Method of and apparatus for vacuum casting

• US 5,431,212 A
• Filed: 07/06/1994
• Issued: 07/11/1995
• Est. Priority Date: 07/20/1993
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Uozumi, Minoru, Arakawa, Yasuyuki, Hasegawa, Tamotsu, Ota, Atushi
• Primary Examiner(s): BATTEN JR, J REED
• Application Number:
  US08/267,901
• Time in Patent Office: 370 Days
• Field of Search: 164/63, 164/119, 164/120, 164/254, 164/306, 164/309
• US Class Current: 164/63
• CPC Class Codes: B22D 18/06 Vacuum casting, i.e. making use of vacuum to fill the mould

Abstract

In a method of vacuum casting wherein when the molten metal previously introduced into a molten metal reservoir is fed into a cavity, the lowest head of the molten metal in the molten metal reservoir is held to be higher than the level of a sprue, so that the cycle time of casting may be shortened and the quality of cast products may be improved. To this end, the interior of the molten metal reservoir is held gas tight while the sprue is opened by a gate member of straight tubular shape.

Claims

1. A method of vacuum casting comprising:

a first step of closing, with a gate member, a sprue of a cavity formed in a die;

a second step of feeding molten metal stored in a molten metal storage tank through a molten metal passage to a molten metal reservoir which is communicated with the sprue through the gate member and is also communicated with the molten metal storage tank via the molten metal passage, until the lowest head of the molten metal fed into the molten metal reservoir becomes higher than the level of the sprue;

a third step of reducing the pressure in the cavity, the third step being executed either before, simultaneously with or after the second step;

a fourth step of communicating the sprue with the molten metal reservoir and also with the molten metal passage by moving the gate member when the pressure in the cavity has been reduced to a predetermined pressure; and

a fifth step of having the interior of the molten metal reservoir isolated from the atmosphere and held gas tight while the molten metal having been fed into the molten metal reservoir is introduced into the cavity as a result of the communication brought about in the fourth step between the sprue and the molten metal reservoir, with the lowest head of molten metal in the reservoir being held to be higher than the level of the sprue during this time.

2. The method of vacuum casting according to claim 1 further comprising a step of lowering an insertion member which is slidable through the molten metal reservoir, which has an atmosphere communication hole and which forms the top wall of the molten metal reservoir, down to a level right above the head of the molten metal having been fed into the molten metal reservoir in the second step, and then closing the atmosphere communication hole, said further step being executed between the second and fourth steps.

3. The method of vacuum casting according to claim 1 further comprising a step of lowering an insertion member which is slidable through the molten metal reservoir, which has an atmosphere communication hole and which forms the top wall of the molten metal reservoir, down to a level right above the head of the molten metal having been fed into the molten metal reservoir in the second step, then closing the atmosphere communication hole and then raising the insertion member up to a predetermined level, said further step being executed between the second and fourth steps.

4. The method of vacuum casting according to claim 1 further comprising a step of solidifying the head of the molten metal having been fed into the molten metal reservoir in the second step, said further step being executed between the second and fourth steps.

5. The method of vacuum casting according to claim 4, wherein the solidifying step includes a step of lowering a plug member which is slidable through the molten metal reservoir and which forms the top wall of the molten metal reservoir until the plug member is brought into contact with the head of molten metal, thus cooling the head with the plug member.

6. The method of vacuum casting according to claim 1, wherein the second step includes:

a first sub-step of communicating the molten metal reservoir with the atmosphere; and

a second sub-step of applying pressure to the head of molten metal in the molten metal storage tank.

7. The method of vacuum casting according to claim 6 further comprising a step of tentatively increasing the pressure applied to the head of molten metal in the molten metal storage tank, said further step being executed simultaneously with the fourth step.

8. The method of vacuum casting according to claim 1, wherein the second step includes a step of feeding molten metal in the molten metal storage tank into the molten metal reservoir by reducing the pressure in the molten metal reservoir.

9. The method of vacuum casting according to claim 1, wherein the molten metal is fed into the molten metal reservoir in the second step such that the head of molten metal in the molten metal reservoir satisfies the following relation:

space="preserve" listing-type="equation">Molten metal head=(Sprue level)+(Cavity volume)/(Sectional area of molten metal reservoir)+(50 to 150 mm).

10. An apparatus for vacuum casting comprising:

a die having an internal cavity;

a gate member for switching a sprue of the cavity between a closed state and an open state;

a molten metal storage tank for storing molten metal;

a molten metal passage communicated with the molten metal storage tank;

a molten metal reservoir communicated with the sprue via the gate member and also communicated with the molten metal passage;

a change-over valve operable to be switched between a state to hold the molten metal reservoir interior gas tight and a state not to hold the molten metal reservoir interior gas tight;

an evacuating pump for reducing the pressure in the cavity;

molten metal introducing means for introducing the molten metal in the molten metal storage tank through the molten metal passage into the molten metal reservoir with the sprue held closed by the gate member and the molten metal reservoir interior not held gas tight by the change-over valve, the molten metal being introduced until the lowest head of molten metal introduced into the molten metal reservoir becomes higher than the level of the sprue; and

gate member drive means for switching the gate member to an open state after the pressure in the cavity has been reduced to a predetermined pressure by the evacuating pump, molten metal has been introduced by the molten metal introducing means into the molten metal reservoir, and the change-over valve has been switched to hold the molten metal reservoir interior gas tight.

11. The apparatus for vacuum casting according to claim 10, wherein the molten metal reservoir is formed by a cylindrical member having a uniform sectional area, the cylindrical member also serving as the gate member.

12. The apparatus for vacuum casting according to claim 11 further comprising an insertion member slidable through the cylindrical member, having an atmosphere communication hole and forming the top wall of the molten metal reservoir, the insertion member being lowered down to a level right above the head of introduced molten metal after the introduction thereof by the molten metal introducing means, the atmosphere communication hole being closed after the reaching of that level by the insertion member.

13. The apparatus for vacuum casting according to claim 11 further comprising an insertion member slidable through the cylindrical member, having an atmosphere communication hole and forming the top wall of the molten metal reservoir, the insertion member being lowered down to a level right above the head of introduced molten metal after the introduction thereof by the molten metal introducing means, the atmosphere communication hole being closed after the reaching of that level by the insertion member, the insertion member being raised up to a predetermined level after the closing of the atmosphere communication hole.

14. The apparatus for vacuum casting according to claim 11 further comprising a plug member slidable through the cylindrical member, the plug member being lowered until it is in contact with introduced molten metal to cool the head thereof after the molten metal has been introduced into the molten metal reservoir by the molten metal introducing means.

15. The apparatus for vacuum casting according to claim 10 further comprising pressurizing means for applying pressure to the head of molten metal in the molten metal storage tank, the pressurizing means being driven while the change-over valve is not holding the molten metal reservoir gas tight.

16. The apparatus for vacuum casting according to claim 15 further comprising pressure increasing means for increasing the pressure applied to the head by the pressurizing means in synchronism with the driving timing of the gate member drive means.

17. The apparatus for vacuum casting according to claim 10, wherein:

the change-over valve is switched between a state of holding the molten metal reservoir interior isolated from the atmosphere and gas tight and a state of communicating the molten metal reservoir interior with the pressure reducing means; and

the change-over valve holds the molten metal reservoir interior with the pressure reducing means while the sprue is held closed by the gate member and maintains this state until the molten metal having been introduced into the cavity is solidified.