Use of a feeder insert and method for manufacturing a casting mold having a vertical mold separation

Abstract

A use of a feeder insert, having a volumetric center of gravity which is offset in relation to the opening axis of the passage opening of said feeder insert, in the manufacture of a casting mold having a vertical mold separation and a feeder insert which for dense feeding of the mold cavity during the casting procedure is attached to the casting mold, is described, wherein the feeder insert is positioned in a prefabricated mold part of the casting mold such that the opening axis of said feeder insert runs below the volumetric center of gravity of the latter.

Claims

1. A method of manufacturing a casting mold, comprising: feeding a feeder insert (24, 24′), having a volumetric center of gravity which is offset in relation to the opening axis (62) of the passage opening (60) of said feeder insert (24, 24′), in the manufacture of a casting mold (1) having a vertical mold separation, wherein the feeder insert (24, 24′) is attached to the casting mold (1) and feeds a mold cavity (26) during the casting procedure, wherein the feeder insert (24, 24′) is positioned in a prefabricated mold part (20, 22, 34) of the casting mold (1) such that the opening axis (62) of said feeder insert (24, 24′) runs below the volumetric center of gravity of the feeder insert.

2. The method according to claim 1, wherein the feeder insert (24, 24′) for positioning in the prefabricated mold part (20, 22, 34) of the casting mold (1) is inserted into a recess (32) in the prefabricated mold part (20, 22, 34) of the casting mold (1).

3. The method according to claim 1, wherein the casting mold (1) having a vertical mold separation and a feeder insert (24, 24′) which for feeding of the mold cavity (26) during the casting procedure is attached to the casting mold (1) is manufactured in a molding plant (2) having an endless mold parts string (28).

4. The method according to claim 1, wherein the mold part (20, 22, 34) is prefabricated in a mold chamber (6) which is partially delimited by a positive pattern (40) of at least one portion of the feeder insert (24, 24′).

5. The method according to claim 1, wherein the feeder insert (24, 24′) is inserted manually or in an automated manner by means of an insertion installation (30) into the recess (32).

6. The method according to claim 1, wherein the feeder insert (24, 24′) has a first end (50) having a passage opening (60), a second end (52), and one or a plurality of side walls (54) which extend from the first to the second end (50, 52) and which delimit a feeder cavity (58) for receiving liquid metal, and has a wall portion (56) which is disposed at the first end (50) and which forms a lateral wall region of the mold cavity (26) of the casting mold (1).

7. The method according to claim 6, wherein additionally one or a plurality of openings (66) for ventilating the feeder cavity (58) and/or for holding means of an insertion installation (30) engaging therein is/are disposed in the wall portion (56) which has the passage opening (60).

8. The method according to claim 6, wherein the feeder insert (24, 24′) in relation to the longitudinal extent thereof in the direction of the opening axis (62) is non-destructively longitudinally compressible by not more than 5%.

9. The method according to claim 6, wherein the feeder insert (24, 24′) has a cross section having an external cross-sectional face which proceeding from the second end increases in the direction of the first end.

10. The method according to claim 6, wherein the feeder insert (24, 24′) at the second end (52) thereof, which is disposed so as to be opposite the wall portion (56) having the passage opening (60), is configured so as to be open.

11. A method for manufacturing a casting mold (1) having a vertical mold separation and a feeder insert (24, 24′) which for feeding of the mold cavity (58) during the casting procedure is attached to the casting mold (1), the method comprising the following steps: providing or manufacturing a first mold part (20, 22), having a vertically running first separation face (20′, 22′), for partially defining the mold cavity (26), providing or manufacturing a second mold part (22, 34), having a second separation face (22″, 34″) running so as to be complementary to the first separation face (20′, 22′), for partially defining the mold cavity (26), wherein the first separation face (20′, 22′) of the first mold part (20, 22) and the second separation face (22″, 34″) of the second mold part (22, 34) are provided for being joined together, configuring part of the mold cavity (26), providing or manufacturing a feeder insert (24, 24′) for positioning in one of said mold parts (20, 22, 34), wherein the feeder insert (24, 24′) has a volumetric center of gravity which is offset in relation to the opening axis of the passage opening of said feeder insert (24, 24′), positioning of the feeder insert (24, 24′) in one of said mold parts (20, 22, 34), so that the opening axis (62) of the feeder insert (24, 24′) runs below the volumetric center of gravity of the feeder insert, and subsequently producing the casting mold (1) having the mold cavity (58), by joining together the first separation face (20′, 22′) of the first mold part (20, 22) and the second separation face (22″, 34″) of the second mold part (22, 34), wherein one of said mold parts (20, 22, 34) has a recess (32), and the feeder insert (24, 24′) for positioning in the mold part (20, 22, 34) of the casting mold (1) is inserted into this recess (32).

12. The method according to claim 11, wherein the casting mold (1) having a vertical mold separation and a feeder insert (24, 24′) which is attached to the casting mold (1) is manufactured in a molding plant (2) having an endless mold parts string (28).

13. The method according to claim 11, wherein the first and/or the second mold part(s) (20, 22, 34) is/are manufactured in a mold chamber (6) of said molding plant (2), which is partially delimited by a positive pattern (40) of at least one portion of the feeder insert (24, 24′).

14. The method according to claim 11, wherein the feeder insert (24, 24′) is positioned manually or in an automated manner by means of an insertion installation (30) in the first and/or second mold part (20, 22, 34).

15. A feeder insert (24, 24′) having a volumetric center of gravity which is offset in relation to the opening axis of the passage opening of said feeder insert (24, 24′), for use according to claim 1, wherein the feeder insert (24, 24′) has a first end (50) having a passage opening (60), a second end (52), and one or a plurality of side walls (54) which extend(s) from the first to the second end and which delimit(s) a feeder cavity (58) for receiving liquid metal, and has a wall portion (56) which is disposed at the first end (50) and which forms a lateral wall region of the mold cavity (26) of the casting mold (1), wherein additionally one or a plurality of openings (66) for ventilating the feeder cavity (58) and/or for an insertion installation (30) engaging therein are disposed in the wall portion (56) which has the passage opening (60), wherein the feeder insert (24, 24′) in relation to the longitudinal extent thereof in the direction of the opening axis (62) is non-destructively longitudinally compressible by not more than 5%, and wherein the feeder insert (24, 24′) at the second end (52) thereof, which is disposed so as to be opposite the wall portion (56) having the passage opening (60), is configured to be open.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The invention will be explained in more detail hereunder by means of a potential exemplary embodiment with reference to the appended figures in which:

(2) FIG. 1 shows a schematic illustration of two mold parts which have previously been manufactured in the mold chamber and have already been joined together by joining the separation faces;

(3) FIG. 2. shows a schematic illustration in which the molding material which is located in the now completely closed mold chamber is compressed;

(4) FIG. 3. shows a schematic illustration of the molding material in the mold chamber further compressed between the displaceable press piston having the pressing plate and the pressing plate;

(5) FIG. 4 shows a schematic illustration of the casting mold having the vertical mold separation at that point in time at which the feeder insert has been positioned in the recess of the mold part by the insertion installation;

(6) FIG. 5 shows a schematic illustration of the ejection of the prefabricated mold part from the mold chamber;

(7) FIG. 6 shows a schematic illustration of the prefabricated mold part ejected from the mold chamber by means of the press piston;

(8) FIG. 7 shows a schematic illustration of the prefabricated mold part bears on the separation face of the mold part;

(9) FIG. 8 shows a schematic illustration of the empty mold chamber where there system is ready to start producing a new part;

(10) FIG. 9 shows a sectional illustration of a first exemplary embodiment of a feeder insert according to the invention; and

(11) FIG. 10 shows a perspective illustration of a second exemplary embodiment, toward the second open end thereof.

DETAILED DESCRIPTION OF THE INVENTION

(12) A continuous method for manufacturing casting molds 1 in a schematically illustrated molding plant 2 is shown in FIGS. 1 to 8. In the present case, for the following description one cycle of the method, proceeding from the method step of filling molding material 4 into a mold chamber 6 of the molding plant 2, is assumed as being the first step of a continuously progressing method. The molding material 4 which is preferably injected into the mold chamber 6 is provided above the mold chamber 6 in a supply installation 8. The mold chamber 6 is formed by stationary upper and lower wall regions 10, 12, to the left by a pressing plate 14, and to the right by a pivoting plate 16. The pressing plate 14 is connected to a press piston 18 which is held in a linearly displaceable manner. To the right in FIG. 1, two mold parts 20, 22 which have previously been manufactured in the mold chamber 6 and have already been joined together by joining the separation faces 20″, 22′ thereof which face one another to form a casting mold 1 are depicted. The mold part 20 of the casting mold 1 is already equipped with a feeder insert by which follow-on feeding of liquid metal is guaranteed from the side through the mold cavity 26 of the casting mold 1, which is formed by the mold parts 20, 22. The lined-up mold parts configure an endless mold parts string 28.

(13) FIG. 2 shows in a next step of the method according to the invention, in which the molding material 4 which is located in the now completely closed mold chamber 6 is compressed. In order to be compressed, the pressing plate 14 by way of the press piston 18 is moved in the direction of the pivoting plate 16 (arrow 29), on account of which the spacing between the pressing plate 14 and the pivoting plate 16 is reduced. The mold parts string 28 of lined-up mold parts 20, 22 with the aid of a conveying installation (not illustrated in more detail) is moved or transported further to the right, so as to create free space for the mold part which is just about to be produced in the mold chamber 6. At the same time, an insertion installation 30 is driven in a perpendicular manner to the viewing plane between the mold chamber 6 and the mold parts string 28 of the mold parts 20, 22, by means of which insertion installation 30 a feeder insert 24 which is to be positioned in a recess 32 in the mold part 22 is received. In order for the feeder insert 24 to be positioned in the recess 32, the insertion installation 30 is displaced in the direction of the separation face 22″ of the mold part 22 (arrow 33).

(14) FIG. 3 shows a subsequent step of the method according to the invention, wherein the molding material 4 in the mold chamber 6 is further compressed between the displaceable press piston 18 having the pressing plate (arrow 29) and the pressing plate 16. At the same time, the feeder insert 24 is positioned by the insertion installation 30 in the recess 32 of the mold part 22, wherein the feeder insert 24 is inserted into the prefabricated mold part 22 such that the opening axis (not shown in more detail) of the passage opening of said feeder insert for the liquid metal runs below the volumetric center of gravity of said feeder insert. The feeder insert is received on the insertion installation by way of a holding part (not illustrated in more detail), wherein the feeder insert 24 by means of negative pressure which is generated by the insertion installation 30 and acts on the feeder insert is held on or fixed to the insertion installation 30, respectively.

(15) FIG. 4 shows the step of the method according to the invention for manufacturing the casting mold having the vertical mold separation at that point in time at which the feeder insert 24 has been positioned in the recess of the mold part 22 by the insertion installation 30 and is subsequently moved back in the direction (arrow 33′) of the mold chamber 6. Subsequently (not shown in more detail), the insertion installation 30 is retracted perpendicularly to the viewing plane from between the mold chamber 6 and the mold parts string 28. Moreover, it is shown in FIG. 4 how the press piston 18 having the pressing plate 14 thereof (arrow 29) at the end of the compression procedure of the molding material 4 in the mold chamber 6 is displaced to the terminal position of the former, on account of which manufacturing of the mold part 34 having a recess 32 for a feeder insert is terminated. The mold part 34 now has a design embodiment which is identical to that of the previously manufactured mold parts 20 and 22.

(16) FIG. 5 shows the ejection of the prefabricated mold part 24 from the mold chamber 6, wherein the pivoting plate 16 is moved in the direction (arrow 35) of the mold parts string 28 of mold parts 20, 22 and by way of a pivoting movement (arrow 37) is upwardly pivoted about the pivot axis 36. After the pivoting plate 16 has been displaced to the stand-by position thereof, the former has a substantially horizontal alignment.

(17) In FIG. 6 it is shown how the prefabricated mold part is ejected (arrow 39) from the mold chamber 6 by means of the press piston 18, until the mold part 34 by way of the separation face 34′ thereof bears on the separation face 22″ of the mold part 22, as can be seen in FIG. 7. A predetermined amount of molding material 4 for the subsequent cycle is filled into the supply installation 8 of the molding plant 6.

(18) Once the mold part 34 has been brought to bear on the previously manufactured mold part 22, the press piston moves back into the initial position thereof (arrow 39′) prior to the commencement of the compression procedure shown in FIG. 1. It can be seen here that the pressing plate 14, apart from the positive pattern 38 for the contour region 41 on the separation face 34″ of the mold part 34, also comprises the positive pattern 40 of at least one portion of the feeder insert 24 to be inserted into the mold part 34 for producing the recess 32 in the mold part 34. As can be seen from the present figures, the contour regions 41, 41′ of two adjacent mold cavities 26 of casting molds 1 to be produced are configured on the separation faces 34, 34″ of the mold part 34 which face away from one another. The positive pattern 38′ which produces the contour region 41′ is disposed on the pivoting plate 16. As can be furthermore seen in FIG. 7, apart from manufacturing the casting molds 1 by way of the molding plant 2 and from producing an endless mold parts string of mold parts 20, 22, 34 casting of castings is performed by filling liquid metal 42 into the casting molds 1 which are lined up behind one another.

(19) In order for a cycle of the method according to the invention to be completed, the pivoting plate 16 from the stand-by position thereof, having the horizontal alignment, is pivoted back about the pivot axis 36 into the vertical position thereof (arrow 37′) and, for configuring the mold chamber 6, is likewise displaced in the direction (arrow 35′) of the pressing plate 14, back to the operating position thereof for the pending compression process. In this way, one cycle of the method according to the invention is completed, and the next cycle for manufacturing a mold part starts, commencing with the method step shown in FIG. 1, wherein molding material 4 is injected from the supply installation 8 into the mold chamber 6.

(20) A sectional illustration of a feeder insert 24 according to the invention, which is only schematically depicted in FIGS. 1 to 8, is shown in FIG. 9, said feeder insert 24 having a first end 50, a second end 52, and one or a plurality of side walls 54 which extend between the first and the second end 50, 52. A wall portion 56 which is disposed at the first end 50 and the side wall 54 which protrudes substantially perpendicularly from the wall portion 56 partially delimit the feeder cavity 58 for receiving liquid metal. The wall portion 56 has a passage opening 60 by way of which the connection between the mold cavity 26 of a casting mold 1 (FIG. 1) and the feeder cavity 58 is established. The passage opening 60 has an opening axis 62 which is aligned so as to be offset in relation to the volumetric center of gravity of the feeder insert 24. The wall portion 56 has an internal wall face 64 which delimits a cavity portion of the feeder cavity which tapers in the direction of the passage opening 60. The wall face 64 is conically configured. The wall face 64′ of the wall portion 56 which faces the mold cavity in the shown embodiment is configured so as to be planar. Moreover, an opening 66 for ventilating the feeder cavity 58 is disposed on the wall portion 56, the opening axis 68 of said opening 66 running parallel to the opening axis 62 of the passage opening 60. The feeder insert 24 according to the invention has an external cross-sectional face which proceeding from the second end 52 increases in the direction of the first end 50. However, the cross section of the feeder cavity 58 which is delimited by the side wall 54 proceeding from the second end 52 decreases in the direction of the first end 50 of the feeder insert 24; as can be seen in FIG. 9, the feeder insert 24 is integrally configured, wherein the feeder insert is formed from an exothermal and/or insulating molding material, or in portions comprises exothermal and/or insulating molding material. In the shown embodiment, the feeder insert 24 at the second end 52 is configured so as to be open and is configured without a web which extends parallel with the opening axis 62 of the passage opening 60 along a portion of the side wall 54.

(21) FIG. 10 shows a second exemplary embodiment of a feeder insert 24′ according to the invention, which is configured in an almost identical manner to that of the exemplary embodiment shown in FIG. 9. As is the feeder insert 24, the feeder insert 24′ at the second end 52 is configured so as to be open. The feeder insert 24′ differs from the feeder insert 24 (FIG. 9) in that the former has a web or a wall portion 70 which subdivides the feeder cavity 58′ in a chamber-like manner. For use of the feeder insert 24, the web 70 which is also known by the term Williams strip or Williams wedge, is disposed above the opening axis 62 (FIG. 9).

(22) Preferred aspects of the present invention are stated hereunder, using the reference signs which have been introduced above. The reference signs here are not to be understood as limiting but rather merely as means for facilitating understanding by reading, since the stated aspects do not relate exclusively to the figures discussed above. The aspects stated hereunder comprise features which may be combined with other preferred features which may be derived from the description and/or the claims.

LIST OF REFERENCE SIGNS

(23) 1 Casting mold 2 Molding plant 4 Molding material 6 Mold chamber 8 Supply installation 10, 12 Wall region 14 Pressing plate 16 Pivoting plate 18 Press piston 20, 22 Mold part 20′, 20″ Separation face 22′, 22″ Separation face 24, 24′ Feeder insert 26 Mold cavity 28 Mold parts string 29 Compression press piston 30 Insertion installation 32 Recess 33, 33′ Movement insertion installation 34 Mold part 34′, 34″ Separation face 35, 35′ Movement pivoting plate 36 Pivot axis 37, 37′ Pivoting movement pivoting plate 38 Positive pattern casting 39 Ejecting mold part 39′ Returning movement press piston 40 Positive pattern feeder insert 41, 41′ Contour region 42 Metal 50 First end 52 Second end 54 Side wall 56 Conversion portion 58 Feeder cavity 60 Passage opening 62 Opening axis 64, 64′ Wall face 66 Ventilation opening 68 Opening axis 70 Web