JP2003311389A - Method for casting metal and casting apparatus used therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To stably and easily cast a high quality metal cast block in a good productivity, in a casting method with which a mold is stood up from almost horizontal state to the vertical direction. <P>SOLUTION: This casting apparatus for metal is composed of a mold inclined angle driving device which disposes a pouring hole in the mold at the lower part of a molten metal discharging hole so as to pour the molten metal from the discharging hole having an opening/closing plug arranged in a molten metal receiving vessel and stands up the mold from almost the horizontal state to the vertical direction according to the pouring of the molten metal from the pouring hole, a molten metal surface level measuring device for measuring the surface level of the molten metal in the receiving vessel, a mold inclined angle measuring device for measuring the mold inclined angle, a molten metal distributing device for distributing the molten metal into the receiving vessel, a plug opening degree adjusting device for performing the opening degree adjustment of this plug and an automatic control unit which adjusts flowing speed and flowing rate of the molten metal flowing down while bringing into contact with the wall surface of the mold so as to match to the shape of the mold by outputting indicating information for working the molten metal distributing device, the mold inclined angle driving device and the plug opening degree adjusting device, after inputting the molten metal surface level, the mold inclined angle data and the opening degree data of the plug. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a metal molded product made of a metal, particularly a non-ferrous metal, using a mold, and more specifically, aluminum (including alloys below) and magnesium. The present invention relates to a method and a casting apparatus for casting a molten metal such as non-ferrous metal such as zinc using a mold capable of tilting.

[0002]

2. Description of the Related Art Typical examples of casting methods for casting products of various metals include sand casting, die casting and die casting. Among them, die casting is shrinkage cavity or micro shrinkage. Is generally used as a method for obtaining a good quality product with less occurrence of. In this mold casting method, a stationary casting method of injecting molten metal into a fixed mold,
There is an inclined casting method in which molten metal is poured into a tiltable mold.
One of the inclined casting methods is disclosed in JP 2001-35355 A.
No. 4 publication. A casting method is provided in which a pond is provided in the pouring port of the mold, and the metal mold is filled with molten metal in the pond while vertically raising the mold, which is positioned approximately horizontally, with the pouring port facing up. The method of putting the ingot into a forging press to obtain a forged product is disclosed.

In this tilt casting method, the melt can be poured gently along the wall of the mold while adjusting the tilt angle of the mold, so that the poured melt is not disturbed in the mold. The amount of metal oxide generated is less than when pouring the molten metal into a vertically placed mold.
It is said that there is no occurrence of void defects due to inclusion of non-metallic inclusions or air inside the resulting ingot.

In this tilt casting method, the molten metal remaining in the pool after filling the mold acts as a push, so that the molten metal is supplied to the microscopic shrinkage portion in the metal structure caused by solidification shrinkage. As a result, defects inside the cast ingot can be eliminated. The higher the height of the surface of the hot water remaining in the pool is, the higher the effect of the hot water is obtained. Therefore, in order to further improve the quality, the hot water having a higher hot water surface is provided.

As a more recent technology, Japanese Patent No. 32472
No. 65 discloses that a mold is placed on a cooling plate, the mold is closed from a melt receiving tank provided on the upper part of the mold, the mold is filled with a metal melt without leaving a void, and then the mold is filled with the melt. A casting method is disclosed in which the metal is unidirectionally solidified by cooling the cooling plate by shutting off with an opening / closing plug. According to this casting method, the molten metal filled in the mold is unidirectionally solidified toward the pouring port by heat removal from the cooling plate,
It is possible to obtain a sound ingot without casting defects such as void defects, shrinkage cavity defects, and micro-shrinkage inside the ingot. Moreover, since the molten metal in the mold and the molten metal in the molten metal receiving tank are separated by closing the opening / closing plug after pouring the molten metal, the obtained ingot does not have the pushing metal. Since continuous casting is possible by repeated work, productivity is high. Also, the volume of the obtained ingot is constant because the volume in the mold is constant,
Since the variation in the volume of the forging material is reduced, the dimensional accuracy of the product is improved and the forging die life is extended.

[0006]

In the above-described inclined casting method, while gradually raising the mold integrated with the molten metal pool, the molten metal in the mold cavity is not disturbed violently in the molten metal pool. The molten metal is poured along the wall of the mold into the mold. At this time, the amount of tapping water from the pool changes depending on the amount of change in the inclination angle of the mold, so if the tilt angle is changed little by little, the change in tapping amount will be small, and if it is changed significantly, the tapping amount will increase rapidly. If the wall surface of the mold has no protrusions that obstruct the flow-down, the poured molten metal will flow into the mold with acceleration, accelerating into the molten metal surface, and the speed at which it reaches the filled molten metal surface will be maximum. Will be. Particularly, in the latter half of the casting process, when the mold approaches a vertical direction, the gradient of the wall surface of the mold increases, so that the flow velocity of the molten metal flowing down the wall surface of the mold must be much higher than that at the start of casting.

In particular, when a mold having a narrow cavity at the tip (rear of the mold) and a wide shape on the injection port side is used, the gradient of the mold is structurally smaller at the beginning of the casting process, so that the wall surface of the mold is reduced. The speed of the molten metal flowing down becomes slower,
A small amount of molten metal can be poured without disturbing. However, when the mold rises in the latter half, the flow velocity increases, and a large amount of molten metal is poured at a high speed, which causes quality problems in the mold.

At this time, when the injected molten metal reaches a rate exceeding the rate of causing disturbance on the molten metal surface, the molten metal reacts with oxygen in the air to generate metal oxides (non-metallic inclusions). However, they may float on the surface of the molten metal and may be caught on the surface of the ingot after solidification or may be caught inside the ingot, which may deteriorate the quality.

On the contrary, in the case of using a mold having a cavity shape in which the vicinity of the injection port is narrow and the tip (the inside of the mold) is branched into several parts, the volume suddenly increases at the branching part, so that the inside of the cavity is increased. The inflow of molten metal becomes slower, and part of the molten metal in the previously filled cavity begins to solidify, causing discontinuous solidification with the unsolidified molten metal, causing casting defects such as the melt boundary. There is a risk. In order to prevent this, a method is used in which the angle of inclination is increased, the amount of molten metal discharged is increased, and the molten metal is quickly filled in each of the branched cavities. However, although the amount of molten metal discharged increases with increasing the inclination angle, the flow velocity of the molten metal also increases because the inclination angle rises. In particular, when the inclination angle approaches vertical, the molten metal flowing down is accelerated and the flow velocity becomes large. It drops violently into the molten metal in the cavity, causing the above-mentioned quality problem.

On the other hand, if the molten metal is always flowed at a low flow rate without acceleration, a certain amount of molten metal needs to flow out of the pool at any inclination angle.
There is no choice but to make the pool of water extremely large and store a large amount of molten metal. As a result, the number of defective parts to be discarded as the hot water increases, and the amount of molten metal used increases, which significantly deteriorates the productivity.

As described above, in the tilt casting method in which the tilt angle of the mold is raised in the vertical direction, it is structurally difficult to secure a required flow rate at a desired position of the tilt angle while keeping the flow velocity low. there were.

The present invention has been proposed in view of the above,
A casting method that causes the mold to rise from a substantially horizontal state to a vertical direction as the molten metal is injected from the injection port of the mold, and the flow velocity of the molten metal injected into the tilting mold flowing down the mold wall surface according to the shape of the mold cavity. And a device that enables independent control of the flow rate, and that stably and easily casts a high-quality metal ingot that has not been obtained in the past with good productivity,
It is an object to provide a manufacturing method thereof.

[0013]

[0014]

In order to achieve the above object, the present invention has the following constitutions. 1) A first aspect of the invention for solving the above-mentioned problems is to dispose a casting port of a mold below the pouring port so that the molten metal is poured from a pouring port having an opening / closing plug provided in the molten metal receiving tank.
A mold tilt angle drive that raises the mold from a substantially horizontal state to a vertical direction as the molten metal is poured from the inlet, a level measuring device that measures the level of the molten metal in the molten metal receiving tank, and the mold tilt angle. Mold inclination angle measuring device for measuring the molten metal, a molten metal distribution device for distributing the molten metal to the molten metal receiving tank, an opening / closing plug opening adjusting device for adjusting the opening / closing plug opening, and a molten metal level obtained from the molten metal level measuring device. Level data, mold tilt angle data obtained from the mold tilt angle measuring device, and opening / closing plug opening data obtained from the opening / closing plug opening adjustment device are input, and the molten metal distribution device, mold tilt angle drive device, and opening / closing plug opening adjustment are input. Outputs instruction information to operate the device, and includes a casting automatic control device that adjusts the flow velocity and flow rate of the metal melt flowing down in contact with the mold wall surface according to the shape of the mold, and the mold is filled with the melt. Immediately before Is a casting machine for metals, characterized in that the casting mold is installed in such a manner that the injection port of the casting mold is closed by the lower surface of the member constituting the molten metal receiving tank and the pouring mouth having an opening / closing plug. . 2) A second aspect of the invention for solving the above-mentioned problems is that the mold tilt angle drive device converts a linear motion of a drive source into a rotary motion of a rotary shaft, and rotates by changing a speed of the rotary motion of the drive source. 1) A device having any one kind or a combination of two or more kinds selected from a mechanism for converting the shaft into rotary motion and a mechanism for directly applying rotary motion of a drive source to the rotary shaft. It is a metal casting machine. 3) A third invention for solving the above-mentioned problems is the metal casting apparatus described in 1) or 2), wherein the distribution device is a batch type device using a ladle. 4) According to a fourth aspect of the invention for solving the above-mentioned problems, a distribution device is a siphon type distribution device in which an external molten metal holding furnace and a receiving tank are connected by a molten metal supply pipe, a power pump type distribution device, and a molten metal holding furnace surface. Or a combination of two or more selected from a molten metal surface pressure pump type distribution device by applying pressure to the molten metal, or a distribution device that supplies from a gutter or a supply pipe to a molten metal supply hole provided on the side surface of the molten metal receiving tank. The metal casting apparatus as described in 1) or 2) above. 5) A fifth invention for solving the above-mentioned problems is characterized in that a height difference h between a lower end portion of the outlet of the pouring port and a mold wall surface where the injected molten metal first reaches is 200 mm or less. The metal casting apparatus according to any one of 1) to 4). 6) A sixth invention for solving the above-mentioned problem is that the height H of the molten metal stored in the molten metal receiving tank during pouring is at least 10 mm or more from the lower end of the outlet of the pouring port. The metal casting apparatus according to any one of 1) to 5). 7) A seventh invention for solving the above-mentioned problem is that the height H1 of the molten metal surface stored in the molten metal receiving tank immediately before closing the opening / closing plug is at least 10 m from the outlet upper end of the pouring port.
The metal casting apparatus according to any one of 1) to 6), wherein the casting apparatus is for metal. 8) The eighth invention for solving the above-mentioned problems is that the mold inclination angle α during injection is 10 to 90 ° from the vertical direction to the horizontal direction.
The metal casting apparatus as described in any one of 1) to 7) above. 9) A ninth aspect of the invention for solving the above-mentioned problems is that the open molten metal surface of the molten metal stored in the molten metal receiving tank is any one or two types of inert gas selected from Ar gas and nitrogen gas. The metal casting apparatus according to any one of 1) to 8), which is covered by the above. 10) A tenth aspect of the invention for solving the above-mentioned problems is that a molten metal receiving tank, a pouring port, an opening / closing stopper, an opening / closing mechanism of the opening / closing stopper, and a heating furnace surrounding the molten metal receiving tank are housed in a closed container that can be opened and closed. A pressurized gas supply device is connected to the container via a gas inflow valve, an exhaust valve for discharging gas to the outside of the container is provided in the closed container, and the exhaust valve is closed after the molten metal is filled in the mold. Open the gas inflow valve to inject gas to increase the pressure in the closed container, then close the opening / closing plug, and then open the exhaust valve that was closed with the gas inflow valve to release the pressure in the closed container. 10. The device according to claim 1, further comprising a control mechanism.
It is a metal casting apparatus as described in the item. 11) An eleventh invention for solving the above-mentioned problems is that pressure is applied to a closed container by a pressurized gas, and the gas is any one selected from air, nitrogen gas and Ar gas. The metal casting apparatus described in 10) is characterized in that the gas is one kind or two or more kinds of gas. 12) A twelfth invention for solving the above-mentioned problems is characterized in that the magnitude of pressure applied to the molten metal surface in the molten metal receiving tank in the closed container is 0.001 to 5 megapascals. The metal casting apparatus according to 10) or 11). 13) A thirteenth invention for solving the above-mentioned problems is characterized in that the material of the mold is any one kind or a combination of two or more kinds selected from iron, cast iron, heat-resistant steel, copper, and respective alloys. The metal casting apparatus according to any one of 1) to 12). 14) A fourteenth aspect of the present invention for solving the above-mentioned problems is to provide a casting method in which a casting port is provided in a molten metal receiving tank in a casting method in which the casting mold is raised from a substantially horizontal state to a vertical direction as the molten metal is poured from the casting port. It is arranged below the pouring port so that the molten metal can be injected from the pouring port having the open / closed plug, and the height of the molten metal surface stored in the bottom end of the pouring port and the molten metal receiving tank By controlling the difference, the inclination angle of the mold, and the opening degree of the opening / closing plug, the molten metal is injected while adjusting the flow rate and flow rate of the molten metal flowing down in the mold while contacting the mold wall surface, Immediately before solidification is completed as the final solidification portion of the molten metal of the injection port injected into the mold in a state where the injection port of the mold is closed by the lower surface of the member constituting the molten metal receiving tank and the pouring port having an opening / closing plug Close the opening and closing stopper to complete coagulation, Is a method of casting metal, characterized. 15) A fifteenth invention for solving the above-mentioned problems is that the metal is aluminum or an aluminum alloy,
The method for casting a metal as described in 14) above.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, an example of a manufacturing apparatus of the present invention will be described with reference to FIG. FIG. 1 shows a mold injection port provided below the pouring port so that the molten metal is injected from a pouring port having an opening / closing plug provided in the molten metal receiving tank, a mold tilt angle driving device, and a level measurement of the molten metal surface. Vessel, a mold inclination angle measuring device, a molten metal distribution device, an opening and closing plug opening adjusting device, and an automatic casting control device, immediately before the molten metal is filled in the mold, and the lower surface of the member constituting the molten metal receiving tank. It is an example of a metal casting apparatus characterized in that the casting mold is installed in such a manner that the casting port of the casting mold is closed by a pouring port having an opening / closing plug.

FIG. 1 is a schematic sectional view of an apparatus during casting using an inclined casting apparatus in which the molten metal receiving tank 1 and the mold 7 are integrally tilted.

The molten metal receiving tank 1 is fixedly installed in an electric furnace 5 equipped with an electric resistance heating body 5'by a spacer 16 and a fixing plate 15 below the molten metal receiving tank. The small diameter portion 15 ′ of the lower portion of the receiving tank is fitted to the fixed plate 15. Further, the upper part of the furnace is covered with a lid 80 in order to prevent heat dissipation in the furnace. In order to prevent the molten metal from flowing out of the molten metal receiving tank when the molten metal receiving tank is tilted, a protruding portion 1'is installed at least half or more around the central axis of the molten metal receiving tank 1 on the innermost surface of the molten metal receiving tank 1. preferable.

A pouring port 4 is provided in the lower portion of the molten metal receiving tank 1, and the pouring port has an opening / closing plug 2 which can be moved up and down. By controlling the degree of opening / closing of this, the amount of the molten metal 3 in the molten metal receiving tank discharged from the pouring port can be adjusted. The opening / closing plug opening adjusting device 70 includes the support 1 installed on the base plate 14.
3 is composed of an electric cylinder 11 attached to the upper part of the No. 3 and a piston 11 'connected to it. Open / close plug 2
Is connected to the piston 11 ′ of the opening / closing plug opening adjustment device 70 via the support rod 12. For example, the opening / closing plug 2 is fixed to the tip of the support rod 12 with a bolt 41, and is vertically moved by an opening / closing plug opening adjusting device. The opening degree of the opening / closing plug can be adjusted by controlling the refusal separation L from the tip of the opening / closing plug to the pouring port.

The position information of the opening / closing plug 2 is sent as input information from the electric cylinder 11 to the terminal X2 of the input device 50 of the automatic casting control device between the opening / closing plug opening adjusting device 70 and the automatic casting control device 71. On the other hand, the opening control instruction of the opening / closing plug 2 based on the information of the opening / closing plug opening given from the terminal Y1 of the output device 52 of the automatic casting control device to the electric cylinder 11 by the arithmetic unit 51 of the automatic casting control device. Control lines are connected so that information can be sent. The opening / closing plug opening adjustment device uses the opening control instruction information to control the electric cylinder 1
The opening / closing plug 2 can be moved to a predetermined position by activating 1.

The electric cylinder 11 is preferable because it can output the position information and control the position by inputting the control instruction information from the outside by an integrated device. Open / close stopper lifting mechanism 70
In addition to the electric cylinder, examples of the power source include linear motors, electric stepping motors, hydraulic cylinders, hydraulic cylinders, pneumatic cylinders, and the like. An electric cylinder, a linear motor, and an electric stepping motor are preferable because they have excellent positional accuracy.

A molten metal level measuring instrument is inserted in the molten metal 3. In this figure, an electromagnetic liquid level gauge 17 is inserted as an example of the molten metal level measuring device. A control line for transmitting the detection signal from the electromagnetic level gauge 17 to the automatic casting control device is connected to the terminal X1 of the input device 50 of the automatic casting control device. The liquid level gauge is fixed by bolts 42 to the tip of a support rod 18 installed on the base plate 14. The level of the molten metal surface 3 ′ in the molten metal receiving tank 1 is measured by the electromagnetic liquid level gauge 17, and the data is sent to the automatic casting control device 7.

Examples of the melt level measuring device include a float type liquid level gauge with a transmitter, a laser type liquid level gauge, and a photoelectric type liquid level gauge in addition to the electromagnetic type level gauge.

The mold 7 is composed of a lower mold 7A located below when the mold is tilted and an upper mold 7B located above, and the upper mold 7B and the lower mold 7A are joined at the mold dividing surface 6 to be integrated at the time of injection. Those having a structured structure are preferable.

As a material for the mold, it is preferable to use a material having a high thermal conductivity, a high heat resistance and a high melt reactivity. Examples of the material of the mold include iron, cast iron, heat resistant steel, copper and their alloys. The whole may be made of the same material, but may be divided and each part may be made of a combination of different materials. JIS standard SK due to its high thermal conductivity, prevention of mold deformation, and corrosion prevention by molten metal
Heat-resistant steel such as D61 is preferable.

The mold tilt angle driving device for raising the mold from the substantially horizontal state to the vertical direction as the molten metal is injected from the injection port is, for example, a hydraulic cylinder, an electric cylinder, or a hydraulic cylinder as a power source for performing linear motion. Cylinders, pneumatic cylinders, electric chain blocks, etc. are used, and these are connected to the mold through a rotatable connecting pin installed on the base plate or an arm attached to a part of the casting machine, which enables linear movement. A device having a mechanism for converting the mold into rotational motion can be used. Among the power sources that perform linear motion, the hydraulic cylinder is preferable because it has the highest degree of freedom for changing the tilting speed and the accuracy of position control. The electric cylinder is preferable because the device can be made compact and convenient for use.

Further, as a mechanism for converting the motion of the drive source into the rotary motion of the rotary shaft by changing the speed, there is a speed reducer with an electric motor directly mounted on the rotary shaft. Furthermore, as a mechanism for directly giving rotary motion to the rotary shaft as a drive source,
A low speed electric motor directly connected to the rotating shaft may be used.

In the example of FIG. 1, the operation of rotating the mold from the substantially horizontal state to the vertical direction is performed by the operation of the piston 24 of the hydraulic cylinder 23 which is the power source of the linear movement. The oil 27 is stored in the oil tank 26, and is operated from the suction pump 28 by the operation of the oil pump 22.
It is supplied to the hydraulic cylinder 23 through 9. The lower mold 7A is fixed to a mold fixing base 19 (fixing jig is not shown). The mold fixing base 19 constitutes a part of the base plate 14, and is connected to a rotary shaft 20 installed on a column 21.

As a result, the piston 24 moves forward to lift the base plate 14 upward and raise the mold 7 in the vertical direction. The length of the piston 24 is adjusted so that the longitudinal direction of the mold is substantially horizontal in the initial state. The oil in the upper part of the hydraulic cylinder returns to the oil tank through the return pipe 30.

In the middle of the return pipe 30, the throttle valve 2 connected by a control line to the terminal Y2 of the output device 52 of the automatic casting control system.
5 is provided. The opening of the throttle valve 25 can be controlled by a signal transmitted from the terminal Y2 of the output device 52 of the automatic casting control device, whereby the inclination angle α of the mold can be controlled to a predetermined value or the inclination angle of the mold. The change speed of can be controlled.

The position of the axis of rotation is not limited to the position of the contact portion between the base plate 14 and the mold fixing base 19 shown in FIG. It can be set within a range that does not hinder the function of the casting device. For example, it may be rotated by a horizontal axis at a position including the pouring port, and further, a position near the upper end of the receiving tank may be rotated as an axis. Further, as will be described later, when the molten metal is supplied from a gutter or a pipe connected to the molten metal receiving tank (FIG. 7), a rotary shaft may be provided at the position of the center of gravity of the cross section of the gutter or the pipe for swirling.

A mold tilt angle measuring instrument 31 connected to the terminal X3 of the input device 50 of the automatic casting control device by a control line is installed on the lower die fixing base 19. Mold tilt angle measuring device 31
The information on the inclination angle α at any time when the mold is inclined can be sent to the automatic casting control device in real time. As the mold tilt angle measuring device 31, an encoder /
Examples include a rack and pinion type angle measuring device with a transmitter and a linear gauge with a transmitter.

The metal melt 8 injected from the pouring port 4 flows into the mold along the mold wall surface 53 of the lower mold 7A. The poured molten metal is accelerated in flow velocity by the inclination of the mold and comes into contact with the wall surface of the mold to flow down. Reference numeral 9 is a molten metal that has flowed into the mold. In FIG. 1, the receiving tank and the mold are arranged so that the pouring port of the receiving tank is included in the injection port of the mold, and the molten metal receiving tank 1 and the mold 7 are integrally tilted. It is an example of an apparatus in which an injection port of a mold is arranged below the pouring port so that the molten metal is injected from the pouring port having the opening and closing plug.

Terminal Y3 of the output device of the automatic casting control device
Is connected to a molten metal distributor that distributes the molten metal to the molten metal receiving tank. A known method can be used for the molten metal distribution device as long as the molten metal supply amount can be controlled by a control signal from the Y3 terminal of the output device of the automatic casting control device.

It is preferable that the device for delivering the molten metal to the molten metal receiving tank is of a batch type such as a ladle type feeding device, because a fixed amount of the molten metal can be supplied to the receiving container at each constant temperature during the casting process.

FIG. 6 (a) shows a state in which a molten metal is drawn from an external molten metal holding furnace by a ladle and distributed to a receiving tank.

The following apparatus can be given as another molten metal delivery apparatus. When the molten metal holding furnace and the receiving tank installed outside are connected by a molten metal supply pipe, a siphon type distribution device, a power type pump distribution device, and a pressure pump distribution device by applying pressure to the molten metal holding furnace surface can be used. it can.

Another example is a device for continuous distribution by connecting a gutter or hot water supply pipe to a molten metal supply hole provided on the side surface of the receiving tank. FIG. 7A shows a state in which a side wall of the receiving tank is opened and a molten metal supply hole is provided, and a gutter is connected to the hole to distribute the molten metal from the gutter to the receiving tank.

In a siphon system connecting an external molten metal holding furnace and a receiving tank, or in a feeder equipped with a power pump, since the molten metal does not come into contact with air during transfer to the receiving tank, generation of metal oxide can be suppressed. Therefore, it is preferable since a clean molten metal can always be used.

These molten metal distributors may be used alone or in combination.

The molten metal can be distributed to the receiving tank at any stage of the casting process. For example, the distribution amount can be adjusted as follows. The amount of molten metal poured into the casting mold is distributed to the receiving tank by inputting the data of the molten metal level measuring instrument 17 installed in the receiving tank to the input device 50 of the automatic casting control device, and the terminal Y3 of the output device 52. The molten metal supply device may be operated intermittently by a signal from the. Alternatively, the siphon device or the power pump may be operated intermittently.

When the pouring amount and flow velocity of the molten metal flowing out from the pouring port are constant, the molten metal may be continuously supplied so that the level of the molten metal in the receiving tank is kept constant during the casting process.
Alternatively, during pouring, the level of the molten metal in the receiving tank should be kept low to reduce the speed of pouring into the mold, and when the pouring is completed, the molten metal should be raised to raise the molten metal level. It is also possible to distribute the molten metal in the tank to sufficiently enhance the effect of pushing the molten metal in the receiving tank. While pouring the molten metal into the mold, the molten metal may be received in the receiving tank while the mold is lying down, or may be received while standing.

The casting may be carried out in a casting mold which is laid substantially horizontally, and at the same time, it may be delivered to the receiving tank. Alternatively, the casting may be performed in a substantially vertical mold, and at the same time, it may be delivered to the receiving tank.

As described above, by continuously supplying the molten metal into the molten metal receiving tank while controlling the amount of the molten metal to be supplied, it is possible to give the maximum effect of the molten metal to the final solidification portion in the mold, which results in high quality. Can be obtained.

In these siphons, pump distributors, and hot water supply pipes, the molten metal in the devices and pipes is kept warm so as not to reach the solidification start temperature of the molten metal or heated as necessary. Is preferred.

When the receiving tank and the mold are integrally inclined, the power pump type supply device does not impair the quality of the molten metal,
Simple and easy to use. When only the mold is tilted without rotating the molten metal receiving tank as described later (FIG. 5), the gutter connected to the receiving tank is simple and easy to use.

When the receiving tank and the mold are integrally tilted, the receiving tank is sealed by sealing the molten metal so that the molten metal does not flow out from the rotary joint between the molten metal supply pipe and the receiving trough of the supply gutter. Even if it is inclined, the molten metal can be stably supplied to the receiving tank.

The automatic casting control system uses the melt level data obtained from the melt level measuring device, the mold tilt angle data obtained from the mold tilt angle measuring device, and the opening / closing plug opening obtained from the opening / closing plug opening adjusting device. The data is input, and the instruction information for operating the molten metal distribution device, the mold tilt angle drive device, and the opening / closing plug opening adjustment device is output, and the flow velocity and flow rate of the molten metal flowing down in contact with the mold wall surface are determined by the shape of the mold. It is a device that adjusts according to.

The arithmetic unit 51 receives the information of the molten metal surface level 3'of the molten metal receiving tank inputted to the input unit 50 and the mold inclination angle α.
And the position information of the opening / closing plug 2, the opening of the pouring port by the opening / closing plug 2 and the mold so as to obtain the optimum flow velocity and flow rate of the molten metal flowing in contact with the mold wall surface according to the shape of the mold. And the level of the molten metal surface are determined, and the output device 52
Sends command information to each device. Based on this command information, the opening / closing plug opening adjustment device 70, the throttle valve 25 of the mold tilt drive device, and the distribution device (not shown) operate.

In the arithmetic unit, the average initial velocity of the molten metal at the pouring port 4, which is the flow velocity of the molten metal flowing in contact with the mold wall surface that is optimum for the shape of the cavity in the mold, based on the input information, and the mold In order to obtain the optimum flow rate for the shape of the cavity, the target value of the control parameter is calculated and output to the output device. In order to calculate the target value, it is preferable to incorporate a relation between the optimum average initial velocity and flow rate and the output control parameter as a database in the form of a table. This is because the optimum output can be instantly obtained for the input information.

For example, from the height H of the molten metal in the receiving tank, the distance L to the opening / closing plug for controlling the opening / closing of the opening / closing plug and the pouring port, and the inclination angle α of the mold, the average initial molten metal flowing out from the tapping port. The velocity V is experimentally obtained in advance, and the combination of these parameters (H, L, α) for obtaining the average initial velocity V is previously obtained. Further, the flow rate Q at that time is measured in advance.
Further, the quality of the solidified ingot when the average initial velocity V and the flow rate Q are changed is investigated in advance. Based on these results, a database associating the combination of parameters (H, L, α, V, Q) with the result of coagulation is prepared and stored in the storage device of the arithmetic unit. At the time of actual operation, the current value of each parameter from each measuring device is input to the input device, and from the value of each parameter input in the computing device, conversely, the optimum average initial speed and flow rate that satisfy the quality are set. The target value of each parameter is obtained by comparison and reference from the database, and output information for controlling each device is output so that the value is obtained, and each device is controlled. As a result, the quality of the ingot to be cast satisfies the required level.

FIG. 2 shows a method of adjusting the flow velocity and flow rate of the molten metal flowing down in the mold while contacting the wall surface of the mold with the automatic casting control device when pouring the molten metal into the mold. Explained.

If the inclination angle α of the mold is large and nearly horizontal, the flow velocity of the molten metal flowing down along the inner wall surface 53 of the mold becomes slow, so that an ingot of good quality can be obtained. Not only does it take time, but the amount of heat removed from the mold increases, solidification starts in the middle of the mold, and casting defects such as the molten metal boundary and the hot water flow defect occur. When the inclination angle α is small and the mold is close to vertical, the flow rate of the molten metal flowing down becomes faster and the casting time is shortened to improve productivity, but the molten metal collides violently with the bottom of the mold, causing air entrapment and non-metallic inclusions. As a result, the quality of the ingot is deteriorated due to the entrainment of the steel.

Average initial velocity V of the molten metal flowing out from the pouring port
Is increased in proportion to the height of the molten metal surface from the pouring port due to the hydrostatic pressure generated by the level of the molten metal 3'in the receiving tank. Since the molten metal reaching the wall surface of the mold has already reached the wall surface with the average initial velocity V, the molten metal flows down the wall surface with the average initial velocity. The molten metal injected is accelerated in the flow velocity by the inclination of the mold and flows down in contact with the mold wall surface.Therefore, in order to prevent defects from occurring inside the ingot, the inclination of the mold considering the average initial velocity is considered. The angle α needs to be determined.

Next, the amount of molten metal flowing out from the pouring port is
It is also determined by the opening of the pouring port by the opening and closing plug. When the opening / closing plug is completely inserted into the pouring port, the opening of the opening / closing plug becomes 0 and the amount of tapping water becomes 0. When the opening / closing plug is located sufficiently above the pouring port, the opening / closing plug is fully opened. When the opening / closing plug is in the middle of them, the pouring port is partially closed. Therefore, by appropriately controlling the position of the opening / closing plug by the opening / closing plug raising / lowering device 11, the opening degree of the opening / closing plug is controlled and an arbitrary amount of tapping water is discharged. Can be obtained.

Further, for example, as shown in FIG. 1, when the lower mold has the protrusions 10 on the inner surface thereof, the molten metal jumps at the protrusions 10 when the flow velocity of the molten metal is high, so that the molten metal is violent. It is disturbed and air is entrained in the molten metal and non-metallic inclusions are entrained. Therefore, the tilting angle of the mold is increased until the protrusion 10 is covered with the molten metal surface 9'of the molten metal in the mold. It is preferable to elevate the mold in the vertical direction to reduce the tilt angle to such an extent that the inclusion of oxides and oxides does not occur.

As described above, since the casting apparatus of the present invention is a casting apparatus having a function of adjusting the injection amount independently of the inclination angle of the casting mold, pouring is performed with the casting mold kept in a substantially horizontal state. It is possible to make hot water. Further, even if the flow rate of the molten metal poured into the mold is changed, it is possible to suppress the change in the flow velocity of the molten metal.

In addition to the above, the input device may be supplied with information from a temperature measuring device for measuring the temperature of the vicinity of the upper end of the lower mold or the like, and may be used as a trigger for the operation in the arithmetic unit of the automatic casting control system. preferable.

Extrusion of molten metal from an external molten metal holding furnace,
Tilt of mold, start of pouring, opening degree of opening / closing plug, opening of mold after completion of solidification and removal of ingot, reset of mold, installed in mold or installed outside (not shown) It is preferable to control the operation timing of the casting process, such as the cooling timing of the mold, by setting the time of the timer in the arithmetic unit because the control device can be simplified. Further, it can be linked to the timing of inflowing and excluding gas when the inert gas is filled into the closed container and the pressure of the gas in the closed container is increased, which will be described later.

Next, an enlarged view of the vicinity of the tap hole of FIG.
Based on the above, the operation of pouring the molten metal when the present apparatus is used will be described.

The height h between the outlet lower end 101 of the pouring port 4 and the wall surface of the mold to which the molten metal 103 injected into the mold first reaches is preferably 100 mm or less (more preferably 70 mm or less). Since the drop between the lower end of the pouring mouth and the inner wall surface 53 of the mold is small, the molten metal that has fallen onto the inner wall surface is not disturbed violently. This is because an ingot can be obtained. The height h between the lower end of the outlet of the pouring mouth and the wall of the casting mold to which the injected molten metal first reaches is 100 mm or less by arranging the wall surface of the casting mold that constitutes the mold pouring port close to the lower end of the pouring spout. I am trying.

The height H1 from the outlet upper end 105 of the pouring port to the surface of the molten metal in the receiving tank is preferably at least 0 (more preferably 15 mm or more). When the height H1 becomes negative, the pouring port 4 is exposed to the atmosphere during pouring, and a metal oxide (non-metallic inclusion) is generated on the inner surface of the pouring port.
It becomes a foreign substance and is caught in the ingot, or the opening / closing plug 2
This is because there is a possibility that a problem such as incomplete closing may occur due to being caught by the sliding surfaces of the pouring port. The amount of molten metal in the receiving tank is more than the amount required to form the ingot, or the molten metal is continuously replenished by the molten metal supply device so that the molten metal level in the receiving tank rises from the upper end of the outlet of the pouring port. The height H1 is at least 0 mm or more.

It is preferable that the height H of the molten metal surface 3'in the receiving tank immediately before the opening / closing plug is closed is 10 mm or more (more preferably 15 mm or more) from the outlet lower end 101 of the pouring port. This is because the molten metal in the receiving tank can sufficiently exert the effect of the molten metal on the final solidified portion, and a sound metal ingot with suppressed shrinkage defects inside the ingot can be obtained. The amount of molten metal in the molten metal receiving tank should be stored in advance as more than the amount necessary to form the ingot, or by continuously replenishing the molten metal with the molten metal supply device, The height H from the lower end of the pouring spout is set to 10 mm or more.

The flow rate can be adjusted by controlling the distance L of the tip 106 of the opening / closing plug 2 from the inlet upper end 107 of the tap hole 4. When the distance L is 0, or when the tip of the opening / closing plug is inserted into the tap hole, the amount of tapping water becomes 0, and if the distance L is sufficiently large, the flow rate becomes maximum. By setting the distance L to any value in between, the opening degree is controlled and the flow rate is adjusted. That is, the amount of tapping can be controlled by adjusting the distance L, regardless of the inclination angle α of the mold.

The mold inclination angle α during pouring is 10 to 90 ° (more preferably 20 to 75 °) from the vertical direction to the horizontal direction.
Is preferred. This is because the molten metal 104 flowing into the mold cavity 55 is not disturbed significantly, so that a metal ingot having excellent internal quality can be obtained.
For example, when the apparatus of FIG. 1 is used, the piston 24 of the hydraulic cylinder 23 connected to the end of the base plate is contracted to tilt the mold 7 integrated with the receiving tank 1 about the rotation shaft 20. By doing so, the inclination angle α during pouring is 10 to 90 ° from the vertical direction to the horizontal direction.

The average initial velocity V at the outlet of the molten metal is 1 to 150 cm / s (more preferably 10 to 150 cm).
/ S. ) Is preferable. This is because the molten metal discharged from the tap hole is not disturbed violently, so that a metal ingot with excellent internal quality can be obtained. The amount of molten metal in the molten metal receiving tank should be stored in advance as more than the amount required to form an ingot, or the molten metal should be continuously replenished by the molten metal supply device so that the molten metal surface level does not drop below a predetermined level. By controlling the opening degree of the opening / closing plug and controlling the inclination angle of the mold, the average initial velocity V at the pouring outlet of the molten metal is set to 1
~ 150 cm / s.

Next, as another embodiment, an example of an apparatus in which only the mold is tilted without tilting the molten metal receiving tank will be described with reference to FIG. FIG. 5 has the same configuration as that of FIG. 1 except that the receiving tank and the mold are not integrated and only the mold is tilted without tilting the receiving tank. The rotary shaft 154 is used as an axis, and the shaft includes a shaft core on a receiving tank lower surface 155. When the mold 151 changes from a substantially horizontal state to a vertical position, the mold tops 156A, 15
6B is in close contact with the lower surface of the receiving tank and forms a state in which the injection port 153 of the mold is closed by the lower surface 155 of the member forming the receiving tank and the pouring port 4 having the opening / closing plug 2. The molten metal 103 discharged from the pouring port 4 at the average initial speed V is the mold wall surface 1
Flow down along 50 with increasing velocity. At this time, the speed is adjusted so that the internal quality of the ingot becomes a constant level by controlling the inclination angle α according to the shape of the mold cavity. Reference numeral 151A is a lower mold, 151B
Is the upper mold. Also in the example of FIG. 5, the amount of molten metal discharged is adjusted by adjusting the distance L between the end face 106 of the opening / closing plug 2 and the inlet upper end 107 of the pouring port 4.
Can be done independently of.

As described above, since the apparatus of the present invention is a casting apparatus having a function of adjusting the injection amount independently of the inclination angle of the mold, the flow rate of the molten metal is suppressed and the shape is adjusted according to the shape of the mold cavity. The amount of molten metal can be changed to prevent the molten metal from being disturbed in the mold to prevent casting defects, and conversely, the flow rate can be increased without increasing the flow rate to shorten the pouring time. For example, the flow rate can be adjusted without changing the inclination angle α of the mold, for example, with the mold fixed in a horizontal state. Alternatively, it is possible to combine the variation of the inclination angle, the variation of the opening degree of the opening and closing plug, and the level of the molten metal surface while changing the flow velocity. Thereby, a high quality ingot can be obtained. Filling can be completed by pouring the molten metal while the mold is lying down to fill the wall surface of the mold at a slow flow rate and raising the mold near the completion of filling. After obtaining a large effect of the molten metal, the molten metal remaining in the receiving tank can be used for the next casting.

Next, an example of the manufacturing method of the present invention using this apparatus will be described. The raw material of the molten metal is aluminum or aluminum alloy, but other than this, non-ferrous metals such as magnesium (hereinafter alloys are included), copper, zinc, etc. can also be used. The metal is melted in advance in a melting furnace (not shown) to prepare a metal melt having necessary components adjusted.

When the molten metal is supplied to the receiving tank, the molten metal should be transferred gently into the receiving tank in order to prevent generation of non-metallic inclusions in the molten metal receiving tank and increase in the amount of hydrogen in the molten metal. It is preferably carried out.

FIG. 6 shows an outline of an example of a series of steps in which the casting mold 7 and the receiving tank 1 are integrated with each other by using the apparatus shown in FIG.

FIG. 6A shows a process in which the molten metal is drawn out from the external molten metal holding furnace by the ladle 170 and is distributed to the receiving tank 1.

In FIG. 6 (b), the mold is tilted in a substantially horizontal direction with the rotary shaft 20 as an axis, the opening / closing plug is opened, and the molten metal in the receiving tank is poured from the pouring port to the cavity of the mold. The process of pouring is shown. At this time, the difference H in height between the lower end of the pouring port and the molten metal surface stored in the molten metal receiving tank, the inclination angle α of the mold, and the opening L of the opening / closing plug should be controlled. The molten metal is injected while the flow velocity and flow rate of the molten metal flowing down in the mold while being in contact with the wall surface of the mold are adjusted.

FIG. 6 (c) shows a process at the time when the cavity in the mold is filled with the molten metal and the mold is vertically raised to complete the filling. At this point, the mold is vertical, the opening / closing plug 2 is open, and the injection port of the mold is closed by the lower surface of the member forming the molten metal receiving tank and the pouring port having the opening / closing plug. The molten metal in the tank works as a pusher. Reference numeral 172 is solidified, reference numeral 1
73 is a molten metal state.

FIG. 6 (d) shows that the molten metal at the injection port injected into the mold is closed as the final solidification part by closing the opening / closing plug to complete the solidification, and then the upper die 7B is opened. The process of taking out the ingot 174 is shown. The drive device for the upper mold 7B and the device for taking out the ingot 174 are not shown.

FIG. 7 schematically shows an example of a series of steps in which the receiving tank 1 is fixed and the casting mold 7 is tilted by the shaft 154 as a rotation axis to cast by using the apparatus shown in FIG.

In FIG. 7 (a), a distribution hole is provided in the side wall of the receiving tank, and a gutter 180 is connected thereto, so that the molten metal 181 flows from the gutter to the receiving tank.
Shows the process of distributing.

In FIG. 7 (b), the mold is tilted in a substantially horizontal direction around the axis of rotation, the opening / closing plug is opened, and the molten metal in the receiving tank is poured into the cavity from the pouring port of the mold through the pouring port. The following shows the process. At this point, the difference H in height between the lower end of the pouring port and the molten metal surface stored in the molten metal receiving tank, which is enlarged in FIG. 5, the inclination angle α of the mold, and the opening / closing plug By controlling the opening degree, the molten metal is injected while the flow velocity and flow rate of the molten metal flowing down in the mold while being in contact with the wall surface of the mold are adjusted. In order to prevent the molten metal discharged from the pouring port from directly contacting the wall surface of the lower mold, insert an inclined plate from the outside between the pouring port and the mold wall surface at an angle that relaxes the inclination angle of the mold wall surface. May be. This is because it is possible to suppress the acceleration of the flow velocity by first bringing the molten metal into contact with the inclined plate. Further, it is possible to prevent the mold wall surface from being corroded by the molten metal. It is preferable that the series of operations in which the inclined plate is inserted at the time of pouring and removed at the end is performed in conjunction with the inclination operation of the mold.

FIG. 7 (c) shows a process at the time when the cavity is filled with the molten metal and the mold is vertically raised to complete the filling. At this point, the mold was vertical, the open / closed plug was open, and the injection port of the mold was closed by the lower surface of the member forming the molten metal receiving tank and the pouring opening having the open / closed stopper. Pushing water is effective due to the molten metal inside. The fixing device after joining the mold and the lower surface of the receiving tank is not shown.

FIG. 7 (d) shows that the molten metal at the injection port injected into the mold is closed as a final solidification part by closing the opening / closing plug to complete the solidification, and then the lower mold 151A is opened for casting. It shows how the lump 174 is taken out. Lower mold 151
The drive device A and the device for taking out the ingot 174 are not shown.

The mold is disposed below the pouring port so that the pouring port of the mold is poured from the pouring port having an opening / closing plug provided in the melt receiving tank. In the case of using the apparatus shown in FIGS. 1 and 2, the receiving layer and the mold are integrated or are in contact with each other, so that the molten metal is injected from the pouring port.

When the apparatus shown in FIG. 5 is used, the molten metal 1 is fed from the inner wall 150 of the lower mold 151A of the tilted mold.
By arranging so that 03 does not flow out, the molten metal is injected from the pouring port 4, and as the molten metal is injected from the pouring port 153 of the casting mold, the casting mold is raised from a substantially horizontal state to a vertical direction.

Further, the molten metal of the injection port injected into the mold is used as the final solidification portion in a state where the injection port of the mold is closed by the lower surface of the member constituting the molten metal receiving tank and the injection port having the opening / closing plug. Immediately before the solidification is completed, the opening / closing plug is closed to complete the solidification.

As described above, for example, as shown in FIGS. 6 (c) and 7 (c), when the molten metal in the mold is in an unsolidified state and the opening / closing plug is opened, the molten metal in the receiving tank is used to push the molten metal. It can be effective. In that state, FIG.
As shown in (d) and FIG. 7 (d), the opening and closing plug is closed immediately before the completion of solidification of the molten metal in the mold, and the ingot is taken out after cooling. In this way, solidification is completed by using the unsolidified part in the mold as the final solidified part, which means that the molten metal has worked until the end of solidification, and a sound metal ingot with suppressed defects in the ingot can be obtained. You can

The mold 7 shown in FIG. 1 is cooled so that the solidification proceeds unidirectionally and the solidification is completed just below the pouring port. When unidirectional solidification proceeds, natural cooling is preferable. When it is difficult to coagulate in one direction, for example, when coagulation does not complete immediately below the pouring port,
After pouring, it is preferable to apply a cooling water shower to the outer periphery of the mold to promote cooling of the mold, or to provide a cooling medium passage inside the mold to control cooling by passing cooling water or air as the cooling medium. For example, it is possible to unidirectionally advance the solidification interface of the molten metal filled in the cavity in the mold by controlling the heat removal distribution of the mold using an apparatus as shown in FIGS. It is preferable to carry out it if necessary.

Here, the average initial velocity V and the flow rate Q are stored in the lower end of the outlet of the pouring port and in the molten metal receiving tank so that the quality of the ingot cast in the actually used mold satisfies the required level. The difference H in height between the molten metal surfaces and the end face 106 of the opening / closing plug 2 and the upper end 1 of the inlet of the pouring port 4 that determine the opening of the opening / closing plug.
The distance L from 07 and the inclination angle α of the mold are controlled to inject the molten metal for casting. For example, an average initial velocity V of the molten metal flowing out from the tap hole is experimentally obtained in advance from the height H of the molten metal in the receiving tank and the opening L of the opening / closing plug to obtain the average initial velocity V. A combination of the above parameters (H, L, α) is obtained in advance. Further, the flow rate Q at that time is measured in advance. Further, the quality of the solidified ingot when the average initial velocity V and the flow rate Q are changed is investigated in advance. On the contrary, based on the information obtained in advance, each device is controlled by setting the target value of the control item of each device so that the optimum average initial speed and flow rate satisfy the quality. As a result, the level required for casting defects such as oxides and microshrinkage of the cast ingot is satisfied.

Particularly, the average initial velocity V at the outlet of the molten metal is 1 to 1 in order to prevent the disturbance of the molten metal flowing into the mold.
It is preferably 50 cm / s.

As for the flow rate, if there is a narrowed portion inside the cavity, the flow velocity is increased by passing through this portion, so that the molten metal mixes violently on the inner surface of the mold, or collides violently with the projection or bottom of the wall surface of the mold. . It is preferable to adjust the hot water discharge amount in advance so that such a situation does not occur.

Next, an embodiment in which a device for covering the inside of the receiving tank with an inert gas is described. By covering the inside of the receiving tank with an inert gas, metal oxides that are generated by reacting with oxygen in the air when the molten metal moves or fluctuates inside the receiving tank accumulate in layers. Is preferable because it can suppress For example, the configuration and operation of the device will be described based on FIG.
An inert gas supply pipe 120 is installed on the lid 80 of the heating furnace 5, the tip of the pipe is open to the inside of the furnace, and the origin of the pipe is an inert gas supply device 123 by a pipe 121.
The supply device 123 is provided with a pressure reducing valve 124 and a flow meter 125 so that a constant amount of inert gas can be supplied from the gas cylinder 128. The inside of the receiving tank can be always kept in the inert atmosphere 126. As a result, it is possible to prevent metal oxides from being deposited in a layered manner on the boundary line 129 where the molten metal surface 3 ′ in the receiving tank 1 contacts the inner surface 127 of the receiving tank 1.

Examples of the inert gas include Ar gas and nitrogen gas. From the viewpoint of inertness, Ar gas is preferable.

Further, an embodiment using a device for applying a gas pressure to the surface of the molten metal after the pouring is completed will be described. By applying gas pressure to the surface of the molten metal after the pouring is completed, the effect of pushing the molten metal in the receiving tank is further enhanced. A molten metal can be supplied. As a result, it is possible to obtain a good quality metal ingot with suppressed microshrinkage. For example, the configuration and operation of the gas pressurizing device will be described with reference to FIG. An opening / closing plug 2, an opening / closing mechanism for the opening / closing plug (not shown in the figure), and a heating furnace 5 equipped with a receiving tank 1 have a lid 13 that can be opened and closed in part
It is housed in a closed container 132 including 0. Mold 7
After the molten metal 9 is filled therein, the pressurized gas flows into the closed container 132 by the gas supply pipe 135 connecting the pressurized gas supply device 134 and the closed container 132. The gas is introduced by immediately opening the gas inflow valve 131 installed in the middle of the pipe 135. As a result, the pressure in the closed container 132 is increased. Next, the gas inlet valve 131 is closed after the opening / closing plug is closed, and then the exhaust valve 13 which is closed.
Open 3 to open to the atmosphere and depressurize. The depressurized gas can be returned to the pressurized gas supply device 134 by piping and reused. If necessary, a clamping load is applied to the mold so that the divided surface of the mold does not open through the molten metal in the mold due to the pressurization of the gas applied to the melt surface.

The lid 130 is for pouring the molten metal into the receiving tank 1 in the closed container 132 and for maintaining the apparatus including the receiving tank 1, and the lid 130 is closed before pressurizing the gas. It is sealed and hermetically sealed by the sealing metal fitting 137.

Then, from the input information from the device 138 for transmitting the closing condition of the sealing metal, the timer built in the pressurization control device 136, and the electromagnetic level gauge 17 which is an example of the melt level measuring instrument. It is preferable that the opening / closing timing of the inert gas opening / closing valve is automatically operated by an output signal from the pressurization control device 136, based on input information that the rate of change of the molten metal surface has reached a certain value or less.

The magnitude of the pressure applied to the molten metal surface is 0.
001-5 megapascals (more preferably 0.01-3
Mega Pascal. ) Is preferable. This is because, in addition to the effect of pushing, the molten metal is sufficiently supplied to the unsolidified molten metal in the mold, so that a sound metal ingot with suppressed micro-shrinkage can be obtained.

As the gas used for pressurization, any one or two selected from air, nitrogen gas, and Ar gas, which are stable to the molten metal and do not burn with reacting with metal or generating harmful gas, are used. One or more gases can be mentioned. From the viewpoint of ease of use, air is preferable. From the viewpoint of inexpensive inert gas, nitrogen gas is preferable.
Ar gas is preferable from the viewpoint of high inertness.

Next, an embodiment of the mold for adjusting the heat removal distribution from the mold according to the shape of the ingot will be described.

When the molten metal in the mold finally solidifies near the pouring port, the pushing effect of the molten metal in the receiving tank effectively acts on the unsolidified molten metal. If the final solidification part does not exist near the pouring mouth, the molten metal will not work in the final solidification part, so casting defects such as porosity and micro-shrinkage due to solidification shrinkage will occur, and a sound ingot can be obtained. Absent. In order to prevent this, it is preferable to adjust the heat removal distribution from the mold according to the shape of the ingot so that the solidification proceeds unidirectionally from the bottom to the top of the mold.

As an example, a mold shown in FIG. 8 in which a part is constricted in the middle of the cavity is given. At the time of injection, the mold 190A and the mold 190B are in contact with each other at the dividing surface 196 and integrated. A passage 191 for passing cooling water is provided inside the mold of the mold 190A, and a passage 192 is provided with a heating element so that the molten metal does not preferentially start solidifying at the constricted portion in the middle portion of the mold prior to other portions. Is provided, and hollow passages 193 having excellent heat insulating properties are formed in the upper and lower portions with the heating element 192 sandwiched therebetween. The mold 190B has a similar structure. The molten metal 197 in the mold solidifies 194 from the bottom of the mold, and the solidification interface 195 moves toward the pouring port. The code with () attached to the passage means that the same code with () is equivalent.

The shape and number of the respective passages arranged, the amount of water, the output of the heating element, and the flow rate of the gas in the hollow passage are set in advance so that this solidification interface becomes the final solidification portion in the lower part of the pouring port. It can be determined based on the solidification analysis simulation data, experimental data, and the like. These conditions include, for example, injecting the molten metal with several thermocouples inserted in the mold cavity in advance, and sequentially changing the liquidus temperature and the solidus temperature from the bottom of the cavity toward the injection port. It is possible to determine the combination of the shape and the number of each passage, the amount of water, the output of the heating element, and the balance of the gas flow rate in the hollow passage while confirming that the solidification is progressing while cutting.

Next, an example of another mold for adjusting the heat removal distribution from the mold according to the shape of the ingot will be described.

As shown in FIG. 9, there is a moving mold 200B (a mold moving device is not shown) with respect to the fixed mold 200A, and there is a hollow passage 202, and a part of the moving mold 200B is divided. The split mold 20 including the cooling water passage 201 inside the split mold 203 and the heating element 204.
5 is electric cylinder A (206), electric cylinder B
The pistons 207 and 209 of (208) are connected to enable forward and backward movement. The reference signs with () attached to the respective passages in the fixed mold 200A mean that they are equivalent to the same reference signs with () in the moving mold 200B and the split molds 203 and 205. The molten metal is poured in a state where these molds are sealed, but an air gap is generated as the solidification progresses. The air gap lowers the heat transfer coefficient between the ingot and the mold, and thus lowers the cooling ability and heating ability of the die. In order to reduce the air gap between the mold and the ingot, the split molds 203 and 205 are advanced toward the cavity and brought into contact with the surface of the ingot. As a result, the cooling or heating capability of the ingot by the split mold is enhanced, and the solidification interface 211 can be advanced toward the pouring port to make the final solidification part immediately below the pouring port. The timing at which the split mold moves forward, the stroke at which the split mold moves forward, the timing at which the split mold moves backward, and the stroke thereof are operated according to the position of the solidification interface of the molten metal in the mold by a control device not described. It is possible to operate while estimating the position of the solidification interface from the actual measurement data of the temperature by the thermocouple embedded in the mold. Alternatively, the progress time of the interface can be experimentally obtained in advance and operated by timer control.

Next, another embodiment of the mold for adjusting the heat removal distribution from the mold according to the shape of the ingot will be described.

An example is shown in FIG. The mold is a fixed mold 220.
The movable mold 222 and a part of the movable mold are divided into a divided mold 221 that is moved forward and backward by a cylinder 223. The split mold 221 at the time of injection is integrated with the fixed mold 220 and the moving mold 222. If the shape of the cavity is such that there is a larger pool of molten metal in the lower part of the cavity than in the upper part, solidification from the other parts will start before the solidification of the part is completed, and the solidification end part will move toward the pouring port. It occurs not only near the pouring spout. As a result, casting defects such as porosity and micro-shrinkage occur in the large pool. In order to prevent this, the split mold 221 of the portion corresponding to the molten metal pool is withdrawn by the cylinder 223 to expose the ingot, and the exposed surface 233 of the ingot 232 is exposed to the cooling water spray 225 from the cooling water spray 225. The discharged cooling water 226 is brought into contact with the ingot to forcibly cool it. The cooling water spray is a cooling water pump 229 and a pipe 227.
And the solenoid valve 228 opens and closes the valve to turn it on and off. These series of operations are performed by the mold 220.
It can be realized by measuring the temperature of the mold by the thermocouple 231 inserted in the mold and giving the timing of the operation of the cooling water spray 225 from the relationship between the solidification interface position in the mold and the temperature which is experimentally obtained in advance. As a result, one solidification interface 23
5 can be moved, and the solidification of the molten metal 234 can be completed by using the area immediately below the pouring port as the final solidification portion. For example, input the information from the thermocouple 231 to the control panel XA1,
Based on that, the cylinder 2 according to the set conditions
Signal YA for activating 23 to retract split mold 221
2 and the cooling water spray 225 are turned so as to face the casting surface 233 (the turning device is omitted), and the signal YA1 for performing the spray 226 is output to each device to operate.

The means for completing the solidification of the molten metal in the mold with one solidification interface is not limited to each of the above-mentioned embodiments alone, but may be combined with each other under optimum cooling conditions. It is possible.

When the mold is filled with the molten metal, especially in a device in which the molten metal receiving tank and the mold are integrally tilted,
Since the molten metal flows into the cavity where the injection port of the mold is blocked by the lower surface of the member forming the molten metal receiving tank and the pouring port having the opening / closing plug, the replacement of the molten metal with the air in the cavity is smooth. Is preferably carried out. For example, it is preferable to provide a passage for allowing the air in the cavity to escape on the dividing surface of the mold and the contact surface between the molten metal receiving tank and the mold. The dividing surface of the mold, the surface that contacts the lower surface of the receiving tank of the mold,
A spacer is sandwiched or a step or a gap is mechanically provided at the position of any surface selected from the surface of the bottom surface of the receiving tank that comes into contact with the mold or any combination of surfaces. Is preferably provided.
The spacer is preferably made of metal such as stainless steel, the plate thickness is 0.03 to 0.1 mm, and the height of the step or the gap is preferably 0.03 to 0.1 mm.
If it is less than 0.03 mm, the escape of air is poor and the inflow of the molten metal becomes insufficient, and if it exceeds 0.1 mm, the molten metal may flow into the gap and block the passage, so that air cannot flow out, which is not preferable.

Further, in order to prevent the erosion of the mold by the molten metal, it is preferable to apply a release material to the wall surface of the mold as needed.

The present invention is not construed as being limited to these examples, and various changes, modifications and improvements can be made without departing from the scope of the present invention.

[0107]

EFFECT OF THE INVENTION The casting apparatus of the present invention is provided with a casting port of a mold below the pouring port so that the molten metal can be poured from the pouring port having an opening / closing plug provided in the molten metal receiving tank. A mold tilt angle driving device that raises the mold from a substantially horizontal state to a vertical direction as the molten metal is injected, and a level measuring device for measuring the level of the molten metal in the molten metal receiving tank.
Obtained from a mold tilt angle measuring device that measures the mold tilt angle, a molten metal distribution device that distributes the molten metal to the molten metal receiving tank, an opening and closing plug opening adjusting device that adjusts the opening and closing of the opening and closing plug, and the molten metal level measuring device. The molten metal leveling device, the mold inclination angle data obtained from the mold inclination angle measuring device, and the opening / closing plug opening data obtained from the opening / closing plug opening adjusting device are input, and the molten metal distribution device, the mold inclination angle driving device, and the opening / closing plug are input. Outputting instruction information for operating the opening adjustment device, and including a casting automatic control device that adjusts the flow velocity and flow rate of the metal melt flowing down in contact with the mold wall surface according to the shape of the mold, Immediately before being filled, the mold is installed in such a state that the injection port of the mold is closed by the lower surface of the member constituting the molten metal receiving tank and the pouring port having an opening / closing plug. Is a casting machine , Depending on the mold cavity shape,
Since it becomes possible to independently control the flow velocity and flow rate of the molten metal injected into the tilting mold, which flow down the mold wall surface,
It is possible to cast a high-quality metal ingot, which has not been obtained in the past, with high productivity.

[Brief description of drawings]

FIG. 1 is a schematic view of an example of a casting apparatus of the present invention.

FIG. 2 is an explanatory view of the operation of the casting apparatus of the present invention.

FIG. 3 is a schematic view of another embodiment of the casting apparatus of the present invention.

FIG. 4 is a schematic view of another embodiment of the casting apparatus of the present invention.

FIG. 5 is a schematic view of another example of the casting apparatus of the present invention.

FIG. 6 is an explanatory view of an example of steps of the casting method of the present invention. (A) is a diagram of the process of delivering to the receiving tank, (b) is a diagram of the process of pouring while raising the mold, (c) is a diagram of the process of filling the mold and progressing coagulation, (d) [Fig. 4] is a diagram of a process in which solidification is completed and the ingot is taken out.

FIG. 7 is an explanatory diagram of another example of steps of the casting method of the present invention. (A) is a diagram of the process of delivering to the receiving tank, (b) is a diagram of the process of pouring while raising the mold, (c) is a diagram of the process of filling the mold and progressing coagulation, (d) [Fig. 4] is a diagram of a process in which solidification is completed and the ingot is taken out.

FIG. 8 is a schematic cross-sectional view of an example of a mold used in the present invention.

FIG. 9 is a schematic cross-sectional view of another embodiment of the mold used in the present invention.

FIG. 10 is a schematic sectional view of another embodiment of the mold used in the present invention.

[Explanation of symbols]

1: Molten metal receiving tank, 1 ': Outflow prevention protruding part 2: Opening / closing plug, 3: Molten metal in molten metal receiving tank 3': Molten metal surface in molten metal receiving tank 1: Pouring port, 5: Electric furnace, 5 ': Electric Resistance heating element 6: Mold dividing surface 7: Mold 7A: Lower mold 7B: Upper mold 7B: Upper mold 8: Molten metal 9: Molten metal in mold 9 ': Molten metal surface in mold 10: Lower part Protruding part 11 on the inner surface of the mold: Electric cylinder 11 ': Piston 12: Support rod 13: Strut 14: Base plate, 15: Fixed plate, 15': Small diameter part under the receiving tank, 16: Spacer, 17: Electromagnetic Liquid level gauge 18: Support bar 19: Mold fixing base 20: Rotating shaft 21: Strut 22: Oil pump 23: Hydraulic cylinder 24: Piston 25: Throttle valve 26: Oil tank 27: Oil 28: Suction 29: Oil pipe 30 : Oil return pipe 31: Mold tilt angle measuring device 41: Fixed bolt 42: Fixing bolt 50: Input device of automatic casting control device 51: Calculation device of automatic casting control device 52: Output device 53 of automatic casting control device: Mold wall surface 55 of lower mold 7A: Mold cavity 70: Opening / closing plug opening adjustment device 71: Automatic casting control device 80: Lid 101: Pouring mouth outlet lower end portion 103: Metal melt 104: Inflowing metal melt 105: Pouring mouth outlet upper end portion 106: Opening / closing plug tip 107: Pouring Entrance upper end 120: Inert gas supply pipe 121: Pipe 123: Inert gas supply device 124: Pressure reducing valve 125: Flow meter 126: Inside of receiving tank 127 of inert atmosphere: Inner surface of receiving tank 128: Gas cylinder 129: Receiving tank Boundary line 130 in which the surface of the molten metal contacts the inner surface of the receiving tank: Openable lid 131: Gas inflow valve 132: Closed container 133: Exhaust valve 134: Pressurized air Supply device 135: Gas supply pipe 136: Pressurization control device 137: Sealing metal fitting 138: Transmitting device of closing status of sealing metal fitting 150: Inner wall surface 151 of lower mold 151: Mold 151A: Lower mold 151B: Upper mold 153: Mold Injection port 154: rotating shaft 155: lower surface 156A, 156B of a member constituting a receiving tank: mold top 170: handle ladle 172: solidifying state 173; molten metal state 174: ingot 180: trough 181: molten metal 190A: mold 190B : Molds 191, 192: Passage 193: Hollow passage 196: Dividing surface 197: Molten metal 194: Solidified ingot 195: Solidification interface 200A: Fixed mold 200B: Moving mold 201: Cooling water passage 202: Hollow passage 203, 205: split mold 204: heating element 205: split mold 206: electric cylinder A 208: electric cylinder B 207, 09: Piston 211: Solidification interface 220: Fixed mold 220: Mold 221: Split mold 222: Moving mold 223: Cylinder 225: Cooling water spray 226: Spraying cooling water 227: Pipe 228: Solenoid valve 229: Cooling water pump 231 : Thermocouple 232: Exposed ingot 233: Cast surface 234: Molten metal 235: Solidification interface L: Refusal separation from the tip of the opening / closing plug to the pouring port X1, X2, X3: Input terminals Y1, Y2 of the input device , Y3: output terminal of output device α: inclination angle of mold V: average initial velocity of molten metal flowing out of pouring port Q: flow rate of molten metal flowing out of pouring port H: in molten metal receiving tank from lower end of pouring port The height of the surface of the stored molten metal H1: The height of the surface of the molten metal stored in the molten metal tank from the upper end of the outlet of the pouring port h: The lower end of the outlet of the pouring port and the injected molten metal Reaches first Height difference from mold wall XA1: Control panel input terminals YA1, YA2: Control panel output terminals

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Claims (15)

[Claims] 1. An injection port of a mold is disposed below the pouring port so that the molten metal is injected from a pouring port having an opening / closing plug provided in the molten metal receiving tank, and the casting mold is filled with the molten metal from the pouring port. A mold inclination angle drive device that causes the vertical direction from a substantially horizontal state, a molten metal level measuring device that measures the molten metal level in the molten metal receiving tank, and a mold tilt angle measuring device that measures the mold tilt angle, Obtained from the molten metal distribution device that distributes the molten metal to the molten metal receiving tank, the opening and closing plug opening adjustment device that adjusts the opening and closing plug opening, and the molten metal level data obtained from the molten metal level measuring device and the mold tilt angle measuring device. The mold inclination angle data to be obtained and the opening / closing plug opening data obtained from the opening / closing plug opening adjusting device are input, and the instruction information for operating the molten metal distribution device, the mold inclination angle driving device and the opening / closing plug opening adjusting device is output. , On the mold wall It includes an automatic casting control device that adjusts the flow velocity and flow rate of the molten metal flowing down by touching according to the shape of the mold, and immediately before the molten metal is filled in the mold, the lower surface of the member constituting the molten metal receiving tank and the opening / closing plug A casting machine for metals, characterized in that the casting mold is installed in such a manner that the pouring port of the casting mold is closed by the pouring port. 2. A mechanism for converting the linear motion of the drive source into a rotary motion of the rotary shaft, a mechanism for converting the rotational motion of the drive source into a rotary motion of the rotary shaft, and a mechanism in which the mold tilt angle drive device converts The metal casting device according to claim 1, wherein the device is a device having any one kind or a combination of two or more kinds selected from a mechanism for directly giving a rotary motion of a drive source to the shaft. 3. The metal casting apparatus according to claim 1, wherein the distribution device is a batch type device using a ladle. 4. A siphon type distribution device in which an external molten metal holding furnace and a receiving tank are connected by a molten metal supply pipe, a power pump type distribution device, and a molten metal surface pressure pump type by applying pressure to the molten metal holding furnace surface. 2. A distribution device, or a distribution device in which any one kind or a combination of two or more kinds selected from a distribution device which supplies from a gutter or a supply pipe to a molten metal supply hole provided on a side surface of the molten metal receiving tank is used. Or 2
The metal casting apparatus according to 1. 5. A height difference h between the lower end portion of the outlet of the pouring port and the wall surface of the mold where the poured molten metal reaches first is 200.
The metal casting apparatus according to any one of claims 1 to 4, wherein the casting apparatus has a diameter of not more than mm. 6. The height H of the molten metal stored in the molten metal receiving tank being poured is at least 1 from the lower end of the outlet of the pouring port.
It is 0 mm or more, The metal casting apparatus of any one of Claim 1 thru | or 5 characterized by the above-mentioned. 7. The height H1 of the metal surface of the molten metal stored in the molten metal receiving tank immediately before closing the opening / closing plug is at least 10 mm or more from the upper end of the outlet of the pouring port. 7. The metal casting apparatus according to any one of items 1 to 6. 8. The mold inclination angle α during pouring is 10 to 90 ° from the vertical direction to the horizontal direction.
The metal casting apparatus according to any one of claims 1 to 7. 9. The open molten metal surface of the molten metal stored in the molten metal receiving tank is covered with one or more inert gas selected from Ar gas and nitrogen gas. The metal casting apparatus according to any one of claims 1 to 8. 10. A molten metal receiving tank, a pouring port, an opening / closing plug, an opening / closing mechanism for the opening / closing plug, and a heating furnace surrounding the molten metal receiving tank are housed in an openable / closable closed container, and the closed container is heated via a gas inflow valve. A pressurized gas supply device is connected, and an exhaust valve for discharging gas to the outside of the container is provided in the closed container.After the molten metal is filled in the mold, the gas inflow valve is opened with the exhaust valve closed to allow gas to flow in. To increase the pressure in the closed container, then close the opening / closing plug, and then open the exhaust valve that had closed the gas inflow valve to release the pressure in the closed container. The metal casting apparatus according to any one of claims 1 to 9. 11. The pressure is applied to the airtight container by a pressurized gas, and the gas is air, nitrogen gas, Ar.
The metal casting apparatus according to claim 10, wherein the gas is one or more gases selected from gases. 12. The metal according to claim 10, wherein the magnitude of the pressure applied to the molten metal surface in the molten metal receiving tank in the closed container is 0.001 to 5 megapascals. Casting equipment. 13. The mold material is any one or two selected from iron, cast iron, heat-resistant steel, copper, and their alloys.
The metal casting apparatus according to any one of claims 1 to 12, which is a combination of two or more kinds. 14. A casting method for raising a mold from a substantially horizontal state to a vertical direction as the molten metal is poured from the casting port of the casting mold, wherein the casting port of the casting mold is a metal from a pouring port having an opening / closing plug provided in a molten metal receiving tank. It is arranged below the pouring port so that the molten metal can be injected, and the difference in height between the lower end of the pouring port outlet and the molten metal surface stored in the molten metal receiving tank, the inclination angle of the mold, and the opening / closing By controlling the opening degree of the stopper, the molten metal is injected while adjusting the flow rate and flow rate of the molten metal flowing in the mold while contacting the wall surface of the mold, and the injection port of the mold constitutes the molten metal receiving tank. In the state where the lower surface of the member and the pouring port having the opening / closing plug are closed, the opening / closing plug is closed just before the molten metal at the pouring port injected into the mold is completed as the final solidification portion and the solidification is completed. And a method for casting metal. 15. The method of casting a metal according to claim 14, wherein the metal is aluminum or an aluminum alloy.