Metal founding – Process – Shaping liquid metal against a forming surface
Patent
1997-11-13
1998-11-24
Batten, Jr., J. Reed
Metal founding
Process
Shaping liquid metal against a forming surface
164120, 164312, 164319, B22D 1712, B22D 1722
Patent
active
058394974
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a vertical die casting method and apparatus for casting and charging a melt into a mold cavity from below the mold in order to obtain a cast product, e.g., an aluminum wheel.
BACKGROUND ART
To obtain a cast product, e.g., aluminum wheel, which requires a high strength by die casting, a vertical die casting machine is often used in order to prevent inclusion of air in the melt when the melt is to be cast.
In a method of casting an automobile aluminum wheel by using a vertical die casting machine, it is already known that casting is performed by using a gate having a diameter smaller than the inner diameter of the casting sleeve, and a unit in which a pressure pin having a diameter slightly smaller than the inner diameter of the gate can be projected into and retracted from an upper movable mold toward the lower gate, as shown in, e.g., Japanese Patent Publication No. 3-4297 (Japanese Patent Laid-Open No. 63-140747) and U.S. Pat. No. 4,840,557.
The major part of the apparatus described in Japanese Patent Publication No. 3-4297 or U.S. Pat. No. 4,840,557 is shown in FIG. 8.
Referring to FIG. 8, reference numeral 5 denotes a stationary mold serving as a lower mold; 6, a movable mold serving as an upper mold; 7, a casting sleeve joined to a casting port 25 of the stationary mold 5 from below; 12, a casting plunger; and 11, a plunger tip attached to the distal end portion of the plunger 12 and slidably arranged in the casting sleeve 7.
The upper surface of the plunger tip 11 is flat. A cooling water passage 61 is formed inside the plunger tip 11 between the outer circumferential surface and upper surface of a plunger insert block 60. A guide pipe 62 and passages 63 are formed in the axial portions of the plunger insert block 60 and plunger 12. The plunger tip 11 can be cooled by flowing cooling water to the guide pipe 62 and passages 63.
In the vertical die casting method, a stationary mold 5 having a gate 27 with a diameter smaller than that of the casting port 25 is often used in order to prevent an oxide from mixing in the melt and a chill layer formed in the melt on the inner surface portion of the casting sleeve 7 from mixing in a cavity 26, or because of the shape of the cast product, e.g., an aluminum wheel. Reference numeral 28 denotes a pressure pin arranged on the movable mold 6 side. After the melt is cast into the mold cavity 26, the pressure pin 28 is advanced downward to push the melt, and is moved downward to the gate 27 portion to cut apart solidified product portion and biscuit portion.
As shown in, e.g., Utility Model Publication No. 8-4198, it is also known that die casting is performed by using a center gate having a diameter smaller than the inner diameter of the casting sleeve, and a unit in which a center plunger that can enter the center gate can project into and retract from an outer plunger.
As shown in Japanese Patent Laid-Open No. 1-138051, it is known that, in a melt forging method of forging a melt by pushing a melt in a casting sleeve into an upper mold cavity through a gate with a plunger that can vertically move with respect to the casting sleeve, an apparatus is used in which the mold includes upper and lower molds vertically movable independently of each other, the plunger is formed as a double acting plunger consisting of an outer plunger and an inner plunger, and the gate has a diameter smaller than the diameter of the casting sleeve and larger than that of the inner plunger. First, the outer plunger and inner plunger are moved upward simultaneously to inject the melt in the casting sleeve into the cavity. Subsequently, the inner plunger is actuated to project into the gate, thus pressurizing the melt in the cavity. After the melt is solidified appropriately, the mold and the plunger are moved upward simultaneously toward the casting sleeve. When the mold and the plunger are moved upward to a predetermined height, upward movement of the lower mold and outer plunger is stopped and the upper mold and the inner plunger are mov
REFERENCES:
patent: 4337817 (1982-07-01), Komatsu et al.
patent: 4840557 (1989-06-01), Ishimoto et al.
Fujino Kiyoshi
Okamura Minoru
Batten, Jr. J. Reed
U-Mold Co., Ltd.
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