DE102016106256B3 - Apparatus for the production of castings, such as cast aluminum, in the low-pressure casting process - Google Patents

Abstract

The invention relates to a device for producing cast parts, such as cast aluminum, in the low-pressure casting method with the aid of a casting tool (1) which consists of movably arranged side parts (4) with a lower part or lower molded part (3) and an upper part (5). wherein at least the upper part (5) and / or the side parts (4) by means of at least one adjusting device (13) are adjustable. The invention has for its object the device by means of a compression device or multi-adjustable device in such a way that cavitation avoided and after the removal of the mold from the casting no after-treatment will be more necessary. The object is achieved according to the invention in that the mold cavity for receiving the melt is associated with a closing device and a device for compressing the melt, wherein the closing device is designed as a multi-stage adjusting device (13) or as a hydraulically or mechanically adjustable device.

Description

The invention relates to a device for producing castings, such as cast aluminum, in the low-pressure method using a casting tool, which consists of movably arranged side parts with a lower part or lower mold part and an upper part, wherein at least the upper part and / or the side parts by means of at least one adjusting device are adjustable.

It is already a tool from the DE 102 34 026 C1 known, which relates to a device for the production of castings, such as aluminum casting, low-pressure casting, which consists of movably arranged side parts with a lower part or a lower mold receiving base plate and a top or upper molding having plate, wherein at least the upper part with a Entformungsplatte and the upper mold part with respect to the footprint of the casting tool by means of at least one adjusting device in the vertical direction is adjustable and the side parts are also adjustable by means of and / or other adjusting devices in the horizontal direction. In such a device no short and simultaneous or simultaneous movement of the adjustable components can be achieved. Furthermore, the production of the known device is complicated and expensive.

Furthermore, a method for the production of products made of metal and a rotor produced by the method for an electric motor is known (US Pat. DE 10 2013 208 151 A1 ). With the known method, metal or copper alloy melt under pressure of a casting mold is supplied by means of a casting machine. The casting machine is for this purpose equipped with a relative to a horizontal obliquely, preferably vertically arranged piston. The piston is moved in the direction of a longitudinal axis of the casting mold so that the molten copper in the filling chamber is pressed into a cavity of the casting mold. It is known that voids porosity occurs because most of the cast metals have a slightly lower density in the liquid state than in the solid state. As a result, the metal takes less space when it solidifies. The shrinkage can be minimized as the liquid metal enters the mold while it solidifies. However, so-called hot spots can occur in complicated cross sections. Voids porosity can be controlled by improved die design, print intensity, and metal temperature.

Furthermore, a metal die casting machine with a casting or storage chamber for storing the molten metal to be processed and with at least one casting mold is known (US Pat. DE 10 2009 051 879 B3 ), whose mold cavity is intended for pressing and solidification of the molten metal. It is characteristic of the metal die-casting machine according to the invention that the casting or storage chamber is designed for pressureless storage of the molten metal and that the casting or storage chamber is connected to the casting mold via at least one molten metal pump, which transfers the molten metal from the casting or storage chamber sucks and presses into the mold cavity of the mold. With the aid of the metal die casting machine according to the invention, the desired castings can be produced in a high quality in a cyclic continuous process. By means of a locking slide, which closes the inlet opening provided in one of the mold parts and completely closes the mold cavity of the mold from the supply, a pressure on the molten metal in the mold can be exerted and permanently maintained during the solidification phase. The main difference with respect to the device according to the invention and the known device consists in the use of the pump device, which is integrated into the overall system. The pump device sucks the melt from a storage chamber and then presses it into the mold cavity. The pump device is part of the overall system or the melting furnace and not the mold and thus tailored specifically to the device, while the inventive device forms an independent unit that can be integrated into any overall system or in a melting furnace. In the known device, no suction takes place in the furnace in which the degassing should take place. Even at the onset of melt pressure is exerted on the melt during solidification. See also 3 and the text page 8/13 paragraph 0045 with 3 ,

In the device according to the invention pressure is exerted before the solidification process, increased and then the solidification process is initiated. With the 3-stage device, the suction of the melt can take place via the piston and then the closure of the casting mold can be carried out with the aid of the piston. Only then does the compression in the mold and then the demoulding of the casting from the mold. This is achieved in a simple manner by the three-stage arrangement, suction of the melt, closing of the casting mold, compression of the melt and subsequent demolding of the casting. The overall device forms a compact unit and is compared to the known device much easier to manufacture and thus cheaper. Furthermore, shorter working cycles can be achieved with the device according to the invention, whereby energy costs can be saved. Lower turbulent flows in the melt are achieved because the melt is free of the gravitational force in the casting mold is directed. By the negative pressure generated, the gases are passed in the mold in the upper part of the mold and can thus escape from the mold and at the same time be removed from the surface of the melt. This gives a simple, inexpensive and universal system.

The invention has for its object the device by means of a compression device or multi-adjustable device in such a way that cavitation avoided and after the removal of the mold from the casting no after-treatment will be more necessary.

The object is achieved in that the mold cavity for receiving the melt is associated with a closing device and a device for compressing the melt, wherein the closing device is designed as a multi-stage adjusting device or as a hydraulically or mechanically adjustable device.

This ensures that the chamber for receiving the melt, hereinafter referred to as molding chamber, is filled at low pressure or low pressure and only when the mold chamber is closed, so that no melt can flow out of the chamber, the compression process begins. The entire mold chamber is filled evenly in all the smallest spaces of the casting chamber with melt and prevented by the corresponding adjustable pressure void formation. The filling pressure may be 1 bar or greater, with the compression pressure at about 50 bar and may be much higher, depending on how the melt is composed. For this purpose, the closing device is used as a multi-stage adjusting device or as a hydraulically or mechanically adjustable device. In this way, the pressure on the melt can be used variably after closing the chamber, since the extendable actuator used independently of the closing part.

After the closing process, the melt present in the runner area can flow away by gravity, so that it does not solidify as before and adhere to the casting, since the closure device with its pointing into the front gate opening on the same transverse plane as the outer end of the bore of the rim for receiving the hub is located. Due to the advantageous embodiment of the closure device is obtained after removal of the blank from the mold chamber a fully formed hole in the rim, which then hardly treated or, as before, still has to be drilled.

As a result, it is achieved in a simple manner with the aid of the compacting device or multiply adjustable device that higher pressures in the melt structure can be achieved even in the low-pressure casting method after filling the casting tool, thereby achieving better casting quality and more homogeneous microstructure while avoiding voids. This makes it possible to significantly reduce the rejection compared to the usual casting process. Furthermore, with the device according to the invention, a high accuracy of the casting is achieved and a subsequent surface treatment is avoided, as eliminated by the advantageous closure device of the sprue bushing of the casting or cast blank, which is particularly advantageous in the production of wheels. With the method according to the device according to the invention no longer needs, as before, the sprue on the blank or on the rim removed and the bore for receiving the wheel hub subsequently screwed or drilled. By eliminating the mentioned processing steps considerable costs can be saved.

It is advantageous for this purpose that the closing device has the adjusting device, which is controlled by means of a control device such that immediately after closing of the chamber for receiving the melt, the device for compressing the melt is activated.

Furthermore, it is advantageous that the adjusting device is designed as a multi-stage adjusting device or as a hydraulically or mechanically adjustable device.

It is also advantageous that the mechanically or hydraulically adjustable adjusting device has an extendable actuating part, which cooperates with a closing part in a first working process and presses against the opening of a sprue bush and acts in a further working process by means of an insert part or pressure part in the melt and compresses them.

It is advantageous that the closing part has a cooling core ( 7 ) or is formed as a cooling core and having supply openings and / or supply lines for coolant.

It is also advantageous that the hydraulically adjustable device is designed as adjustable in several stages hydraulic cylinder with a piston rod.

Further, it is advantageous that the hydraulically adjustable device is designed as adjustable in at least two or three stages hydraulic cylinder with the piston rod.

Of particular importance for the present invention that the connected to the adjustable device actuator with the help of a Pressure plate or with respect to the direction of movement of the adjusting concentrically arranged pressure plate against the likewise concentrically arranged insert part or pressure part comes to rest and moves the insert part or pressure part in the direction of sprue bushing while pressing the closure member against the sprue bushing.

Furthermore, it is advantageous that the closing part has a cooling core or is designed as a cooling core and can be supplied with coolant via supply openings and / or supply lines.

It is advantageous for this purpose that the adjusting device comprises as a multi-stage actuator the adjustable hydraulic cylinder, on the piston, the control part is connected to the pressure plate, which can be brought against the pressure part to the plant, which is designed as a multipart guide column, the coaxially adjustable in the top or molding provided openings is performed.

Furthermore, it is advantageous for the piston of the hydraulic cylinder of the adjustable device to extend through a concentrically arranged opening provided in the insert part or the guide column, to which the cooling core designed as a closing part is connected, which upon closing the piston rod extends the closing part or the cooling core against the inlet opening or sprue opening.

It is also advantageous that the insert part or pressure part or guide column has one or more guide rods which extend through openings provided in the upper mold part and are guided, surround the cooling core and are fixedly connected to a connecting part or center insert which is firmly connected to the cooling core is.

Of particular importance is that the melt is compressed in a further stage or an adjustment of the insert or the pressure member or the guide column with its lower part and / or connected thereto connection part or center insert in the mold chamber for receiving the melt.

An additional possibility is according to an embodiment of the invention that the cooling core can also be closing part and with its lower pointing in the direction of the gate opening end on the same transverse plane as the end face of the bore of the rim when it is received in the mold chamber.

Further advantages and details of the invention are explained in the patent claims and in the description and illustrated in the figures. Showing:

1a the first stage and the beginning of the filling process, wherein the gate of the casting tool is still open;

1b the second stage of internal closure of the casting tool, wherein the cooling core moves downwardly in the direction Z by the three-stage telescopic cylinder, thereby closing the opening of the sprue bushing;

1c the third working stage, wherein the pressure plate, the guide column and the center insert is moved by means of the 3-stage telescopic cylinder down in the direction Z and thereby enters the compression of the melt;

1d the fourth stage, which is released after the cooling process of the blank or the rim by adjusting the side parts to the outside and demolding can take place, so that the rim can be removed;

2 the rim according to the previous aluminum die-casting process,

3 the rim according to the inventive method without sprue and with molded bore for receiving a wheel hub.

In the 1a to 1d is part of a casting tool 1 shown schematically. The overall device, in particular the demolding, is described in detail in the not yet published patent application 10 2016 104 019.3, pages 7-11.

In 1a is with 1 a casting tool for a device for producing castings or rims 18 in aluminum casting or wheel rims for motor vehicles in the low-pressure method or high-pressure method, wherein the filling pressure of the molding chamber for the device described below can be about 2 bar or higher.

The casting tool 1 according to 1a is via a sprue bush 2 filled with melt at a low pressure of about 1 bar or 2 to 5 bar.

side panels 4 have a position according to 1a to 1c ingested.

The casting tool 1 consists of several movably arranged side parts 4 with a lower part or a lower molded part 3 receiving base plate 1b as well as a shell or upper molding 5 having plate 17 , At least the top part 5 is at the plate 17 and thus also at a distance column 11 and a cover plate 12 connected to the device. A demoulding plate 10 is to an actuator 13 connected. With the help of the demoulding plate 10 For example, after the melt is cooled, the rim can be repelled from the mold, as shown in unpublished patent application 10 2016 104 019.3 on pages 7-11, and then removed.

The in the 1a to 1d shown side parts 4 consist of at least two, in particular four, side panel segments, which are led away by oblique slide or slide strips from each other and thus the casting tool 1 after the demolding process, as described in detail in the patent application 10 2016 104 019.3 on pages 7-11.

For demolding the molding or the rim 18 acts at least one adjusting device, not shown in the drawing with the side parts 4 medium or directly together and is thereby from the rim 18 moved away.

The actuator cooperates with positive control elements that provide continuous or uniform movement of the side members or sideshifters 4 effect in the vertical and horizontal directions with respect to the footprint of the casting tool, as described in detail on pages 4 to 7 of the patent application 10 2016 104 019.3.

The device for producing castings, such as cast aluminum, in the low-pressure method using the casting tool 1 consists, as already mentioned, of movably arranged side parts 4 with a lower part or lower molded part 3 and a top 5 , wherein at least the upper part 5 and / or the side panels 4 be adjustable by means of at least one adjusting device, not shown in the drawing.

The device 1 For the production of castings, such as cast aluminum, a further device has in particular a hydraulically or mechanically adjustable device with several individual parts. This includes a three-stage actuator, which is an adjustable telescopic cylinder 13 and interact with a compression tool when the casting tool 1 is closed and no liquid melt can flow into the mold chamber more. The liquid melt is then compressed by means of a melt compression device described below, depending on the melt at a pressure of 50 bar or higher.

The device 1 has the locking device and the associated adjusting device 13 on, which can be a threefold adjustable telescopic and / or hydraulic cylinder. With the aid of a control device, the adjusting device 13 controlled so that immediately after the closure of the chamber for receiving the melt, the means for compressing the melt is activated.

The adjusting device 1 can also be designed as a mechanically multi-stage adjustable device.

After the molding chamber is filled in a first operation ( 1a ), the mechanically or hydraulically adjustable device or the telescopic and / or hydraulic cylinder 13 controlled and an extendable, on the device 13 or on a piston rod 25 arranged control part 15 is moved downwards in the Z-direction, with a closing part 14 towards the opening of the sprue bushing 2 extends. A cooling core 7 can therefore also be closing part and lie with its lower pointing in the direction of the gate opening end on the same transverse plane as the end face of the bore of the rim 18 when it is received in the molding chamber. This gives you after removal of the rim 18 from the mold a rim 18 according to 3 with molded hole and smooth outside. The in 2 shown sprue core is omitted in this casting process.

The piston rod 25 the hydraulic cylinder of the adjustable device 13 extends through a in an insert or guide column 8th provided concentrically arranged opening 27 , on which the cooling core designed as a closing part 7 connected. When extending the on the piston rod 25 arranged pressure plate 26 the pressure plate settles 26 against the closing part or the cooling core 7 and presses the cooling core 7 against the inlet opening or gate 2 ( 1b ).

The insert part or pressure part or guide column 8th has one or more guide rods 28 on, passing through in the upper molding 5 provided openings 29 extend and are guided, the cooling core 7 surrounded and to a connection part or center insert 6 are firmly connected, which is firmly connected to the cooling core.

In a further work step or a setting process is the insert part or the pressure part or the guide column 8th with its lower part or the connecting part or middle insert connected to it 6 received in the mold chamber for receiving the melt ( 1c ) and with a further adjustment of the piston rod 25 the melt is compressed.

The cooling core is via supply openings or via inlet openings 21 . 23 supplied with coolant through the outlet openings 22 . 24 can flow away ( 1d ).

For demolding after cooling the melt, the side parts 4 driven outwards, so the rim 18 is exposed and can be removed.

LIST OF REFERENCE NUMBERS

1

 casting tool

1b

 baseplate

2

 Sprue bush, gate

3

 Lower part, lower part

4

 Side part, sideshifter

5

 Upper part, upper part

6

 center insert

7

 cooling core

8th

 Insert, pressure part, guide column, pressure plate, center insert

9

 Pressure plate, center insert

10

 Demolding plate, ejector package

11

 Spacer column, plate, upper part

12

 cover plate

13

 Adjusting device, hydraulically adjustable device, telescopic cylinder (3-stage)

14

 Actuating device, closing part

15

 Actuator, retractable actuator

16

 Actuator, telescopic cylinder

17

 Plate, shell

18

 Molding, wheel, rim

19

 sprue

20

 Cooling core cover

21

 Cooling for Angus entrance

22

 Cooling for Angus output

23

 Cooling for cooling core input

24

 Cooling for cooling core output

25

 piston rod

26

 printing plate

27

 concentric opening

28

 guide rod

29

 opening

Z

 direction

Claims (9)

Apparatus for the production of castings, such as cast aluminum, in the low-pressure casting process with the aid of a casting tool ( 1 ), which consists of movably arranged side parts ( 4 ) with a lower part or lower molded part ( 3 ) and a top ( 5 ), wherein at least the upper part ( 5 ) and / or the side parts ( 4 ) by means of at least one adjusting device ( 13 ) are adjustable, characterized in that the mold cavity for receiving the melt is associated with a closing device and a device for compressing the melt, wherein the closing device as a multi-stage adjusting device ( 13 ) or is designed as a hydraulically or mechanically adjustable device. Device according to one of the preceding claims, characterized in that the mechanically or hydraulically adjustable adjusting device ( 13 ), as in several stages adjustable piston rod ( 25 ) is trained. Device according to one of the preceding claims, characterized in that the hydraulically adjustable device ( 13 ) as in at least two or three stages adjustable hydraulic cylinder with the piston rod ( 25 ) is trained. Device according to one of the preceding claims, characterized in that the mechanically or hydraulically adjustable adjusting device ( 13 ) an extendable actuator ( 15 ), which in a first working process with a closing part ( 14 ) and this against the opening of a sprue bushing ( 2 ) and in a further work process with the aid of an insert or pressure part ( 8th ) acts in the melt and compresses it. Device according to one of the preceding claims, characterized in that the closing part is a cooling core ( 7 ) or is formed as a cooling core and having supply openings and / or supply lines for coolant. Device according to one of the preceding claims, characterized in that the adjusting device ( 13 ) as a multi-stage adjusting device comprises the adjustable hydraulic cylinder, on the piston of the control part ( 15 ) with the pressure plate ( 26 ) connected to the printing part ( 8th ) can be brought to the plant, which is designed as a multi-part guide column, the coaxially adjustable in the upper part or molded part ( 5 ) provided openings is guided. Device according to one of the preceding claims, characterized in that the piston of the hydraulic cylinder of the adjustable device ( 13 ) by a in the insert part or the guide column ( 8th ) provided concentrically arranged opening ( 27 ), on which the cooling core designed as a closing part ( 7 ) connected when extending the piston rod ( 25 ) the closing part or the cooling core ( 7 ) against the inlet opening or outlet opening ( 2 ) presses. Device according to one of the preceding claims, characterized in that the insert part or pressure part or the guide column ( 8th ) one or more guide rods ( 28 ), which extends through in the upper molding ( 5 ) provided openings ( 29 ) and are guided, the cooling core ( 7 ) and to a connecting part or Medium Use ( 6 ) are firmly connected, which is firmly connected to the cooling core. Device according to one of the preceding claims, characterized in that the cooling core ( 7 ) can also be closing part and with its lower pointing in the direction of the gate opening end on the same transverse plane as the end face of the bore of the rim ( 18 ) when received in the mold chamber.

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