APPARATUS AND METHOD OF CASTING

Abstract

A casting apparatus may include a mold. The mold may include a first mold and a second mold. A cavity may be defined by the first mold and the second mold. The mold may include a molten metal inlet connected to the cavity. The mold may include at least one first channel configured to allow a coolant to flow or to form a vacuum.

Claims

1. A casting apparatus comprising: a mold, wherein the mold comprises: a first mold and a second mold; a cavity defined by the first mold and the second mold; a molten metal inlet connected to the cavity; and at least one first channel configured to allow a coolant to flow into the mold or to form a vacuum within the mold.

2. The casting apparatus of claim 1, wherein the at least one first channel is configured to extend through the mold and be spaced apart from the cavity by a predetermined distance.

3. The casting apparatus of claim 1, further comprising: a pipe inserted into the at least one first channel; a fluid pump connected to the pipe and configured to supply the coolant to the pipe; and a first valve configured to allow or block a flow of the coolant through the pipe.

4. The casting apparatus of claim 1, further comprising: a pipe inserted into the at least one first channel; a vacuum pump connected to the pipe and configured to supply a vacuum to the pipe; and a second valve configured to allow or block a flow of the vacuum through the pipe.

5. The casting apparatus of claim 1, wherein the mold further comprises: at least one second channel configured to form a vacuum, and extending through the mold to the cavity, and sand and an inorganic binder.

6. The casting apparatus of claim 5, further comprising a first vacuum pipe inserted into the at least one second channel.

7. The casting apparatus of claim 5, further comprising: a first vacuum pipe configured to communicate with the cavity through a sintered vent, wherein the first vacuum pipe is inserted into the at least one second channel; and a vacuum pump connected to the first vacuum pipe and configured to supply a vacuum to the first vacuum pipe.

8. The casting apparatus of claim 5, further comprising: a second vacuum pipe configured to communicate with the cavity through a riser disposed in the mold, wherein the second vacuum pipe is inserted into the at least one second channel; and a vacuum pump connected to the second vacuum pipe and configured to supply a vacuum to the second vacuum pipe.

9. The casting apparatus of claim 1, further comprising: a pipe inserted into the at least one first channel; a fluid pump connected to the pipe and configured to supply the coolant to the pipe; a first vacuum pump connected to the pipe and configured to supply a vacuum to the pipe; a first valve configured to allow or block a flow of the coolant through the pipe; a second valve configured to allow or block a flow of the vacuum through the pipe; at least one second channel configured to form a vacuum, extending through the mold to the cavity; a first vacuum pipe inserted into the at least one second channel; a second vacuum pump connected to the first vacuum pipe and configured to form a vacuum in the first vacuum pipe; a first vacuum valve configured to allow or block a flow of the vacuum through the first vacuum pipe; and a controller circuit configured to adjust operations of the fluid pump, the first vacuum pump, the second vacuum pump, the first valve, the second valve, and the first vacuum valve.

10. The casting apparatus of claim 9, wherein the controller circuit is configured to control: at a predetermined first time point, the first valve to close, the second valve to open, and the first vacuum pump to operate, and at a predetermined second time point, the first valve to open, the second valve to close, and the fluid pump to operate.

11. The casting apparatus of claim 9, wherein the controller circuit is configured to control: at a predetermined first time point, the first valve to close, the second valve to open, the first vacuum pump to operate, the first vacuum valve to open, and the second vacuum pump to operate, and at a predetermined second time point, the first valve to open, the second valve to close, and the fluid pump to operate.

12. The casting apparatus of claim 9, wherein the controller circuit is configured to control: at a predetermined first time point, the first valve to close, the second valve to open, the first vacuum pump to operate, the first vacuum valve to open, and the second vacuum pump to operate, at a predetermined second time point, the first valve to open, the second valve to close, and the fluid pump to operate, and after the second valve has been closed, the first vacuum valve to stay open.

13. The casting apparatus of claim 9, further comprising: a second vacuum pipe inserted into the second channel and configured to form a vacuum by the second vacuum pump, wherein the second vacuum pipe is configured to communicate with the cavity through a riser disposed in the mold; and a second vacuum valve configured to allow or block a flow of the vacuum through the second vacuum pipe, wherein the controller circuit is configured to control: at a predetermined first time point, the first valve to close, the second valve to open, the first vacuum pump to operate, the first vacuum valve to open, the second vacuum valve to open, and the second vacuum pump to operate, and at a predetermined second time point, the first valve to open, the second valve to close, and the fluid pump to operate.

14. A casting method performed by a casting apparatus, the casting method comprising: forming a vacuum in a pipe extending through a mold comprising a cavity; pouring molten metal into the cavity; supplying a coolant through the pipe after ending the forming of the vacuum in the pipe; and removing a cast product formed in the mold after a predetermined period of time.

15. The casting method of claim 14, further comprising, prior to pouring of the molten metal, forming a vacuum in a first vacuum pipe extending through the mold to the cavity.

16. The casting method of claim 15, wherein the forming of the vacuum in the first vacuum pipe comprises maintaining the vacuum in the pipe through the first vacuum pipe during the supplying of the coolant through the pipe.

17. The casting method of claim 14, further comprising, prior to pouring of the molten metal, forming a vacuum in a second vacuum pipe connected to the cavity through a riser disposed in the mold.

18. The casting method of claim 17, wherein the forming of the vacuum in the second vacuum pipe comprises maintaining the vacuum in the pipe through the second vacuum pipe during the supplying of the coolant through the pipe.

19. The casting method of claim 14, wherein the pipe comprises a first pipe disposed at a first position in the mold and a second pipe disposed at a second position in the mold, and wherein the supplying of the coolant comprises: supplying the coolant through the first pipe at a predetermined first time point; and supplying the coolant through the second pipe at a predetermined second time point.

20. An apparatus comprising: a mold including a first mold and a second mold that together define a cavity configured to receive molten metal and form a cast product; at least one channel formed in the mold and extending to a position spaced from the cavity by a predetermined distance; a pipe inserted into the at least one channel and configured to selectively supply a coolant to the mold or form a vacuum within the mold; a pump configured to deliver the coolant to the pipe; a vacuum pump configured to form the vacuum through the pipe; and a controller circuit operatively connected to the pump and the vacuum pump and configured to control an operation time point of the pump and the vacuum pump and a timing of supplying the coolant to the mold after the molten metal has been poured, wherein a flow rate and timing of the coolant for each portion of the mold is controlled so that the cast product is cooled at predetermined rates and times across different regions of the mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The above and other features of the present disclosure will now be described in detail with reference to examples thereof illustrated in the accompanying drawings which are given herein below by way of illustration only, and thus are not limitative of the present disclosure, and wherein:

[0034] FIG. 1 shows an example of a casting apparatus;

[0035] FIG. 2 shows an example of a casting apparatus;

[0036] FIG. 3 shows an example of pipes of a casting apparatus;

[0037] FIG. 4 shows an example of a sintered vent of a casting apparatus;

[0038] FIG. 5 shows an example of a control system of a casting apparatus;

[0039] FIG. 6 shows an example of a casting method;

[0040] FIG. 7 shows an example of a casting method; and

[0041] FIG. 8 shows an example computing system.

[0042] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the present disclosure. The specific design features of the present disclosure, including, for example, specific dimensions, orientations, locations, and shapes, will be determined in part by the particular intended application and usage environment.

[0043] In the figures, the reference numerals refer to the same or equivalent parts of the present disclosure throughout the several figures of the drawing.

DETAILED DESCRIPTION

[0044] Descriptions of specific structures or functions presented in the examples of the present disclosure are merely exemplary for the purpose of explaining the examples according to the concept of the present disclosure, and the examples according to the concept of the present disclosure may be implemented in various forms. In addition, the descriptions should not be construed as being limited to the examples described herein, and should be understood to include all modifications, equivalents and substitutes falling within the idea and scope of the present disclosure.

[0045] For purposes of this application and the claims, using the exemplary phrase at least one of: A; B; or C or at least one of A, B, or C, the phrase means at least one A, or at least one B, or at least one C, or any combination of at least one A, at least one B, and at least one C. Further, exemplary phrases, such as "A, B, or C", "at least one of A, B, and C", "at least one of A, B, or C", etc. as used herein may mean each listed item or all possible combinations of the listed items. For example, "at least one of A or B" may refer to (1) at least one A; (2) at least one B; or (3) at least one A and at least one B.

[0046] Hereinafter, the present disclosure is described in detail with reference to the accompanying drawings.

[0047] Casting process is one of the product processing methods. In the casting process, molten metal is poured into a mold, and the molten metal is cooled and solidified to create a product (a cast product) having a desired shape. Once cooling and solidification are complete, the cast product may be removed from the mold and undergo a shake-out process, completing the processing of the product.

[0048] Molten metal may be prepared by melting a solid ingot, such as aluminum, into a liquid state in a melting furnace. The molten metal may be poured into a mold by low-pressure casting or gravity casting. Low-pressure casting involves forcing molten metal upward into a mold under low pressure to fill the mold. Specifically, low-pressure casting involves applying low pressure (e.g., 0.05 to 0.8 kilograms per square centimeter (kg/cm.sup.2)) compressed air to a holding furnace of a low-pressure casting machine, forcing molten metal upward through a guide tube into a mold including a sand core, and solidifying the molten metal to create a product. Gravity casting is a method of pouring molten metal into a mold from above without using external pressure. Specifically, in gravity casting, a mold is set in a gravity casting machine, and then molten metal may fill the mold. The pressure applied in gravity casting corresponds to the gravity of a product riser.

[0049] A variety of components of a vehicle may be manufactured through a casting process. As a non-limiting example, vehicle components manufactured through the casting process may include powertrain components, chassis components, and the like. As described below, the casting apparatus and method according to the disclosed examples may enable the manufacture of vehicle body components requiring high elongation.

[0050] The term module or unit used in the specification means a software and/or hardware component, and the module or unit performs certain operations/functions/roles. However, the module or unit is not construed as being limited to software or hardware. The module or unit may be configured to be in an addressable storage medium or to execute one or more processors. Therefore, as an example, the module or unit may include at least one of components such as software components, object-oriented software components, class components, and task components, processes, functions, attributes, procedures, sub-routines, segments of program codes, drivers, firmware, micro-codes, circuits, data, databases, data structures, tables, arrays, or variables. Functions provided in the components, modules, or units may be combined into a smaller number of components, modules, or units or further divided into additional components, modules, or units.

[0051] In the present disclosure, the module or unit may be realized as a processor and a memory. The processor should be widely construed to include a general-purpose processor, a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), a microcontroller, a state machine, or the like. In some environments, the processor may refer to an application-specific integrated circuit (ASIC), a programmable logic device (PLD), or a field-programmable gate array (FPGA), and the like. For example, the processor may refer to a combination of processing devices such as a combination of a DSP and a microprocessor, a combination of a plurality of microprocessors, a combination of one or more microprocessors combined with a DSP core, or any other such combination. Moreover, the memory should be widely construed to include any electronic component capable of storing electronic information. The memory may refer to various types of processor-readable medium such as a random access memory (RAM), a read only memory (ROM), a non-volatile random access memory (NVRAM), a programmable read only memory (PROM), an erasable programmable read only memory (EPROM), an electrically erasable programmable read only memory (EEPROM), a flash memory, a magnetic or optical data storage device, and registers. When the processor can read information from a memory and/or record the information in the memory, the memory may be in a state of electronic communication with a processor. Memory integrated into a processor is in a state of electronic communication with the processor.

[0052] The one or more features described herein may be provided as a computer program stored in a computer-readable recording medium in order to be executed on a computer. The medium may either continuously store a computer-executable program or temporarily store the program for execution or download. Furthermore, the medium may be a variety of recording or storage means in the form of a single hardware device or multiple combined hardware devices, and is not limited to media directly connected to some computer system but may also be distributed across a network. Examples of such media include magnetic media such as a hard disk, a floppy disk, or a magnetic tape, optical recording media such as a CD-ROM or a DVD, magneto-optical media such as a floptical disk, and a ROM, RAM, or flash memory, among others, configured to store program instructions. Additional examples of such media include media or storage media that are managed by an app store that distributes applications or by various other sites or servers that provide or distribute software.

[0053] In a hardware implementation, processing units used for performing the techniques may be implemented within one or more ASICs, DSPs, digital signal processing devices, programmable logic devices, field-programmable gate arrays, processors, controllers, microcontrollers, microprocessors, electronic devices, or computers or combinations thereof designed to perform the functions described in the present disclosure.

[0054] According to the present disclosure, a casting apparatus and method are provided that enable production of metal components with improved fluidity and enhanced mechanical properties. A mold composed of sand and an inorganic binder defines a cavity for forming a cast product and includes at least one channel configured to allow either a vacuum to be formed or a coolant to flow. Molten metal may be poured into the mold under gravity or low pressure while a vacuum is formed to eliminate back pressure and improve the flow of the molten metal into the cavity. After a predetermined time delay, coolant such as water may be supplied through pipes inserted into the channels at pre-selected positions and timings so as to rapidly cool different parts of the cast product. A controller may operate pumps and valves to adjust the flow rate and timing of the vacuum and coolant supply. By coordinating these steps, the cooling rate of the cast product may be increased, thereby refining the metal structure, improving elongation and strength, reducing thickness, and enabling application of sand casting to vehicle body and powertrain components that require high mechanical performance.

[0055] As illustrated in FIG. 1, a casting apparatus 1 may include a mold 100. The mold 100 may include sand and a binder. The mold 100 may be manufactured through sand molding. In sand molding, sand and a binder are mixed, and the mixed sand and binder are hardened (e.g., by chemical curing, heating, microwave drying, or steam treatment, etc.) to manufacture the mold 100. In an example, the binder used to manufacture the mold 100 may be an inorganic binder (e.g., a silicate-based binder, phosphate-based binder, or aluminosilicate binder, etc.). Inorganic binders are safe and environmentally friendly because inorganic binders do not generate harmful gases and may prevent quality degradation of a cast product due to core gas.

[0056] Molten metal (M) may be supplied to the mold 100. The molten metal (M) in a liquid state may be prepared in advance by melting a solid ingot in a melting furnace (e.g., an induction furnace, a gas-fired furnace, or an electric arc furnace, etc.). As a non-limiting example, the solid ingot may be aluminum (e.g., aluminum-silicon alloy, aluminum-magnesium alloy, or aluminum-copper alloy, etc.). In an example, the mold 100 may include an inlet 110. The molten metal (M) may be supplied to the mold 100 through the inlet 110. The inlet 110 may be formed in an upper mold or a lower mold of the mold 100. The illustrated example shows a gravity casting method, in which the inlet 110 is formed in a first mold 102, which is illustrated as the upper mold. However, the inlet 110 may be formed in a second mold 104, which is illustrated as the lower mold, when a low-pressure casting method is used (e.g., counter-gravity casting, vacuum-assisted casting, or tilt-pour casting, etc.). In other words, the casting apparatus 1 may use a gravity casting method or a low-pressure casting method.

[0057] The mold 100 may include the first mold 102 and the second mold 104. A cavity 120 may be defined by the first mold 102 and the second mold 104. A cast product may be formed by the cavity 120. The cavity 120 is configured to be in fluid communication with the inlet 110, and the molten metal (M) may fill the cavity 120 through the inlet 110. As the molten metal (M) filling the cavity 120 cools and solidifies, a cast product, which is a final product, may be formed (e.g., an automotive engine block, a turbine blade, or a pump housing, etc.). The cavity 120 may further include a core. The cavity 120 may define the external shape of the cast product, and the core may define the internal shape of the cast product, such as a hole or space formed in the cast product (e.g., internal cooling passages, oil channels, or structural ribs, etc.).

[0058] Referring further to FIG. 2, the mold 100 may include a riser 130. To prevent shrinkage that may occur during the solidification of the metal, the riser 130 may supply the molten metal (M) into the mold 100 while the metal solidifies (e.g., for feeding thin-walled sections, maintaining pressure head, or reducing porosity, etc.). The riser 130 may be provided at a predetermined position in the mold 100 (e.g., at the highest point of the cavity, near a junction of thick and thin sections, or adjacent to a core print, etc.).

[0059] The mold 100 may include a first channel 140. The first channel 140 may extend through the mold 100. In an example, the first channel 140 may be formed in the first mold 102. The first channel 140 may extend through the first mold 102 and may extend from a surface of the first mold 102 to a position spaced apart from the cavity 120 by a predetermined distance (e.g., 5 mm, 10 mm, or 15 mm, etc.). In an example, the first channel 140 may be provided in plurality along the mold 100. The plurality of first channels 140 may be placed within the first mold 102, with each of the first channels 140 positioned at a predetermined distance from the others (e.g., uniformly spaced, staggered, or concentrated near hot spots, etc.). In some examples, the first channel 140 may be formed in the second mold 104.

[0060] The first channel 140 may be configured to allow coolant to flow or to form a vacuum. In an example, the casting apparatus 1 may include a pipe 200. The pipe 200 may be inserted into the first channel 140. The coolant or vacuum may be supplied to the cavity 120 or to the product through the pipe 200 (e.g., to cool thin sections, to improve directional solidification, or to extract gases, etc.). According to the disclosed example, the coolant may reach the cast product based on the water-absorbing properties of the inorganic binder included in the mold 100. An end portion of the first channel 140 may be positioned as close as possible to the cast product or to the cavity 120, enhancing cooling and improving the physical properties of the cast product (e.g., tensile strength, hardness, or fatigue resistance, etc.). The distance between the cavity 120 and the end portion of the first channel 140 may be pre-adjusted depending on the shape curvature of the cast product (e.g., sharp corners, thin fins, or thick bosses, etc.). In a case where the distance between the first channel 140 or the pipe 200 and the cavity 120 is too small, deformation may occur (e.g., cracking, warping, or surface defects, etc.). In a case where the distance between the first channel 140 or the pipe 200 and the cavity 120 is too large, cooling performance may be degraded (e.g., uneven solidification, shrinkage cavities, or poor mechanical properties, etc.).

[0061] The coolant may be supplied to the pipe 200. The casting apparatus 1 may include a reservoir 210 and a fluid pump 220. The coolant may be stored in the reservoir 210. The coolant stored in the reservoir 210 may be supplied to the pipe 200 by an operation of the fluid pump 220. In an example, the coolant may be water (e.g., plain water, water with corrosion inhibitors, or a glycol-water mixture, etc.). The flow rate of the coolant supplied to the pipe 200 may be regulated by adjusting the rotational speed of the fluid pump 220 (e.g., by using a variable frequency drive, manual throttling, or automatic feedback control, etc.). A flowmeter 230 configured to measure the flow rate of the coolant passing through the pipe 200 may be disposed in the pipe 200 (e.g., a turbine flowmeter, an electromagnetic flowmeter, or an ultrasonic flowmeter, etc.). In an example, the pipe 200 may include a plurality of outlets (e.g., multiple nozzles, perforated sections, or spray tips, etc.).

[0062] A first valve 240 may be disposed in the pipe 200. Opening the first valve 240 allows the coolant to flow through the pipe 200, and closing the first valve 240 blocks the flow of coolant through the pipe 200 (e.g., during mold filling, solidification, or post-cast cooling, etc.).

[0063] Referring to FIG. 3, in an example, the pipe 200 may include a plurality of pipes (e.g., arranged in parallel, arranged radially, or arranged concentrically, etc.). In an example, the pipe 200 may include a first pipe 202 and a second pipe 204. The first pipe 202 may include a plurality of outlets 202a (e.g., nozzles, spray tips, or perforations, etc.). The second pipe 204 may include a plurality of outlets 204a (e.g., slots, jets, or diffusers, etc.). The coolant introduced into the first pipe 202 may be supplied to the mold 100 through the plurality of outlets 202a, and the coolant flowing through the second pipe 204 may be supplied to the mold 100 through the plurality of outlets 204a.

[0064] The first pipe 202 may be disposed at a predetermined first position in the first mold 102 (e.g., near a hot spot, close to a riser, or adjacent to a thin section, etc.). Similarly, the second pipe 204 may be disposed at a predetermined second position in the second mold 104 (e.g., opposite the first position, around a core print, or near a gating system, etc.).

[0065] In an example, a valve 240a may be positioned in the first pipe 202. Opening the valve 240a allows the coolant to be supplied to the first position in the mold 100. In an example, a valve 240b may be positioned in the second pipe 204. Adjusting the position of the valve 240b allows the coolant to be supplied or blocked to the second position in the mold 100. As illustrated in the drawing, the pipe 200 may include more pipes (e.g., a third, fourth, or fifth pipe, etc.). For example, the pipe 200 may include a third pipe 206. A valve 240c may be positioned in the third pipe 206 to allow or block the flow of coolant through the third pipe 206.

[0066] The first pipe 202 and the second pipe 204 may supply coolant to the mold 100 simultaneously or at different times. By adjusting the injection timing of each pipe 202, 204, 206 or controlling the position of their valves (e.g., 240a, 240b, 240c, etc.), the supply of coolant may be controlled for each position in the mold 100, and the cooling sequence may be optimized or enhanced (e.g., staged cooling, zone cooling, or pulsed cooling, etc.). The injection timing of each pipe 202, 204, 206 may be predetermined (e.g., based on casting simulation, empirical data, or thermal sensor feedback, etc.).

[0067] The casting apparatus 1 may form a vacuum in the pipe 200. The vacuum may draw air through the pipe 200, removing residual air within the cavity 120 connected to the pipe 200 and eliminating back pressure within the cavity 120 that impedes the flow of the molten metal (e.g., entrapped gases, air pockets, or turbulence, etc.).

[0068] In an example, the casting apparatus 1 may include a first vacuum pump 300 and a second valve 310. The first vacuum pump 300 may be connected to the pipe 200, and the second valve 310 may be disposed in the pipe 200. For example, the first vacuum pump 300 may be connected through a purging portion of the pipe 200 (e.g., at a side port, at a T-junction, or at a dedicated vacuum manifold, etc.). When the second valve 310 is in an open position, a vacuum may be supplied to the pipe 200 by the operation of the first vacuum pump 300. When the second valve 310 is in a closed position, the flow of the vacuum to the pipe 200 may be blocked. In some examples, a vacuum tank may be further included or may be used instead of the first vacuum pump 300 (e.g., a buffer tank, a receiver, or a vacuum reservoir, etc.). The formation of a vacuum may improve the fluidity of the molten metal (M) by relieving pressure within the mold 100. The improved fluidity of the molten metal (M) may enable minimizing the thickness of the cast product (e.g., to form thin-walled housings, complex fins, or lightweight structural parts, etc.).

[0069] The casting apparatus 1 may include a first vacuum pipe 400. The first vacuum pipe 400 may be inserted into a second channel 150. The second channel 150 may be, like the first channel 140, a passage or hole extending through the first mold 102. However, a channel into which the first vacuum pipe 400 is inserted is referred to as the second channel 150 so as to distinguish the channel from the first channel 140 into which the pipe 200 is inserted.

[0070] The first vacuum pipe 400 may be connected to a second vacuum pump 510 (e.g., for surge capacity, emergency backup, or continuous evacuation, etc.). In some examples, a vacuum tank may be further included or may be used instead of the second vacuum pump 510. Operating the second vacuum pump 510 may form a vacuum in the first vacuum pipe 400. In an example, a first vacuum valve 420 may be disposed in the first vacuum pipe 400. Opening the first vacuum valve 420 may supply the vacuum to the first vacuum pipe 400, and closing the first vacuum valve 420 may block the supply of the vacuum to the first vacuum pipe 400.

[0071] In an example, the first vacuum pipe 400 may extend to the cavity 120 through the second channel 150 (e.g., through a straight bore, an angled passage, or a stepped hole, etc.). In other words, the first vacuum pipe 400 may penetrate the first mold 102 and be connected to the cavity 120. In an example, the first vacuum pipe 400 may be configured to communicate with the cavity 120 through a sintered vent 430 (e.g., a porous bronze insert, a stainless steel vent, or a ceramic filter, etc.). The first vacuum pipe 400 may form a vacuum within the cavity 120, improving the fluidity of the molten metal and enabling the production of a thinner cast product (e.g., thin-walled engine components, lightweight brackets, or intricate housings, etc.).

[0072] As illustrated in FIG. 4, the sintered vent 430 may be disposed between the first vacuum pipe 400 and the cavity 120 to prevent the molten metal (M) from flowing back into the first vacuum pipe 400 (e.g., during turbulence, during pouring surges, or when back-pressure develops, etc.). The sintered vent 430 may include, as illustrated in the drawing, a plurality of small-sized holes 432 (e.g., circular pores, slotted pores, or tapered pores, etc.). The holes 432 formed in the sintered vent 430 may allow air to pass through while blocking the intrusion of the molten metal (M) (e.g., by capillary action, by surface tension, or by pressure differential, etc.). As a non-limiting example, the sintered vent 430 may be made of steel (e.g., stainless steel, bronze, or sintered ceramic-metal composite, etc.).

[0073] The casting apparatus 1 may include a second vacuum pipe 500. The second vacuum pipe 500 may be inserted into the second channel 150. The second vacuum pipe 500 may be connected to the riser 130 (e.g., at a top-feeding riser, a side-feeding riser, or a bottom riser, etc.). The second vacuum pipe 500 may form a vacuum within the cavity 120 through the riser 130, improving the fluidity of the molten metal and enabling the production of a thinner cast product (e.g., thin-walled brackets, lightweight automotive parts, or complex heat-exchanger components, etc.).

[0074] In some examples, a vacuum may be formed in the second vacuum pipe 500 by the second vacuum pump 510. The second vacuum pipe 500 may be provided with a second vacuum valve 510 configured to allow or block the flow of the vacuum through the second vacuum pipe 500 (e.g., via manual actuation, electric solenoid actuation, or pneumatic actuation, etc.). In some examples, the second vacuum pipe 500 may be supplied with vacuum by a third vacuum pump, separate from the second vacuum pump 510 (e.g., for redundancy, for staged evacuation, or for independent zone control, etc.).

[0075] Referring to FIG. 5, the casting apparatus 1 may include a controller 10. The controller 10 may control the operation of the casting apparatus 1. In an example, the controller 10 may operate or stop the fluid pump 220. The controller 10 may determine the operation time point of the fluid pump 220 and operate the fluid pump 220 at the determined operation time point. Moreover, the controller 10 may adjust the rotational speed of the fluid pump 220 (e.g., by PWM control, variable-frequency drive, or closed-loop feedback, etc.). In an example, the controller 10 may adjust the position or position adjustment time point of the valve 240, 310. The controller 10 may adjust the position of the first valve 240, the second valve 310, the first vacuum valve 420, or the second vacuum valve 510 at a predetermined time point (e.g., before pouring, during solidification, or during coolant injection, etc.). In an example, the controller 10 may operate or stop the first vacuum pump 300. The controller 10 may determine the operation time point of the first vacuum pump 300 and operate the first vacuum pump 300 at the determined operation time point. In an example, the controller 10 may operate or stop the second vacuum pump 510. The controller 10 may determine the operation time point of the second vacuum pump 510 and operate the second vacuum pump 510 at the determined operation time point. In an example, the controller 10 may control the operation of the first vacuum pump 300 so that a vacuum is formed through the pipe 200 right before the molten metal (M) is poured and until the coolant is supplied. In an example, the controller 10 may control the operation of the second vacuum pump 510 so that a vacuum is formed in the first vacuum pipe 400 and the second vacuum pipe 500 right before the molten metal (M) is poured and until the product is formed (e.g., until complete solidification, until mold shake-out, or until riser feeding is complete, etc.).

[0076] The controller 10 may include a processor and memory. The processor, which is hardware, may execute computer-readable codes or a series of instructions stored in the memory and process data. As a non-limiting example, the processor may include a central processing unit (CPU), a graphics processing unit (GPU), a multi-core processor, a multiprocessor, an application-specific integrated circuit (ASIC), or a field programmable gate array (FPGA) (e.g., for real-time control, parallel sensor processing, or adaptive casting parameter tuning, etc.).

[0077] The memory may be coupled to the processor. The memory may store data, code, or a series of instructions executable by the processor. The memory may be volatile or non-volatile memory. As a non-limiting example, the volatile memory may include dynamic random access memory (DRAM) or static random access memory (SRAM). As another non-limiting example, the non-volatile memory may include electrically erasable programmable read-only memory (EEPROM), flash memory, magnetic random access memory (MRAM), a CD-ROM, or a DVD-ROM (e.g., or other optical/solid-state storage such as Blu-ray or SSD, etc.). According to an example, the memory may include instructions that, when executed by the processor, control the operation time point of the fluid pump 220, the first vacuum pump 300, and/or the second vacuum pump 510, and the opening and closing time point or position of the first valve 240, the second valve 310, the first vacuum valve 420, and/or the second vacuum valve 510 (e.g., via preprogrammed recipes, adaptive control algorithms, or sensor-driven feedback loops, etc.).

[0078] Referring to FIG. 6, according to an example of the present disclosure, casting by the casting apparatus 1 may be performed as follows.

[0079] At operation S600, a vacuum may be formed through the pipe 200. The controller 10 may operate the first vacuum pump 300, open the second valve 310, and place the first valve 240 in the closed position (e.g., within milliseconds, within one second, or in a programmed sequence, etc.). Accordingly, a vacuum may be formed in the pipe 200 (e.g., to evacuate trapped air, reduce turbulence, or draw off core gases, etc.).

[0080] At operation S610, molten metal (M) may be poured into the mold 100 through the inlet 110 in the presence of the vacuum. As described above, the molten metal (M) may be supplied using gravity casting or low-pressure casting method (e.g., counter-gravity pouring, tilt-pour low-pressure casting, or vacuum-assisted casting, etc.).

[0081] At operation S620, the flow of the vacuum formed in the pipe 200 may be blocked. The controller 10 may stop the operation of the first vacuum pump 300 and close the second valve 310. After the molten metal (M) is poured, a vacuum may be maintained in the pipe 200 through the first vacuum pump 300 until the coolant is supplied to the mold 100 (e.g., to stabilize pressure, prevent backflow of molten metal, or allow riser feeding, etc.).

[0082] After the flow of the vacuum formed in the pipe 200 is blocked, the coolant may be supplied to the pipe 200 (operation S630). The controller 10 may supply the coolant to the mold 100 through the pipe 200 by opening the first valve 240 and operating the fluid pump 220. In an example, the controller 10 may vary the opening and closing time point of the valve 240a of the first pipe 202 and the valve 240b of the second pipe 204 of the first valves 240 (e.g., for zone-specific cooling, sequential cooling, or simultaneous multi-zone cooling, etc.). The time point of supplying the coolant through the first pipe 202 and the time point of supplying the coolant through the second pipe 204 may be determined in advance. For example, the time point of supplying the coolant may be determined for each part of the product to be cast based on casting analysis (e.g., computer simulation, thermal imaging, or historical production data, etc.). In an example, the coolant may be supplied after a predetermined time delay following the pouring of molten metal (M). To prevent direct contact between the molten metal (M) and water before the molten metal (M) solidifies, water may be allowed to reach the molten metal (M) at the earliest possible time point after the molten metal (M) has solidified (e.g., based on temperature sensors, microstructure prediction, or empirical solidification times, etc.). The time point may be determined in advance through experimentation or analysis (e.g., pilot runs, simulation software, or sensor calibration, etc.).

[0083] At operation S640, the cast product may be cooled while the coolant is supplied. Cooling may be completed after a predetermined period of time has elapsed (e.g., 30 seconds, 1 minute, or 5 minutes depending on product thickness, etc.).

[0084] At operation S650, the cast product that has cooled and solidified may be removed from the mold 100. After removal, the cast product goes through a shake-out process, deburring, or initial inspection (e.g., visual inspection, ultrasonic testing, or hardness check, etc.), completing the manufacture of the product.

[0085] As shown in FIG. 7, according to an example of the present disclosure, casting by the casting apparatus 1 may be performed as follows.

[0086] At operation S700, a vacuum may be formed through the pipe 200. The controller 10 may operate the first vacuum pump 300, open the second valve 310, and place the first valve 240 in the closed position (e.g., in a programmed sequence, at a pre-triggered time, or automatically from sensor input, etc.). Accordingly, a vacuum may be formed in the pipe 200 (e.g., to remove entrapped gases, draw off core gases, or stabilize mold pressure, etc.).

[0087] At operation S710, a vacuum may be formed through the first vacuum pipe 400 and/or the second vacuum pipe 500 while a vacuum is formed through the pipe 200. The controller 10 may operate the second vacuum pump 510 and open the first vacuum valve 420 and/or the second vacuum valve 510 to form a vacuum in the first vacuum pipe 400 and/or the second vacuum pipe 500 (e.g., simultaneously, sequentially, or in staggered zones, etc.).

[0088] At operation S720, the molten metal (M) may be poured into the mold 100 through the inlet 110 in the presence of the vacuum. The molten metal (M) may be supplied to the mold 100 using gravity casting or low-pressure casting method (e.g., counter-gravity pour, tilt-pour, or vacuum-assisted low-pressure casting, etc.).

[0089] At operation S730, the flow of the vacuum formed in the pipe 200 may be blocked. The controller 10 may stop the operation of the first vacuum pump 300 and close the second valve 310. After the molten metal (M) is poured, a vacuum may be maintained in the pipe 200 through the first vacuum pump 300 until the coolant is supplied to the mold 100 (e.g., to prevent backflow, stabilize riser feeding, or reduce turbulence, etc.). The vacuum through the first vacuum pipe 400 and/or the second vacuum pipe 500 may be maintained (e.g., throughout solidification, until temperature thresholds are met, or until cooling is initiated, etc.).

[0090] After the flow of the vacuum formed in the pipe 200 is blocked, the coolant may be supplied to the pipe 200. The controller 10 may supply the coolant to the mold 100 through the pipe 200 by opening the first valve 240 and operating the fluid pump 220. Here, the vacuum supplied through the first vacuum pipe 400 and/or the second vacuum pipe 500 may be maintained (operation S740) (e.g., to hold negative pressure in hot spots, vent remaining gases, or improve directional solidification, etc.). In an example, the controller 10 may vary the opening and closing time point of the valve 240a of the first pipe 202 and the valve 240b of the second pipe 204 among the first valves 240 (e.g., for zone-by-zone cooling, pulsed injection, or alternating coolant flows, etc.). The time point of supplying the coolant through the first pipe 202 and the time point of supplying coolant through the second pipe 204 may be determined in advance. For example, the time point of supplying the coolant may be determined for each part of the product to be cast based on casting analysis (e.g., thermal simulation, mold-filling analysis, or historical production data, etc.). In an example, the coolant may be supplied after a predetermined time delay following the pouring of molten metal (M). To prevent direct contact between the molten metal (M) and water before the molten metal (M) solidifies, water may be allowed to reach the molten metal (M) at the earliest possible time point after the molten metal (M) has solidified (e.g., based on temperature sensors, cooling curves, or microstructure prediction, etc.). The time point may be determined in advance through experimentation or analysis (e.g., pilot runs, test molds, or process simulations, etc.).

[0091] At operation S750, the cast product may be cooled while the coolant is supplied. Cooling may be completed after a predetermined period of time has elapsed (e.g., 30 seconds, 2 minutes, or 5 minutes depending on product thickness and alloy, etc.).

[0092] At operation S760, the cast product that has cooled and solidified may be removed from the mold 100. After removal, the cast product goes through a shake-out process, deburring, or initial quality checks (e.g., visual inspection, ultrasonic test, or hardness check, etc.), completing the manufacture of the product.

[0093] FIG. 8 shows an example computing system (e.g., a computing device of a casting apparatus or any other apparatus). One or more controllers, processors, etc. described herein, such as one or more components of the controller 10, or any other components and devices disclosed herein, may be implemented by or in the computing system as shown in FIG. 8.

[0094] A computing system 1000 may include at least one processor 1100, memory 1300, a user interface input device 1400, a user interface output device 1500, a storage 1600, and a network interface 1700, which are connected with each other via a bus 1200.

[0095] The processor 1100 may be a central processing unit (CPU) or a semiconductor device that processes instructions stored in the memory 1300 and/or the storage 1600. Each of the memory 1300 and the storage 1600 may include various types of volatile or nonvolatile storage media. For example, the memory 1300 may include a read-only memory (ROM) and a random-access memory (RAM).

[0096] Communication interface(s) (also referred to as communication device(s), communicator(s), communication module(s), communication unit(s), etc.), such as the network interface 1700, may allow software and/or data to be transferred between a device and one or more external devices, and/or between one or more components of a device. Communication interface(s) may include a receiver, a transmitter, a transceiver, a modem, a network interface and/or adapter (such as an Ethernet adapter), a radio transceiver, an antenna, a communication port, a Personal Computer Memory Card International Association (PCMCIA) slot and card, or the like. Software and data transferred via communication interface(s) may be in the form of signals, which may be electronic, electromagnetic, optical, infrared, or other signals capable of being received by communication interface(s). These signals may be provided to communication interface(s) via a communication path of a device, which may be implemented using, for example, wire or cable, fiber optics, a cellular link, a radio frequency (RF) link and/or other communications channels. Communication interface(s) may communicate using one or more communication protocols, such as Ethernet, Wi-Fi, near-field communication (NFC), Infrared Data Association (IrDA), Bluetooth, Bluetooth low energy (BLE), Zigbee, Long-Term Evolution (LTE), 5G New Radio (NR), vehicle-to-everything (V2X), a controller area network (CAN), or a local interconnect network (LIN), etc.

[0097] Accordingly, the operations of the method or algorithm described in connection with example embodiment(s) disclosed in the specification may be directly implemented with a hardware module, a software module, or a combination of the hardware module and the software module, which is executed by the processor 1100. The software module may reside on a storage medium (e.g., the memory 1300 and/or the storage 1600) such as RAM, a flash memory, ROM, an erasable and programmable ROM (EPROM), an electrically EPROM (EEPROM), a register, a hard disk drive, a removable disc, or a compact disc-ROM (CD-ROM).

[0098] The storage medium may be coupled to the processor 1100. The processor 1100 may read out information from the storage medium and may write information in the storage medium. Alternatively, the storage medium may be integrated with the processor 1100. The processor and storage medium may be implemented with an application specific integrated circuit (ASIC). The ASIC may be provided in a user terminal. Alternatively, the processor and storage medium may be implemented with separate components in the user terminal.

[0099] According to an example, a casting apparatus may include a mold. The mold may include a first mold and a second mold. A cavity may be defined by the first mold and the second mold. The mold may include a molten metal inlet connected to the cavity. The mold may include at least one first channel configured to allow coolant to flow or to form a vacuum.

[0100] In an example, the at least one first channel may extend through the mold and may be spaced apart from the cavity by a predetermined distance.

[0101] In an example, the casting apparatus may further include a pipe inserted into the at least one first channel, a fluid pump connected to the pipe and configured to supply the coolant to the pipe, and a first valve configured to allow or block a flow of the coolant through the pipe.

[0102] In an example, the casting apparatus may further include a pipe inserted into the at least one first channel, a vacuum pump connected to the pipe and configured to supply a vacuum to the pipe, and a second valve configured to allow or block a flow of the vacuum through the pipe.

[0103] In an example, the mold may further include at least one second channel configured to form a vacuum and extending through the mold to the cavity.

[0104] In an example, the casting apparatus may further include a first vacuum pipe inserted into the at least one second channel.

[0105] In an example, the casting apparatus may further include a first vacuum pipe inserted into the at least one second channel, and a vacuum pump connected to the first vacuum pipe and configured to supply a vacuum to the first vacuum pipe. The first vacuum pipe may be configured to communicate with the cavity through a sintered vent.

[0106] In an example, the casting apparatus may further include a second vacuum pipe inserted into the at least one second channel, and a vacuum pump connected to the second vacuum pipe and configured to supply a vacuum to the second vacuum pipe. The second vacuum pipe may be configured to communicate with the cavity through a riser disposed in the mold.

[0107] In an example, the mold may include sand and an inorganic binder.

[0108] In an example, the casting apparatus may further include a pipe inserted into the at least one first channel, a fluid pump connected to the pipe and configured to supply coolant to the pipe, a first vacuum pump connected to the pipe and configured to supply a vacuum to the pipe, a first valve configured to allow or block a flow of the coolant through the pipe, a second valve configured to allow or block a flow of the vacuum through the pipe, a first vacuum pipe inserted into at least one second channel configured to form a vacuum and extending through the mold to the cavity, a second vacuum pump connected to the first vacuum pipe and configured to form a vacuum in the first vacuum pipe, a first vacuum valve configured to allow or block a flow of the vacuum through the first vacuum pipe, and a controller configured to control operations of the fluid pump, the first vacuum pump, the second vacuum pump, the first valve, the second valve, and the first vacuum valve.

[0109] In an example, the controller may be configured to close the first valve, open the second valve, and operate the first vacuum pump at a predetermined first time point, and may be configured to open the first valve, close the second valve, and operate the fluid pump at a predetermined second time point.

[0110] In an example, the controller may be configured to close the first valve, open the second valve, and operate the first vacuum pump at a predetermined first time point, may be configured to open the first valve, close the second valve, and operate the fluid pump at a predetermined second time point, and may be configured to open the first vacuum valve and operate the second vacuum pump at the first time point.

[0111] In an example, the controller may be configured to close the first valve, open the second valve, and operate the first vacuum pump at a predetermined first time point, may be configured to open the first valve, close the second valve, and operate the fluid pump at a predetermined second time point, and may be configured to, at the first time point, open the first vacuum valve, operate the second vacuum pump, and maintain the first vacuum valve open after the second valve is closed.

[0112] In an example, the casting apparatus may further include a second vacuum pipe inserted into the second channel and configured to form a vacuum by the second vacuum pump, wherein the second vacuum pipe is configured to communicate with the cavity through a riser disposed in the mold, and a second vacuum valve configured to allow or block a flow of the vacuum through the second vacuum pipe. The controller may be configured to close the first valve, open the second valve, and operate the first vacuum pump at a predetermined first time point, may be configured to open the first valve, close the second valve, and operate the fluid pump at a predetermined second time point, and may be configured to open the first vacuum valve and the second vacuum valve and operate the second vacuum pump at the first time point.

[0113] According to an example, a casting method may include forming a vacuum in a pipe extending through a mold including a cavity, pouring molten metal into the cavity, supplying coolant through the pipe after ending the forming the vacuum in the pipe, and removing a cast product formed in the mold after a predetermined period of time has elapsed.

[0114] In an example, the casting method may further include, prior to the pouring molten metal, forming a vacuum in a first vacuum pipe extending through the mold to the cavity.

[0115] In an example, the forming the vacuum in the first vacuum pipe may include maintaining the vacuum through the first vacuum pipe while supplying the coolant.

[0116] In an example, the casting method may further include, prior to the pouring molten metal, forming a vacuum in a second vacuum pipe connected to the cavity through a riser disposed in the mold.

[0117] In an example, the forming the vacuum in the second vacuum pipe may include maintaining the vacuum through the second vacuum pipe while supplying the coolant.

[0118] In an example, the pipe may include a first pipe disposed at a first position in the mold and a second pipe disposed at a second position in the mold. The supplying coolant may include supplying the coolant through the first pipe at a predetermined first time point, and supplying the coolant through the second pipe at a predetermined second time point.

[0119] According to the present disclosure, the mechanical properties of components made by sand casting may be improved. Cooling performance may be enhanced by increasing the cooling rate of the cast product through the pipe that is configured to supply coolant to the mold. A casting process may lack a separate cooling device and only allow for slow cooling of cast products. However, the disclosed example enables rapid cooling of the cast product. Such enhanced cooling performance may, for example, refine the aluminum structure and improve mechanical properties such as elongation and strength. In experiments, it was confirmed that the structure size was reduced by approximately 20%, elongation was improved by over 150%, and strength was increased by approximately 8%.

[0120] According to the present disclosure, by adjusting the cooling timing or cooling time for each part of the product being cast, the deviation among parts of the product may be reduced. Moreover, the flow rate of the coolant may also be adjusted.

[0121] According to the present disclosure, it is possible to obtain products having a small thickness by casting. By supplying a vacuum during casting, back pressure within the mold is eliminated and the fluidity of the molten metal is improved, enabling a reduction in the thickness of the case product. While the minimum thickness of cast products was approximately 4 millimeters (mm), the casting apparatus and method of the present disclosure enable obtaining products having a thickness of 3 mm.

[0122] According to the present disclosure, the range of components applicable to sand casting may be expanded. Cast components lacked sufficient physical properties (elongation), making it difficult to apply the casting process to vehicle body components requiring high elongation. However, according to the present disclosure, as described above, sand casting may be applied to vehicle body components requiring high elongation (e.g., 8% or above) for shock absorption or heterogeneous bonding owing to the increased elongation.

[0123] In the present disclosure, terms such as first and/or second may be used to distinguish one component from another. For example, a first component may be termed a second component, and similarly, a second component may be termed a first component.

[0124] In the present disclosure, the singular form may include the plural sense, unless specified otherwise.

[0125] In the present disclosure, it will be understood that, when a component is referred to as being connected to or coupled to another component, the component may be directly connected to or coupled to the other component, or intermediate components may also be present. In contrast, when a component is referred to as being directly connected to or directly brought into contact with another component, there is no intermediate component present. Other terms used to describe relationships between components such as between versus directly between and adjacent versus directly adjacent may be interpreted in the same manner.

[0126] As is apparent from the above description, the present disclosure provides the following effects.

[0127] According to the present disclosure, a casting apparatus and method capable of increasing the cooling rate of a cast product manufactured by a casting process are provided.

[0128] According to the present disclosure, a casting apparatus and method capable of improving the mechanical properties of a cast product manufactured by a casting process are provided.

[0129] Effects of the present disclosure are not limited to what has been described above, and other effects not mentioned herein will be clearly recognized by those skilled in the art based on the above description.

[0130] It will be apparent to those of ordinary skill in the art to which the present disclosure pertains that the present disclosure described above is not limited by the above-described examples and the accompanying drawings, and various substitutions, modifications and changes are possible within a range that does not depart from the technical idea of the present disclosure.