EP3194094B1 - Lost pattern intended for use in casting - Google Patents

Lost pattern intended for use in casting Download PDF

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Publication number
EP3194094B1
EP3194094B1 EP15753404.1A EP15753404A EP3194094B1 EP 3194094 B1 EP3194094 B1 EP 3194094B1 EP 15753404 A EP15753404 A EP 15753404A EP 3194094 B1 EP3194094 B1 EP 3194094B1
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EP
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Prior art keywords
lost pattern
enclosed
cavities
cavity
stack
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EP15753404.1A
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German (de)
French (fr)
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EP3194094A1 (en
Inventor
Jean Marc BIZEAU
Franck Hautefeuille
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PSA Automobiles SA
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PSA Automobiles SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould

Definitions

  • the invention is in the field of foundry casting using a lost model. It relates to the lost models used for the manufacture of a casting, and to the method of assembling parts constituting lost models.
  • a lost model In the field of foundry, it is known to manufacture a piece of metal material from the use of a lost model.
  • the latter has a conformation and dimensions identical to the desired part.
  • the lost model is formed of a sublimable material, such as for example polystyrene, polyurethane or polyethylene.
  • the lost model is placed inside a matrix made of sand that receives the molten metal material. In contact with the molten metal material, the sublimable material is sublimated to make room for the metallic material. After cooling of the latter, the metal part obtained is of shape and dimensions identical to those of the lost model.
  • Polystyrene molded parts in this case called strata, may be, after molding, assembled to form foundry models called “non-permanent models” or “lost models", since the models will be destroyed and replaced by molten metal when molding metal parts. This assembly is necessary especially when the castings to be obtained are of complex shape, which is the case of the cylinder heads.
  • the assembling of the layers is usually done by gluing, for example using a hot melt glue.
  • An example of sizing technique by spray of a polyurethane-based glue in aqueous emulsion is given in the patent FR-2 768 068 .
  • publications JP-01202338 and WO00 / 15370 disclose casting methods using lost models, the models comprising closed cavities to reduce the volume of gas produced during casting of the metal.
  • the object of the invention is therefore to remedy this drawback.
  • it aims to reduce or even eliminate the occurrence of blow-type defects in foundry metal parts with lost models.
  • the subject of the invention is a lost model intended to be used in a foundry for obtaining metal parts and comprising a stack of layers assembled to each other by gluing, as defined by claim 1, as well as a method of performing a lost model as defined by claim 9.
  • lower and upper and / or “upper” and “lower” faces will be used throughout the present text because the method of assembling the strata to constitute the lost model is generally done by stacking strata vertically, where one begins stacking with a stratum, whose lower face is glued and then placed on the upper face of another layer, the set of both layers being then glued on a new so-called lower stratum etc. ...
  • this recess does not open once the model is constituted. Thus, in particular, when one comes to dispose the model in the foundry sand, this sand can not penetrate them.
  • closed recess can be defined jointly not by two successive layers, but three or more.
  • these recesses are not functional, in that they do not participate in the shape of the final metal part, since, during casting, the molten metal will fill these cavities / recesses, just as the metal would replace the polystyrene if these cavities did not exist.
  • the lost model according to the invention comprises several closed recesses.
  • the cylinder head mentioned above it will be particularly in all areas corresponding to the valve support areas (intake and / or exhaust).
  • the closed recess or recesses are located in one or more zones of the model having a thickness (including that of the recess) of at least 10 mm measured along the stacking axis of the strata.
  • the volume of the closed recess or at least one of them is distributed substantially equally between the two recess portions that define it.
  • the two recess portions (when, in the most frequent case, the recess is defined jointly by only two strata), each define approximately half the volume of the complete closed recess. It can also be provided that the shape of these two recess portions is similar, and even that they have a symmetry with respect to their sharing plane corresponding to the interface area between the two layers.
  • the volume of the closed recess or at least one of them is distributed differently between the two recess portions that define it.
  • one of the recess portions defines more than 50% of the total volume of the complete recess, for example 60, 70 or even 90% and more.
  • the shape of the wall of the recess portion belonging to a stratum at least partially follows the shape of the opposite wall of said stratum.
  • the volume of the closed recess or at least one of them is of the order of 1 cm 3 , in particular between 0.5 and 1.5 cm 3 .
  • the thickness of the closed recess or at least one of them, measured along the stacking axis of the strata is about 1 cm, and especially between 0.5 and 1.5 cm.
  • the invention also relates to such a lost model, which corresponds to the shape of a cylinder head or a portion of the engine cylinder head, and such that the closed recesses are located in the corresponding areas. to the supports of the valves intended to be associated with the cylinder head.
  • the recesses have flat upper walls parallel to the upper walls of the upper stratum corresponding to the valve supports, also planes. This configuration allows in particular to have a maximum volume of recess.
  • the subject of the invention is also a process for producing a lost model intended to be used in a foundry for obtaining metal parts and comprising a stack of layers assembled to each other by gluing, where the lost model comprises at least a closed recess which is defined jointly by two recess portions respectively belonging to two successive strata, respectively called lower stratum and upper stratum in the stack, and in particular being as defined above.
  • the invention also relates to a device for implementing the method described above, which comprises the lost model in question.
  • the invention also relates to a foundry piece obtained from the lost model described above.
  • the figure 1 represents in vertical section the lost model M in polystyrene, composed of 5 layers 1,2,3,4,5 assembled in known manner by gluing according to a stack along a vertical axis X.
  • Two recesses 6,7 are represented, which are entirely closed in the complete lost model, and which are not “functional", in that they are not intended to define the shape of the metal part to be produced.
  • the recess 6 thus has a substantially trapezoidal section, with an upper partition belonging to the stratum 4 and defining a planar and oblique zone 61 facing an equally flat and oblique zone 41 belonging to the upper face of the stratum 4 (that is to say the face of the stratum 4 directed towards the next stratum, the stratum 5.
  • This zone 41 corresponds, in the cylinder head once produced, to a zone of support of the valves which will be mounted in the breech.
  • the lower partition 62 belonging to the lower layer 3 is curved, with a substantially flat bottom.
  • the zone under this surface 41 would be relatively "thick” (at least 10 mm), with, consequently, locally, a gas evolution due to the sublimation of the larger polystyrene, and therefore a risk blowholes in the metal part.
  • the recess 6 one comes to "dig” in this massive part, to limit the gas release.
  • the metal will fill during casting, and the shape of the final piece remains unchanged, whether the recess 6 is present or not in the lost model.
  • the scrap rate on the cylinder heads could drop significantly.
  • the recess 7 its upper partition define an oblique planar zone 71 which "follows" also the outer face 42 of the stratum 4 facing said wall and also corresponding to a valve bearing face in the breech.
  • Its lower partition 72 belonging to the lower stratum 3 is substantially entirely flat and in continuity with the outer face of the stratum 3.
  • the recesses 6 and 7 define a volume of about 0.5 to 1.5 cm 3 , of the order of cm 3, therefore. It can be seen that, in the case of the recess 6, approximately one-third of the volume is defined by the profile of the lower stratum 3 and the remainder by that of the upper stratum 4. In the case of the recess 7, it appears that it is the upper layer 4 which really defines the volume of the cavity, whereas the stratum 3 only comes to close it without any very significant modification of its profile: one sees that any form of recess is possible, and any distribution of the volume between the two strata is so too.
  • the number and geometry of the recesses thus adapt to the constitution of each lost model.
  • the creation of these recesses does not complicate the manufacture of the lost model, and tends to lighten it by using less polystyrene, which is very advantageous.
  • each closed recess 6 consists of a recess portion 6a of the stratum 3 and of a recess portion 6b complementary to the stratum 4. It can be seen that the recess 7 is defined by a portion of recess only in one of the strata 4, the other stratum 3 being unmodified and simply closing the cavity 7.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

L'invention est du domaine du moulage en fonderie utilisant un modèle perdu. Elle est relative aux modèles perdus utilisés pour la fabrication d'une pièce de fonderie, et au procédé d'assemblage de parties constitutives de modèles perdus.The invention is in the field of foundry casting using a lost model. It relates to the lost models used for the manufacture of a casting, and to the method of assembling parts constituting lost models.

Dans le domaine de la fonderie, il est connu de fabriquer une pièce en un matériau métallique à partir de l'utilisation d'un modèle perdu. Ce dernier présente une conformation et des dimensions identiques à la pièce souhaitée. Le modèle perdu est formé d'une matière sublimable, telle que par exemple le polystyrène, le polyuréthane ou le polyéthylène. Le modèle perdu est placé à l'intérieur d'une matrice constituée de sable qui reçoit le matériau métallique en fusion. Au contact du matériau métallique en fusion, la matière sublimable est sublimée pour laisser place au matériau métallique. Après refroidissement de ce dernier, la pièce métallique obtenue est de forme et de dimensions identiques à celles du modèle perdu.In the field of foundry, it is known to manufacture a piece of metal material from the use of a lost model. The latter has a conformation and dimensions identical to the desired part. The lost model is formed of a sublimable material, such as for example polystyrene, polyurethane or polyethylene. The lost model is placed inside a matrix made of sand that receives the molten metal material. In contact with the molten metal material, the sublimable material is sublimated to make room for the metallic material. After cooling of the latter, the metal part obtained is of shape and dimensions identical to those of the lost model.

Une utilisation de cette technologie intéressant la présente invention est le moulage de pièces métalliques de fonderie, notamment des pièces de moteur thermique comme des culasses. Le modèle perdu utilisé dans ce type de technologie est généralement en polystyrène expansé.One use of this technology of interest to the present invention is the casting of foundry metal parts, especially engine parts such as cylinder heads. The lost model used in this type of technology is usually expanded polystyrene.

Comme cela est, par exemple, décrit dans le brevet EP- 2 052 799 , dans le brevet EP- 2 357 049 , dans le brevet EP- 2 397 245 , ou dans le brevet FR-2 959 145 , des pièces moulées en polystyrène, dans ce cas appelées strates, peuvent être, après moulage, assemblées pour constituer des modèles de fonderie appelés « modèles non permanents » ou « modèles perdus », puisque les modèles seront détruits et remplacés par du métal en fusion lors du moulage des pièces métalliques. Cette assemblage est nécessaire notamment quand les pièces de fonderie à obtenir sont de forme complexe, ce qui est le cas des culasses de moteur.As is, for example, described in the patent EP-2,052,799 in the patent EP-2,357,049 in the patent EP-2,397,245 , or in the patent FR-2 959 145 Polystyrene molded parts, in this case called strata, may be, after molding, assembled to form foundry models called "non-permanent models" or "lost models", since the models will be destroyed and replaced by molten metal when molding metal parts. This assembly is necessary especially when the castings to be obtained are of complex shape, which is the case of the cylinder heads.

L'assemblage des strates se fait généralement par collage, par exemple à l'aide d'une colle thermofusible. Un exemple de technique d'encollage par pulvérisation d'une colle à base de polyuréthane en émulsion aqueuse est donné dans le brevet FR- 2 768 068 .The assembling of the layers is usually done by gluing, for example using a hot melt glue. An example of sizing technique by spray of a polyurethane-based glue in aqueous emulsion is given in the patent FR-2 768 068 .

Par ailleurs, les publications JP-01202338 et WO00/15370 divulguent des procédés de coulée à l'aide de modèles perdus, les modèles comprenant des cavités fermées afin de réduire le volume de gaz produit lors de la coulée du métal.In addition, publications JP-01202338 and WO00 / 15370 disclose casting methods using lost models, the models comprising closed cavities to reduce the volume of gas produced during casting of the metal.

Prenons l'exemple d'une coulée en aluminium en fusion sur un modèle perdu en polystyrène expansé : pendant la coulée, le polystyrène se vaporise sous l'effet de la chaleur, et l'aluminium liquide prend la place du polystyrène avant de se solidifier. Lors de cette coulée, s'opère un dégagement gazeux dû à la vaporisation du polystyrène (et de la colle liant les strates entre elles), ce qui peut entraîner l'apparition de ce que l'on appelle des « soufflures » pendant la solidification de la pièce en aluminium. Ces « soufflures » sont des défauts se manifestant par de la porosité dans la pièce en métal/ de la rugosité à sa surface. Le risque d'apparition de ces défauts est d'autant plus élevé dans les zones où la pièce présente une épaisseur importante.Take the example of a molten aluminum casting on a lost model of expanded polystyrene: during casting, polystyrene vaporizes under the effect of heat, and liquid aluminum takes the place of polystyrene before solidifying . During this casting, there is a gas evolution due to the vaporization of the polystyrene (and the adhesive bonding the layers together), which can cause the appearance of what are called "blowholes" during solidification of the aluminum part. These "blisters" are defects manifested by porosity in the metal part / roughness on its surface. The risk of occurrence of these defects is even higher in areas where the piece has a significant thickness.

L'invention a alors pour but de remédier à cet inconvénient. Elle a notamment pour but de réduire, voire supprimer, l'apparition de défauts du type soufflures dans des pièces métalliques obtenues par fonderie avec des modèles perdus.The object of the invention is therefore to remedy this drawback. In particular, it aims to reduce or even eliminate the occurrence of blow-type defects in foundry metal parts with lost models.

L'invention a pour objet un modèle perdu destiné à être utilisé en fonderie pour l'obtention de pièces métalliques et comportant un empilement de strates assemblées les unes aux autres par collage, tel que défini par la revendication 1, ainsi qu'un procédé de réalisation d'un modèle perdu tel que défini par la revendication 9.The subject of the invention is a lost model intended to be used in a foundry for obtaining metal parts and comprising a stack of layers assembled to each other by gluing, as defined by claim 1, as well as a method of performing a lost model as defined by claim 9.

On utilisera dans tout le présent texte les termes de strates « inférieure » et « supérieure » et/ou de faces « supérieure » et « inférieure », car le procédé d'assemblage des strates pour constituer le modèle perdu se fait généralement par un empilement de strates verticalement, où l'on commence l'empilement avec une strate, dont la face inférieure est encollée puis posée sur la face supérieure d'une autre strate, l'ensemble des deux strates étant ensuite encollé sur une nouvelle strate dite inférieure etc... Ces termes spatiaux sont donc indiqués par soucis de concision et de clarté, mais l'invention doit se comprendre comme englobant aussi toute technique d'assemblage où l'empilement de strates se ferait différemment, par exemple selon un axe horizontal (strates disposées selon des plans verticaux) ou verticalement mais en sens inverse (on vient ajouter une strate au-dessus de l'empilement en cours de constitution, au lieu d'ajouter l'empilement en cours de constitution à une strate disposée en dessous de celui-ci).The terms "lower" and "upper" and / or "upper" and "lower" faces will be used throughout the present text because the method of assembling the strata to constitute the lost model is generally done by stacking strata vertically, where one begins stacking with a stratum, whose lower face is glued and then placed on the upper face of another layer, the set of both layers being then glued on a new so-called lower stratum etc. ... These spatial terms are therefore indicated for the sake of brevity and clarity, but the invention must be understood as also encompassing any assembly technique where the stacking of layers would be different, for example according to a horizontal axis (strata arranged in vertical planes) or vertically but in opposite direction (we add a layer above the stack being formed, instead of adding the stack being formed to a layer disposed below this one).

On comprend également par évidement « clos » le fait que cet évidement ne soit pas débouchant une fois le modèle constitué. Ainsi, notamment, quand on vient disposer le modèle dans le sable de fonderie, ce sable ne peut pas pénétrer dans ceux-ci.It is also understood by "closed" recess that this recess does not open once the model is constituted. Thus, in particular, when one comes to dispose the model in the foundry sand, this sand can not penetrate them.

On inclut également dans la définition de l'invention le fait que l'évidement clos puisse être défini conjointement non pas par deux strates successives, mais trois ou plus.It is also included in the definition of the invention that the closed recess can be defined jointly not by two successive layers, but three or more.

On comprend également dans l'esprit de l'invention que ces évidements ne sont pas fonctionnels, en ce sens qu'ils ne participent pas à la forme de la pièce métallique finale, puisque, lors de la coulée, le métal en fusion va remplir ces cavités/évidements, tout comme le métal viendrait remplacer le polystyrène si ces cavités n'existaient pas.It is also understood in the spirit of the invention that these recesses are not functional, in that they do not participate in the shape of the final metal part, since, during casting, the molten metal will fill these cavities / recesses, just as the metal would replace the polystyrene if these cavities did not exist.

Il s'est avéré que ces évidements permettaient, de façon surprenante, de limiter les dégagements gazeux à l'origine des soufflures évoquées plus haut, ou, à tout le moins, d'en canaliser mieux l'évacuation : les pièces mécaniques obtenues avec des modèles perdus présentant au moins un de ces évidements clos, et tout particulièrement quand on les localise dans les zones les plus « épaisses » du modèle, sont de meilleure qualité, avec beaucoup moins de soufflures et donc avec un taux de rebut bien inférieur. Ceci a notamment pu être vérifié lors de la production de pièces métalliques pour faire des moteurs thermiques, notamment des culasses de moteur. En effet, les culasses sont faites à partir de moules perdus constitués de nombreuses strates, généralement au moins quatre ou cinq, toutes de formes complexes et venant s'emboiter les unes dans les autres, et présentent certaines zones assez « épaisses », notamment à proximité des zones d'appui des soupapes, propices à l'apparition de soufflures. C'est pour ce type de pièce aux formes complexes que l'invention est la plus avantageuse.It has been found that these recesses surprisingly make it possible to limit the gaseous emissions at the origin of the blowholes mentioned above, or, at the very least, to better channel the evacuation: the mechanical parts obtained with lost models with at least one of these closed recesses, and especially when they are located in the "thickest" areas of the model, are of better quality, with much less blistering and therefore with a much lower scrap rate. This has notably been verified during the production of metal parts to make heat engines, including engine cylinder heads. Indeed, the cylinder heads are made from lost molds consisting of many strata, usually at least four or five, all of complex shapes that fit into each other, and have some fairly "thick" areas, including proximity of the bearing zones of the valves, conducive to the appearance of blowholes. It is for this type of piece with complex shapes that the invention is the most advantageous.

De préférence, le modèle perdu selon l'invention comprend plusieurs évidements clos. Pour l'exemple de la culasse cité plus haut, ce sera notamment dans toutes les zones correspondant aux zones d'appui des soupapes (admission et/ou échappement).Preferably, the lost model according to the invention comprises several closed recesses. For the example of the cylinder head mentioned above, it will be particularly in all areas corresponding to the valve support areas (intake and / or exhaust).

Selon l'invention, le ou les évidements clos sont localisés dans une ou des zones du modèle présentant une épaisseur (y compris celle de l'évidement) d'au moins 10 mm mesurée selon l'axe d'empilement des strates.According to the invention, the closed recess or recesses are located in one or more zones of the model having a thickness (including that of the recess) of at least 10 mm measured along the stacking axis of the strata.

Selon un mode de réalisation, le volume de l'évidement clos ou d'au moins un d'entre eux est réparti de façon sensiblement égale entre les deux portions d'évidement qui le définissent. Donc les deux portions d'évidement (quand, dans le cas le plus fréquent, l'évidement est défini conjointement par deux strates seulement), définissent chacune approximativement la moitié du volume de l'évidement clos complet. On peut aussi prévoir que la forme de ces deux portions d'évidement est analogue, et même qu'elles présentent une symétrie par rapport à leur plan de partage correspondant à la zone d'interface entre les deux strates.According to one embodiment, the volume of the closed recess or at least one of them is distributed substantially equally between the two recess portions that define it. Thus, the two recess portions (when, in the most frequent case, the recess is defined jointly by only two strata), each define approximately half the volume of the complete closed recess. It can also be provided that the shape of these two recess portions is similar, and even that they have a symmetry with respect to their sharing plane corresponding to the interface area between the two layers.

Selon un autre mode de réalisation, le volume de l'évidement clos ou d'au moins un d'entre eux est réparti différemment entre les deux portions d'évidement qui le définissent. Dans ce cas-là, une des portions d'évidement définit plus que 50% du volume total de l'évidement complet, par exemple 60, 70 voire 90% et plus. On peut avoir ainsi la portion d'évidement complémentaire définissant une part de volume très faible, et venant juste « fermer » l'autre portion.According to another embodiment, the volume of the closed recess or at least one of them is distributed differently between the two recess portions that define it. In this case, one of the recess portions defines more than 50% of the total volume of the complete recess, for example 60, 70 or even 90% and more. One can thus have the complementary recess portion defining a very small volume share, and just just "close" the other portion.

Avantageusement, la forme de la paroi de la portion d'évidement appartenant à une strate suit au moins partiellement la forme de la paroi opposée de ladite strate. Ainsi, si on reprend l'exemple des zones d'appui de soupapes de culasses de moteur thermique, on peut prévoir que l'évidement va se trouver localisé en dessous de ce qui correspondra à la surface d'appui de la soupape dans la culasse, et que sa partie supérieure sera plane et parallèle à la surface plane de la strate qui correspondra à la surface d'appui de la soupape.Advantageously, the shape of the wall of the recess portion belonging to a stratum at least partially follows the shape of the opposite wall of said stratum. Thus, if we take the example of the engine cylinder head valve support zones, we can predict that the recess will be located below what will correspond to the bearing surface of the valve in the cylinder head , and that its upper part will be flat and parallel to the flat surface of the stratum which will correspond to the bearing surface of the valve.

De préférence, le volume de l'évidement clos ou de l'un d'entre eux au moins est de l'ordre de 1 cm3, notamment entre 0,5 et 1,5 cm3.Preferably, the volume of the closed recess or at least one of them is of the order of 1 cm 3 , in particular between 0.5 and 1.5 cm 3 .

Avantageusement l'épaisseur de l'évidement clos ou d'au moins l'un d'entre eux, mesuré selon l'axe d'empilement des strates (c'est-à-dire sa hauteur quand l'axe d'empilement est vertical), est d'environ 1 cm, et notamment comprise entre 0,5 et 1,5 cm.Advantageously the thickness of the closed recess or at least one of them, measured along the stacking axis of the strata (that is to say its height when the stacking axis is vertical), is about 1 cm, and especially between 0.5 and 1.5 cm.

Selon un exemple déjà mentionné, l'invention a également pour objet un tel modèle perdu, qui correspond à la forme d'une culasse ou d'une portion de culasse de moteur thermique, et tel que les évidements clos sont localisés dans les zones correspondant aux appuis des soupapes destinées à être associées à la culasse.According to an example already mentioned, the invention also relates to such a lost model, which corresponds to the shape of a cylinder head or a portion of the engine cylinder head, and such that the closed recesses are located in the corresponding areas. to the supports of the valves intended to be associated with the cylinder head.

Notamment dans ce cas de figure, il est alors préférable que les évidements présentent des parois supérieures planes parallèles aux parois supérieures de la strate supérieure correspondant aux appuis de soupapes, plans également. Cette configuration permet notamment d'avoir un volume d'évidement maximal.Especially in this case, it is preferable that the recesses have flat upper walls parallel to the upper walls of the upper stratum corresponding to the valve supports, also planes. This configuration allows in particular to have a maximum volume of recess.

L'invention a également pour objet un procédé de réalisation d'un modèle perdu destiné à être utilisé en fonderie pour l'obtention de pièces métalliques et comportant un empilement de strates assemblées les unes aux autres par collage, où le modèle perdu comprend au moins un évidement clos qui est défini conjointement par deux portions d'évidement appartenant respectivement à deux strates successives, dites respectivement strate inférieure et strate supérieure dans l'empilement, et notamment étant comme défini précédemment.The subject of the invention is also a process for producing a lost model intended to be used in a foundry for obtaining metal parts and comprising a stack of layers assembled to each other by gluing, where the lost model comprises at least a closed recess which is defined jointly by two recess portions respectively belonging to two successive strata, respectively called lower stratum and upper stratum in the stack, and in particular being as defined above.

L'invention a également pour objet un dispositif de mise en oeuvre du procédé décrit précédemment, qui comporte le modèle perdu en question.The invention also relates to a device for implementing the method described above, which comprises the lost model in question.

L'invention a également pour objet une pièce de fonderie obtenue à partir du modèle perdu décrit plus haut.The invention also relates to a foundry piece obtained from the lost model described above.

D'autres caractéristiques et avantages de l'invention apparaîtront à la lecture de la description détaillée qui suit d'un mode de réalisation de l'invention, donné à titre d'exemple uniquement et en références aux dessins qui montrent :

  • figure 1, une section verticale d'un modèle perdu assemblé selon l'invention et comprenant deux évidements clos définis par deux strates successives du modèle ;
  • figure 2, un agrandissement de la figure 1 dans la zone des deux évidements clos ;
  • figure 3, une vue en perspective des deux strates successives définissant les deux évidements clos selon les figures précédentes.
Other features and advantages of the invention will appear on reading the following detailed description of an embodiment of the invention, given by way of example only and with reference to the drawings which show:
  • figure 1 a vertical section of a lost model assembled according to the invention and comprising two closed recesses defined by two successive layers of the model;
  • figure 2 , an enlargement of the figure 1 in the area of the two closed recesses;
  • figure 3 , a perspective view of the two successive layers defining the two closed recesses according to the preceding figures.

Les composants identiques d'une figure à l'autre comportent la même référence. Les figures ne représentent pas nécessairement tous les composants à l'échelle et restent schématiques.The identical components from one figure to another have the same reference. The figures do not necessarily represent all the components at scale and remain schematic.

Il est proposé dans l'exemple suivant un modèle perdu pour mouler une pièce métallique par exemple ici à base d'aluminium, en l'occurrence une culasse de moteur thermique de véhicule automobile. On ne rentrera pas dans le détail du moulage à moule perdu, ou dans la fabrication du modèle, on pourra avantageusement se reporter aux brevets cités au préambule de la présente demande décrivant cette technique.It is proposed in the following example a lost model for molding a metal part for example here based on aluminum, in this case a motor vehicle engine cylinder head. It will not be possible to refer to the patents cited in the preamble of the present application describing this technique.

La figure 1 représente en section verticale le modèle perdu M en polystyrène, composé de 5 strates 1,2,3,4,5 assemblées de façon connue par collage selon un empilement selon un axe vertical X. Sont représentés deux évidements 6,7, qui sont entièrement clos dans le modèle perdu complet, et qui ne sont pas « fonctionnels », en ce sens qu'ils ne sont pas destinés à définir la forme de la pièce métallique à produire.The figure 1 represents in vertical section the lost model M in polystyrene, composed of 5 layers 1,2,3,4,5 assembled in known manner by gluing according to a stack along a vertical axis X. Two recesses 6,7 are represented, which are entirely closed in the complete lost model, and which are not "functional", in that they are not intended to define the shape of the metal part to be produced.

Des agrandissements de ces deux évidements sont représentés à la figure 2 : ils sont délimités par des cloisons dont une partie appartient à la strate dite inférieure 3 et une partie à la strate dite supérieure 4. L'évidement 6 présente ainsi une section sensiblement trapézoïdale, avec une cloison supérieure appartenant à la strate 4 et définissant une zone plane et oblique 61 qui se trouve en regard d'une zone également plane et oblique 41 appartenant à la face supérieure de la strate 4 (c'est-à-dire la face de la strate 4 dirigée vers la strate suivante, la strate 5. Cette zone 41 correspond, dans la culasse une fois produite, à une zone d'appui des soupapes qui seront montées dans la culasse. La cloison inférieure 62 appartenant à la strate inférieure 3 est incurvée, avec un fond sensiblement plat.Enlargements of these two recesses are represented at figure 2 they are delimited by partitions, part of which belongs to the so-called lower stratum 3 and part to the so-called upper stratum 4. The recess 6 thus has a substantially trapezoidal section, with an upper partition belonging to the stratum 4 and defining a planar and oblique zone 61 facing an equally flat and oblique zone 41 belonging to the upper face of the stratum 4 (that is to say the face of the stratum 4 directed towards the next stratum, the stratum 5. This zone 41 corresponds, in the cylinder head once produced, to a zone of support of the valves which will be mounted in the breech. The lower partition 62 belonging to the lower layer 3 is curved, with a substantially flat bottom.

Sans l'évidement 6, on voit que la zone sous cette surface 41 serait relativement « épaisse » (au moins 10 mm), avec, par conséquent, localement, un dégagement gazeux dû à la sublimation du polystyrène plus important, et donc un risque de soufflures dans la pièce métallique. Avec l'évidement 6, on vient « creuser » dans cette partie massive, pour limiter le dégagement gazeux. Le métal va le remplir lors de la coulée, et la forme de la pièce finale reste donc inchangée, que l'évidement 6 soit présent ou non dans le modèle perdu. Par contre, avec l'évidement 6, le taux de rebut sur les culasses a pu chuter significativement.Without the recess 6, it can be seen that the zone under this surface 41 would be relatively "thick" (at least 10 mm), with, consequently, locally, a gas evolution due to the sublimation of the larger polystyrene, and therefore a risk blowholes in the metal part. With the recess 6, one comes to "dig" in this massive part, to limit the gas release. The metal will fill during casting, and the shape of the final piece remains unchanged, whether the recess 6 is present or not in the lost model. By cons, with the recess 6, the scrap rate on the cylinder heads could drop significantly.

Il en est de même pour l'évidement 7 : sa cloison supérieure définir une zone plane oblique 71 qui « suit » également la face extérieure 42 de la strate 4 en regard de ladite paroi et correspondant également à une face d'appui de soupape dans la culasse. Sa cloison inférieure 72 appartenant à la strate inférieure 3 est sensiblement entièrement plane et dans la continuité de la face extérieure de la strate 3.It is the same for the recess 7: its upper partition define an oblique planar zone 71 which "follows" also the outer face 42 of the stratum 4 facing said wall and also corresponding to a valve bearing face in the breech. Its lower partition 72 belonging to the lower stratum 3 is substantially entirely flat and in continuity with the outer face of the stratum 3.

On a ainsi un volume important pour l'évidement, et les strates en question restent démoulables lors de leur fabrication.There is thus a large volume for the recess, and the strata in question remain demoldable during their manufacture.

On prévoir avantageusement autant d'évidements que de zones « massives/épaisses » dans le modèle, ou, tout au moins, prévoir des évidements dans celles de ces zones « épaisses » qui sont les plus susceptibles de générer des défauts de type soufflure dans les pièces de fonderie obtenues.It is advantageous to provide as many recesses as "massive / thick" zones in the model, or, at least, to provide recesses in those of these "thick" zones which are most likely to generate blow-type defects in the foundry parts obtained.

Pour donner un ordre de grandeur, les évidements 6 et 7 définissent un volume d'environ 0,5 à 1,5 cm3, de l'ordre du cm3 donc. On voit que, dans le cas de l'évidement 6, environ un tiers du volume est défini par le profil de la strate inférieure 3 et le reste par celui de la strate supérieure 4. Dans le cas de l'évidement 7, il apparaît que c'est la strate supérieure 4 qui définit réellement le volume de la cavité, alors que la strate 3 ne vient que la fermer sans modification très significative de son profil : on voit que toute forme d'évidement est possible, et toute répartition du volume entre les deux strates l'est donc également.To give an order of magnitude, the recesses 6 and 7 define a volume of about 0.5 to 1.5 cm 3 , of the order of cm 3, therefore. It can be seen that, in the case of the recess 6, approximately one-third of the volume is defined by the profile of the lower stratum 3 and the remainder by that of the upper stratum 4. In the case of the recess 7, it appears that it is the upper layer 4 which really defines the volume of the cavity, whereas the stratum 3 only comes to close it without any very significant modification of its profile: one sees that any form of recess is possible, and any distribution of the volume between the two strata is so too.

Le nombre et la géométrie des évidements s'adaptent donc à la constitution de chaque modèle perdu. La création de ces évidements ne complexifie pas la fabrication du modèle perdu, et tend à l'alléger, en utilisant moins de polystyrène, ce qui est très avantageux.The number and geometry of the recesses thus adapt to the constitution of each lost model. The creation of these recesses does not complicate the manufacture of the lost model, and tends to lighten it by using less polystyrene, which is very advantageous.

La figure 3 est une représentation des strates 3 et 4 complètes avant assemblage, les flèches f indiquant la façon dont l'assemblage est fait. On voit ainsi que chaque évidement clos 6 se compose d'une portion d'évidement 6a de la strate 3 et d'une portion d'évidement 6b complémentaire de la strate 4. On voit que l'évidement 7 est défini par une portion d'évidement présente que dans l'une des strates 4, l'autre strate 3 étant non modifiée et venant simplement fermer la cavité 7.The figure 3 is a representation of strata 3 and 4 complete before assembly, the arrows f indicating how the assembly is done. It can thus be seen that each closed recess 6 consists of a recess portion 6a of the stratum 3 and of a recess portion 6b complementary to the stratum 4. It can be seen that the recess 7 is defined by a portion of recess only in one of the strata 4, the other stratum 3 being unmodified and simply closing the cavity 7.

Claims (9)

  1. Lost pattern (M) intended for use in casting to obtain metal parts and comprising a stack of layers (1, 2, 3, 4, 5) joined to each other by adhesive bonding, characterized in that said lost pattern includes at least one enclosed cavity (6, 7) which is defined jointly by two cavity sections which belong respectively to two successive layers (3, 4), referred to respectively as lower layer (3) and upper layer (4), in the stack, the one or more enclosed cavities (6,7) being located in one or more of the zones of the pattern having a thickness of at least 10 mm measured along the axis (X) of the stack of layers (1, 2, 3, 4, 5).
  2. Lost pattern (M) according to the preceding claim, characterized in that it includes a plurality of enclosed cavities (6, 7).
  3. Lost pattern (M) according to either of the preceding claims, characterized in that the volume of the enclosed cavity (6, 7) or of at least one of such cavities is divided substantially equally between the two cavity portions that define it.
  4. Lost pattern (M) according to either of Claims 1 or 2, characterized in that the volume of the enclosed cavity (6, 7) or of at least one of such cavities is divided differently between the two cavity portions that define it.
  5. Lost pattern (M) according to any one of the preceding claims, characterized in that the shape of the wall of the cavity portion (61, 71) belonging to one layer at least partially follows the shape of the opposite wall (41, 42) in said layer.
  6. Lost pattern (M) according to any one of the preceding claims, characterized in that the volume of the enclosed cavity (6, 7) or of at least one of said cavities is in the order of 1 cm3, and particularly in a range from 0.5 to 1.5 cm3.
  7. Lost pattern (M) according to any one of the preceding claims, characterized in that it corresponds to the shape of a cylinder head or part of a cylinder head of a combustion engine, and in that the enclosed cavities (6, 7) are located in the zones corresponding to the valve seatings that are intended to be associated with the cylinder head.
  8. Lost pattern (M) according to the preceding claim, characterized in that the enclosed cavities (6, 7) have flat upper walls (61, 71) parallel to the upper walls (41, 42) of the upper layer (4) corresponding to the valve seatings, which are also flat.
  9. Method for producing a lost pattern (M) for use in casting to obtain metal parts and comprising a stack of layers (1, 2, 3, 4, 5) joined to each other by adhesive bonding, characterized in that the lost pattern comprises at least one enclosed cavity (6, 7) which is defined jointly by two cavity portions belonging respectively to two successive layers (3, 4), called respectively lower layer (3) and upper layer (4) in the stack, the one or more enclosed cavities (6, 7) being located in one or more of the zones of the pattern having a thickness of at least 10 mm measured along the axis (X) of the stack of layers (1, 2, 3, 4, 5).
EP15753404.1A 2014-09-16 2015-07-28 Lost pattern intended for use in casting Active EP3194094B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1458727A FR3025733B1 (en) 2014-09-16 2014-09-16 LOST MODEL FOR USE IN FOUNDRIES
PCT/FR2015/052095 WO2016042225A1 (en) 2014-09-16 2015-07-28 Lost pattern intended for use in casting

Publications (2)

Publication Number Publication Date
EP3194094A1 EP3194094A1 (en) 2017-07-26
EP3194094B1 true EP3194094B1 (en) 2019-04-10

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EP15753404.1A Active EP3194094B1 (en) 2014-09-16 2015-07-28 Lost pattern intended for use in casting

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EP (1) EP3194094B1 (en)
FR (1) FR3025733B1 (en)
WO (1) WO2016042225A1 (en)

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Publication number Priority date Publication date Assignee Title
CN111014588A (en) * 2019-10-18 2020-04-17 徐州江宏阀门有限公司 Casting process of valve body

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Publication number Priority date Publication date Assignee Title
JPH01202338A (en) * 1988-02-08 1989-08-15 Asahi Malleable Iron Co Ltd Casting method and lost foam pattern
GB9820073D0 (en) * 1998-09-16 1998-11-11 Rover Group Casting die pattern
FR2959145B1 (en) * 2010-04-23 2013-01-04 Peugeot Citroen Automobiles Sa PROCESS FOR MAKING A MECHANICAL PART COMPRISING COMPLEX AND EVOLUTIVE FORMS, IN PARTICULAR A VEHICLE CULASSE

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Also Published As

Publication number Publication date
FR3025733A1 (en) 2016-03-18
FR3025733B1 (en) 2016-11-18
EP3194094A1 (en) 2017-07-26
WO2016042225A1 (en) 2016-03-24

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