtung zum Giessen von Teilen aus Leichtmetall-Legierungen Revoked EP0941789B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR9803028 1998-03-10
FR9803028A FR2775917B1 (fr) 1998-03-10 1998-03-10 Procede de moulage en grande serie de pieces d'alliage d'aluminium et equipements associes

Publications (2)

Publication Number Publication Date
EP0941789A1 EP0941789A1 (de) 1999-09-15
EP0941789B1 true EP0941789B1 (de) 2003-05-28

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EP99400547A Revoked EP0941789B1 (de) 1998-03-10 1999-03-08 Verfahren und Einrichtung zum Giessen von Teilen aus Leichtmetall-Legierungen

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Country Link
US (1) US6540007B2 (de)
EP (1) EP0941789B1 (de)
JP (1) JPH11320071A (de)
AT (1) ATE241441T1 (de)
BR (1) BR9904551A (de)
CA (1) CA2265231C (de)
DE (1) DE69908212T2 (de)
FR (1) FR2775917B1 (de)
HU (1) HU221249B1 (de)
PL (1) PL189660B1 (de)

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CN102009125B (zh) * 2010-06-28 2012-10-03 芜湖新兴铸管有限责任公司 一种大口径球铁管芯盒半模
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CN116921623A (zh) * 2023-06-27 2023-10-24 共享铸钢有限公司 一种缸体铸件的成型方法
CN117103420B (zh) * 2023-10-11 2026-04-10 南京福翊铭环保新材料有限公司 一种环保砖制坯设备
CN118357450B (zh) * 2024-06-19 2024-08-23 江苏华杰不锈钢制品有限公司 一种不锈钢板铸造装置
CN119525427B (zh) * 2025-01-22 2025-04-25 四川简阳海特有限公司 一种用于消失模涂料的流涂装置

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PL331874A1 (en) 1999-09-13
PL189660B1 (pl) 2005-09-30
US20010050156A1 (en) 2001-12-13
BR9904551A (pt) 2001-10-09
CA2265231A1 (fr) 1999-09-10
EP0941789A1 (de) 1999-09-15
FR2775917A1 (fr) 1999-09-17
HU221249B1 (en) 2002-09-28
DE69908212D1 (de) 2003-07-03
HU9900591D0 (en) 1999-05-28
HUP9900591A2 (hu) 1999-11-29
US6540007B2 (en) 2003-04-01
FR2775917B1 (fr) 2000-06-02
ATE241441T1 (de) 2003-06-15
DE69908212T2 (de) 2004-04-08
JPH11320071A (ja) 1999-11-24
HUP9900591A3 (en) 2000-05-29
CA2265231C (fr) 2009-01-27

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