US20090145570A1 - Method for casting moulded pieces - Google Patents

Method for casting moulded pieces Download PDF

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Publication number
US20090145570A1
US20090145570A1 US12/065,823 US6582306A US2009145570A1 US 20090145570 A1 US20090145570 A1 US 20090145570A1 US 6582306 A US6582306 A US 6582306A US 2009145570 A1 US2009145570 A1 US 2009145570A1
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US
United States
Prior art keywords
thermally insulating
mold
bulk material
core packet
casting
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Abandoned
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US12/065,823
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English (en)
Inventor
Gelson G. Montero
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Individual
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Individual
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Publication date
Application filed by Individual filed Critical Individual
Publication of US20090145570A1 publication Critical patent/US20090145570A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/003—Removing cores using heat

Definitions

  • the invention relates to a method for casting molded pieces.
  • the invention relates very generally to the casting of molded pieces, i.e. to foundry technology.
  • foundry cores and/or molds are usually produced from separate parts, put together, and joined to form a casting mold or to form a core packet or mold packet.
  • mold/core packets are then filled with molten metal for producing, for example, a metal workpiece, whereby in mass production the mold/core packets to be filled with molten metal pass through the assembly line in succession.
  • molded pieces have been cast in a mold consisting in turn of cores or a core packet. After the mold is shot and formed, it is integrated into a further mold or enclosure made of core sand, i.e. into a type of support mold, in order, that is, to be able to ensure the required mechanical stability. Specifically in the case of grey cast iron or cast steel, the static pressure during casting is so high that one core packet alone is not sufficient and the provision of the support mold is crucial. In the past, the support mold has been in the form of green sand molds into which the core packet is inserted. In the past, metal molds have likewise been used, wherein such metal molds are extremely expensive and, in addition, wear rapidly.
  • the molding material which forms the mold/core packet must be removed from the cast molded piece.
  • the binder necessitates special disposal or recycling of the molding material.
  • the costs associated with the recycling of the molding sand/green sand are considerable, especially as additives such as bentonite, etc. must be removed in expensive preparation systems.
  • the present invention is therefore based on the object of configuring and developing the above-discussed generic method in such a way as to reduce, especially in the case of grey cast iron or cast steel, the costs to be incurred with reproducible results, in particular with regard to the recycling of the materials used.
  • the residual heat in the set molded piece should also be utilized.
  • the invention has found that although the support mold, which in the past has consisted of green sand, is required, the costs associated on the one hand with manufacture and on the other hand with recycling, i.e. the overall production costs, can be reduced quite considerably.
  • a support mold which is however—deliberately—set apart from the core packet.
  • the support mold may thus, for example, be generated from plates of differing thermally stable materials, i.e. in accordance with the building block principle.
  • the individual parts could be positionable one within another, engageable with one another or otherwise fastenable to one another.
  • the important thing in this regard is that a space is left between the casting mold itself, i.e. the core packet, and the support mold.
  • This space between the core packet and the support mold is back-filled with a free-flowing bulk material.
  • This bulk material defines all the way round the core packet an isostatic pressure so that, owing to this pressure, the core packet is able to resist the outwardly directed pressure which forms during casting with metal melt.
  • the bulk material ensures that the core packet withstands the pressure which forms during casting while at the same time preventing any melt from seeping outward through any joints, cracks or the like.
  • Simple means ensure, based on an isostatic pressure, that the metal melt can be cast into the casting mold without jeopardizing the dimensional stability of the core packet.
  • the invention has found that the energy stored in the melt or in the molded piece and in the core packet is not immediately sufficient to carry out a more extensive process, i.e. for example to burn the binder contained in the core packet. This is due to the fact that the mass to be heated is, not least owing to the bulk material located in the interior of the support mold, too large.
  • the invention also provides for the support mold to be opened or removed, once the melt has solidified, so that the actual supporting function of the support mold is no longer required. At least the majority of the bulk material is removed. Afterwards, the remaining core packet with the already set molded piece located therein is repeatedly insulated, thus allowing the residual heat contained therein to be utilized without the mass of the bulk material.
  • the core packet is placed on a thermally insulating base as part of the support mold.
  • This base remains under the core packet.
  • a thermally insulating wall and a thermally insulating lid part are added to the base to form the support mold.
  • the support mold is opened or completely removed by removing the lid part and the walls.
  • the bulk material may then be removed without difficulty. Drawing-off of the bulk material is conceivable.
  • a thermally insulating hood which may be configured in one piece or else in a plurality of pieces.
  • the hood could for example be slipped over the core packet via a lifting block, a manipulator or using other aids.
  • the hood is placed on the base around the core packet with the molded piece located therein and the base is added to the hood to form all-round thermal insulation.
  • the hood is repeatedly removed, thus leaving the molded piece, which now contains substantially no molding sand, on the base.
  • the bulk material is substantially the same material as the molding material for producing the cores, preferably without any additives.
  • the cores consist of molding material (for example of quartz sand) with binder
  • the bulk material used may be the same molding material, preferably without binder.
  • the bulk material could have substantially the same grain size as the molding material, thus allowing the molding material to be reused in conjunction with the bulk material—once the molding material has been recycled—at identical or differing grain size.
  • the bulk material used could be pure sand, preferably what is known as dry sand without additives, which does not cause any problems during further processing with the molding sand. This applies, in particular, in the case of identical or almost identical grain size. Quartz sand is a particularly suitable bulk material.
  • the back-filling in the space between the core packet and the support mold may be carried out by means of funnels or suitable technical aids by mere pouring-in of the bulk material so as to obtain a bulk density.
  • the weight of the bulk material produces an isostatic pressure which acts on the core packet and counteracts the outwardly directed pressure which occurs during casting with metal melt so as to obtain the mold.
  • the individual cores of the core packet are thus securely held together.
  • the back-filling can be carried out by blowing in the bulk material. This allows a density of the bulk material to be achieved that is above bulk density. Furthermore, it is conceivable to post-compact the bulk material by means of compressed air once the bulk material has been poured in.
  • Further compaction of the bulk material may be achieved when the back-filling by means of bulk material is assisted by vibration.
  • the vibration can be induced, for example, ultrasonically or else mechanically, for which purpose the entire support mold, or a functional element which is located therein or can be introduced into the support mold, serves as a resonator. In any case, the important thing is that preferably ultrasonically induced vibration promotes compaction of the bulk material.
  • post-compaction for the purposes of further compaction of the bulk material, for post-compaction to be carried out mechanically, i.e. by pressing or even forcibly pressing the bulk material into the mold using mechanical equipment. Point-by-point or zone-by-zone post-compaction by means of punches or the like used for this purpose is conceivable.
  • the support mold is used to thermally insulate the casting mold before and/or after the casting and purposefully to utilize the process heat within the casting mold or insulation for the controlled treatment of the cast molded piece and/or of the molding material forming the core packet.
  • the process heat can be used to burn the organic or inorganic binder in the molding material, so that special recycling measures are subsequently no longer required. Special disposal of the molding material as special waste is then no longer required either, should it no longer be desirable to use the molding material.
  • the process heat may be used for the thermal treatment of the cast molded piece.
  • the molded part could be cooled in a regulated manner, in which case thermal insulation by means of the support mold, in addition to back-filling, is most particularly important.
  • the flue gases which form during burning of the binder are retained within the device for heat insulation. They may be drawn off at the end of the insulation process. The concentrated presence of the harmful gases facilitates disposal or destruction thereof quite considerably, thus greatly simplifying the method.
  • FIG. 1 is a schematic view of the arrangement of a core packet with a set-apart support mold and space, back-filled by means of bulk material, between the core packet and the support mold;
  • FIG. 2 is a schematic view of the arrangement of a core packet according to FIG. 1 , but without bulk material and with a hood slipped thereon for the purposes of thermal insulation.
  • FIG. 1 shows an arrangement in which the casting mold 2 , which is to be understood as a core packet 1 , is prepared for casting-in of the melt.
  • the core packet 1 comprises a plurality of individual cores which are combined jointly to form the core packet 1 .
  • the core packet 1 forms the casting mold 2 .
  • FIG. 1 furthermore reveals that the core packet 1 is positioned in a support mold 3 which, in turn, is composed in a frame-like manner of individual parts 4 or configured in one piece.
  • a space which is back-filled by a free-flowing bulk material 5 and thus builds up between the support mold 3 and the core packet 1 an isostatic pressure which is defined by the weight, is formed between the support mold 3 and the core packet 1 .
  • the metal mold is cast into the casting mold or into the core packet 1 and it is ensured that the core packet 1 withstands in a dimensionally stable manner the internal pressure which forms during casting.
  • the parts 4 of the support mold 3 may be used a plurality of times.
  • the casting mold 2 or the core packet 1 is supported via the bulk material 5 which is specifically what is known as dry sand without any form of additives.
  • dry sand is quartz sand, preferably having the same grain size as the molding material of the individual cores or of the core packet 1 .
  • the bulk material 5 can be compacted beyond bulk density, for example by means of vibration, in order to increase the isostatic pressure with respect to the core packet 1 .
  • the support mold 3 in addition to the bulk material 5 , serves to thermally insulate the casting mold 2 and may therefore be used, before or after the casting, purposefully to utilize the process heat within the casting mold or insulation and thus for the controlled treatment of the cast molded piece and/or of the molding material forming the core packet.
  • the process heat is excessively absorbed by the bulk material 5 and also by the support mold 3 .
  • both the support mold 3 and the bulk material 5 have been removed. Instead, a thermally insulating hood 6 is placed on the likewise thermally insulating base 8 , thus allowing the residual heat held under the hood 6 to be used, for example, to burn the binder contained in the molding material.
  • the hood 6 is removed and the molded piece 7 now contains substantially none of the molding material of the former core packet 1 as, that is to say, the bond between the constituents of the molding material has been eliminated.
  • the method according to the invention has the enormous advantage, on the one hand, of utilizing process heat and, on the other hand, of requiring no molding system to mold the molded piece.
  • the utilization of process heat is promoted as a result of the fact that removal of the bulk material benefits the sand-to-iron ratio.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US12/065,823 2005-09-05 2006-09-01 Method for casting moulded pieces Abandoned US20090145570A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
DE102005042226.8 2005-09-05
DE102005042226 2005-09-05
DE102005046027A DE102005046027A1 (de) 2005-09-05 2005-09-26 Verfahren zum Gießen von Formteilen
DE102005046027.5 2005-09-26
PCT/DE2006/001541 WO2007028362A1 (fr) 2005-09-05 2006-09-01 Procede pour couler des pieces

Publications (1)

Publication Number Publication Date
US20090145570A1 true US20090145570A1 (en) 2009-06-11

Family

ID=37598179

Family Applications (1)

Application Number Title Priority Date Filing Date
US12/065,823 Abandoned US20090145570A1 (en) 2005-09-05 2006-09-01 Method for casting moulded pieces

Country Status (5)

Country Link
US (1) US20090145570A1 (fr)
EP (1) EP1960137A1 (fr)
BR (1) BRPI0615461A2 (fr)
DE (1) DE102005046027A1 (fr)
WO (1) WO2007028362A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105705274A (zh) * 2013-09-04 2016-06-22 尼玛克股份有限公司 将由轻金属熔液铸造的铸件从铸模中脱模的方法
CN106536083A (zh) * 2014-07-30 2017-03-22 弗里茨温特铸造有限及两合公司 用于铸造铸件的方法
CN117529375A (zh) * 2021-06-17 2024-02-06 弗里茨温特铸造有限及两合公司 用于铸造铸件的方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2185302B1 (fr) * 2007-09-10 2020-05-13 Weir Minerals Australia Ltd Procédé et appareil pour la production d'une pièce coulée
CN120551338B (zh) * 2025-07-30 2025-09-23 襄汾县世达铸造有限公司 一种带有可开闭式排气结构的铁型覆砂造型机

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2020184A (en) * 1930-01-27 1935-11-05 Walter D Hodson Portable hood
US2682692A (en) * 1950-10-25 1954-07-06 Everard F Kohl Process of preparing precision castings
US3551271A (en) * 1964-07-30 1970-12-29 British Nylon Spinners Ltd Nonwoven fabrics containing heterofilaments
US4033401A (en) * 1974-05-29 1977-07-05 Sulzer Brothers Limited Precision casting process
US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
US4612968A (en) * 1980-11-21 1986-09-23 Steel Castings Research And Trade Association Method of casting using expendable patterns
US4819711A (en) * 1988-09-30 1989-04-11 Ford Motor Company Compactability and permeability control for fabricating ECP mold
US5069271A (en) * 1990-09-06 1991-12-03 Hitchiner Corporation Countergravity casting using particulate supported thin walled investment shell mold
US6463991B1 (en) * 1999-07-02 2002-10-15 International Engine Intellectual Property Company, L.L.C. Iron alloy casting method and apparatus
US20040118548A1 (en) * 1999-07-02 2004-06-24 Cagle Billy J. Casting method and apparatus
US6889745B2 (en) * 2002-09-10 2005-05-10 Metal Casting Technology, Incorporated Method of heating casting mold
US20060185814A1 (en) * 2003-10-28 2006-08-24 Hos Hottinger Systems Gbr Method for casting molded parts

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1926163B2 (de) * 1969-05-22 1974-08-15 Herbert 5928 Laasphe Grolla Metalle
JP2680535B2 (ja) * 1993-12-20 1997-11-19 本田技研工業株式会社 鋳造品の搬送装置

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2020184A (en) * 1930-01-27 1935-11-05 Walter D Hodson Portable hood
US2682692A (en) * 1950-10-25 1954-07-06 Everard F Kohl Process of preparing precision castings
US3551271A (en) * 1964-07-30 1970-12-29 British Nylon Spinners Ltd Nonwoven fabrics containing heterofilaments
US4033401A (en) * 1974-05-29 1977-07-05 Sulzer Brothers Limited Precision casting process
US4222429A (en) * 1979-06-05 1980-09-16 Foundry Management, Inc. Foundry process including heat treating of produced castings in formation sand
US4612968A (en) * 1980-11-21 1986-09-23 Steel Castings Research And Trade Association Method of casting using expendable patterns
US4819711A (en) * 1988-09-30 1989-04-11 Ford Motor Company Compactability and permeability control for fabricating ECP mold
US5069271A (en) * 1990-09-06 1991-12-03 Hitchiner Corporation Countergravity casting using particulate supported thin walled investment shell mold
US6463991B1 (en) * 1999-07-02 2002-10-15 International Engine Intellectual Property Company, L.L.C. Iron alloy casting method and apparatus
US20040118548A1 (en) * 1999-07-02 2004-06-24 Cagle Billy J. Casting method and apparatus
US6889745B2 (en) * 2002-09-10 2005-05-10 Metal Casting Technology, Incorporated Method of heating casting mold
US20060185814A1 (en) * 2003-10-28 2006-08-24 Hos Hottinger Systems Gbr Method for casting molded parts

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105705274A (zh) * 2013-09-04 2016-06-22 尼玛克股份有限公司 将由轻金属熔液铸造的铸件从铸模中脱模的方法
CN106536083A (zh) * 2014-07-30 2017-03-22 弗里茨温特铸造有限及两合公司 用于铸造铸件的方法
US9890439B2 (en) 2014-07-30 2018-02-13 Fritz Winter Eisengiesserei Gmbh & Co. Kg Method for casting cast parts
CN117529375A (zh) * 2021-06-17 2024-02-06 弗里茨温特铸造有限及两合公司 用于铸造铸件的方法
JP2024524150A (ja) * 2021-06-17 2024-07-05 フリッツ ビンター アイゼンギーセライ ゲゼルシャフト ミット ベシュレンクテル ハフツング ウント コンパニー コマンディトゲゼルシャフト 鋳造品の鋳造方法
US12337377B2 (en) 2021-06-17 2025-06-24 Fritz Winter Eisengiesserei Gmbh & Co. Kg Method for casting castings

Also Published As

Publication number Publication date
DE102005046027A1 (de) 2007-03-08
WO2007028362A1 (fr) 2007-03-15
BRPI0615461A2 (pt) 2011-05-17
EP1960137A1 (fr) 2008-08-27

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