Machine and method for treating cast components

Abstract

A machine for cooling and truing cast components made from cast material, and includes a construction for holding cast components and a holder to supply cooling liquids. A method to treat a cast component after removal of the cast component from the casting mold, the cast component being loaded immediately with a cooling liquid in a water spray.

Claims

1. A method for treating a cast component after removal of the cast component from a casting mould, the method comprising: after removal of the cast component from the casting mould, overbending the cast component while in a hot state by bending the cast component beyond target dimensions for the cast component, wherein a cooling liquid is applied to the cast component in parallel with the bending of the cast component; and after applying the cooling liquid to the cast component, subjecting the cast component to a thermal treatment that partially reverses the bending of the cast component to obtain the target dimensions for the cast component.

2. The method of claim 1, wherein the truing comprises bending the cast component via at least one truing tip.

3. The method of claim 1, wherein the truing comprises bending the cast component against at least one truing pad.

4. The method of claim 3, wherein the truing pad is adjustably moveable.

5. The method of claim 1, further comprising stamping the cast component, after applying the cooling liquid and before subjecting the cast component to a thermal treatment.

6. The method of claim 1, further comprising machining the cast component, after applying the cooling liquid.

Description

DRAWINGS

(1) Embodiments will be illustrated by way of example in the drawings and explained in the description below.

(2) FIG. 1a illustrates a diagram of a conventional process.

(3) FIG. 1b illustrates a diagram of a method in accordance with embodiments.

(4) FIG. 2 illustrates a machine for a water spray and for truing.

(5) FIG. 3 illustrates a section through the machine.

DESCRIPTION

(6) As illustrated in FIG. 1b, the method in accordance with embodiments includes casting whereby the casting component is produced using die casting or else in another casting process.

(7) A subsequent step 2 includes cooling of the cast component 10 using a liquid having a high thermal capacity for a defined time period. Alternatively or additionaly, the cast component 10 may also be dipped. As a result, the cast component is cooled rapidly from the removal temperature from the casting mould to a temperature at which the cast component can be fed to subsequent steps.

(8) In order to optimize the cast components, the method in accordance with embodiments uses a combined step which takes place in the cooling phase 2 of the water spray and includes truing in the warm state 30. To this end, the cast component is removed from the casting mould by way of a robot and, held on the casting tablet, is introduced into the water spray station.

(9) In the water spray, the cast component is pressed against a pad and is held by way of fastening rams from the side which faces away from the pad. The fastening rams are extended pneumatically or hydraulically with the aid of fastening ram pressure cylinders. In order to mount the cast component appropriately, at least two fastening rams are used. The fastening rams are seated flush on the cast component from both sides. Subsequently, truing rams are extended via truing cylinders. They come into contact with the cast component which is not seated flush on a truing pad at this point. Via the pressure of the truing ram, the cast component is deformed until it bears on the truing pad.

(10) The cast component is trued with regard to its dimensions by way of said process step. Here, the truing process either takes place until the target dimensions are reached, or the cast component is pre-deformed beyond the target dimensions, since the following thermal treatment reverses the deformation partially and the cast component therefore finally reaches the correct dimensions.

(11) A subsequent step 3 involves, after the cooling time, stamping the cast component 10. The casting tablet and casting flow runners are cut off using a cutting tool. Alternatively, sawing, laser and plasma cutting may also be used.

(12) In subsequent step 4, a thermal treatment of the cast component 10 may occur. takes place. The thermal treatment, however, may occur optionally. The thermal treatment can be thermal treatment in accordance with T5, i.e., artificial ageing, or solution annealing. In solution annealing, a customary thermal treatment process for aluminium die cast parts, a temperature is set between 460 C. and 500 C.

(13) In subsequent step 6, machining 6 of the cast component 10 is conducted.

(14) Accordingly, in contrast to the conventional method illustrated in FIG. 1a, in accordance with embodiments, the method in accordance with embodiments differs essentially in that the step 5 (truing in the cold state) may be dispensed with or can be reduced to a minimum in the case of complex components.

(15) FIGS. 2 and 3 illustrate the water spray/part-truing station as a machine tool. The entire water spray 11 is constructed and welded from grid rails 17. The casting tablet 15 and the casting flow runners 16 can be seen in the upper part of the water spray station in FIG. 2. The reference numeral 10 marks the cast component. In the lower half, pressure cylinders 13, 14 are mounted on a cylinder plate 18, the pressure cylinders serving firstly for fastening and secondly for truing. In a conventional water spray, the cast component 10 would be held fixedly on the casting tablet only via the uppermost pressure cylinder 13. Cooling with water or another liquid subsequently takes place.

(16) In accordance with embodiments, for the water spray, the cast component is held by a plurality of pressure cylinders 13. There are fastening pads 12 opposite the pressure cylinders and behind the cast component 10, which fastening pads 12 bear flush against the cast component at the fastening points. The fastening rams which are extended by the pressure cylinders 13 fix and clamp the cast component between themselves and the fastening pads 12.

(17) Truing rams 23 which bend the cast component are extended via truing cylinders 24. Here, bending deflections of several millimeters are possible, until the cast component reaches the truing pads 14. Here, the illustration in FIG. 2 illustrates fastening rams 22 and truing rams 23, the connection to the individual pressure cylinders not being illustrated.

(18) The entire situation can be seen once again in FIG. 3. The fastening rams 22 and the truing rams 23 are seated on the cast component 10. Here, the fastening pad 12 is already connected to the rear side of the cast component during the introduction of the cast component into the water spray. In contrast, the truing pad 14 is provided at a spacing from the cast component at the beginning The spacing from the truing pad 14 is reduced to zero only after the truing pressure cylinder 24 presses the truing tip 22 onto the cast component. The cast component is trued or overbent. After all the truing cylinders have reached their setpoint value, the water is released via the water supply 21 and the cast component is cooled to the end temperature within the water spray.

(19) It can be seen on the left-hand side of the drawing that the grid rails 17 form a pad holder 19 in the region of the pad. The pad holder 19 is connected to the rest of the construction via screws 20 and can be detached from it. The pad holder can therefore be removed from the machine with all the fastening pads 12 and truing pads 14 and can be measured and adjusted on a measuring machine. Here, the pads are optimized by way of adapting shims.

(20) The embodiment which is illustrated of the machine for cooling and truing cast components is advantageously configured in such a way that all the pressure cylinders are attached on one side of the processing station. As a result, the space requirement which is produced as a result of the overall size of the pressure cylinders can be optimized.

(21) It is also possible, however, to use a machine of this type for more complicated and more complex truing tasks and therefore to deform the cast component 10 with truing rams from both sides. To this end, pressure cylinders have to be attached on the left-hand side of FIG. 3, and truing rams have to extend through the pad holder 19. The corresponding truing pads 14 would of course have to be attached on the right-hand side.

(22) In terms of the time sequence, it is not absolutely necessary to delay cooling until the truing tools are extended and the bending of the component is concluded.

(23) In order to optimize the process, the cooling process can be started in parallel with the truing process.

(24) The term coupled or connected may be used herein to refer to any type of relationship, direct or indirect, between the components in question, and may apply to electrical, mechanical, fluid, optical, electromagnetic, electromechanical or other connections. In addition, the terms first, second, etc. are used herein only to facilitate discussion, and carry no particular temporal or chronological significance unless otherwise indicated.

(25) Those skilled in the art will appreciate from the foregoing description that the broad techniques of the embodiments may be implemented in a variety of forms. Therefore, while the embodiments have been described in connection with particular examples thereof, the true scope of the embodiments should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification, and following claims.

LIST OF REFERENCE NUMERALS

(26) 1 Casting

(27) 2 Cooling of the cast component in the water spray

(28) 3 Stamping

(29) 4 Thermal treatment

(30) 5 Truing

(31) 6 Machining

(32) 10 Cast component

(33) 11 Water spray

(34) 12 Fastening pads

(35) 13 Pressure cylinder

(36) 14 Truing pad

(37) 15 Casting tablet

(38) 16 Casting flow runners

(39) 17 Grid rails

(40) 18 Cylinder plate

(41) 19 Pad holder

(42) 20 Screws

(43) 21 Water supply

(44) 22 Fastening ram

(45) 23 Truing ram

(46) 24 Setting pressure cylinder

(47) 30 Hot truing