WO2007121875A1

WO2007121875A1 - Moulding block for series-casting of workpieces

Info

Publication number: WO2007121875A1
Application number: PCT/EP2007/003282
Authority: WO
Inventors: Xaver Stemmer
Original assignee: Audi Ag
Priority date: 2006-04-18
Filing date: 2007-04-13
Publication date: 2007-11-01
Also published as: DE102006017922A1

Abstract

The invention relates to a moulding block consisting of a moulding billet which comprises several serially arranged moulding blocks for the series-casting of parts, especially combustion engine components, wherein adjoining moulding blocks in a lost form retrofit to at least one of the form openings intended for the production of a part. It is intended that at least one of the form blocks (1) consists of several separate moulding block workpieces (3, 4, 5, 6, 28, 43, 44, 54, 66). In addition, the invention relates to the production method of a moulding block and the use thereof.

Description

Mold block for serial casting of workpieces

The invention relates to a molding block of a mold series consisting of a plurality of serially arranged mold blocks for the series casting of workpieces, in particular combustion engine components, wherein adjacent mold blocks complement each other to form a lost shape with at least one mold cavity serving to form a workpiece.

Such a mold block for use in a boxless molding line is known. In this molding system mold blocks are produced in succession and arranged serially, with the particular horizontally extending mold string results for the series casting. The mold blocks are designed so that each complementary to the beginning of the mold string back of a mold block and the front of the subsequent mold block of the mold string to form a complementary. The resulting molds are lost molds, the mold blocks are mostly made of a mineral granules and a binder. For example, if the mold blocks are made at a fixed station, each mold block is attached to the end of the mold string after manufacture and the mold string is advanced accordingly. In the feed direction behind the station for the production of the mold blocks is a casting station for the serial casting of castings. The binder is usually chosen so that it is destroyed by the temperature generated during the casting process and the molds then decay. If this is not or only partially the case, the mold blocks are mechanically destroyed at a further, lying in the feed direction behind the casting station station and removed the casting. In a further machining process arise from the castings, for example, by post-processing in which, for example, excess material is removed, the workpieces. If you work with a stationary mold string, the individual stations are moved accordingly. The insertion of the mold blocks is done for example with an automatic loading device and the series casting by a Vergießeinrichtung, so that the production of castings on the boxless molding plant is very inexpensive. The construction of the molds from each two adjacent one-piece mold blocks makes the automation quite simple, but limits the ability to create more complex castings.

In the mold blocks according to the invention, at least one of the mold blocks is composed of a plurality of separate mold block parts. Such a thing Compound mold block makes it possible to create more complex castings on a boxless molding line. The different shape block parts can be manufactured individually depending on the required imaging accuracy of a surface portion of the casting.

According to a development of the invention it is provided that at least two of the mold block parts of the same mold block are arranged horizontally next to each other transversely to the orientation of the mold string. The mold block parts can be arranged directly adjacent thereto and, for example, completely form the part of the mold cavity which is assigned to the corresponding mold block. However, the horizontally juxtaposed mold block parts can also form side walls of the mold block, between which further mold block parts or parts of further mold block parts are arranged. The horizontal juxtaposed blocks form, for example, the end portions of the mold cavity.

Furthermore, it may be advantageous if at least two of the mold block parts of the same mold block are formed one behind the other along the orientation of the mold string. Such a composition of the molding block of mold block parts may be advantageous in a workpiece shape which can not be realized by a two-part mold.

It may be advantageous if at least one of the mold block parts is arranged over at least one other of the mold block parts of the same mold block.

According to a development of the invention, it is provided that at least two of the mold block parts are positively connected. A positive connection between the mold block parts increases the stability of the individual mold block, which can be handled easier after assembly. If the form fit results in a sufficiently inherently stable mold block, it can be assembled separately and then attached to the end of the mold string. The positive connection can counteract the casting process during the subsequent casting process and ensure the stability of the molding block during the casting process.

It is advantageous if at least two of the mold block parts of the same mold block are positively connected in a direction extending transversely to the orientation of the mold strand. In the case of a form fit transversely to the orientation of the mold string, in particular the component of the casting pressure arising during casting is counteracted. knitted, which can not be compensated by the mass of the molding blocks surrounding the mold block.

According to a development of the invention, it is provided that at least two of the mold block parts of the same mold block are positively connected in a direction running along the orientation of the mold strand. The positive engagement of the mold block parts along the orientation of the mold string stabilizes the molded block composed of mold block parts in this direction, so that the mold blocks can be assembled in a first step and then attached to the end of the mold string.

In addition, it is provided that the mold block parts of at least one mold block are connected by positive weight of the upper mold block part and / or an additional weight vertically. In superimposed mold block parts can additionally or alternatively to a positive connection in the vertical direction hold a force fit by gravity the mold block. In this case, the weight of the upper mold block part and / or an additional weight, which is placed for example on the upper mold block part can be used.

According to a development of the invention it is provided that adjacent mold blocks are positively connected in a direction transverse to the orientation of the mold strand direction. The positive connection can be ensured, for example, by pins on the front of the mold block, which engage in corresponding recesses of the adjacent mold block, so that the mold blocks forming the shape are exactly aligned and results in a guide in the advance of the mold string.

Furthermore, it can be advantageous if adjacent shaped blocks, in particular with regard to their shape, are designed differently. A different configuration of adjacent mold blocks results, for example, when cast in alternation at least two different mold cavities. In this case, different workpieces can be formed or the mold cavity periodically alternately aligned, for example, to form a workpiece with optimized space utilization.

According to a development of the invention, it is provided that at least one of the mold block parts of the mold block is at least partially associated with at least one further mold block. A strict assignment of the mold block parts to one of the mold blocks It is not absolutely necessary that individual mold block parts can extend over several mold blocks.

According to a development of the invention it is provided that in at least one of the mold blocks is at least one associated with him only mold cavity. By means of such a further mold cavity, it is possible to cast in a mold at least two workpieces arranged one behind the other in alignment of the mold string.

Furthermore, it can be advantageous if each of the mold block parts is shaped cavity-forming. Particularly in the case of workpieces with a complex structure, a plurality of mold block parts forming the shape of a cavity are required, so that it is favorable to keep the total number of mold block parts low in that each of the mold block parts is shaped cavity-forming.

Preferably, the mold block parts consist in particular of compacted sand and in particular temperaturunbeständigem binder. This combination of materials is preferred in lost forms, as can be made of these low-cost materials stable shapes that are destroyed by the high temperature during the casting process.

In particular, it is provided that adjacent mold blocks are held against each other by adhesion. In the direction of the mold string, the mass of the juxtaposed mold blocks ensures a frictional connection, which counteracts the resulting casting pressure in the direction of the mold string.

In addition, any use of a mold block according to the invention for the production of workpieces, in particular engine components falls within the scope of the appended claims.

The invention further relates to a method for producing a molding block of a mold series consisting of a plurality of serially arranged mold blocks for the serial casting of workpieces, in particular combustion engine components, wherein adjacent mold blocks complement each other to form a lost shape with at least one mold cavity serving to form a workpiece. It is provided that at least one of the mold blocks is composed of a plurality of separate mold block parts. Finally, it is provided that the mold block parts are assembled so that they result in a coherent mold block by form and / or adhesion. For this purpose, the individual mold block parts are successively joined together so that with the onset of the last mold block part all mold block parts are connected so that they can withstand the casting pressure arising during casting.

The invention will be explained in more detail in an embodiment with reference to the accompanying drawings. Show it:

FIG. 1 shows a composition of a molding block subassembly which forms a bottom of a molding block subassembly

Form mold blocks,

FIG. 2 shows a pre-assembly of sub-group elements of a molding block part designed as an intermediate core,

FIG. 3 shows a retraction of the molding block part designed as an intermediate core,

FIG. 4 shows a swiveling in of two mold block parts designed as front side cores,

FIG. 5 shows a pre-assembly of sub-group elements of a mold block part designed as a separating core,

FIG. 6 shows a retraction of the mold block part designed as a separating core,

FIG. 7 shows a pre-assembly of sub-group elements of a shaped block part designed as a lid,

Figure 8 is a placement of the formed as a lid mold block part on the mold block and

Figure 9 shows a completely assembled mold block for the series casting of two crankcases.

Figures 1 to 9 show the structure of a mold block 1 for a series casting of two crankcases for two-cylinder four-cylinder engines with a single casting on one not shown, boxless molding plant, in which form a plurality of serially arranged mold blocks 1 a mold string, not shown.

A single mold block 1 has as a base on a bottom 2 shown in Figure 1, which is formed by four mold block parts 3, 4, 5, 6. The mold block parts 3, 4, 5, 6 are aligned with their longitudinal axes in the direction of the mold string, not shown, and arranged horizontally next to one another transversely to the alignment of the mold string (arrow 7) to each other. The mold block parts 3, 4, 5, 6 each consist of one, the bottom 2 of the mold block 1 forming bottom portion 8, 9, 10, 11 and two in the direction of the mold strand, not shown (arrow 7) spaced from each other aligned molding portions 12 to 19, the each have a cylindrical upper end portion 20. The molding portions 12, 13, 14, 15 together form a mold portion 21, the mold portions 16, 17, 18, 19 together form a mold portion 22, wherein the mold portions 21, 22 determine the shape of each crankcase of the two resulting during casting crankcase. In opposite side regions 23, 24 of the bottom 2, which are assigned to the bottom regions 8, 11, there are recesses 25 and recesses 26, which can only be seen in the side region 24 in the figures. Between the mold regions 21, 22, in the case of the assembled mold block 1, directly above the bottom regions 8, 9, 10, 11, there is a mold block part 28 designed as an intermediate core 27 (see FIG. 3). The intermediate core 27 aligned transversely to the longitudinal sides of the mold block parts 3, 4, 5, 6 has a planar upper side 29, two partially planar, partially cavity-forming end faces 30, 31 and two longitudinal side regions 32, 33 which also face the mold regions 21, 22 , On the longitudinal side region 32 facing the molding region 21, two subgroup elements 34, 35 are arranged (see FIG. 2). On the longitudinal side region 33 opposite the longitudinal side region 33 of the intermediate core 27 there are two further subgroup elements 36, 37. On an underside 38 opposite the upper side 29, the intermediate core 27 has an edge region 39, 40 at the level of the side regions 31, 32. 3 shows the installation position of the intermediate core 27 within the molding block 1. The intermediate core 27 spans all mold block parts 3, 4, 5, 6 of the bottom 2 and engages with the edge regions 39, 40 of its underside 38 in the recesses 25 of the bottom regions 8, 11th Figure 4 shows the bottom 2 and the intermediate core 27 together with two adjacent to the end faces 30, 31 of the intermediate core 27, formed as front side cores 41, 42 mold block parts 43, 44. The front side cores 41, 42 have on their undersides 45, 46 rear handles 47, in which the recesses 26 of the bottom regions 8, 11 engage and connect the front side cores 41, 42 with the bottom 2 in a form-fitting manner. The front pages 30, 31 of the intermediate core 27 are inner sides 48, 49 of the front side cores 41, 42 facing, which are partially formmitbildend. On two the undersides 45, 46 opposite upper sides 50, 51 of the front side cores 41, 42 are each a plurality of pins 52. In the direction of the mold string (arrow 7), not shown behind the bottom 2 and the side cores 41, 42 is immediately thereafter as Separating core 53, which is oriented transversely to the longitudinal sides of the mold block parts 3, 4, 5, 6, has a bottom region 55, two plane end faces 56, 57 and a longitudinal side region 58 which also faces the cavity 22 and also faces the mold region 22 a subgroup element 59 is arranged (see FIG. 5). A further sub-group element 61 is located on a longitudinal side region 60 of the separating core 53 opposite the longitudinal side region 58. The longitudinal side region 60 and the sub-group element 61 together with a subsequent shaping block, not shown, form the following mold cavity of the molding strand. At a top surface 55 opposite the bottom surface 55, the separating core 53 has a plurality of pins 63. Back grips 64 in the bottom area 55 and on the front sides 56, 57 engage in corresponding structures of the Stimseitenkeme 41, 42 and the bottom 2 and ensure positive engagement (see Figure 6). FIG. 7 shows the composition of a last mold block part 66 designed as a cover 65 with two subassembly elements 67, 68, wherein the cover 65 shown in FIG. 7 is turned upside down by 180 ° relative to its installation position within the mold block 1, so that its underside 69 is cylindrical Form elements 70 to 77 of the lid 65 can be seen. The sub-group element 67 surrounds the mold elements 70 to 73 and the sub-group element 68 surrounds the mold elements 74 to 77. In the direction of the mold string (arrow 7), not shown in front of the mold elements 70 to 73 are on the front side of the lid 65 frustoconical pin 78, the in Recesses of the aligned in alignment (arrow 7) mold block of the mold string, not shown, engage. Recesses 79 are located behind the mold elements 74 to 77 on the underside 69, and recesses 82 are located in the lateral edge regions 80, 81. An elongate recess 83 is located between the mold elements 70 to 73 and the mold elements 74 to 77. FIG. 8 shows The cylindrical shaped elements 70 to 77 are based on the cylindrical end regions 20 of the mold sections 12 to 19 of the mold block parts 3, 4, 5, 6. The pins 52 of the front side cores 41, 42 as well as the pins 63 of the separating core 53 engage positively in the recesses 79, 82 of the formed as a lid 65 mold block part 66. The top 29 of the intermediate core 27 engages in the recess 83 of the lid 65 and also forms a positive connection. FIG. 9 shows the completely assembled molding block 1, which with its front 84 is brought to the back of another, not shown mold block, so that a shape is formed. The mold has in this embodiment two serving to form two crankcases, not shown, mold cavities lying in alignment of the mold string (arrow 7), not shown, one behind the other. The corresponding feeders of the mold, which are located in the lid 65 of the mold block 1, are not shown in the figures.

The following, five successive steps for mounting a mold block 1 for a series casting of two crankcases for in-line four-cylinder engines with only one shape: First, (step 1), the four mold block parts 3, 4, 5, 6 transversely to the orientation of the shown mold string (arrow 7) pushed together (arrow 85), wherein the bottom 2 of the mold block 1 is formed (see Figure 1). In a pre-assembly step shown in FIG. 2, the subgroup elements 34, 35, 36, 37 are positioned on the longitudinal side regions 32, 33 of the intermediate core 27 (arrow 86). According to Figure 3 (step 2), the preassembled intermediate core 27 between the two mold portions 21, 22 retracted to the bottom 2 (arrow 87), wherein the edge portions 39, 40 of the intermediate core 27 in recesses 25 of the bottom portions 8 and 11 engage and provide a positive connection that connects the mold block parts 3 to 6 firmly. Subsequently, in a third assembly step, the front side cores 41, 42 placed directly on the bottom portion 8, 11, wherein the rear handle 47 of the end side cores 41, 42 engage in the recesses 26 of the bottom portions 8, 11 and then in the direction of the end faces 30, 31 of the intermediate core 27 pivoted in (arrow 88). In a preassembly step shown in FIG. 5, the subgroup elements 59, 61 are mounted on the longitudinal side regions 58, 60 (arrow 89). Subsequently, in the fourth assembly step, a preassembled separating core 53 is moved up to the end of the forming region 22 (arrow 90), wherein the separating core 53 engages with undercut 64 in structures of the bottom 2 and the front side cores 41, 42 and separates the forming block 1 from a subsequent forming block, not shown , For pre-assembly of the lid 65, the sub-group elements 67, 68 mounted on the bottom 69 of the lid 65 (arrow 91) that they surround the mold elements 70 to 77 of the lid 65. Subsequently, in a fifth assembly step, the lid 65 as the last mold block part 66 of the mold block 1 is placed on the upper sides 50, 51 of the end face 41, 42 and the upper sides 29, 62 of the intermediate core 27 and the separating core 53 (arrow 92). The pins 52 and 63 and the top 29 of the intermediate core 27 engage in the recesses 79, 82 and 83 of the lid 65. The lid 65 ensures a positive connection of all other mold block parts 3, 4, 5, 6, 28, 43, 44, 54, where he himself horizontally also form-fitting and is vertically connected by its weight force frictionally connected to the rest of the mold block 1.

FIG. 9 shows the completely assembled molding block 1 for the series casting of two crankcases for in-line four-cylinder engines with only one mold on a boxless molding installation (not shown). On the front side 83 of the lid 65, which faces the end of the mold string, not shown, there are truncated conical pins 78, which engage in recesses of a preceding mold block of the mold string, not shown, so that the two mold blocks 1 are exactly aligned and together form a precisely fitting mold 84.

NOT FURNISHED UPON FILING

Subgroup element Subgroup element Subgroup element Subgroup element Bottom Edge area Edge area Face core Face core Form block part Block shape Bottom side Bottom handle Back inside Inside top Top top Tenon Separator core Form block part Bottom area End face Front side Longitudinal side section Subgroup element Longitudinal side subgroup element Top side Tenon Rear grip Lid Form block part Subgroup element Subgroup element Bottom Form element 71 molded element

72 shaped element

73 form element

74 shaped element

75 form element

76 shaped element

77 molded element

78 cones

79 recess

80 border area

81 border area

82 recess

83 recess

84 front side

85 arrow

86 arrow

87 arrow

88 arrow

89 arrow

90 arrow

91 arrow

92 arrow

Claims

PAT EN TA NSPR O CHE

1. molding block of a plurality of serially arranged mold blocks existing mold string for the series casting of workpieces, in particular combustion engine components, wherein adjacent mold blocks complement each other to form a lost mold with at least one forming a workpiece cavity, characterized in that at least one of the mold blocks (1) is composed of several separate mold block parts (3,4,5,6,28,43,44,54,66).

2. mold block according to claim 1, characterized in that at least two of the mold block parts (3,4,5,6,28,43,44,54,66) of the same mold block (1) are arranged horizontally side by side transversely to the orientation of the mold string.

3. mold block according to one of the preceding claims, characterized in that at least two of the mold block parts (3,4,5,6,28,43,44,54,66) of the same mold block (1) are arranged one behind the other along the orientation of the mold string ,

4. mold block according to one of the preceding claims, characterized in that at least one of the mold block parts (3,4,5,6,28,43,44,54,66) on at least one other of the mold block parts (3,4,5,6 , 28, 43, 44, 54, 66) of the same mold block (1).

5. mold block according to one of the preceding claims, characterized in that at least two of the mold block parts (3,4,5,6,28,43,44,54,66) are positively connected.

A mold block according to any one of the preceding claims, characterized in that at least two of the mold block parts (3,4,5,6,28,43,44,54,66) of the same mold block (1) extend in a direction transverse to the orientation of the mold string Direction are positively connected.

7. mold block according to one of the preceding claims, characterized in that at least two of the mold block parts (3,4,5,6,28,43,44,54,66) of the same Chen mold block (1) are positively connected in a direction extending along the alignment of the mold strand direction.

8. mold block according to one of the preceding claims, characterized in that the mold block parts (3,4,5,6,28,43,44,54,66) at least one mold block (1) vertically by own weight of the upper mold block part (28,43 , 44, 54, 66) and / or an additional weight are non-positively connected.

9. mold block according to one of the preceding claims, characterized in that adjacent mold blocks (1) are positively connected in a direction transverse to the orientation of the mold strand direction.

10. mold block according to one of the preceding claims, characterized in that adjacent mold blocks (1) are formed differently in particular with respect to their shape.

11. Molding block according to one of the preceding claims, characterized in that at least one of the mold block parts (3,4,5,6,28,43,44,54,66) of the mold block (1) at least one further mold block (1) at least partially assigned.

12. Molding block according to one of the preceding claims, characterized in that in at least one of the mold blocks (1) is at least one associated with him only mold cavity.

13. Molding block according to one of the preceding claims, characterized in that each of the mold block parts (3,4,5,6,28,43,44,54,66) is formhohlraummit forming.

14. Molding block according to one of the preceding claims, characterized in that the mold block parts (3,4,5,6,28,43,44,54,66) consist in particular compacted sand and in particular temperaturunbeständigem binder.

15. Molding block according to one of the preceding claims, characterized in that adjacent mold blocks (1) are held by adhesion to each other.

16. Use of a molding block according to one of claims 1 to 15 for the production of workpieces, in particular engine components, in the series casting.

17. A method for producing a molding block of a mold series consisting of a plurality of serially arranged mold blocks for the series casting of workpieces, in particular combustion engine components, wherein adjacent mold blocks to form a lost mold with at least one forming the formation of a workpiece cavity, characterized in that at least one of Mold blocks of several, separate mold block parts is assembled.

18. A method for producing a molding block according to claim 17, characterized in that the mold block parts are assembled so that they result in a coherent mold block by form and / or adhesion.