EP3164236B1 - Method and device for casting at least one component - Google Patents

Method and device for casting at least one component Download PDF

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Publication number
EP3164236B1
EP3164236B1 EP15729747.4A EP15729747A EP3164236B1 EP 3164236 B1 EP3164236 B1 EP 3164236B1 EP 15729747 A EP15729747 A EP 15729747A EP 3164236 B1 EP3164236 B1 EP 3164236B1
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European Patent Office
Prior art keywords
nozzle
component
mould
plug
mold
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EP15729747.4A
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German (de)
French (fr)
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EP3164236A1 (en
Inventor
Christian PLATZER
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Ltc GmbH
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Ltc GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2272—Sprue channels
    • B22D17/2281—Sprue channels closure devices therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2023—Nozzles or shot sleeves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2038—Heating, cooling or lubricating the injection unit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2061—Means for forcing the molten metal into the die using screws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium

Definitions

  • the invention relates to a method for casting at least one component, wherein flowable material, in particular magnesium or a magnesium alloy in the thixotropic state, to form the at least one component is injected under pressure into a cavity of a multi-part mold via at least one nozzle, after which the component is in the The mold is allowed to solidify, with a particularly solid plug forming in the nozzle, whereupon the mold is opened and the at least one component is removed, after which the mold is closed and the next component is created.
  • flowable material in particular magnesium or a magnesium alloy in the thixotropic state
  • the invention relates to a device for casting at least one metallic component with a conveying device for material in the flowable state, in particular magnesium or a magnesium alloy in the thixotropic state, and at least one nozzle with a heating device and a multi-part mold which has at least one cavity for the having creating component, wherein the material for forming the at least one component can be injected into the at least one cavity of the mold via the conveying device and the downstream downstream at least one nozzle and the mold can be opened to remove the at least one component after it has solidified in order to Component and closing the mold to start a new creation cycle.
  • magnesium and magnesium-based alloys are also used, since magnesium and corresponding alloys, in addition to mechanical parameters that are sufficient for many areas, have the advantage of a low density and thus a low weight of components.
  • Magnesium and magnesium-based alloys can in particular be processed using die-casting technology. Under certain circumstances, however, this can lead to problems, especially if burn-off, oxidation and / or segregation of alloy additives occur in a crucible. In such cases, so-called thixo injection molding or thixomolding, which works in a closed process sequence, has proven itself.
  • magnesium is heated up to a transition temperature for the phase transition from solid to liquid and at this temperature is transported by a conveyor to a downstream nozzle. In this state there are fine crystallites surrounded by melt.
  • the conveying means is usually designed as a screw, which is located in the so-called barrel or is held in it. In the barrel, the material is transported by propulsion with the screw to the nozzle, which in turn is integrated in a part of a multi-part mold.
  • the multi-part mold is generally designed in two parts, the part opposite the part integrating the nozzle having one or more cavities for the component or components to be produced. The second part of the mold is mounted so that it can be moved so that the mold can be repeatedly opened and closed for removing and manufacturing components.
  • thixotropic material is injected at high pressure via the barrel and the nozzle, so that the cavities are completely filled.
  • injection molding takes place at a single point, from which the sections to be filled lead to the individual cavities.
  • the components can be allowed to solidify.
  • the mold is then opened and the components removed, which can then be separated. If there is only one cavity or if only a (larger) component is to be created, the procedure is analogous, with the cavity then being filled with the flowable material at several points.
  • Patent documents WO2013067567 , DE10239817 , DE69637088 , WO2007028265 , US2005006046 disclose such methods of die casting thixotropic material.
  • the material in the nozzle solidifies due to heat transfer from the mold, which is at this stage to a temperature below the temperature level of the melt, as well as the material solidifying in the mold, so that a plug usually forms.
  • This plug formation is not only desirable, but also necessary so that when the mold is opened later and when magnesium is replenished, magnesium does not escape freely in the area of the nozzle or the gate, which of course is not desired.
  • the plug is ejected by a correspondingly high pressure.
  • a Well which receives the plug and is referred to as a plug catcher.
  • a plug catcher receives the plug and is referred to as a plug catcher.
  • problems are also associated with it.
  • the plug leads to the fact that enormous forces act at the beginning of the shooting due to the counterpressure generated in the barrel. It is believed that the pressure splash in the barrel caused by the plug significantly limits its lifespan. This is where the invention comes into play.
  • the object of the invention is to provide a method of the type mentioned at the outset and a device suitably designed for this purpose, in which component production can take place under more gentle conditions for the device.
  • the procedural object is achieved by a method according to claim 1 and a suitable device according to claim 5 for implementing such a method.
  • the method-related object is achieved if, in a method of the type mentioned at the beginning, the nozzle is heated with the mold open in order to at least soften the plug formed in the nozzle before the next component is produced.
  • a heating power at the nozzle is set in such a way that the plug softens without material entering the cavity. After the mold has been closed, the heating power at the nozzle can then be increased. In this state, the plug in particular can be fully melted because any material can only enter the closed mold and thus the cavities. It can furthermore be expedient that a heating power at the nozzle is reduced when the component is allowed to solidify, so that the temperature falls below a temperature for plug formation in the nozzle. Overall, a controlled temperature control at or in the nozzle can thus achieve an optimal situation with regard to plug formation on the one hand and plug dissolution on the other hand, without any restrictions with regard to quality or quality Cycle duration would have to be accepted. Rather, a heating and, if necessary, cooling program can be specifically and variably adapted to the individual steps of a creation cycle including injection, opening of the mold and component removal, mold cleaning and release agent application and closing of the mold for a new injection.
  • the further aim is achieved if, in a device of the type mentioned at the beginning, a control is provided for the heating device which variably controls a temperature on or in the nozzle as a function of the status of the creation cycle.
  • the temperature at or in the nozzle can be controlled in such a way that, according to the above statements, optimal conditions for plug formation before opening the mold and plug softening and / or plug dissolution before the next injection of material always result .
  • any heating elements that can be controlled accordingly can be used.
  • the heating device is a resistance heater, since inductive heating of the at least one nozzle, which is ultimately an integral part of a part of a mold, including the required control, can be implemented with difficulty. With resistance heating, on the other hand, this is possible in a relatively simple manner.
  • the heating device can comprise a plurality of resistance heating elements that can be controlled separately from one another.
  • the nozzle is made of hot-work steel. This allows the temperature in the nozzle, which is essential, to be controlled particularly precisely.
  • the heating device is soldered to the at least one nozzle in order to ensure efficient heat transfer.
  • the heating device is arranged in depressions on the outside of the at least one nozzle. In fact, it has also proven to be particularly useful, again for good heat transfer and thus rapid temperature setting on or in the nozzle, when the heating device is arranged in depressions on the outside of the at least one nozzle.
  • the heating device can run spirally around the at least one nozzle.
  • a device 5 which is designed for thixomolding of components made of magnesium or a magnesium alloy.
  • the device 5 comprises a container 6 in which the material 1 to be processed is kept in stock in the form of granules.
  • Material 1 is conveyed from container 6 into a filler neck 7 via a conveying element such as a suction conveyor. Via the filler neck 7, the material 1 reaches a barrel 8 which is provided with a screw with a corresponding drive.
  • the barrel 8 is kept at a suitable temperature by means of a heater, so that the material 1 assumes a thixotropic state or, in this state, is transported to a downstream nozzle 2.
  • the nozzle 2 is integrated in a first part 9 of a mold.
  • a second part 10 of the mold lies opposite the first part 9 of the mold and is horizontally displaceable so that the mold can be opened, for example in order to remove components produced by means of a robot arm 11.
  • the nozzle 2 of the device 5 is subjected to a temperature program which, without extending the cycle time, leads to lower pressure peaks in the barrel 8 and thus significantly increases its service life.
  • the variable temperature control at or in the nozzle 2 is in Fig. 3 shown for one creation cycle.
  • the nozzle 2 is subjected to maximum heating power so that the material 1 can flow freely through the nozzle 2. This corresponds to state A.
  • the heating power can be reduced in a first section of the nozzle 2, which is closer to a gate, as indicated by a changed hatching in the heating device 4 is shown. This corresponds to state B.
  • a plug 3 then forms in the nozzle 2 in that area which is at the beginning of the nozzle 2. Cooling may be useful for plug formation, but does not necessarily have to be implemented. Since the mold is cooled in order to solidify the component (s) and magnesium has good thermal conductivity, the plug 3 can in principle also form when the nozzle 2 is heated further, albeit at a reduced rate. When the mold is opened and the component is removed, the plug 3 breaks off in the area of the nozzle 2, but remains essentially intact. This corresponds to state C. The mold is still open, but the heating device 4 can already operate at a higher power in order to soften the plug 3. This corresponds to state D. As soon as the mold is closed again, the heating device 4 can be operated at full power, so that the plug 3 ideally melts completely.
  • a structure of a nozzle 2 including heating device 4 is shown, which is particularly suitable for these purposes.
  • the heating device 4 is designed as a resistance heater, the heating device 4 extending in a spiral shape around the nozzle 2 and being soldered into depressions on the outside of the nozzle 2.
  • the nozzle 2 itself usually consists of a steel, in particular a hot-work steel.
  • the intimate connection of the heating device 4 to the nozzle 2 enables rapid heat transfer to be achieved, which enables the times of the usual injection processes to be adhered to.
  • the heating device 4 with the nozzle 2 can be integrated relatively easily into the first part 9 of the mold.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Gießen zumindest eines Bauteils, wobei fließfähiges Material, insbesondere Magnesium oder eine Magnesiumlegierung im thixotropen Zustand, zur Bildung des zumindest einen Bauteils über zumindest eine Düse unter Druck in eine Kavität einer mehrteiligen Form eingespritzt wird, wonach das Bauteil in der Form erstarren gelassen wird, wobei sich in der Düse ein insbesondere fester Pfropfen bildet, worauf die Form geöffnet und das zumindest eine Bauteil entnommen wird, wonach die Form geschlossen und das nächste Bauteil erstellt wird.The invention relates to a method for casting at least one component, wherein flowable material, in particular magnesium or a magnesium alloy in the thixotropic state, to form the at least one component is injected under pressure into a cavity of a multi-part mold via at least one nozzle, after which the component is in the The mold is allowed to solidify, with a particularly solid plug forming in the nozzle, whereupon the mold is opened and the at least one component is removed, after which the mold is closed and the next component is created.

Des Weiteren betrifft die Erfindung eine Vorrichtung zum Gießen zumindest eines metallischen Bauteils mit einer Fördereinrichtung für Material im fließfähigen Zustand, insbesondere Magnesium oder eine Magnesiumlegierung im thixotropen Zustand, und zumindest einer Düse mit einer Heizeinrichtung sowie einer mehrteiligen Form, welche zumindest eine Kavität für das zu erstellende Bauteil aufweist, wobei das Material zur Bildung des zumindest einen Bauteils über die Fördereinrichtung und die stromabwärts nachgeordnete zumindest eine Düse in die zumindest eine Kavität der Form einspritzbar und die Form zur Entnahme des zumindest einen Bauteils nach Erstarrung desselben öffenbar ist, um nach Erstellen des Bauteils und Schließen der Form einen neuen Erstellungszyklus zu beginnen.Furthermore, the invention relates to a device for casting at least one metallic component with a conveying device for material in the flowable state, in particular magnesium or a magnesium alloy in the thixotropic state, and at least one nozzle with a heating device and a multi-part mold which has at least one cavity for the having creating component, wherein the material for forming the at least one component can be injected into the at least one cavity of the mold via the conveying device and the downstream downstream at least one nozzle and the mold can be opened to remove the at least one component after it has solidified in order to Component and closing the mold to start a new creation cycle.

In der Automobilbranche sowie in der Luft- und Raumfahrt ist ein anhaltender Trend zu hoch belastbaren, gleichzeitig aber möglichst leichtgewichtigen Bauteilen gegeben. Neben Verbundwerkstoffen wird hier besonders auch auf Magnesium und Magnesiumbasislegierungen gesetzt, da Magnesium und entsprechende Legierungen neben für viele Bereiche ausreichenden mechanischen Kennwerten den Vorteil einer geringen Dichte und damit ein geringes Gewicht von Bauteilen mit sich bringen.In the automotive industry as well as in the aerospace industry, there is a sustained trend towards highly resilient, but at the same time as lightweight components as possible. In addition to composite materials, magnesium and magnesium-based alloys are also used, since magnesium and corresponding alloys, in addition to mechanical parameters that are sufficient for many areas, have the advantage of a low density and thus a low weight of components.

Magnesium und Magnesiumbasislegierungen können insbesondere mittels Druckgusstechnologie verarbeitet werden. Unter Umständen kann es dabei jedoch zu Problemen kommen, insbesondere wenn Abbrand, Oxidation und/oder Seigerungen von Legierungszusätzen in einem Schmelztiegel auftreten. In solchen Fällen bewährt sich das sogenannte Thixospritzgießen bzw. Thixomolding, das in einem geschlossenen Prozessablauf arbeitet.Magnesium and magnesium-based alloys can in particular be processed using die-casting technology. Under certain circumstances, however, this can lead to problems, especially if burn-off, oxidation and / or segregation of alloy additives occur in a crucible. In such cases, so-called thixo injection molding or thixomolding, which works in a closed process sequence, has proven itself.

Beim Thixomolding wird Magnesium bis auf eine Übergangstemperatur für den Phasenübergang von fest zu flüssig erhitzt und auf dieser Temperatur mit einem Fördermittel zu einer stromabwärts nachgeordneten Düse transportiert. In diesem Zustand liegen feine Kristallite umgeben von Schmelze vor. Für eine entsprechende Ausbildung des zu spritzenden Materials wird bei Magnesiumbasislegierungen zwischen der Soliduslinie und der Liquiduslinie gearbeitet. Das Fördermittel ist in der Regel als Schnecke ausgeführt, die sich im sogenannten Barrel befindet bzw. in diesem gehalten ist. Im Barrel wird das Material durch Vortrieb mit der Schnecke zur Düse transportiert, welche wiederum in einem Teil einer mehrteiligen Form integriert ist. Die mehrteilige Form ist in der Regel zweiteilig ausgebildet, wobei jenes Teil, welches dem die Düse integrierenden Teil gegenüberliegt, eine oder mehrere Kavitäten für das oder die zu erstellenden Bauteile aufweist. Das zweite Teil der Form ist dabei verschiebbar gelagert, sodass die Form zur Entnahme und Fertigung von Bauteilen wiederholt geöffnet und geschlossen werden kann.In thixomolding, magnesium is heated up to a transition temperature for the phase transition from solid to liquid and at this temperature is transported by a conveyor to a downstream nozzle. In this state there are fine crystallites surrounded by melt. For an appropriate design of the material to be sprayed, work is carried out with magnesium-based alloys between the solidus line and the liquidus line. The conveying means is usually designed as a screw, which is located in the so-called barrel or is held in it. In the barrel, the material is transported by propulsion with the screw to the nozzle, which in turn is integrated in a part of a multi-part mold. The multi-part mold is generally designed in two parts, the part opposite the part integrating the nozzle having one or more cavities for the component or components to be produced. The second part of the mold is mounted so that it can be moved so that the mold can be repeatedly opened and closed for removing and manufacturing components.

Bei einem entsprechenden Thixomoldingverfahren wird bei geschlossener Form über das Barrel und die Düse thixotropes Material mit hohem Druck eingespritzt, sodass die Kavitäten vollständig gefüllt werden. Hierbei wird in einem einzelnen Punkt angespritzt, von dem zu füllende Strecken zu den einzelnen Kavitäten führen. Sind die Kavitäten gefüllt, können die Bauteile erstarren gelassen werden. Anschließend wird die Form geöffnet und die Bauteile entnommen, die dann abgetrennt werden können. Ist nur eine Kavität vorhanden bzw. nur ein (größerer) Bauteil zu erstellen, wird analog vorgegangen, wobei die Kavität dann an mehreren Stellen mit dem fließfähigen Material gefüllt wird. Patentdokumente WO2013067567 , DE10239817 , DE69637088 , WO2007028265 , US2005006046 offenbaren solche Verfahren des Druckgießens von thixotropen Material.In a corresponding thixomolding process, with the mold closed, thixotropic material is injected at high pressure via the barrel and the nozzle, so that the cavities are completely filled. In this case, injection molding takes place at a single point, from which the sections to be filled lead to the individual cavities. If the cavities are filled, the components can be allowed to solidify. The mold is then opened and the components removed, which can then be separated. If there is only one cavity or if only a (larger) component is to be created, the procedure is analogous, with the cavity then being filled with the flowable material at several points. Patent documents WO2013067567 , DE10239817 , DE69637088 , WO2007028265 , US2005006046 disclose such methods of die casting thixotropic material.

Während der Erstarrung der Bauteile in den Kavitäten verfestigt sich aufgrund eines Wärmetransportes von der in diesem Stadium auf eine unter das Temperaturniveau der Schmelze temperierten Form sowie des in der Form erstarrenden Materials auch das Material in der Düse, sodass sich in der Regel ein Pfropfen bildet. Diese Pfropfenbildung ist nicht nur erwünscht, sondern auch notwendig, damit beim späteren Öffnen der Form und beim Nachdosieren von Magnesium nicht Magnesium frei im Bereich der Düse bzw. des Angusspunktes austritt, was selbstverständlich nicht gewünscht ist. Beim nächsten Einspritzen, wenn also neues Material in die Form und damit auch die Kavitäten eingespritzt wird, wird der Pfropfen durch entsprechend hohen Druck ausgeschossen. Hierfür ist in der Form im Bereich des Anschusspunktes in vielen Anwendungen eine Vertiefung vorgesehen, welche den Pfropfen aufnimmt und als Pfropfenfänger bezeichnet wird.
Wenngleich die Ausbildung eines Pfropfens im Laufe eines Zyklus wie erwähnt wünschenswert ist, so gehen damit doch auch Probleme einher. Insbesondere führt der Pfropfen dazu, dass bei Beginn des Anschießens aufgrund des erzeugten Gegendruckes im Barrel enorme Kräfte wirken. Es wird vermutet, dass die durch den Pfropfen verursachten Druckspritzen im Barrel die Lebensdauer desselben signifikant begrenzen. Hier setzt die Erfindung an. Aufgabe der Erfindung ist es, ein Verfahren der eingangs genannten Art und eine hierfür geeignet ausgelegte Vorrichtung anzugeben, wobei eine Bauteilfertigung unter schonenderen Bedingungen für die Vorrichtung erfolgen kann.During the solidification of the components in the cavities, the material in the nozzle solidifies due to heat transfer from the mold, which is at this stage to a temperature below the temperature level of the melt, as well as the material solidifying in the mold, so that a plug usually forms. This plug formation is not only desirable, but also necessary so that when the mold is opened later and when magnesium is replenished, magnesium does not escape freely in the area of the nozzle or the gate, which of course is not desired. During the next injection, i.e. when new material is injected into the mold and thus also into the cavities, the plug is ejected by a correspondingly high pressure. For this purpose, there is in the form in the area of the connection point in many applications a Well provided, which receives the plug and is referred to as a plug catcher.
Although the formation of a plug in the course of a cycle is desirable, as mentioned, problems are also associated with it. In particular, the plug leads to the fact that enormous forces act at the beginning of the shooting due to the counterpressure generated in the barrel. It is believed that the pressure splash in the barrel caused by the plug significantly limits its lifespan. This is where the invention comes into play. The object of the invention is to provide a method of the type mentioned at the outset and a device suitably designed for this purpose, in which component production can take place under more gentle conditions for the device.

Die verfahrensmäßige Aufgabe wird durch ein Verfahren nach Anspruch 1 und eine geeignete Vorrichtung nach Anspruch 5 zur Implementierung eines solchen Verfahrens gelöst. Speziell wird die verfahrensmäßige Aufgabe gelöst, wenn bei einem Verfahren der eingangs genannten Art die Düse bei geöffneter Form beheizt wird, um den in der Düse gebildeten Pfropfen vor dem Erstellen des nächsten Bauteils zumindest zu erweichen.
Ein mit der Erfindung erzielter Vorteil ist insbesondere darin zu sehen, dass der Pfropfen wie im Stand der Technik zwar gebildet wird und damit während einer Öffnung der Form für die gewünschte Dichtheit sorgt, allerdings bereits in diesem Zustand ohne Verlust der Dichtwirkung aktiv erwärmt wird, sodass bei der Erstellung des nächsten Bauteils ein Gegendruck durch den Pfropfen wesentlich geringer ist als bislang.
Insbesondere kann vorgesehen sein, dass nach Öffnen der Form eine Heizleistung an der Düse so eingestellt wird, dass der Pfropfen ohne Eintritt von Material in die Kavität erweicht. Nach Schließen der Form kann dann die Heizleistung an der Düse gesteigert werden. In diesem Zustand kann insbesondere der Pfropfen voll aufgeschmolzen werden, weil allfälliges Material ohnedies nur in die geschlossene Form und damit die Kavitäten eintreten kann. Zweckmäßig kann es des Weiteren sein, dass eine Heizleistung an der Düse verringert wird, wenn das Bauteil erstarren gelassen wird, sodass eine Temperatur für eine Pfropfenbildung in der Düse unterschritten wird. Insgesamt lässt es sich somit durch eine kontrollierte Temperaturführung an bzw. in der Düse eine optimale Situation in Bezug auf eine Pfropfenbildung einerseits und eine Propfenauflösung andererseits erreichen, ohne dass irgendwelche Einschränkungen in Bezug auf eine Qualität oder eine Zyklusdauer hinzunehmen wären. Vielmehr kann ein Heiz- und gegebenenfalls Kühlprogramm gezielt und variabel auf die einzelnen Schritte eines Erstellungszyklus umfassend Einspritzen, Öffnen der Form und Bauteilentnahme, Formreinigung und Trennmittelauftrag sowie Schließen der Form für ein neuerliches Einspritzen abgestimmt werden.The procedural object is achieved by a method according to claim 1 and a suitable device according to claim 5 for implementing such a method. In particular, the method-related object is achieved if, in a method of the type mentioned at the beginning, the nozzle is heated with the mold open in order to at least soften the plug formed in the nozzle before the next component is produced.
An advantage achieved with the invention is to be seen in particular in the fact that the plug is formed as in the prior art and thus ensures the desired tightness when the mold is opened, but is actively heated in this state without loss of the sealing effect, so that When creating the next component, a counterpressure through the plug is significantly lower than before.
In particular, it can be provided that, after the mold has been opened, a heating power at the nozzle is set in such a way that the plug softens without material entering the cavity. After the mold has been closed, the heating power at the nozzle can then be increased. In this state, the plug in particular can be fully melted because any material can only enter the closed mold and thus the cavities. It can furthermore be expedient that a heating power at the nozzle is reduced when the component is allowed to solidify, so that the temperature falls below a temperature for plug formation in the nozzle. Overall, a controlled temperature control at or in the nozzle can thus achieve an optimal situation with regard to plug formation on the one hand and plug dissolution on the other hand, without any restrictions with regard to quality or quality Cycle duration would have to be accepted. Rather, a heating and, if necessary, cooling program can be specifically and variably adapted to the individual steps of a creation cycle including injection, opening of the mold and component removal, mold cleaning and release agent application and closing of the mold for a new injection.

Das weitere Ziel wird erreicht, wenn bei einer Vorrichtung der eingangs genannten Art eine Steuerung für die Heizeinrichtung vorgesehen ist, welche eine Temperatur an bzw. in der Düse in Abhängigkeit vom Status des Erstellungszyklus variabel steuert. Durch eine entsprechende vorrichtungsmäßige Auslegung lässt sich die Temperatur an bzw. in der Düse so steuern, dass entsprechend den vorstehenden Ausführungen während eines Erstellungszyklus stets optimale Bedingungen für eine Pfropfenbildung vor Öffnen der Form und eine Pfropfenerweichung und/oder Pfropfenauflösung vor dem nächsten Einspritzen von Material ergeben.The further aim is achieved if, in a device of the type mentioned at the beginning, a control is provided for the heating device which variably controls a temperature on or in the nozzle as a function of the status of the creation cycle. With an appropriate device design, the temperature at or in the nozzle can be controlled in such a way that, according to the above statements, optimal conditions for plug formation before opening the mold and plug softening and / or plug dissolution before the next injection of material always result .

Grundsätzlich können beliebige Heizelemente eingesetzt werden, die sich entsprechend steuern lassen. Allerdings ist es bevorzugt, dass die Heizeinrichtung eine Widerstandsheizung ist, da sich eine induktive Beheizung der zumindest einen Düse, die letztlich integraler Bestandteil eines Teils einer Form ist, einschließlich der erforderlichen Regelung schwierig umsetzen lässt. Mit einer Widerstandsheizung hingegen ist dies auf relativ einfache Weise möglich. Die Heizeinrichtung kann dabei mehrere voneinander getrennt steuerbare Widerstandsheizelemente umfassen.In principle, any heating elements that can be controlled accordingly can be used. However, it is preferred that the heating device is a resistance heater, since inductive heating of the at least one nozzle, which is ultimately an integral part of a part of a mold, including the required control, can be implemented with difficulty. With resistance heating, on the other hand, this is possible in a relatively simple manner. The heating device can comprise a plurality of resistance heating elements that can be controlled separately from one another.

Die Düse ist aus Warmarbeitsstahl gebildet. Dadurch lässt sich die Temperatur in der Düse, auf die es wesentlich ankommt, besonders exakt steuern. Hierfür ist die Heizeinrichtung an der zumindest einen Düse angelötet, um eine effiziente Wärmeübertragung sicherzustellen.The nozzle is made of hot-work steel. This allows the temperature in the nozzle, which is essential, to be controlled particularly precisely. For this purpose, the heating device is soldered to the at least one nozzle in order to ensure efficient heat transfer.

Die Heizeinrichtung ist in außenseitigen Vertiefungen der zumindest einen Düse angeordnet. In der Tat hat es sich auch als besonders bewährt, wiederum für eine gute Wärmeübertragung und damit rasche Temperatureinstellung an bzw. in der Düse, wenn die Heizeinrichtung in außenseitigen Vertiefungen der zumindest einen Düse angeordnet ist. Dabei kann die Heizeinrichtung spiralförmig um die zumindest eine Düse verlaufen.The heating device is arranged in depressions on the outside of the at least one nozzle. In fact, it has also proven to be particularly useful, again for good heat transfer and thus rapid temperature setting on or in the nozzle, when the heating device is arranged in depressions on the outside of the at least one nozzle. The heating device can run spirally around the at least one nozzle.

Weitere Merkmale, Vorteile und Wirkungen ergeben sich aus dem nachfolgend dargestellten Ausführungsbeispiel. In den Zeichnungen, auf welche dabei Bezug genommen wird, zeigen:

Fig. 1
eine Thixomoldingvorrichtung;
Fig. 2
Abläufe während eines Erstellungszyklus;
Fig. 3
eine schematische Darstellung der Vorgänge in einer Düse während eines Erstellungszyklus gemäß Fig. 2;
Fig. 4
eine Düse.
Further features, advantages and effects result from the exemplary embodiment shown below. In the drawings to which reference is made:
Fig. 1
a thixomolding device;
Fig. 2
Processes during a creation cycle;
Fig. 3
a schematic representation of the processes in a nozzle during a creation cycle according to FIG Fig. 2 ;
Fig. 4
a nozzle.

In Fig. 1 ist eine Vorrichtung 5 dargestellt, die für ein Thixomolding von Bauteilen aus Magnesium oder eine Magnesiumlegierung ausgelegt ist. Die Vorrichtung 5 umfasst einen Behälter 6, in dem das zu verarbeitende Material 1 in Granulatform vorrätig gehalten ist. Über ein Förderelement wie einen Saugförderer wird Material 1 aus dem Behälter 6 in einen Einfüllstutzen 7 gefördert. Über den Einfüllstutzen 7 gelangt das Material 1 in ein Barrel 8, das mit einer Schnecke mit entsprechendem Antrieb versehen ist. Das Barrel 8 wird durch eine Heizung auf einer geeigneten Temperatur gehalten, sodass das Material 1 einen thixotropen Zustand annimmt bzw. in diesem Zustand zu einer stromabwärts nachgeordneten Düse 2 transportiert wird. Die Düse 2 ist in einem ersten Teil 9 einer Form integriert. Ein zweiter Teil 10 der Form liegt dem ersten Teil 9 der Form gegenüber und ist horizontal verschiebbar, sodass die Form geöffnet werden kann, beispielsweise um mittels eines Roboterarmes 11 erstellte Bauteile zu entnehmen.In Fig. 1 a device 5 is shown which is designed for thixomolding of components made of magnesium or a magnesium alloy. The device 5 comprises a container 6 in which the material 1 to be processed is kept in stock in the form of granules. Material 1 is conveyed from container 6 into a filler neck 7 via a conveying element such as a suction conveyor. Via the filler neck 7, the material 1 reaches a barrel 8 which is provided with a screw with a corresponding drive. The barrel 8 is kept at a suitable temperature by means of a heater, so that the material 1 assumes a thixotropic state or, in this state, is transported to a downstream nozzle 2. The nozzle 2 is integrated in a first part 9 of a mold. A second part 10 of the mold lies opposite the first part 9 of the mold and is horizontally displaceable so that the mold can be opened, for example in order to remove components produced by means of a robot arm 11.

Bei der Erstellung eines Bauteils wird gemäß dem Schema nach Fig. 2 vorgegangen. Bei geschlossener Form wird über das Barrel 8 in die nachgeordnete Düse 2 das Material in eine oder mehrere Kavitäten eingespritzt, die im zweiten Teil 10 der Form vorliegen. Sind die Kavitäten vollständig gefüllt, wird das Bauteil gekühlt. Danach wird die Form geöffnet, das Bauteil entnommen und die Form innerhalb weniger Sekunden gereinigt sowie mit einem Trennmittel beaufschlagt, sodass sich ein oder mehrere im nächsten Zyklus erstellte Bauteile leicht entnehmen lassen. Anschließend wird die Form geschlossen, womit der Zyklus beendet ist. Der nächste Zyklus beginnt wiederum mit dem Einspritzen von Material. Ein Zyklus, wie in Fig. 2 dargestellt, ist bei Thixomoldingverfahren üblich.When creating a component, according to the scheme according to Fig. 2 proceeded. When the mold is closed, the material is injected via the barrel 8 into the downstream nozzle 2 into one or more cavities which are present in the second part 10 of the mold. When the cavities are completely filled, the component is cooled. Then the mold is opened, the component is removed and the mold is cleaned within a few seconds and a release agent is applied so that one or more components created in the next cycle can be easily removed. Then the mold is closed, which ends the cycle. The next cycle begins again with the injection of material. A cycle like in Fig. 2 shown is common in thixomolding processes.

Erfindungsgemäß wird die Düse 2 der Vorrichtung 5 einem Temperaturprogramm unterworfen, das ohne Verlängerung der Zykluszeit zu niedrigeren Druckspitzen im Barrel 8 führt und damit dessen Standzeit signifikant erhöht. Die variable Temperaturführung an bzw. in der Düse 2 ist in Fig. 3 für einen Erstellungszyklus dargestellt. Beim Einspritzen in die geschlossene Form wird die Düse 2 mit maximaler Heizleistung beaufschlagt, damit das Material 1 frei durch die Düse 2 fließen kann. Dies entspricht dem Zustand A. Sobald die eine oder mehrere Kavitäten gefüllt sind und das Bauteil gekühlt wird, kann in einem ersten Abschnitt der Düse 2, welcher einem Angusspunkt näher liegt, die Heizleistung verringert werden, wie dies durch eine geänderte Schraffur in der Heizeinrichtung 4 dargestellt ist. Dies entspricht dem Zustand B. Es kommt in der Düse 2 dann zur Bildung eines Pfropfens 3 in jenem Bereich, der am Beginn der Düse 2 liegt. Für die Pfropfenbildung ist eine Kühlung gegebenenfalls zweckmäßig, muss aber nicht unbedingt realisiert sein. Da die Form zur Erstarrung des oder der Bauteile gekühlt wird und Magnesium eine gute Wärmeleitfähigkeit aufweist, kann sich der Pfropfen 3 grundsätzlich auch bei weiterer, allerdings allenfalls abgesenkter Beheizung der Düse 2 bilden. Bei geöffneter Form und Entnahme des Bauteils bricht der Pfropfen 3 im Bereich der Düse 2 ab, bleibt jedoch im Wesentlichen erhalten. Dies entspricht dem Zustand C. Die Form ist jetzt zwar noch offen, aber die Heizeinrichtung 4 kann bereits mit höherer Leistung operieren, um den Pfropfen 3 aufzuweichen. Dies entspricht dem Zustand D. Sobald die Form wieder geschlossen ist, kann mit der Heizeinrichtung 4 mit voller Leistung gefahren werden, sodass der Pfropfen 3 idealerweise ganz aufschmilzt. Dies entspricht dem Zustand E. Dadurch ergibt sich, dass beim nächsten Zyklus bzw. Einspritzen die Düse 2 vollkommen frei ist, sodass Druckspitzen im Barrel 8 eliminiert oder zumindest verringert werden. Die gezielte Erweichung und anschließende Aufschmelzung des Pfropfens 3 kann innerhalb der üblichen Zeit für einen Erstellungszyklus von weniger als 40 Sekunden durchgeführt werden.According to the invention, the nozzle 2 of the device 5 is subjected to a temperature program which, without extending the cycle time, leads to lower pressure peaks in the barrel 8 and thus significantly increases its service life. The variable temperature control at or in the nozzle 2 is in Fig. 3 shown for one creation cycle. When injecting into the closed mold, the nozzle 2 is subjected to maximum heating power so that the material 1 can flow freely through the nozzle 2. This corresponds to state A. As soon as the one or more cavities are filled and the component is cooled, the heating power can be reduced in a first section of the nozzle 2, which is closer to a gate, as indicated by a changed hatching in the heating device 4 is shown. This corresponds to state B. A plug 3 then forms in the nozzle 2 in that area which is at the beginning of the nozzle 2. Cooling may be useful for plug formation, but does not necessarily have to be implemented. Since the mold is cooled in order to solidify the component (s) and magnesium has good thermal conductivity, the plug 3 can in principle also form when the nozzle 2 is heated further, albeit at a reduced rate. When the mold is opened and the component is removed, the plug 3 breaks off in the area of the nozzle 2, but remains essentially intact. This corresponds to state C. The mold is still open, but the heating device 4 can already operate at a higher power in order to soften the plug 3. This corresponds to state D. As soon as the mold is closed again, the heating device 4 can be operated at full power, so that the plug 3 ideally melts completely. This corresponds to state E. This means that the nozzle 2 is completely free during the next cycle or injection, so that pressure peaks in the barrel 8 are eliminated or at least reduced. The targeted softening and subsequent melting of the plug 3 can be carried out within the usual time for a production cycle of less than 40 seconds.

In Fig. 4 ist schließlich ein Aufbau einer Düse 2 samt Heizeinrichtung 4 dargestellt, die für diese Zwecke besonders geeignet ist. Die Heizeinrichtung 4 ist als Widerstandsheizung ausgebildet, wobei sich die Heizeinrichtung 4 spiralförmig um die Düse 2 erstreckt und in außenseitigen Vertiefungen der Düse 2 angelötet ist. Die Düse 2 selbst besteht in der Regel aus einem Stahl, insbesondere einem Warmarbeitsstahl. Durch die innige Verbindung der Heizeinrichtung 4 mit der Düse 2 lässt sich ein rascher Wärmeübergang erreichen, was die Einhaltung der Zeiten üblicher Einspritzvorgänge ermöglicht. Darüber hinaus kann die Heizeinrichtung 4 mit der Düse 2 relativ einfach in den ersten Teil 9 der Form integriert werden.In Fig. 4 Finally, a structure of a nozzle 2 including heating device 4 is shown, which is particularly suitable for these purposes. The heating device 4 is designed as a resistance heater, the heating device 4 extending in a spiral shape around the nozzle 2 and being soldered into depressions on the outside of the nozzle 2. The nozzle 2 itself usually consists of a steel, in particular a hot-work steel. The intimate connection of the heating device 4 to the nozzle 2 enables rapid heat transfer to be achieved, which enables the times of the usual injection processes to be adhered to. About that In addition, the heating device 4 with the nozzle 2 can be integrated relatively easily into the first part 9 of the mold.

Claims (7)

  1. A method for casting at least one component, in which flowable metallic material (1), particularly magnesium or a magnesium alloy in a thixotropic state, is injected under pressure into a cavity of a multi-part mould via at least one nozzle (2) in order to form the at least one component and the component is then allowed to solidify in the mould, wherein a plug (3), particularly a solid plug, is formed in the nozzle (2), whereupon the mould is opened and the at least one component is removed, and wherein the mould is then closed and the next component is produced, characterized in that the nozzle (2) is heated when the mould is open in order to at least soften the plug (3) formed in the nozzle (2) prior to producing the next component.
  2. The method according to claim 1, characterized in that a heating power on the nozzle (2) is after opening the mould adjusted in such a way that the plug (3) softens without material (1) entering the cavity.
  3. The method according to claim 2, characterized in that the heating power on the nozzle (2) is increased after closing the mould.
  4. The method according to one of claims 1 to 3, characterized in that a heating power on the nozzle (2) is reduced when the component is allowed to solidify such that a temperature for a plug formation in the nozzle (2) is not reached.
  5. A device (5) for casting at least one metallic component, particularly for carrying out a method according to one of claims 1 to 4, comprising a conveying device for material (1) in a flowable state, particularly magnesium or a magnesium alloy in a thixotropic state, at least one nozzle (2) with a heating device (4) and a multi-part mould, which has at least one cavity for the component to be produced, wherein the material (1) can be injected into the at least one cavity of the mould via the conveying device and the at least one nozzle (2) arranged downstream thereof in order to form the at least one component and the component is then allowed to solidify in the mould, wherein a plug (3), particularly a solid plug, is formed in the nozzle (2) and the mould can be opened for the removal of the at least one component after its solidification in order to begin a new production cycle after producing the component and closing the mould, wherein a control for the heating device (4) is provided and variably controls a temperature on or in the nozzle (2) in dependence on the status of the production cycle in such a way that the nozzle (2) can be heated when the mould is open in order to at least soften the plug (3) formed in the nozzle (2) prior to producing the next component, and wherein the heating device (4) is arranged in depressions on the outer side of the at least one nozzle (2), characterized in that the heating device (4) is soldered on the at least one nozzle (2) and the nozzle (2) is made of a hot-work steel.
  6. The device (5) according to claim 5, characterized in that the heating device (4) is a resistance heater.
  7. The device (5) according to claim 5 or 6, characterized in that the heating device (4) extends around the at least one nozzle (2) in a helical manner.
EP15729747.4A 2014-07-03 2015-05-18 Method and device for casting at least one component Active EP3164236B1 (en)

Applications Claiming Priority (2)

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ATA50465/2014A AT515970B1 (en) 2014-07-03 2014-07-03 Method and device for casting at least one component
PCT/AT2015/050126 WO2016000007A1 (en) 2014-07-03 2015-05-18 Method and device for casting at least one component

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US6938669B2 (en) * 2001-08-30 2005-09-06 Denso Corporation Metal molding method and apparatus
DE102005042867A1 (en) * 2005-09-08 2007-03-22 Bühler Druckguss AG diecasting
AT512229B1 (en) * 2011-11-10 2014-10-15 Mold Thix Consulting Bueltermann Gmbh DEVICE, APPARATUS AND METHOD FOR THE PRESSURE GASING OF METALLIC MATERIAL IN THE THIXOTROPIC CONDITION
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WO2002030596A1 (en) * 2000-10-13 2002-04-18 Commonwealth Scientific And Industrial Research Organisation Device for high pressure casting
US20040151799A1 (en) * 2002-12-20 2004-08-05 Gellert Jobst U. Lateral gating injection molding apparatus
DE102006041514A1 (en) * 2006-08-28 2008-03-06 Gerhard Schoch Energy-saving nozzle for the hot chamber of a die casting machine comprises a thermocouple in contact with a heating spiral of an electrical tubular heating body and arranged as a measuring value transmitter

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WO2016000007A1 (en) 2016-01-07
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EP3164236A1 (en) 2017-05-10

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