Process for introducing cores into a casting mold

Details Process for introducing cores into a casting mold Process for introducing cores into a casting mold

1997-06-25

1999-12-21

Pyon, Harold

Metal founding

Process

Shaping liquid metal against a forming surface

164339, 164186, 164228, 164368, B22D 3304, B22C 910

Patent

active

060035889

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

Until now it was standard in foundry practice, in particular in the gray iron practice, to insert cores manually into one of the form boxes of the casting mold, comprised of at least two form boxes, which are designed for the production of thin-walled castings, e.g. motor blocks. In particular for the production of motor blocks made of gray iron, increasingly higher requirements must be met with respect to complexity of the motor block, weight savings, accuracy of measurements and surface quality. With respect to core production, this makes it necessary to produce cores with the highest possible filigree and with a very complex geometry, thereby reducing the subsequent processing of the motor blocks to a minimum. It has proven useful in this case to design the respective motor block such that bores, openings or the like, which so far had to be added in a subsequent processing step, are added from the start during the casting process. Owing to this, neighboring cores must have corresponding projections, which "hold open" these openings in the casting mold. However, it has turned out in this connection that burrs develop at the produced openings as a result of unavoidable wear and tear and as a result of deviations in the accuracy that are also unavoidable, especially in this area of contact between neighboring cores. These burrs must subsequently be reworked following the removal of the casting from the mold. It is the object of the invention to create a process that simplifies the insertion of the cores into such a casting mold and avoids a costly subsequent reworking.


SUMMARY OF THE INVENTION

The solution according to the invention lies in that the individual cores are introduced into a template, that the contiguous cores that form a core group are connected to one another in the template via bracing and securing means, that the group of connected cores is dipped into a founder's black bath and is dried, and that the dried core group is inserted into the casting mold and the bracing is subsequently released. Using this process has the advantage that at least some of the cores forming the core group are respectively provided with core prints, which can be designed such that on the one hand they make contact with each other and, on the other hand, they project over the actual, forming core surface to form corresponding contact surfaces, so that the cores in this case can be braced against each other with the aid of a corresponding bracing means, which is frame-shaped for example, can be mutually braced and secured to each other and thus can be handled as one unit. It is useful if the contact surfaces of the cores that touch each other are provided with a so-called green adhesive to further improve the cohesion. If this core group is dipped into a founder's black bath in accordance with the inventive process, and if this founder's black is dried following the draining off, then the unavoidable, relatively thin gaps in the region of the contact surfaces of adjoining individual cores are filled with the founder's black, thereby avoiding the formation of burrs. The core group is subsequently transported further with the aid of the bracing and securing means and is inserted into the prepared casting mold, e.g. a lower box, so that following the release of the bracing means, the upper box can be fitted on and the casting operation can proceed in the standard way.
Depending on the design of the casting to be produced, it is possible based on the inventive process to connect individual cores to each other to form a core group or also to combine several core groups to form a core set as a core assembly for a casting mold and to perform the individual process steps while they are braced in this way until they are inserted into the casting mold. This provides the option of handling even very complex core groups in this manner. It is also possible to connect projections provided for individual core parts, which until now were inserted individually into a casting mold, with the associated

REFERENCES:
patent: 4273182 (1981-06-01), Winterhalter et al.
patent: 4809763 (1989-03-01), Schilling
patent: 5730200 (1998-03-01), Landna

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