Method for producing ready-to-use casting shells or core assembl

Details Method for producing ready-to-use casting shells or core assembl Method for producing ready-to-use casting shells or core assembl

1996-06-03

1998-01-27

Batten, Jr., J. Reed

Metal founding

Process

Shaping a forming surface

164 20, 164 28, 164186, 164200, B22C 910, B22C 1308

Patent

active

057113610

DESCRIPTION:

BRIEF SUMMARY
The invention relates to an apparatus for making ready-to-pour shells or core assemblies, the apparatus comprising at least two in-line core shooting machines or shooting stations, the core shooting machines being provided with two, slightly differing sets of molds or tools, each set consisting of an upper tool and a lower tool, and with identical transfer components or conveyor plates that serve on the one hand as the lower tool of the first core shooting machine and on the other hand for transporting the core or core assembly along a transfer path through the apparatus. Furthermore, the invention relates to a method of making ready-to-pour shells or core assemblies with an apparatus of the present invention.
Basically, the present invention relates to the field of foundry practice. To produce castings, foundry cores or foundry molds are generally made as separate parts, combined and joined together to form a casting mold or core assembly. Thereafter, these core assemblies are filled with molten metal for producing, for example, a metallic workpiece. In mass production, the core assemblies filled with molten metal pass one after the other through the production line.
Apparatus for making core assemblies of the kind under discussion are known already from numerous publications. Only byway of example, reference is made in this connection to DE-OS 23 04 564. Further known from practice is to make the cores that are to be joined to a core assembly in a production line comprising several core shooting machines or shooting stations, a further core being added to the core assembly at each shooting station. To this end, the cores are deposited on a conveyor plate passing through the individual shooting stations, this conveyor plate serving simultaneously as the lower tool of the first shooting station.
The core sands used to make the core assemblies are always mixed with binding agents, which cause considerable soiling of the tools, namely the upper tool and the lower tool. As a result, it is necessary to clean the tools after a certain number of operating cycles and to exchange them at the shooting stations for this purpose. However, in practice such a tool change is extremely problematic, since the tools of the individual shooting stations and, thus, the cores produced therein are exactly adapted to one another. In other words, the contours of the cores being stacked upon their production by one set of tools are adapted to one another, so as to rest against each other. The slightest deviations In contours of adjoining surfaces of the cores being stacked would cause considerable tensions to occur during the stacking, so that it is very likely that the cores would break.
When in the known apparatus a set of tools is exchanged because of soiling, it will be necessary to remove altogether the conveyor plates being in the line with the already finished cores thereon as rejects, since for the aforesaid reasons, it is no longer possible to further add to the previously produced cores the cores that are produced by the exchanged tool set, due to slightest deviations in the contours of the tool surfaces and, thus, also in the surfaces of the cores produced therewith. In other words, in the known apparatus, it will always be necessary to restart the entire production line after completion of a tool change, and to remove or separate cores being in the production line. Apart from the waste of material caused by the rejects, this will involve a considerable loss of time and, thus, reduce the capacity of the production quite significantly, which again will substantially increase the costs of each core assembly.
German Patent No. 43 18 259 addresses the foregoing problem, and it discloses a method and apparatus wherein the tools of a first set are exchanged jointly, i.e. at the same time, at all shooting stations for the tools of a second set. The alternative arrangement to the teaching claimed therein is designed and constructed such that at least one parking station for the conveyor plate with the cores loaded thereon is as

REFERENCES:
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patent: 5014766 (1991-05-01), Weber
patent: 5072775 (1991-12-01), Hale et al.
patent: 5242008 (1993-09-01), Rommel et al.

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