Method for casting

• US 9,415,441 B2
• Filed: 06/17/2014
• Issued: 08/16/2016
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: KSM Castings Group GmbH (CITIC Corp. Ltd.), Fill Gesellschaft mbH
• Original Assignee: KSM Castings Group GmbH (CITIC Corp. Ltd.), Fill Gesellschaft mbH
• Inventors: Golz, Roland, Landgraf, Frank, Heinecke, Sven, Maerz, Ingo, Oppelt, Holger, Boindecker, Alois, Rathner, Thomas, Schneeberger, Alexander, Wiesinger, Alois
• Primary Examiner(s): Kerns, Kevin P
• Application Number:
  US14/306,452
• Publication Number:
  US 20140294664A1
• Time in Patent Office: 791 Days
• Field of Search: 164/61, 164/119, 164/306, 164/253, 164/254, 164/256
• US Class Current: 1/1
• CPC Class Codes: B22D 18/00 Pressure casting; Vacuum casting B22D17/00 takes precedence; treating the metal in the mould by using pressure or vacuum B22D27/00
• CPC Class Codes: B22D 18/04 Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
• CPC Class Codes: B22D 18/06 Vacuum casting, i.e. making use of vacuum to fill the mould
• CPC Class Codes: B22D 18/08 Controlling, supervising, e.g. for safety reasons controlling or regulating in general G05
• CPC Class Codes: B22D 47/00 Casting plants

Abstract

A system and a method for casting under pressure pivots an upper casting mold half out of a horizontal position into an approximately vertical position, in such a manner that the inside surface of the casting mold half can be treated in work-facilitating and time-saving manner, preferably by a person.

Claims

1. Pressure-casting method using a system the pressure-casting method comprising steps of:

conveying a melt through a riser of a casting apparatus of the system,

filling with the melt a cavity of a casting mold,

solidifying in the cavity the melt such that a cast piece is formed,

following the solidifying, removing the cast piece from the casting mold, and

supplying pressure to a lower pressure space or to a lower chamber of the casting apparatus by way of a first valve and a second valve switched in parallel, in each instance,

wherein the first valve is for main filling of the lower pressure space or of the lower chamber,

wherein the second valve is for a more precise pressure adjustment within the lower pressure space or within the lower chamber, and

wherein the first valve is larger than the second valve.

2. Pressure-casting method according to claim 1, further comprising steps of:

after the removing of the cast piece, pivoting at least one of a lower casting mold half and an upper casting mold half of the casting apparatus out of a horizontal position and into a treatment position, and

treating on inside surface of the at least one of the lower casting mold half and the upper casting mold half when the at least one of the lower casting mold half and the upper casting mold half is in the treatment position.

3. Pressure-casting method according to claim 2, wherein the pivoting occurs about a pivot axis that runs horizontally and runs on a side of the casting apparatus.

4. Pressure-casting method according to claim 2, wherein the pivoting occurs over a pivoting angle of up to 135°

.

5. Pressure-casting method according to claim 2, wherein the pivoting comprises pivoting the upper casting mold half downward and/or pivoting the lower casting mold half upward.

6. Pressure-casting method according to claim 1, further comprising a step of:

supplying pressure to an upper pressure space of the casting apparatus by way of a third valve and a fourth valve switched in parallel, in each instance,

wherein the third valve is for main filling of the upper pressure space,

wherein the fourth valve is for a more precise pressure adjustment within the upper pressure space, and

wherein the third valve is larger than the fourth valve.

7. Pressure-casting method according to claim 6, wherein the system comprises a second per-control for regulating of the third and fourth valves,

wherein the second pre-control is implemented as a characteristic field or as a mathematical mold, and

wherein the method further comprises steps of:

filling the upper pressure space by opening the fourth valve to about 40 to 60%,

then applying to the third valve a reference value from the second pre-control, corrected by a pre-set through-flow of the fourth valve, and

finally, regulating the pressure of the pressure space precisely, using the third valve.

8. Pressure-casting method according to claim 1, wherein the system comprises a first pre-control for regulating the pressure that is supplied, in each instance,

wherein the first per-control is implemented as a characteristic field or as a mathematical model, and

wherein the method further comprises steps of:

filling the lower pressure or the lower chamber by first opening the second valve to about 40 to 60%,

then applying to the first valve a reference value from the first pre-control, corrected by a pre-set through-flow of the second valve, and

finally, regulating the pressure precisely, using the second valve.

9. Pressure-casting method according to claim 1, wherein the method is a partial vacuum casting method.

10. Pressure-casting method, according to claim 1, wherein the method is a tilt casting method.

11. Pressure-casting method according to claim 1, further comprising a step of producing at least one member selected from the group consisting of suspension links, longitudinal suspension links, transverse suspension links, corner castings, node castings, frames, swivel bearings, wheel mounts, axle journals, and injection pump housings.

12. Pressure-casting method according to claim 1, further comprising a step of producing at least one high-stress safety component.

13. Pressure-casting method according to claim 1, further comprising a step of producing at least one component from the application sector of chassis casting selected from the group consisting of swivel bearings, wheel mounts, axle journals, and injection pump housings.

14. Pressure-casting method according to claim 1, further comprising a step of producing a chassis part.

15. Pressure-casting method according to claim 1, further comprising a step of producing chassis components or safety components from light metal or a light-metal alloy.

16. Pressure-casting method according to claim 1, wherein a furnace of the casting apparatus is disposed in a lower, hermetically sealable chamber.

17. Pressure-casting method according to claim 1, wherein the casting mold is disposed in an upper, hermetically sealable chamber.

18. Pressure-casting method according to claim 1, wherein the pressure-casting method is a counter-pressure casting method.

19. Pressure-casting method using a system, the method comprising steps of:

introducing a melt into a cavity of a permanent casting mold of a casting apparatus of the system, under the effect of a pressure,

solidifying in the cavity the melt such that a cast piece is formed,

removing the cast piece from the permanent casting mold, and

preparing for a new casting cycle by either

(A)

removing from the casting apparatus a first furnace via a carriage, after the removing of the cast piece,

conveying the carriage along a rail system such that the first furnace is brought via the carriage to a readiness position,

discharging the first furnace at a free location of the readiness position,

providing a second furnace having melt,

picking up the second furnace via the carriage,

conveying the second furnace to the casting apparatus via the carriage, and

transferring the second furnace to the casting apparatus,

or

(B)

moving a carriage along a rail system to the casting apparatus, the carriage comprising a first furnace positioning location and a second furnace positioning location, a filled furnace being disposed in the first furnace positioning location, the filled furnace having melt, the second furnace positioning location being free,

picking up in the second furnace positioning location a first furnace from the casting apparatus,

subsequent to the picking up, transferring from the first furnace positioning location to the casting apparatus the filling furnace,

moving the carriage along the rail system to a free location of a readiness position, and

transferring from the carriage to the free location the first furnace.

20. Pressure-casting method according to claim 19, further comprising steps of:

after the removal of the cast piece, pivoting at least one casting mold part into a treatment position, the at least one casting mold part being of the casting apparatus and comprising a casting mold half, and

treating an inside surface of the at least one casting mold part when the at least one casting mold part is in the treatment position.

21. Pressure-casting method using a system, the method comprising steps of:

introducing a melt into a cavity of a permanent casting mold of a casting apparatus of the system, under the effect of a pressure,

solidifying in the cavity the melt such that a cast piece is formed,

removing the cast piece from the permanent casting mold, and

preparing for a new casting cycle by either

(A)

removing a first casting mold or a first casting mold half from the casting apparatus via a carriage,

conveying the carriage along a rail system such that the first casting mold casting mold or the first casting mold half is brought to a free location of a readiness position,

discharging the first casting mold or the first casting mold half from the carriage to the free location for temporary storage of replacement,

directly subsequent to the discharging, picking up a second casting mold or a second casting mold half via the carriage,

conveying the carriage along the rail system to the casting apparatus, and

transferring from the carriage to the casting apparatus the second casting mold or the second casting mold half,

or

(B)

moving a carriage to the casting apparatus, the carriage comprising a first mold positioning location and a second mold positioning location, a new casting mold or a new casting mold half being disposed in the first mold positioning location, the second mold positioning location being free,

picking up in the second mold positioning location a worn-out casting mold or a worn-out casting mold half from the casting apparatus,

subsequent to the picking up, transferring from the first mold positioning location to the casting apparatus the new casting mold or the new casting mold half, and

moving the carriage along with the worn-out casting mold or along with the worn-out casting mold half for further use.