HOT FORGING MOLD DEVICE FOR LOW-PRESSURE CASTING
20260097433 ยท 2026-04-09
Assignee
Inventors
- Chan Ul Lee (Hwaseong, KR)
- Nam Ik Kim (Hwaseong, KR)
- Si Young Kim (Hwaseong, KR)
- Kyeong Rae Cho (Hwaseong, KR)
Cpc classification
B22D35/04
PERFORMING OPERATIONS; TRANSPORTING
B22D29/04
PERFORMING OPERATIONS; TRANSPORTING
B22D18/08
PERFORMING OPERATIONS; TRANSPORTING
International classification
B22D18/04
PERFORMING OPERATIONS; TRANSPORTING
B22D18/08
PERFORMING OPERATIONS; TRANSPORTING
B22D29/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The hot forging mold device for low-pressure casting includes an upper and lower mold forming a cavity, a riser cavity that supplies molten metal, and a press device positioned above the riser cavity to apply pressure. A sensor and controller can adjust pressure based on the molten metal's temperature or fill level. Cooling fluid circulates through a cylinder base plate, and an insulating plate reduces heat transfer. An ejection device, moved by an actuator, removes the solidified cast product. Guide blocks help align components, and a leakage preventing plate with a seal helps avoid fluid intrusion. The overall design ensures efficient feeding of molten metal, controlled forging pressure, and reliable ejection, improving casting quality and reducing defects.
Claims
1. A hot forging mold device for low-pressure casting, comprising: a mold body comprising an upper mold and a lower mold; a mold cavity formed in the mold body; a riser cavity configured to store molten metal to for filling the mold cavity; and a press device provided on an upper side of the riser cavity and configured to provide pressure to the molten metal in the riser cavity.
2. The hot forging mold device of claim 1, further comprising: a riser runner connecting the mold cavity and the riser cavity.
3. The hot forging mold device of claim 1, wherein a transverse cross section of the riser cavity has a tapered shape, an upper side of which is narrower and a lower side of which is wider.
4. The hot forging mold device of claim 1, wherein the press device comprises: a press plunger; a hydraulic cylinder configured to provide an operation force to the press plunger; and a cylinder base plate supporting the hydraulic cylinder, and in which a cooling fluid circulates along an inner path.
5. The hot forging mold device of claim 4, wherein the press device further comprises: an insulating plate installed on a lower side of the cylinder base plate.
6. The hot forging mold device of claim 4, wherein the press device further comprises: a leakage preventing plate installed on an upper side of the riser cavity and installed at a circumference of the press plunger.
7. The hot forging mold device of claim 6, wherein a through-hole, through which the press plunger passes, is formed in the leakage preventing plate, and wherein a sealing part is formed in the through-hole.
8. The hot forging mold device of claim 5, further comprising: an ejection device installed at a lower end of the cylinder base plate, and configured to separate a finished cast product from the mold cavity, wherein the ejection device comprises: an ejection plate installed between the cylinder base plate and the upper mold, and configured to move forward or rearward with respect to the upper mold along a movement direction of the upper mold; and an ejection pin, to which one side of the ejection plate is fixed, a portion of an opposite side of which is inserted into the upper mold and configured to separate the cast product formed in the mold cavity from the upper mold by pushing the cast product.
9. The hot forging mold device of claim 8, wherein a first guide block configured to guide a press plunger linearly moving while passing through the ejection plate is provided in the ejection plate.
10. The hot forging mold device of claim 8, wherein a through-hole, through which the press plunger passes, is formed in the upper mold, and wherein a second guide block configured to guide the press plunger is formed in the through-hole.
11. A hot forging mold device for low-pressure casting, comprising: a mold body including an upper mold and a lower mold; a mold cavity formed in the mold body; a riser cavity configured to store molten metal to be filled in the mold cavity; a press device disposed above the riser cavity and configured to apply pressure to molten metal in the riser cavity; a sensor configured to detect at least one condition of the molten metal in the riser cavity; and a controller in communication with the sensor and configured to actuate the press device based on the detected condition.
12. The hot forging mold device of claim 11, wherein the sensor is a temperature sensor arranged to measure a temperature of the molten metal in the riser cavity, and the controller is configured to initiate pressure application by the press device when the temperature exceeds a predetermined threshold.
13. The hot forging mold device of claim 11, wherein the sensor is a fill-level sensor arranged to measure how full the riser cavity is with molten metal, and the controller is configured to actuate the press device when the fill level exceeds a predetermined setpoint.
14. The hot forging mold device of claim 11, wherein the press device further comprises a pressure regulator configured to maintain a selected forging pressure for a predetermined dwell time.
15. The hot forging mold device of claim 14, wherein the controller is configured to terminate the forging pressure after determining that the molten metal in the mold cavity has solidified to at least a selected degree, as indicated by data from the sensor.
16. A hot forging mold device for low-pressure casting, comprising: a mold body including an upper mold and a lower mold; a mold cavity formed in the mold body; a riser cavity configured to store molten metal to be filled in the mold cavity; a press device disposed above the riser cavity and configured to apply pressure to molten metal in the riser cavity; an ejection device configured to separate a formed cast product from the mold cavity; and an actuator configured to automatically move the ejection device in response to a control signal.
17. The hot forging mold device of claim 16, wherein the ejection device comprises: an ejection plate movably disposed between the upper mold and a cylinder base plate of the press device; and a plurality of ejection pins coupled to the ejection plate and configured to push the cast product away from the upper mold when the ejection plate is moved by the actuator.
18. The hot forging mold device of claim 16, further comprising a controller configured to send the control signal to the actuator after a predetermined interval has elapsed from the time the press device applies pressure to the molten metal.
19. The hot forging mold device of claim 16, wherein the actuator is a hydraulic or pneumatic cylinder configured to move the ejection device between an extended position and a retracted position relative to the upper mold.
20. The hot forging mold device of claim 16, further comprising a safety sensor configured to detect whether the cast product has fully disengaged from the mold cavity, the safety sensor being in communication with the actuator to prevent reclosure of the upper mold unless disengagement is confirmed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other objects, features and advantages of the present disclosure will be more apparent from the following detailed description taken in conjunction with the accompanying drawings:
[0027]
[0028]
[0029]
[0030]
[0031]
DETAILED DESCRIPTION
[0032] Hereinafter, some embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals will be used throughout to designate the same or equivalent components. In describing embodiments of the present disclosure, detailed descriptions associated with well-known functions or configurations will be omitted if they may make subject matters of the present disclosure unnecessarily obscure.
[0033] The term riser cavity used herein refers to a cavity that stores molten metal and supplies it to the mold cavity during the casting and solidification processes, thereby compensating for volume contraction as the molten metal cools.
[0034] The term press device used herein refers to a mechanical or hydraulic assembly configured to apply a forging pressure to molten metal in the riser cavity, typically including a press plunger driven by a hydraulic cylinder or similar actuator.
[0035] The term ejection device used herein refers to a component or set of components configured to remove a formed cast product from the mold cavity, often including an ejection plate and one or more ejection pins that can push the cast product away from the upper mold.
[0036] The term cooling fluid used herein refers to any liquid or gas, such as water or air, that is circulated through a cylinder base plate or other part of the hot forging mold device in order to regulate temperature during casting.
[0037] The term leakage preventing plate used herein refers to a plate, typically installed around a press plunger, that is configured to prevent unwanted leakage of hydraulic oil or other fluids into the riser cavity.
[0038] The term guide block used herein refers to a structural feature that stabilizes or aligns a moving part, such as a press plunger or ejection plate, to ensure linear or controlled movement within the mold device.
[0039] The term controller used herein refers to any hardware and/or software system-such as a microprocessor, programmable logic controller (PLC), or similar device-configured to monitor or regulate one or more operations of the hot forging mold device, including pressure application or actuator movement.
[0040] The term sensor used herein refers to a device configured to measure a parameter of the molten metal, the mold environment, or related conditions (for example, temperature or fill level) and to provide the corresponding data to the controller.
[0041] The term actuator used herein refers to a component configured to convert fluid power (hydraulic or pneumatic) or electrical energy into mechanical motion, thereby moving an ejection device or another part of the hot forging mold device in response to a control signal.
[0042] Furthermore, in describing components of embodiments of the present disclosure, the terms first, second, A, B, (a), (b), and the like may be used herein. These terms are only used to distinguish one element from another element, but do not limit the corresponding elements irrespective of the nature, order, or priority of the corresponding elements. When it is described that a certain component is connected to, coupled to or electrically connected to a second component, it should be understood that the component may be directly connected or electrically connected to the second component, but a third component may be connected, coupled or electrically connected between the components.
[0043] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. These terms are merely intended to distinguish one component from another component, and the terms do not limit the nature, sequence or order of the constituent components. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. Throughout the specification, unless explicitly described to the contrary, the word comprise and variations such as comprises or comprising will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. In addition, the terms unit, -er, -or, and module described in the specification mean units for processing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.
[0044] Although exemplary embodiment is described as using a plurality of units to perform the exemplary process, it is understood that the exemplary processes may also be performed by one or plurality of modules. Additionally, it is understood that the term controller/control unit refers to a hardware device that includes a memory and a processor and is specifically programmed to execute the processes described herein. The memory is configured to store the modules, and the processor is specifically configured to execute said modules to perform one or more processes which are described further below.
[0045] Further, the control logic of the present disclosure may be embodied as non-transitory computer readable media on a computer readable medium containing executable program instructions executed by a processor, controller or the like. Examples of computer readable media include, but are not limited to, ROM, RAM, compact disc (CD)-ROM s, magnetic tapes, floppy disks, flash drives, smart cards and optical data storage devices. The computer readable medium can also be distributed in network coupled computer systems so that the computer readable media is stored and executed in a distributed fashion, e.g., by a telematics server or a Controller Area Network (CAN).
[0046] Unless specifically stated or obvious from context, as used herein, the term about is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. About can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 33%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term about.
[0047] Hereinafter, a hot forging mold device for low-pressure casting according to an example embodiment of the present disclosure will be described in detail with reference to the accompanying drawings.
[0048]
[0049] As illustrated in
[0050] The upper mold 11 and the lower mold 12 may include a mold cavity 13 that is a space, in which a cast product is formed by injecting a molten metal. The molten metal stored in a temperature keeping furnace may be injected into the mold cavity 13 through a molten metal pipe (not illustrated) by providing pressure to air at a low pressure of up to 0.5 bar and an average of 0.3 bar to the temperature keeping furnace (not illustrated).
[0051] A riser cavity 14 may be formed in the upper mold 11, and the riser cavity 14 and the mold cavity 13 may communicate with each other through a riser runner 15.
[0052] A transverse cross section of the riser cavity 14 may have a tapered shape, an upper side of which is narrower and a lower side of which is wider. The tapered riser cavity 14 is advantageous for the formation of a relatively ideal contraction tube in the riser cavity 14 and may improve a feeding efficiency of the riser cavity 14 and may acquire a good cast product.
[0053] The riser runner 15 serves to guide flow of the molten metal to the mold cavity 13 when the molten metal is supplied through the riser cavity 14. That is, the riser runner 15 is installed between the riser cavity 14 and the mold cavity 13 and may be a path for supplying and supplementing the molten metal when a volume contracts in a process of solidifying the molten metal in the mold cavity 13.
[0054] A part, in which the volume that contracts in the molten metal in the mold cavity 13, is mainly generated in a rear portion of the shape of the cast product.
[0055] Accordingly, a connection direction of the riser runner 15 with respect to the mold cavity 13 is formed at a portion, at which the volume contracts, that is, the mold cavity 13, and the riser runner 15 may be connected toward the thick rear portion. That is, the riser runner 15 may be connected to the rear portion, at which the volume mainly contracts in the molten metal in the mold cavity 13, to supply the molten metal. The riser runner 15 may be connected to a side surface of the rear portion. Because the riser runner 15 is connected to the side surface of the rear portion, the riser may be referred to as a side riser.
[0056]
[0057] Referring to the attached drawings, the press device 100 may provide a pressure to the riser cavity 14 to supply and supplement the molten metal to the rear portion of the mold cavity 13, at which the volume may contract, before a passage of the riser runner 15 is solidified and blocked during the solidification of the molten metal.
[0058] The press device 100 that provides a pressure to the riser cavity 14 may be installed in a frame structure, in which the mold body 10 including the mold cavity 13, the riser cavity 14, and the press device 100 are mounted. In this case, the press device 100 may be disposed on the through-hole 11a on an upper side of the riser cavity 14.
[0059] The press device 100 may include a press plunger 110 that provides a physical pressure to the riser cavity 14.
[0060] The press plunger 110 may supply the molten metal stored in the riser cavity 14 to the rear portion of the mold cavity 13 through the riser runner 15 by providing a pressure to the molten metal in the riser cavity 14 while moving linearly in an upward/downward direction.
[0061] On an upper side of the press plunger 110, a hydraulic cylinder 120 that controls a linear movement is installed in the press plunger 110.
[0062] In general, the hydraulic cylinder 120 may include a cylinder body (not illustrated), in which a bore (not illustrated) is formed, a piston (not illustrated) that linearly moves in a bore of the cylinder body, and a push rod 121 that connects the piston and the press plunger 110.
[0063] A bore, of which one side is open in a lengthwise direction thereof, may be formed in the cylinder body. The piston operated by the operation of the push rod 121 connected to the press plunger 110 may linearly move in the bore. Accordingly, a space between the piston and an opposite inner wall of the bore may be a hydraulic chamber (not illustrated), in which a hydraulic pressure is formed. The hydraulic chamber may store a hydraulic oil. An elastic member (not illustrated), such as a return spring for returning the piston to its original position may be provided in an interior of the cylinder body.
[0064] The press plunger 110 includes a mounting groove 111 formed such that a portion of the push rod 121 is inserted thereinto to be mounted and may be formed at a center of the press plunger 110 in a lengthwise direction thereof. The push rod 121 of the hydraulic cylinder 120 may be inserted through the mounting groove 111 to be firmly fixed.
[0065] The press device 100 may include a cylinder base plate 130 that supports the hydraulic cylinder 120, and in which a cooling fluid circulates along an inner path thereof.
[0066] The cylinder base plate 130 is a chamber, in which an interior space is formed, and may support the hydraulic cylinder 120 on an upper side thereof, and a through-hole 131 may be formed at a center thereof such that the push rod 121 may pass therethrough to perform an elevation operation.
[0067] As illustrated in
[0068] In addition, an insulating plate 140 may be installed on a lower side of the cylinder base plate 130. The insulating plate 140 may have a plate shape including an insulating layer, and may have a through-hole 141, through which the push rod 121 of the hydraulic cylinder 120 passes.
[0069] According to the hot forging mold device for low-pressure casting, a cast product is manufactured in a high-temperature environment due to high-temperature molten metal, and thus, as the hydraulic cylinder 120 of the press device 100 may not operate properly, the temperature of the cylinder base plate 130 may be lowered through the cooling water that circulates in the interior of the cylinder base plate 130. Accordingly, the hydraulic cylinder 120 installed in the cylinder base plate 130 may also be effectively cooled.
[0070] An ejection device 150 for separating a finished cast product from the mold cavity 13 may be installed at a lower end of the cylinder base plate 130.
[0071] The ejection device 150 may include an ejection plate 151 that is disposed between the upper mold 11 that is a movable mold, and the cylinder base plate 130. Furthermore, an ejection cylinder (not illustrated) that moves the ejection plate 151 while moving linearly by a pneumatic or hydraulic pressure may be included on an upper side of the ejection plate 151.
[0072] Because the ejection plate 151 is connected to a rod of the ejection cylinder operated by the pneumatic or hydraulic pressure, it may move forward or rearward with respect to the upper mold 11 along a movement direction of the upper mold 11 together with the rod when the ejection cylinder is operated. One side of an ejection pin 152 may be connected to the ejection plate 151. An opposite side of the ejection pin 152 is inserted into the upper mold 11 to be slidable in the lengthwise direction of the ejection pin 152.
[0073] The ejection plate 151 and the ejection pin 152 may be pushed out by providing a repulsive force against the cast product formed in the mold cavity 13. Sides of a plurality of ejection pins 152 may be connected to a lower end of the ejection plate 151, and the ejection pins 152 may be inserted into the upper mold 11 to be slidable, and opposite sides of the ejection pins 152 may be formed to move linearly toward the lower mold 12.
[0074] The ejection plate 151 may move in the upward/downward direction between the upper mold 11 and the cylinder base plate 130 by the push operation of the ejection cylinder.
[0075] When the ejection cylinder is lowered, the ejection pin 152 may push down the cast product attached to the upper mold 11 to separate it downward while being lowered together with the ejection plate 151.
[0076] Meanwhile, the ejection plate 151 may be provided with a first guide block 160 that guides the press plunger 110 that moves linearly.
[0077] The first guide block 160 may control a stroke of the press plunger 110 that is linearly moved by the push rod 121 of the hydraulic cylinder 120, between the cylinder base plate 130 and the ejection plate 151 depending on a thickness thereof. That is, the first guide block 160 may control the stroke of the press plunger 110 by adjusting the thickness when the press plunger 110 moves linearly.
[0078] It is essential to control the stroke of the press plunger 110 to determine an appropriate pressure and a proper pressing time of the press plunger 110. In this way, the stroke of the press plunger 110 may be set to an optimum value so that the molten metal may be pressed under appropriate conditions by controlling the pressure and the time, at which the press plunger 110 enters the riser cavity 14.
[0079] In the press plunger 110 that is located on an upper side of the riser cavity 14 and moves forward and rearward into the riser cavity 14, the hydraulic oil in the hydraulic cylinder 120 may leak and flow into the riser cavity 14 along the press plunger 110 by its own weight. Accordingly, a leakage preventing plate 180 may be installed on an upper side of the riser cavity 14 to prevent the inflow of the hydraulic oil into the riser cavity 14. That is, the leakage preventing plate 180 may be installed around the press plunger 110. A through-hole 181, through which the press plunger 110 passes, may be formed in the leakage preventing plate 180, and a sealing part 182, such as an O-ring, may be formed in the through-hole 181.
[0080] Furthermore, a through-hole 11a, through which the press plunger 110 passes, may be formed in the riser cavity 14 of the upper mold 11, and a second guide block 170 that guides the press plunger 110 may be inserted into the through-hole 11a of the upper mold 11. In this case, the second guide block 170 has a function of guiding the press plunger 110.
[0081]
[0082] Referring to
[0083] Referring to
[0084] The press device 100 may supplement the molten metal for the contraction voids of the rear portion by providing a molten metal supplement in the riser cavity 14 to compensate for the volume reduction caused by contraction when the molten metal flowing into the mold cavity 13 is solidified. In this case, the riser runner 15 and the molten metal pipe may be solidified.
[0085] As an example embodiment of the present disclosure, an operation mechanism of the press device 100 will be described as follows.
[0086] Referring to
[0087] When the piston provides a pressure to the push rod 121 while being guided by the bore, the push rod 121 may linearly move.
[0088] When the press plunger 110 connected to the lower end of the hydraulic cylinder 120 is lowered while being guided by the first and second guide blocks 160 and 170 and presses the molten metal supplement in the riser cavity 14, the molten metal in the riser cavity 14 may flow into the mold cavity 13 to be supplemented.
[0089] In this case, the press device 100 may continuously supply and supplement the molten metal to the rear portion, at which the volume may contract, before the molten metal that flows through the riser runner 15 is solidified and blocked during the process of solidifying the molten metal.
[0090] While the cast product is completed and finished, the operation of the press device 100 may be stopped. That is, when the operation of the press device 100 is stopped, the stroke operation of the press plunger 110 may be stopped.
[0091] As illustrated in
[0092] As illustrated in
[0093] After the cast product is separated, the ejection plate 151 is lifted from the upper mold 11 to insert the ejection pin 152 into the upper mold 11, and the upper mold 11 is closely attached to the lower mold 12 to repeat the cast product molding process as described above.
[0094] During the low-pressure casting process, the cooling water that circulates in the cooling line 132 of the cylinder base plate 130 of the press device 100 lowers the temperature of the cylinder base plate 130 so that the operation performance of the hydraulic cylinder 120 may be maintained normally even in a high-temperature environment of the hot forging mold device.
[0095] Furthermore, the insulating plate 140 installed on a lower side of the cylinder base plate 130 may also block the high-temperature heat generated by the molten metal to maintain the operational performance of the hydraulic cylinder 120 normally.
[0096] Meanwhile, the leakage preventing plate 180 of the press device 100 may prevent the intrusion of the hydraulic oil with the sealing part 182 provided in the through-hole 181, through which the press plunger 110 passes, so that the hydraulic oil of the hydraulic cylinder 120 is prevented from being introduced into the riser cavity 14.
[0097] Accordingly, the present disclosure applies the mechanical press device 100 to an upper portion of the riser cavity 14 of the hot forging mold device for low-pressure casting to directly provide a high pressure to the molten metal in an interior of the space of the mold cavity 13 to manufacture a cast product having a relatively complex shape with a high precision.
[0098] Furthermore, the molten metal may be filled by providing a physical pressure to the riser cavity 14, and the pressure may be maintained until the molten metal is completely solidified, and thus, defects caused by the solidification contraction in the cast product may be improved during the solidification of the molten metal to ensure an excellent casting quality.
[0099] According to the hot forging mold device for low-pressure casting according to the present disclosure, a complex cast product with a high precision may be manufactured by directly applying the mechanical press device to an upper portion of the riser cavity of the hot forging mold device for low-pressuring to directly provide a high pressure to the molten metal in an interior of the mold cavity space.
[0100] Furthermore, the molten metal may be filled by providing a physical pressure to the riser cavity, and the pressure may be maintained until the molten metal is completely solidified, and thus, defects caused by the solidification contraction in the cast product may be improved during the solidification of the molten metal to ensure an excellent casting quality.
[0101] The above-mentioned description of the present disclosure is intended to be illustrative, and it should be understood by those skilled in the art that the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the above-described embodiments are examples in all aspects, and should be construed not to be restrictive. The scope of the present disclosure is defined by claims to be described below, and it should be interpreted that the scopes or claims of the present disclosure and all modifications or changed forms derived from the equivalent concept are included in the scopes of the present disclosure.