US3868986A - Pattern alignment means for use with lost foam molding process - Google Patents

Pattern alignment means for use with lost foam molding process Download PDF

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Publication number
US3868986A
US3868986A US430972A US43097274A US3868986A US 3868986 A US3868986 A US 3868986A US 430972 A US430972 A US 430972A US 43097274 A US43097274 A US 43097274A US 3868986 A US3868986 A US 3868986A
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United States
Prior art keywords
patterns
frame
sand
flask
pattern
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Lifetime
Application number
US430972A
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English (en)
Inventor
Ralph A Olsen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ford Motor Co
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Ford Motor Co
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Filing date
Publication date
Application filed by Ford Motor Co filed Critical Ford Motor Co
Priority to US430972A priority Critical patent/US3868986A/en
Priority to CA216,626A priority patent/CA1045780A/fr
Application granted granted Critical
Publication of US3868986A publication Critical patent/US3868986A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials

Definitions

  • ABSTRACT An apparatus and method is disclosed for casting parts by the cavityless molding method.
  • a plurality of complex or difficult cored consumable patterns are stabilized on a heat resistant frame.
  • Means is employed to prevent the transfer of heat between the molten charge (subplanting the patterns) and the stabilizing frame.
  • the assembly is installed in a semifilled flask or empty flask; fluidizing means is employed when a partly sand-filled flask is used and a deep pouring spout is used for an empty flask.
  • the expendable pattern may be made from an expanded plastic material, such as expanded polystyrene beads or polyethylene which, as is well known, is porous because it contains air voids in the expanded condition.
  • the material is light weight, economical and easy to form into any desired shape.
  • This pattern material is capable of being volatilized or burned, particularly in the absence of oxygen without appreciable residue remaining.
  • the method of casting conventionally employed by those skilled in the art is to utilize the molten charge for combusting and destroying the pattern. Molten metal poured into a mold containing a polystyrene pattern consumes the pattern, fills the resultant cavity with molten metal, which later solidifies, leaving a casting having the exact contour of the original pattern.
  • the primary object of this invention is to provide a method and apparatus which will permit the casting of a plurality of complex parts (or simple parts having small openings) within a single flask requiring precise alignment with appropriate sprues and risers, the
  • Still another object of this invention is to provide an apparatus for stabilizing a plurality of polystyrene patterns within a single flask; the patterns have removable means for connecting to a stabilizing apparatus and have means to prevent deterioration of the stabilizing apparatus during the metal pouring operation.
  • Yet still another object of the invention is to provide a stabilizing apparatus and accompanying method for coordinating a plurality of polystyrene consumable patterns in a single flask which will prevent damage and distortion of the patterns during handling and filling operations associated with cavityless molding techniques.
  • FIG. 1 is an overall elevational view of a mechanism upon which one or more flasks may be mounted for appropriate sand compacting and filling;
  • FIG. 2 is an enlarged sectional view of a portion of FIG. 1 showing the arrangement of the pattern stabilizing means within the flask;
  • FIG. 3 is a greatly enlarged perspective view of the stabilizing means and consumable patterns mounted thereon.
  • FIG. 4 is a highly enlarged exploded view ofa portion of the pattern and stabilizing means of FIG. 3.
  • One of the key problems to be overcome by this invention is to permit the use of a multiple number of relatively complex shaped or narrowly cored consumable patterns to be used in a high production casting line.
  • Consumable patterns 10 are hung on a fixture which cooperates with air fluidization of mold sand or with special sand pouring spouts to facilitate proper flask filling.
  • Consumable patterns 10 are provided with at least one preformed consumable ear ll typically extending outwardly from one side wall 12 of the pattern 10.
  • at least three of such ears 11 extend outwardly in equi-circumferentially spaced arrangement about the side wall of the pattern to lay in a common plane.
  • Each of the ears is provided with an opening 13 to receive stabilizing means 14, the latter being re-useable in subsequent cycles of the casting method.
  • the stabilizing means 14 comprises a rigid stabilizing frame 15, which is preferably constructed of tubular heat resistant steel.
  • the frame has an annular base 15a adapted to seat in asecure position on a horizontal wall of the molding flask.
  • the frame has uprights 15b along at least two sides thereof which connect with an upper annular ring 150.
  • fingers 16 extend inwardly toward the inner region of the frame wherein the patterns are hung.
  • Each finger has an upright pin 17 at its inner extremity effecof the pattern.
  • Means 18 is provided to prevent the transfer of heat between the molten charge (displacing the pattern 10) and the supporting or stabilizing frame 14.
  • one mode may comprise the use of an annular ceramic insert 19 which is preformed into the polystyrene ear; the insert may have a central opening 20 commensurate in size and shape to receive one of the pins 17 of said stabilizing frame.
  • An annular groove 21 in the side wall 19a of the insert assures a good interlock with the ear.
  • Another mode may comprise the use of a narrow gauge in the connection between the ear and frame; an extremely narrow or wire-like restriction can be provided in pin 17 as a substitute for the separating ceramic insert 19. Accordingly when the molten charge is applied, the narrow gauge of the supporting finger prevents undue transfer of heat therealong and can be easily replaced with low cost replacement for a subsequent molding operation.
  • a preferred method mode would comprise:
  • A. Prepare a skeleton stabilizing frame effective to be seated on a horizontal plane within a molding flask; the frame should have a plurality of fingers extending inwardly of the frame to support a body in spaced vertical orientation,
  • Each pattern should be prepared with a plurality of ears extending outwardly in circumferentially spaced arrangement about the side walls of said patterns so as to mate with the fingers of said frame and be supported in a stabilizing .manner,
  • the consumable pattern is adapted to be displaced in a mold by the poured casting charge; it is converted substantially in its entirety to a gaseous state and permitted to escape from the mold through suitable vent provisions.
  • any suitable material which is '10 tive to extend through the opening 13 in a mating ear readily combustible substantially without residue upon subjection to a molten casting charge can be used as pattern material. It should be sufficiently rigid to safely withstand the stresses induced by the customary ramming of molding sand thereagainst.
  • a suitable material for these purposes is an expanded polystyrene. It has been found that polystyrene is well adapted for the intended purposes if it is expanded to a density substantially but not more than 2 lbs./ft.
  • this material has substantially greater density, it will not readily burn away on subjection to a molten casting charge.
  • the pattern is shown as a simple block having a plurality of ears extending from a continuous side wall thereof, the ears being circumferentially spaced thereabout.
  • FIGS. 1 and 2 A typical preferred apparatus useful in carrying out step (D) of the preferred method is illustrated in FIGS. 1 and 2.
  • a carousel 30 is employed having a turn table 31 or disc mounted at its center upon a tubular support 32 which in turn is stabilized on a base plate 33.
  • a plurality of sand flasks 34 may be carried at various stations about the periphery of the turn table.
  • Each of the flasks 34 is mounted on a pair of trunnions 35 at spaced locations along the turn table, the trunnions permitting the flask to be tilted for emptying of sand upon completion of the casting mode.
  • an electric motor- 36 and transmission 38 may be employed to drive the main bearing ring 37 of the turn table; another electric motor 39 may be employed to rotate the flasks about their trunnions 34, the drive being through chains 40.
  • Each of the flasks 34 may be of one piece or nonseparable construction in which the mold is destroyed upon removal of the cast object and the pattern is destroyed during the casting process.
  • Each flask is preferably provided with an air permeable wall 41 over at least the floor of the flask interior, space, the air permeable plate or wall being preferably formed of a sintered metal (such as iron).
  • the permeable wall divides the interior of the flask into a casting chamber 42 and a gas plenum chamber 43, the latter selectively communicating by way of suitable ducts 44 with a suction source at one side and selectively communicating with a source 45 of fluid under pressure from the opposite side thereof.
  • the communications may be respectively provided by the inlet duct 46 passing through the right hand trunnion and the communication of suction provided by a conduit 44 having a high velocity jet 44 connected to a source of pressure in the interior of the support 32 of the carousel.
  • the interior of the support may act as a compressed air storage tank or accumulator fed by a pump 50.
  • the emptied upwardly oriented flask is halted at a first station of the carousel.
  • Sand (molding medium) of the dry unbonded type is introduced in a predetermined quantity to the interior of the flask. This may be preferably accomplished by use of a deep penetrating pouring spout which would effectively fill chamber 42 in a manner as water would fill a vessel.
  • air is fed through passage 46 from source 45 to the chambers 43 which will effectively fluidize sand in chamber 42 thereby enabling the frame 14 and patterns to be inserted into the flask.
  • the fluidization of the sand is carried such that the motion of the particles is slightly turbulant and yet no substantial tendency to drive the particles out of the mold is maintained. Because of the fluidization of the molding medium, the patterns and frame can be easily seated in the molding chamber 42 without noticeable resistance.
  • the carousel may then be indexed to the next position where the compressed air is interrupted and vibrators 47 are set in motion to compact the sand mass around the pattern.
  • An air impermeable membrane 48 such as aluminum foil or polyester film is placed across the top of the sand body in the flask and may have an aperture for a casting funnel.
  • the carousel is then indexed to a third position where suction is applied through the passage 44 and thus a differential pressure is applied between the membrane 48 and the floor 41 of the sand body. Suction may be created by use of a high velocity jet 49 in conduit 44.
  • the pouring of molten metal can be carried out at the third station and as the molten metal is introduced to the mold, the pattern is destroyed and the mold cavity is filled.
  • Gas evolved by the destruction of the porous polystyrene pattern may be drawn off through the sand mass under suction.
  • the carousel is indexed to a fourth station where the casting is permitted to cool, solidify.
  • the cast body may be removed from the sand mass.
  • the compressed air may be again supplied to the chamber 42 beneath the floor 41 to fluidize and loosen the sand to enable the cast bodies and frame to be drawn outward without effort.
  • the carousel may be indexed to a sixth position where the flask is tilted and the sand medium is withdrawn.
  • Pattern apparatus for use in making multiple castings from a single pouring through a common sprue in a body of sand, the apparatus comprising:
  • a rigid stabilizing frame supported against movement, said frame having at least one extending finger for each of said patterns, each finger providing a support upon which said ear of one of said patterns may be journalled,
  • independent sprue means for conducting a molten metallic charge to said combustible patterns for consummation
  • d. means to prevent consummation of said frame during introduction of said molten charge.
  • said means to prevent consummation of said frame comprises a ceramic annular insert carried by said consumable foam pattern in the ear thereof, said insert having a central opening of a size effective to fit snugly about the finger of said stabilizing frame.
  • said means to prevent consummation of said stabilizing frame comprises a narrow or wire-like restriction in said finger so that the molten charge coming in contact therewith is ineffective to transmit damageable heat content to the remainder of said stabilizing frame.
  • the patterns each have at least three ears extending away from said pattern in a horizontal plane and spaced apart about said pattern to provide a secure horizontal support for said pattern, said stabilizing frame having a finger for each of said ears effective to secure said ears in said predetermined horizontal plane.
  • a method for fabricating a plurality of castings from a single pouring through a common sprue in a body of sand comprising:
  • each said pattern being provided with a plurality of foam ears extending generally away from said pattern to lay in one of said horizontal planes defined by the fingers of said frame, said patterns being joined together by a consumable sprue effective to be combusted without residue by said molten charge for defining a channel to feed said patterns,

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Devices For Molds (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US430972A 1974-01-04 1974-01-04 Pattern alignment means for use with lost foam molding process Expired - Lifetime US3868986A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US430972A US3868986A (en) 1974-01-04 1974-01-04 Pattern alignment means for use with lost foam molding process
CA216,626A CA1045780A (fr) 1974-01-04 1974-12-16 Concept d'alignement du modele ou prevention de la distorsion dans le procede de moulage a la mousse perdue

Applications Claiming Priority (1)

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US430972A US3868986A (en) 1974-01-04 1974-01-04 Pattern alignment means for use with lost foam molding process

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US3868986A true US3868986A (en) 1975-03-04

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CA (1) CA1045780A (fr)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4003423A (en) * 1975-06-09 1977-01-18 Precision Metalsmiths, Inc. Methods and means for making dental castings and the like
US4043379A (en) * 1976-04-12 1977-08-23 Trw Inc. Method of making a mold
US4085790A (en) * 1975-05-02 1978-04-25 Grunzweig & Hartmann Und Glasfaser Ag Casting method using cavityless mold
FR2540761A1 (fr) * 1983-02-15 1984-08-17 Citroen Sa Installation pour le moulage en modele perdu
US4609028A (en) * 1984-06-20 1986-09-02 Outboard Marine Corporation Evaporative pattern assembly for use in sand casting
US4724889A (en) * 1987-04-27 1988-02-16 Ford Motor Company Degating technique for clustered castings made by ECP
GB2265099A (en) * 1992-03-17 1993-09-22 Pont A Mousson Consumable cluster of patterns at several layers; precision casting
US6293968B1 (en) 1999-09-02 2001-09-25 Syde A. Taheri Inflatable intraluminal vascular stent
US6749004B1 (en) * 1999-02-26 2004-06-15 Fata Aluminium Division Of Fata Group S.P.A. Container-filling device for lost-foam casting systems
US20100000950A1 (en) * 2006-01-11 2010-01-07 Mohammad Ghassem Malekmadani Anti-Vibration Rack, Mount and Feet for Computer Servers
US20100155353A1 (en) * 2008-12-22 2010-06-24 Metal Masters Foodservice Equipment Co., Inc. Wall mounted shelving
US10159339B1 (en) * 2017-02-02 2018-12-25 Metal Masters Foodservice Equipment Co., Inc. Shelving bracket
US12310499B2 (en) * 2023-07-14 2025-05-27 Steve Bright Shelf assembly

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3374824A (en) * 1965-07-13 1968-03-26 Thomas E. Snelling Displacement process for the casting of metals
US3581802A (en) * 1968-02-03 1971-06-01 Gruenzweig & Hartmann Method for making castings

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3374824A (en) * 1965-07-13 1968-03-26 Thomas E. Snelling Displacement process for the casting of metals
US3581802A (en) * 1968-02-03 1971-06-01 Gruenzweig & Hartmann Method for making castings

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4085790A (en) * 1975-05-02 1978-04-25 Grunzweig & Hartmann Und Glasfaser Ag Casting method using cavityless mold
US4003423A (en) * 1975-06-09 1977-01-18 Precision Metalsmiths, Inc. Methods and means for making dental castings and the like
US4043379A (en) * 1976-04-12 1977-08-23 Trw Inc. Method of making a mold
FR2540761A1 (fr) * 1983-02-15 1984-08-17 Citroen Sa Installation pour le moulage en modele perdu
EP0117194A1 (fr) * 1983-02-15 1984-08-29 Automobiles Citroen Installation pour le moulage en modèle perdu
US4609028A (en) * 1984-06-20 1986-09-02 Outboard Marine Corporation Evaporative pattern assembly for use in sand casting
US4724889A (en) * 1987-04-27 1988-02-16 Ford Motor Company Degating technique for clustered castings made by ECP
EP0289175A3 (en) * 1987-04-27 1989-07-26 Ford Motor Company Limited Degating technique for clustered castings made by ecp
GB2265099A (en) * 1992-03-17 1993-09-22 Pont A Mousson Consumable cluster of patterns at several layers; precision casting
GB2265099B (en) * 1992-03-17 1995-03-01 Pont A Mousson Method and installation for consumable pattern casting and use of the installation
US6749004B1 (en) * 1999-02-26 2004-06-15 Fata Aluminium Division Of Fata Group S.P.A. Container-filling device for lost-foam casting systems
US6293968B1 (en) 1999-09-02 2001-09-25 Syde A. Taheri Inflatable intraluminal vascular stent
US20100000950A1 (en) * 2006-01-11 2010-01-07 Mohammad Ghassem Malekmadani Anti-Vibration Rack, Mount and Feet for Computer Servers
US8240490B2 (en) * 2006-01-11 2012-08-14 Mohammad Ghassem Malekmadani Anti-vibration rack, mount and feet for computer servers
US20100155353A1 (en) * 2008-12-22 2010-06-24 Metal Masters Foodservice Equipment Co., Inc. Wall mounted shelving
US8025163B2 (en) * 2008-12-22 2011-09-27 Metal Masters Foodservice Equipment Co., Inc. Wall mounted shelving
US10159339B1 (en) * 2017-02-02 2018-12-25 Metal Masters Foodservice Equipment Co., Inc. Shelving bracket
US12310499B2 (en) * 2023-07-14 2025-05-27 Steve Bright Shelf assembly

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CA1045780A (fr) 1979-01-09

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