WO2006078158A2 - Methode et appareil pour fabriquer des produits en metal leger - Google Patents

Methode et appareil pour fabriquer des produits en metal leger Download PDF

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Publication number
WO2006078158A2
WO2006078158A2 PCT/NL2006/000028 NL2006000028W WO2006078158A2 WO 2006078158 A2 WO2006078158 A2 WO 2006078158A2 NL 2006000028 W NL2006000028 W NL 2006000028W WO 2006078158 A2 WO2006078158 A2 WO 2006078158A2
Authority
WO
WIPO (PCT)
Prior art keywords
mold cavity
light metal
mold
volume
wall
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.)
Ceased
Application number
PCT/NL2006/000028
Other languages
English (en)
Other versions
WO2006078158A3 (fr
Inventor
Hendricus Antonius Hoogland
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.)
Fountain Patents BV
Original Assignee
Fountain Patents BV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Fountain Patents BV filed Critical Fountain Patents BV
Priority to EP06701558A priority Critical patent/EP1848557A2/fr
Publication of WO2006078158A2 publication Critical patent/WO2006078158A2/fr
Publication of WO2006078158A3 publication Critical patent/WO2006078158A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2069—Exerting after-pressure on the moulding material

Definitions

  • the invention relates to a method for manufacturing products from light metal. Furthermore, the invention relates to an apparatus for manufacturing products from light metal.
  • light metal is at least understood to include the metals and alloys thereof such as aluminum and magnesium, Zamac and the like, usually indicated as light metal.
  • a further drawback of this known method is that manufacturing products with a relatively complicated and/or non-clearing form requires separate core parts, so that the build-up of a mold for manufacturing is often to be done individually and is time consuming and expensive.
  • the known method is not or not sufficiently satisfactory.
  • the loadability of such products will typically be too low so that often, overdimensioning will occur.
  • the invention contemplates presenting a method for forming . products from light metal, with which at least a number of the above- mentioned drawbacks of the known method are solved.
  • the invention contemplates presenting such a method which offers the possibility of manufacturing relatively complex products with relatively simple means.
  • a further object of the invention is presenting such a method which can supply products relatively rapidly, with little rejection or spoilage and with a high accuracy.
  • a still further object of the invention is to provide a method in which the use of separate core parts and/or lost cores is not required for forming, for instance, undercuts, cavities and other, non-clearing molded parts.
  • the invention further contemplates providing an apparatus with which in a rapid, simple and relatively advantageous manner products can be manufactured from light metal, in particular products with relatively complex forms with cavities, undercuts and similar non-clearing parts.
  • a method according to the invention light metal is introduced into a mold cavity of a mold, substantially in liquid form and with the mold at least substantially closed.
  • the mold cavity has a volume that is somewhat greater than the volume of the product to be eventually formed. This can be achieved with, for instance, the aid of slides or similar pressing means which can be moved, at least partly, into the mold cavity.
  • the volume of the mold cavity is reduced so that the metal is distributed over the entire mold cavity, thereby obtaining a complete filling of the mold cavity.
  • this is brought into a desired final shape which, preferably, corresponds to that of the product to be formed.
  • relatively high is at least understood to include above the ambient temperature, more particularly closer to the melting temperature of the light metal used than to room temperature, and preferably relatively close to the melting temperature of the light metal.
  • relatively high is at least understood to include above the ambient temperature, more particularly closer to the melting temperature of the light metal used than to room temperature, and preferably relatively close to the melting temperature of the light metal.
  • the metal in the mold cavity is somewhat compressed so that any air inclusions that may be present are pressed away.
  • the light metal in the mold cavity is cooled down somewhat. It is then preferably effected that at least an outside of the product hardens, so that the product becomes substantially form-retaining and can be taken out without becoming damaged.
  • the cooling is arranged such that the shrinkage of the light metal is somewhat greater in at least parts thereof than the shrinkage in the adjacent, forming mold parts so that the product detaches as if by itself from the respective forming parts. It is preferred that the means with which the volume of the mold cavity is reduced can be moved back so that the volume of the mold cavity is increased again, while furthermore in this manner, the product is released to be taken out.
  • cooling is at least understood to include reducing the temperature, in particular to below the melting temperature of the light metal used, more particularly to a temperature closer to the room temperature than to the melting temperature of the light metal used, and at least to a temperature such that solidification of at least an outer layer of the light metal is realized without damages occurring to the mold and/or the product as a consequence of, for instance, too strong, too rapid cooling.
  • Reducing the volume of the mold cavity can be done so rapidly that in the light metal, at least in the mold cavity, adiabatic heat development occurs. As a result, it is even better ensured that the metal will fill the entire mold cavity, also in the parts which with normal, unforced flow would not become filled with metal, as a result of an unsuitable melt flow index (MFI).
  • MFI melt flow index
  • the light metal can be introduced into the mold cavity under the influence of, only, gravity, or be drawn into the mold by building up a reduced pressure in the mold cavity, but it is preferred that the light metal is introduced into the mold under pressure.
  • under pressure is at least understood to include in a manner such that the light metal is pressed into the mold cavity under superatmospheric pressure. In this manner, the advantage is achieved that the filling of the mold cavity is effected more rapidly and the risk of air inclusions is further limited. Furthermore, a more complete degree of filling can be achieved more rapidly. As a result of this method, products with non-clearing or difficultly clearing parts such as undercuts, cavities and the like can be manufactured.
  • products can be manufactured having relatively small wall thicknesses in comparison to the other dimensions of the respective part of the product. What is furthermore achieved is that particularly attractive, smooth products can be obtained while no shrinkage cavities are formed, at least much smaller shrinkage cavities than in comparable products manufactured in the conventional manner.
  • a further advantage of a method according to the invention is that the homogeneity of a product can be considerably improved, so that a stronger product is obtained. Spoilage and rejection will be minimized and tolerance limits can be set to be narrower so that overdimensioning can be limited to a minimum.
  • control means for controlling the temperature of the mold cavity, at least the wall thereof, use if made of liquid which can be fed through, for instance, heating and/or cooling channels.
  • Control means can be used for controlling the liquid flows such that each time, the desired amount of heat is supplied or removed.
  • the invention further relates to an apparatus, characterized by the features of claim 13.
  • Fig. 1 schematically shows, in cross-sectional side view, an apparatus according to the invention, in a first embodiment, before introduction of light metal;
  • Fig. 2 schematically shows, in cross-sectional side view, an apparatus according to Fig. 1, after introduction of light metal;
  • FIG. 3 schematically shows, in cross-sectional side view, an apparatus according to the invention, in a second embodiment, in opened condition;
  • Fig. 4 schematically show, in cross-sectional side view, an apparatus according to Fig. 3, in closed condition an before introduction of light metal;
  • FIG. 5 schematically shows, in cross-sectional side view, an apparatus according to Figs. 3 and 4, after introduction of light metal
  • FIG. 6 schematically shows, in cross-sectional side view, an apparatus according to the invention, in a third embodiment, after introduction of light metal and after retraction of pressing means;
  • Fig. 7 shows, in perspective view, a product manufactured with an apparatus according to Fig. 3; and Fig. 8 shows, in side view, an alternative product, manufactured with a method and apparatus according to the invention.
  • Figs. 1 and 2 show, schematically in cross-sectional side view, a mold 1 according to the invention, in closed condition.
  • the mold comprises two mold halves 2, 3 with a mold cavity 4 therebetween.
  • the mold cavity is bounded on one side by a moveable wall part 5 which is movable with the aid of piston-cylinder assemblies or electric motors or like actuators 6 from a retracted position as shown in Fig. 1 to an extended position as shown in Fig. 2.
  • the volume V of the mold cavity 4 is greater than with the movable wall part 5 in the extended position (Fig. 2).
  • heating elements 7 and cooling elements 8 are provided for heating or cooling, respectively, the mold halves, at least the wall 9 of the mold cavity 4.
  • the heating and cooling means 7, 8 are connected to a control device 10 with which the temperature of the mold halves 2, 3, at least the heat supplied to the mold and the heat extracted therefrom, can be controlled in a simple manner.
  • the heating means 7 comprise electric coils and the cooling means 8 cooling channels through which coolant is guided.
  • other means can, naturally, be utilized too, such as, in addition to cooling channels, heating channels for feed-through of heating liquid, or, for heating and cooling, the same channel system can be used.
  • a mold 1 according to Figs. 1 and 2 is used as follows. With the aid of the heating means 7, the wall 9 of the mold cavity 4 is brought to a desired temperature, higher than the ambient temperature, for instance close to the melting temperature of the light metal used. For instance, a temperature of between 200 and 1000°C can be chosen, more particularly between 500 " and 800°C for aluminum or aluminum-containing alloys. Then, with the wall 5 in the retracted position shown in Fig.
  • grooves are provided in the wall 5 for forming ribs 15 in the end product 13. These are directly formed when pressing on the wall 5.
  • Fig. 8 in side view, such a product is shown.
  • the wall thickness D of the parts 14 between the ribs 15 is considerably smaller than that of the ribs themselves. Still, no sags such as shrinkage cavities will be formed at the location of the ribs 15, so that a particularly even and smooth appearance is obtained at the side 18 remote from the ribs 15.
  • moveable wall parts could be provided on other sides of the mold cavity 4 too, in the form of, for instance, slides for forming, for instance, undercuts 16, grooves, cavities and the like, which are retracted before the mold 1 is opened.
  • the heating means 7 are switched off, at least turned down, while the cooling means 8 are started up.
  • the control device 10 operates such that the light metal shrinks more, at least locally, than the material of the mold 1, so that the product substantially detaches from the mold cavity. Then, the mold 1 can be opened and the product 13 can be taken out.
  • FIGs. 3 — 5 in three phases, an alternative embodiment of a mold according to the invention is shown, again for forming light metal products.
  • identical or corresponding parts have identical or corresponding reference numerals.
  • a product 13 with a cavity 17 as shown in Fig. 7 can be manufactured.
  • a slide 20 is provided which actually bears, at least defines, the movable wall 5 of the first embodiment.
  • the lower mold part 3 comprises a space 22 in which fit the slide 20 with an adjacent wall element 21, while forming a mold cavity 4 as shown in Fig. 4 with the mold 1 closed.
  • the slide 20 has been brought into the retracted position as shown in Fig. 4, while the distance H2 from the wall 5 to the bottom 23 of the space 22 is relatively large. The volume of the mold cavity 4 is therefore large.
  • metal is pressed into the mold cavity 4, whereupon the slide 20 is pressed downwards by the actuator 6, so that the distance mentioned is reduced to Hl and the mold cavity 4, and hence the product 13, is brought into the desired shape.
  • the slide 20 can be retracted and the mold can be opened for taking out the product 13.
  • the mold cavity, at least the wall 9, is heated, at least partly. Then, after filling and displacing the slide 20, again, cooling takes place whereupon the product is taken out after the outside has become sufficiently dimensionally stable through cooling and solidifying.
  • the heating and cooling means 7, 8 are integrated.
  • a third embodiment of an apparatus according to the invention is shown, wherein a slide 20 in a mold 1 is operated indirectly, by a second slide 25, movable in a first direction P3 with the aid of an actuator 6.
  • the slide 20 moves in a first direction Pl, approximately at right angles to the direction of movement P2 of the first and second mold part 2, 3 upon opening and closing, as a result of the inclining contact surface 25.
  • identical or corresponding parts have identical or corresponding reference numerals.
  • the heating and cooling means 7, 8 are once more combined as liquid channels.
  • liquid for instance water or oil can be used, externally heated or cooled, respectively.
  • the wall 9 of the cavity 4 is heated again when the metal is introduced and cooled after the slide 20 has been moved maximally to the right hand side of the drawing, to the extended position.
  • the slide 20 is retracted, then the mold is opened and the product is slid from the slide 20. If the cavity 17 is smaller, optionally, a movement of the slide may suffice, such that it can be pulled from the cavity entirely.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne une méthode pour fabriquer des produits à partir d'un métal léger, notamment l'aluminium ou des alliages d'aluminium. Une quantité de métal léger est introduite dans une cavité de moule d'un moule, dans un état sensiblement fondu. Le volume de la cavité de moule est sensiblement réduite aux dimensions voulues du produit, de sorte que la cavité de moule est complètement remplie du métal léger, tandis que, au moins pendant l'introduction du métal léger, le moule est chauffé.
PCT/NL2006/000028 2005-01-20 2006-01-18 Methode et appareil pour fabriquer des produits en metal leger Ceased WO2006078158A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP06701558A EP1848557A2 (fr) 2005-01-20 2006-01-18 Methode et appareil pour fabriquer des produits en metal leger

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1028077 2005-01-20
NL1028077A NL1028077C2 (nl) 2005-01-20 2005-01-20 Werkwijze en inrichting voor het vervaardigen van producten uit lichtmetaal.

Publications (2)

Publication Number Publication Date
WO2006078158A2 true WO2006078158A2 (fr) 2006-07-27
WO2006078158A3 WO2006078158A3 (fr) 2006-12-07

Family

ID=34975054

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/NL2006/000028 Ceased WO2006078158A2 (fr) 2005-01-20 2006-01-18 Methode et appareil pour fabriquer des produits en metal leger

Country Status (3)

Country Link
EP (1) EP1848557A2 (fr)
NL (1) NL1028077C2 (fr)
WO (1) WO2006078158A2 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60247453A (ja) 1984-05-21 1985-12-07 Yasubumi Kosegi 溶鍛用成形型
EP0225523A2 (fr) 1985-11-30 1987-06-16 Akio Nakano Moule à couler sous pression pour utilisation en coulée
JPH08168868A (ja) 1994-12-16 1996-07-02 Honda Motor Co Ltd 高強度金属部材の製造方法
DE19621945C1 (de) 1996-05-31 1997-08-28 Daimler Benz Ag Verfahren zum Schwerkraftgießen von Leichtmetall-Gußteilen im Kokillen-Gießverfahren

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS603958A (ja) * 1983-06-20 1985-01-10 Toyota Motor Corp 溶湯鍛造法
BG63426B1 (bg) * 1999-02-01 2002-01-31 Любомир ПЕТКАНЧИН Метод и устройство за леене на детайли

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60247453A (ja) 1984-05-21 1985-12-07 Yasubumi Kosegi 溶鍛用成形型
EP0225523A2 (fr) 1985-11-30 1987-06-16 Akio Nakano Moule à couler sous pression pour utilisation en coulée
JPH08168868A (ja) 1994-12-16 1996-07-02 Honda Motor Co Ltd 高強度金属部材の製造方法
DE19621945C1 (de) 1996-05-31 1997-08-28 Daimler Benz Ag Verfahren zum Schwerkraftgießen von Leichtmetall-Gußteilen im Kokillen-Gießverfahren

Also Published As

Publication number Publication date
WO2006078158A3 (fr) 2006-12-07
EP1848557A2 (fr) 2007-10-31
NL1028077C2 (nl) 2006-07-21

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