EP3613520B1 - Method and appartus for casting metals under pressure using a cold chamber - Google Patents

Method and appartus for casting metals under pressure using a cold chamber Download PDF

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Publication number
EP3613520B1
EP3613520B1 EP18189842.0A EP18189842A EP3613520B1 EP 3613520 B1 EP3613520 B1 EP 3613520B1 EP 18189842 A EP18189842 A EP 18189842A EP 3613520 B1 EP3613520 B1 EP 3613520B1
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EP
European Patent Office
Prior art keywords
casting
chamber
chambers
bolt
casting chamber
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EP18189842.0A
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German (de)
French (fr)
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EP3613520A1 (en
Inventor
Michael Just
Holger Rammensee
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GF Casting Solutions AG
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GF Casting Solutions AG
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Priority to EP18189842.0A priority Critical patent/EP3613520B1/en
Priority to JP2019150210A priority patent/JP2020028918A/en
Priority to US16/544,951 priority patent/US11040394B2/en
Priority to CN201910774807.3A priority patent/CN110842170B/en
Publication of EP3613520A1 publication Critical patent/EP3613520A1/en
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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
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2053—Means for forcing the molten metal into the die using two or more cooperating injection pistons
    • 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
    • B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • 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
    • B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04—Plunger machines
    • 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
    • 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
    • B22D17/203—Injection pistons
    • 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

Definitions

  • the invention relates to a method and a device for casting metals, preferably light metals, under pressure in the cold chamber process, including a die casting machine, a feeder and a changer, a bolt from the metal to be cast being inserted into a casting chamber and fed to the die casting machine and exchanged.
  • Methods and devices for casting metals under pressure are known from the prior art and are preferably used for light metals.
  • the die casting machine and the furnace are arranged separately from one another and the required melt, which is melted in the furnace, is fed manually or automatically to the casting chamber in the die casting machine.
  • the DE 100 43 717 A1 discloses a method and a device in which the material, which is provided as a bolt, is preheated in a preparation space or a press and is then transferred into the casting chamber via a channel.
  • the EP 0 936 010 A1 discloses a process in which the melt is transferred into a casting chamber which is heated by induction and as a result no undesirable temperature gradient arises. However, here too the melt must first be melted in a furnace.
  • the WO0226426 discloses a die casting apparatus and method using separate casting sleeves.
  • the metal to be cast is inserted as a bolt into one of the at least two casting chambers and is then melted, even small batches of metal alloys can be cast for smaller numbers of cast parts. This enables a more precise coordination of the amount of melt that is required since no furnace has to be filled in order to register a corresponding amount of the 3365FEG
  • Preserving melt in order to be able to operate the furnace and avoids re-melting of the metals for further batches. This in turn saves energy and eliminates the need to repeatedly melt down residual material. Because the amount of alloy can be matched well to the number of cast parts required, a greater variety of alloys can also be cast.
  • the casting chamber, with the bolt inserted therein, made of the metal to be cast, preferably a light metal, is fed to the die casting machine.
  • a changer is used to change the casting chamber into the die casting machine, and the casting chamber is also replaced by it.
  • the feeding and changing of the casting chambers into and out of the die casting machine takes place on the basis of at least two casting chambers present in the device, the changing process taking place alternately.
  • the device can also have more than just two casting chambers which are alternately supplied to and removed from the die casting machine.
  • This enables a fast die-casting process because the casting chambers heat the metal to just below the liquidus temperature before it is fed into the die-casting machine and the bolt is melted into the liquid state in the die-casting machine.
  • the bolt made of the metal to be cast preferably light metal, is completely melted in the casting chamber only after the casting chamber has been fed into and replaced in the die casting machine, but before the pouring opening is opened to cast the liquid metal or to fill the cavities.
  • the metal to be cast is heated to just below the liquidus temperature, i.e. it is heated to the point before it changes to the liquid state. This enables rapid liquefaction when the casting chamber is inserted into the die casting machine and thus a rapid casting process.
  • the complete melting of the bolt is preferably carried out inductively. This ensures precise and rapid melting into the liquid state. It is advantageous if the metal to be cast is heated to close to the liquidus temperature, i.e. before the casting chamber is changed into the die casting machine is also carried out inductively.
  • the heating of the bolt in the casting chamber is preferably carried out before changing the die casting machine and after changing the casting chamber into the die casting machine by means of the same induction element which is arranged in the casting chamber.
  • the billet is heated up to below the liquidus temperature of the billet before it is fed into and replaced with the die casting machine, that is to say not yet liquefied.
  • a claimed embodiment of the method according to the invention consists in that the casting chamber is completely closed after the bolt has been inserted, this preferably being closed with the casting piston. This allows the casting chamber to be filled almost 100% with the metal to be cast, which reduces air inclusions and significantly improves the quality of the castings.
  • the opening for inserting the bolt made of the metal to be cast is preferably closed by means of the casting piston by moving up to the bolt and closing the casting chamber.
  • the invention is preferably also characterized in that, before the metal to be cast is poured into the cavities to be filled, a closure system releases the pouring opening in the pouring chamber.
  • a closure system is preferably located at the opposite end of the casting chamber which, when the metal to be cast has the desired temperature and is liquid, releases the pouring opening, preferably by the closure system moving backwards or in the same direction as the casting piston shifts when the melt is pressed, thereby filling the cavities with the molten metal.
  • the device is disclosed in the attached claim 5. This enables the desired metal to be poured in portions.
  • the device can also have more than two casting chambers which are alternately fed to the die casting machine and exchanged or exchanged.
  • feeding can take place horizontally to the die casting machine or else vertically by means of a transport system, as is also a turret-like arrangement or other feeding systems.
  • a claimed embodiment is that the casting chambers have an induction heating element.
  • Each casting chamber has its own induction heating element, which enables the stud from the metal to be cast to be heated quickly and precisely.
  • the induction heating element is preferably arranged along the circumference of the casting chamber and ensures homogeneous heating of the bolt.
  • the casting chambers preferably each have a closure system which closes the pouring opening in the casting chamber and is released shortly before the cavities are filled.
  • the closure system is preferably arranged at the other end of the casting chamber opposite the casting piston. As soon as the metal has the desired temperature or is liquid, the closure system releases the pouring opening for pouring the liquid metal into the cavities.
  • a piston is preferably provided which moves backwards and thereby clears the opening for the liquid metal.
  • the device has a piston coupling system and the casting chambers each have a casting piston, the casting piston with the piston coupling system being connected to the die casting machine when the casting chamber is changed by means of a changer from the supply to the die casting machine.
  • This ensures that the casting piston is connected to a drive system in the die casting machine in order to press the molten metal in the casting piston into the cavities. Since the casting piston and the locking system are present in each casting chamber also the advantage that the casting chamber can be completely closed and therefore can be filled almost 100%.
  • This circuit can correspond to a vertically as well as horizontally running feed such as a conveyor belt or also a revolver in which the casting chambers are arranged concentrically around a pivot point, as are other feeds.
  • FIG. 1 The drawing shown shows a casting chamber 2 of a device 1 according to the invention, the bolt 5 made of metal to be cast having already been inserted and the casting chamber 2 being completely closed.
  • the induction heating element 3 is arranged along the circumference of the casting chamber 2 and preferably extends over the length of the casting chamber 2 in order to ensure homogeneous heating of the bolt 5. It can be clearly seen that by introducing the metal to be cast as a solid body, a filling of the casting chamber 2 of almost 100% can be achieved, which benefits the reduction of air inclusions in the cast part.
  • the bolt is inserted into the casting chamber 2 through the insertion opening 9, which can be seen in FIG Fig. 2 .
  • the casting piston 4 then moves up to the bolt 5 and the closure system 6 keeps the pouring opening 8 closed, whereby the casting chamber is completely closed.
  • Closure system 6 a closure piston is preferably used, although other possibilities are also conceivable.
  • the piston coupling system 7 arranged on the casting piston 4 serves to connect the casting piston 4 to the die casting machine 10 or to a drive provided for this purpose for pressing the molten metal via the pouring opening 8 into the cavities.
  • Fig. 2 shows a step-by-step representation of the process in a casting chamber 2 of the device 1, with the bolt 5 made of the metal to be cast being inserted into the casting chamber 2 in position A and the casting piston 4 moves up to the bolt 5 in order to close the casting chamber 2.
  • position B it can be seen that the casting chamber 2 is completely closed and that it is almost 100% full.
  • the casting chamber 2 or the bolt 5 is heated by means of the induction heating element 3, the heating being carried out to just below the liquidus temperature before the transfer to the die casting machine 10, preferably during the supply 11 of the casting chamber 2 to the die casting machine 10, see Figs. 3 and 4 .
  • Position C shows the position in which the casting chamber 2 is already arranged in the die casting machine 10 and the metal is liquid and has the desired temperature for casting.
  • the closure system 6 releases the pouring opening 8 and the pouring piston 4, which is connected to a drive via the piston coupling system 7, presses the liquid metal through the pouring opening 8 into the cavities, which can be seen from FIG.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • General Induction Heating (AREA)

Description

Die Erfindung betrifft ein Verfahren und eine Vorrichtung zum Vergiessen von Metallen vorzugsweise Leichtmetallen unter Druck im Kaltkammerverfahren beinhaltend eine Druckgiessmaschine, eine Zuführung und einen Wechsler, wobei ein Bolzen aus dem zu vergiessenden Metall in eine Giesskammer eingelegt wird und an die Druckgiessmaschine zugeführt und eingewechselt wird.The invention relates to a method and a device for casting metals, preferably light metals, under pressure in the cold chamber process, including a die casting machine, a feeder and a changer, a bolt from the metal to be cast being inserted into a casting chamber and fed to the die casting machine and exchanged.

Aus dem Stand der Technik sind Verfahren und Vorrichtungen zum Vergiessen von Metallen unter Druck bekannt und werden vorzugsweise für Leichtmetalle eingesetzt. Im Kaltkammerverfahren sind die Druckgiessmaschine und der Ofen getrennt voneinander angeordnet und die erforderliche Schmelze, welche im Ofen erschmolzen wird, wird manuell oder automatisch der Giesskammer in der Druckgiessmaschine zugeführt.Methods and devices for casting metals under pressure are known from the prior art and are preferably used for light metals. In the cold chamber process, the die casting machine and the furnace are arranged separately from one another and the required melt, which is melted in the furnace, is fed manually or automatically to the casting chamber in the die casting machine.

Solche Verfahren erfordern einen hohen Energieaufwand da in den Öfen meist grössere Mengen eingeschmolzen werden da die Öfen für grosse Mengen konfektioniert sind und kleinere Chargen entsprechend auf eine Menge, welche ein Ofen benötigt, erhöht werden müssen. Diese Mengen an Schmelze muss dann entsprechend warmgehalten werden, wenn nicht die komplette Menge umgehend zum Vergiessen benötigt wird. Dies erfordert zusätzliche Energie um die Schmelze warm zu halten sowie einen logistischen und personellen Mehraufwand .Dies alles bedarf eines hohen Energieaufwands und entsprechend Mehrkosten. Zudem wirkt sich das auf die Legierungsvielfallt negativ aus.Such processes require a high expenditure of energy since larger quantities are usually melted down in the furnaces, since the furnaces are made up for large quantities and smaller batches have to be increased accordingly to the quantity that a furnace requires. This amount of melt must then be kept warm if the entire amount is not needed immediately for casting. This requires additional energy to keep the melt warm as well as additional logistical and personnel expenditure, all of which require a high expenditure of energy and correspondingly additional costs. In addition, this has a negative effect on the variety of alloys.

Die DE 100 43 717 A1 offenbart ein Verfahren und eine Vorrichtung in der in einem Bereitstellungsraum bzw. einer Presse das Material, welches als Bolzen bereitgestellt ist, vorgewärmt wird und anschliessend über einen Kanal in die Giesskammer überführt wird.the DE 100 43 717 A1 discloses a method and a device in which the material, which is provided as a bolt, is preheated in a preparation space or a press and is then transferred into the casting chamber via a channel.

Die EP 0 936 010 A1 offenbart ein Verfahren indem die Schmelze in eine Giesskammer überführt wird, die durch Induktion beheizt wird und dadurch kein unerwünschter Temperaturgradient entsteht. Jedoch auch hier muss die Schmelze vorab in einem Ofen erschmolzen werden.the EP 0 936 010 A1 discloses a process in which the melt is transferred into a casting chamber which is heated by induction and as a result no undesirable temperature gradient arises. However, here too the melt must first be melted in a furnace.

Die WO0226426 offenbart eine Druckgussvorrichtung und ein Druckgussverfahren unter Verwendung getrennter Gießhülsen.the WO0226426 discloses a die casting apparatus and method using separate casting sleeves.

Zudem besteht der Nachteil bei solchen Giesskammern bei denen direkt die flüssige Schmelze eingefüllt wird, dass die Giesskammer aufgrund der Einfüllöffnung und des flüssigen Zustands des zu vergiessenden Metalls nur teilweise gefüllt werden kann, sowohl bei einer horizontalen wie vertikalen Anordnung, wodurch es gerne während des Einpressens der Schmelze in die Kavitäten mittels des Giesskolbens unteranderem zu Lufteinschlüssen in der Legierung kommt, was einen negativen Einfluss auf die Qualität des Gussteils hat.In addition, there is the disadvantage of such casting chambers in which the liquid melt is poured in directly that the casting chamber can only be partially filled due to the filling opening and the liquid state of the metal to be cast, both in a horizontal and vertical arrangement, which means that it is often during the pressing of the melt in the cavities by means of the pouring piston leads to air inclusions in the alloy, which has a negative influence on the quality of the cast part.

Es ist Aufgabe der Erfindung eine Vorrichtung und ein damit verbundenes Verfahren vorzuschlagen, welches den Energieverbrauch reduziert und es ermöglicht kleinere Chargen von Legierungen zu vergiessen und somit auch eine höhere Legierungsvielfalt zu ermögliche wie auch die Bauteilqualität zu verbessern.It is the object of the invention to propose a device and an associated method which reduces energy consumption and makes it possible to cast smaller batches of alloys and thus also to enable a greater variety of alloys as well as to improve the component quality.

Diese Aufgabe wird erfindungsgemäss dadurch gelöst, dass das Verfahren zum Vergiessen von Metallen vorzugsweise Leichtmetallen unter Druck im Kaltkammerverfahren folgende Schritte aufweist:

  • Einlegen eines Bolzens aus dem zu vergiessenden Metall in eine der mindestens zwei Giesskammern,
  • Zuführen und Einwechseln einer Giesskammer in die Druckgiessmaschine, wobei die Giesskammer jeweils eine Ausgussöffnung aufweist, wobei das Zuführen und das Wechseln der Giesskammern aus mindestens zwei vorhandenen Giesskammern alternierend erfolgt,
  • Erwärmen des Bolzens mittels Induktion, wobei dass das Aufschmelzen des Bolzens in der Giesskammer nach dem Zuführen und Einwechseln der Giesskammer in die Druckgiessmaschine aber vor dem Öffnen der Ausgussöffnung der Giesskammer zur Füllung der Kavitäten vollständig erfolgt ist, dadurch gekennzeichnet, dass die Giesskammer nach dem Einlegen des Bolzens komplett mit dem Giesskolben verschlossen wird.
According to the invention, this object is achieved in that the method for casting metals, preferably light metals under pressure in the cold chamber method, has the following steps:
  • Insertion of a bolt made of the metal to be cast into one of the at least two casting chambers,
  • Feeding and changing a casting chamber into the die casting machine, the casting chamber each having a pouring opening, the feeding and changing of the casting chambers from at least two existing casting chambers alternating,
  • Heating of the bolt by means of induction, whereby the melting of the bolt in the casting chamber takes place completely after feeding and changing the casting chamber into the die casting machine but before opening the pouring opening of the casting chamber to fill the cavities, characterized in that the casting chamber after insertion of the bolt is completely closed with the pouring piston.

Dadurch, dass das zu vergiessende Metall als Bolzen in eine der mindestens zwei Giesskammern eingelegt wird und dann aufgeschmolzen wird, können auch kleine Chargen an Metalllegierungen für kleinere Stückzahlen von Gussteilen vergossen werden. Dies ermöglicht eine genauere Abstimmung der Menge der Schmelze die benötigt wird da kein Ofen gefüllt werden muss um eine entsprechende Menge an 3365FEG AnmeldungBecause the metal to be cast is inserted as a bolt into one of the at least two casting chambers and is then melted, even small batches of metal alloys can be cast for smaller numbers of cast parts. This enables a more precise coordination of the amount of melt that is required since no furnace has to be filled in order to register a corresponding amount of the 3365FEG

Schmelze zu erhalten um den Ofen betreiben zu können und vermeidet ein erneutes Einschmelzen der Metalle für weitere Chargen. Dies wiederum erbringt eine Energieeinsparung sowie ein mehrfaches Einschmelzen von anfallendem Restmaterial entfällt. Dadurch, dass die Menge der Legierung gut auf die Stückzahl der benötigten Gussteile abgestimmt werden kann, kann auch eine höhere Legierungsvielfallt vergossen werden. Die Giesskammer wird mit dem darin eingelegten Bolzen aus dem zu vergiessenden Metall, vorzugsweise einem Leichtmetall der Druckgiessmaschine zugeführt. Ein Wechsler dient dem Einwechseln der Giesskammer in die Druckgiessmaschine, wobei auch das Auswechseln der Giesskammer durch diesen erfolgt. Das Zuführen und das Wechseln der Giesskammern in und aus der Druckgiessmaschine erfolgt aufgrund mindestens zwei in der Vorrichtung vorhandener Giesskammern, wobei der Wechselvorgang alternierend erfolgt. Selbstverständlich kann die Vorrichtung auch mehr als nur zwei Giesskammern aufweisen die abwechslungsweise der Druckgiessmaschine zugeführt und herausgenommen werden. Dies ermöglicht einen schnellen Druckgiessprozess da die Giesskammern vor dem Zuführen der Druckgiessmaschine das Metall bis nahe unterhalb der Liquidustemperatur erwärmen und das Aufschmelzen des Bolzens in den flüssigen Zustand in der Druckgiessmaschine erfolgt. Durch die Erwärmung des Metalls in der Giesskammer mittels Induktion ist ein präzises und schnelles Erwärmen möglich. Das heisst, dass der Bolzen aus dem zu vergiessenden Metall vorzugsweise Leichtmetall in der Giesskammer erst nach dem Zuführen und Einwechseln der Giesskammer in die Druckgiessmaschine aber vor dem Öffnen der Ausgussöffnung zum Vergiessen des flüssigen Metalls bzw. zur Füllung der Kavitäten vollständig aufgeschmolzen wird. Bevor die Einwechslung der Giesskammer in die Druckgiessmaschine erfolgt, wird das zu vergiessende Metall bis nahe unter die Liquidustemperatur erwärmt, es wird also soweit erwärmt bevor es in den flüssigen Zustand übergeht. Dies ermöglicht ein rasches Verflüssigen, wenn die Giesskammer in der Druckgiessmaschine eingeführt ist und so einen schnellen Giessprozess.Preserving melt in order to be able to operate the furnace and avoids re-melting of the metals for further batches. This in turn saves energy and eliminates the need to repeatedly melt down residual material. Because the amount of alloy can be matched well to the number of cast parts required, a greater variety of alloys can also be cast. The casting chamber, with the bolt inserted therein, made of the metal to be cast, preferably a light metal, is fed to the die casting machine. A changer is used to change the casting chamber into the die casting machine, and the casting chamber is also replaced by it. The feeding and changing of the casting chambers into and out of the die casting machine takes place on the basis of at least two casting chambers present in the device, the changing process taking place alternately. Of course, the device can also have more than just two casting chambers which are alternately supplied to and removed from the die casting machine. This enables a fast die-casting process because the casting chambers heat the metal to just below the liquidus temperature before it is fed into the die-casting machine and the bolt is melted into the liquid state in the die-casting machine. By heating the metal in the casting chamber by means of induction, precise and rapid heating is possible. This means that the bolt made of the metal to be cast, preferably light metal, is completely melted in the casting chamber only after the casting chamber has been fed into and replaced in the die casting machine, but before the pouring opening is opened to cast the liquid metal or to fill the cavities. Before the casting chamber is exchanged for the die casting machine, the metal to be cast is heated to just below the liquidus temperature, i.e. it is heated to the point before it changes to the liquid state. This enables rapid liquefaction when the casting chamber is inserted into the die casting machine and thus a rapid casting process.

Vorzugsweise erfolgt das vollständige Aufschmelzen des Bolzens induktiv. Dadurch wird ein präzises und schnelles Aufschmelzen in den flüssigen Zustand gewährleistet. Es ist von Vorteil, wenn das Erwärmen des zu vergiessenden Metalls bis nahe an die Liquidustemperatur also vor dem Einwechseln der Giesskammer in die Druckgiessmaschine ebenfalls induktiv erfolgt. Das Erwärmen des Bolzens in der Giesskammer wird vorzugsweise vor dem Einwechseln der Druckgiessmaschine wie nach dem Einwechseln der Giesskammer in die Druckgiessmaschine mittels demselben Induktionselements, welches in der Giesskammer angeordnet ist, durchgeführt.The complete melting of the bolt is preferably carried out inductively. This ensures precise and rapid melting into the liquid state. It is advantageous if the metal to be cast is heated to close to the liquidus temperature, i.e. before the casting chamber is changed into the die casting machine is also carried out inductively. The heating of the bolt in the casting chamber is preferably carried out before changing the die casting machine and after changing the casting chamber into the die casting machine by means of the same induction element which is arranged in the casting chamber.

Als bevorzugte Variante hat sich gezeigt, wenn das Erwärmen des Bolzens bis vor dem Zuführen und Einwechseln an die Druckgiessmaschine bis unterhalb der Liquidustemperatur des Bolzens erfolgt, das heisst noch nicht verflüssigt.It has been shown as a preferred variant if the billet is heated up to below the liquidus temperature of the billet before it is fed into and replaced with the die casting machine, that is to say not yet liquefied.

Eine beanspruchte Ausführung des erfindungsgemässen Verfahrens besteht darin, dass die Giesskammer nach dem Einlegen des Bolzens komplett verschlossen wird, wobei diese vorzugsweise mit dem Giesskolben verschlossen wird. Dies erlaubt eine beinahe 100% Füllung der Giesskammer mit dem zu vergiessenden Metall, wodurch Lufteinschlüsse verringert werden und die Qualität der Gussstücke wesentlich verbessert wird. Die Öffnung zum Einlegen des Bolzens aus dem zu vergiessenden Metall wird vorzugsweise mittels dem Giesskolben verschlossen indem er an den Bolzen heranfährt und die Giesskammer verschliesst. Vorzugsweise zeichnet sich die Erfindung auch dadurch aus, dass vor dem Vergiessen des zu vergiessenden Metalls in die zu füllenden Kavitäten ein Verschlusssystem die Ausgussöffnung in der Giesskammer frei gibt. Vorzugsweise befindet sich an dem Giesskolben entgegengesetzten Ende der Giesskammer ein Verschlusssystem, das wenn das zu vergiessende Metall die gewünschte Temperatur hat sowie flüssig ist, die Ausgussöffnung frei gibt, vorzugsweise indem sich das Verschlusssystem nach hinten verschiebt bzw. in dieselbe Richtung in die sich der Giesskolben beim Verpressen der Schmelze verschiebt, dadurch ist ein Füllen der Kavitäten mit dem aufgeschmolzenen Metall möglich.A claimed embodiment of the method according to the invention consists in that the casting chamber is completely closed after the bolt has been inserted, this preferably being closed with the casting piston. This allows the casting chamber to be filled almost 100% with the metal to be cast, which reduces air inclusions and significantly improves the quality of the castings. The opening for inserting the bolt made of the metal to be cast is preferably closed by means of the casting piston by moving up to the bolt and closing the casting chamber. The invention is preferably also characterized in that, before the metal to be cast is poured into the cavities to be filled, a closure system releases the pouring opening in the pouring chamber. A closure system is preferably located at the opposite end of the casting chamber which, when the metal to be cast has the desired temperature and is liquid, releases the pouring opening, preferably by the closure system moving backwards or in the same direction as the casting piston shifts when the melt is pressed, thereby filling the cavities with the molten metal.

Diese Aufgabe wird erfindungsgemäss dadurch gelöst, dass die Vorrichtung im beigefügten Anspruch 5 offenbart ist. Dadurch wird ein portionenweises Vergiessen des gewünschten Metalls möglich. Selbstverständlich kann die Vorrichtung auch mehr als zwei Giesskammern aufweisen die abwechselnd der Druckgiessmaschine zugeführt und eingewechselt bzw. ausgewechselt werden.This object is achieved according to the invention in that the device is disclosed in the attached claim 5. This enables the desired metal to be poured in portions. Of course, the device can also have more than two casting chambers which are alternately fed to the die casting machine and exchanged or exchanged.

Beispielsweise kann eine Zuführung horizontal zur Druckgiessmaschine oder auch vertikal erfolgen mittels eines Transportsystems, wie auch eine revolverartige Anordnung denkbar ist oder andere Zuführungssysteme.For example, feeding can take place horizontally to the die casting machine or else vertically by means of a transport system, as is also a turret-like arrangement or other feeding systems.

Eine beanspruchte Ausführungsform besteht darin, dass die Giesskammern ein Induktionsheizelement aufweisen. Jede Giesskammer weist ein eigenes Induktionsheizelement, dies ermöglicht ein schnelles und präzises Erwärmen des Bolzens aus dem zu vergiessenden Metall. Das Induktionsheizelement ist vorzugsweise entlang des Umfangs der Giesskammer angeordnet und gewährleistet eine homogene Erwärmung des Bolzens.A claimed embodiment is that the casting chambers have an induction heating element. Each casting chamber has its own induction heating element, which enables the stud from the metal to be cast to be heated quickly and precisely. The induction heating element is preferably arranged along the circumference of the casting chamber and ensures homogeneous heating of the bolt.

Vorzugsweise weisen die Giesskammern jeweils ein Verschlusssystem auf, das die Ausgussöffnung in der Giesskammer verschliesst und kurz vor dem Füllen der Kavitäten frei gegeben wird. Das Verschlusssystem ist vorzugsweise am anderen Ende der Giesskammer gegenüberliegend dem Giesskolben angeordnet. Sobald das Metall die gewünschte Temperatur hat bzw. flüssig ist, gibt das Verschlusssystem die Ausgussöffnung zum Eingiessen des flüssigen Metalls in die Kavitäten frei. Vorzugsweise ist dazu ein Kolben vorgesehen der sich nach hinten verschiebt und dadurch die Öffnung für das flüssige Metall frei gibt.The casting chambers preferably each have a closure system which closes the pouring opening in the casting chamber and is released shortly before the cavities are filled. The closure system is preferably arranged at the other end of the casting chamber opposite the casting piston. As soon as the metal has the desired temperature or is liquid, the closure system releases the pouring opening for pouring the liquid metal into the cavities. For this purpose, a piston is preferably provided which moves backwards and thereby clears the opening for the liquid metal.

Gemäss einer beanspruchten Ausführungsform weist die Vorrichtung ein Kolbenkupplungssystem und die Giesskammern jeweils einen Giesskolben auf, wobei beim Wechseln der Giesskammer mittels Wechslers von der Zuführung in die Druckgiessmaschine der Giesskolben mit dem Kolbenkupplungssystem mit der Druckgiessmaschine verbunden wird. Dadurch wird erreicht, dass der Giesskolben mit einem Antriebssystem in der Druckgiessmaschine verbunden wird um das geschmolzene Metall im Giesskolben in die Kavitäten zu pressen. Da der Giesskolben und das Verschlusssystem jeweils pro Giesskammer vorliegen besteht auch der Vorteil, dass die Giesskammer komplett schliessbar sind und dadurch auch beinahe zu 100% füllbar.According to a claimed embodiment, the device has a piston coupling system and the casting chambers each have a casting piston, the casting piston with the piston coupling system being connected to the die casting machine when the casting chamber is changed by means of a changer from the supply to the die casting machine. This ensures that the casting piston is connected to a drive system in the die casting machine in order to press the molten metal in the casting piston into the cavities. Since the casting piston and the locking system are present in each casting chamber also the advantage that the casting chamber can be completely closed and therefore can be filled almost 100%.

Als vorteilhaft hat sich gezeigt, wenn die Giesskammern in einem in sich geschlossenen Kreislauf zueinander angeordnet sind und alternierend der Druckgiessmaschine zugeführt werden. Dieser Kreislauf kann einer vertikal wie auch horizontal verlaufenden Zuführung entsprechen wie bspw. einem Förderband oder aber auch einem Revolver in dem die Giesskammern konzentrisch um einen Drehpunkt angeordnet sind, wie auch andere Zuführungen denkbar sind.It has been shown to be advantageous if the casting chambers are arranged in a closed circuit with respect to one another and are alternately fed to the die casting machine. This circuit can correspond to a vertically as well as horizontally running feed such as a conveyor belt or also a revolver in which the casting chambers are arranged concentrically around a pivot point, as are other feeds.

Alle Ausgestaltungmöglichkeiten sind untereinander frei kombinierbar sowie die Verfahrens- und die Vorrichtungsmerkmale miteinander individuell kombinierbar sind.All design options can be freely combined with one another and the process and device features can be individually combined with one another.

Ein Ausführungsbeispiel der Erfindung wird anhand der Figuren beschrieben, wobei sich die Erfindung nicht nur auf das Ausführungsbeispiel beschränkt. Es zeigen:

Fig. 1
einen Längsschnitt durch eine Giesskammer zur Durchführung des erfindungsgemässen Verfahrens,
Fig. 2
eine schrittweise Darstellung des Verfahrens in einer Giesskammer,
Fig. 3
eine erfindungsgemässe Vorrichtung mit linearer Zuführung und
Fig. 4
eine erfindungsgemässe Vorrichtung mit revolverartiger Zuführung.
An exemplary embodiment of the invention is described with reference to the figures, the invention not being restricted to the exemplary embodiment. Show it:
Fig. 1
a longitudinal section through a casting chamber for carrying out the method according to the invention,
Fig. 2
a step-by-step presentation of the process in a casting chamber,
Fig. 3
a device according to the invention with linear feed and
Fig. 4
a device according to the invention with a revolver-like feed.

Die in Fig. 1 dargestellte Zeichnung zeigt eine Giesskammer 2 einer erfindungsgemässen Vorrichtung 1, wobei der Bolzen 5 aus zu vergiessendem Metall bereits eingelegt ist und die Giesskammer 2 vollständig geschlossen ist. Entlang des Umfangs der Giesskammer 2 ist das Induktionsheizelement 3 angeordnet, welches sich vorzugsweise über die Länge der Giesskammer 2 erstreckt um eine homogene Erwärmung des Bolzens 5 zu gewährleisten. Gut ersichtlich ist, dass durch das Einbringen des zu vergiessenden Metalls als Festkörper eine Füllung der Giesskammer 2 von nahezu 100% erreichbar ist, was der Minderung von Lufteinschlüssen im Gussteil zugutekommt. Bei der Giesskammer 2 der erfindungsgemässen Vorrichtung 1 wird der Bolzen durch die Einführöffnung 9 in die Giesskammer 2 eingelegt ersichtlich in Fig. 2. Anschliessend fährt der Giesskolben 4 bis an den Bolzen 5 heran und das Verschlusssystem 6 hält die Ausgussöffnung 8 verschlossen, wodurch die Giesskammer komplett geschlossen ist. Als Verschlusssystem 6 wird vorzugsweise ein Verschlusskolben verwendet, wobei auch andere Möglichkeiten denkbar sind. Das am Giesskolben 4 angeordnete Kolbenkupplungssystem 7 dient dem Anschliessen des Giesskolbens 4 an die Druckgiessmaschine 10 bzw. an einen dafür vorgesehenen Antrieb zur Pressung des geschmolzenen Metalls über die Ausgussöffnung 8 in die Kavitäten.In the Fig. 1 The drawing shown shows a casting chamber 2 of a device 1 according to the invention, the bolt 5 made of metal to be cast having already been inserted and the casting chamber 2 being completely closed. The induction heating element 3 is arranged along the circumference of the casting chamber 2 and preferably extends over the length of the casting chamber 2 in order to ensure homogeneous heating of the bolt 5. It can be clearly seen that by introducing the metal to be cast as a solid body, a filling of the casting chamber 2 of almost 100% can be achieved, which benefits the reduction of air inclusions in the cast part. In the case of the casting chamber 2 of the device 1 according to the invention, the bolt is inserted into the casting chamber 2 through the insertion opening 9, which can be seen in FIG Fig. 2 . The casting piston 4 then moves up to the bolt 5 and the closure system 6 keeps the pouring opening 8 closed, whereby the casting chamber is completely closed. as Closure system 6, a closure piston is preferably used, although other possibilities are also conceivable. The piston coupling system 7 arranged on the casting piston 4 serves to connect the casting piston 4 to the die casting machine 10 or to a drive provided for this purpose for pressing the molten metal via the pouring opening 8 into the cavities.

Fig. 2 zeigt eine schrittweise Darstellung des Verfahrens in einer Giesskammer 2 der Vorrichtung 1, wobei in Stellung A der Bolzen 5 aus dem zu vergiessenden Metall in die Giesskammer 2 eingelegt wird und der Giesskolben 4 an den Bolzen 5 heranfährt um die Giesskammer 2 zu schliessen. In Stellung B ist ersichtlich, dass die Giesskammer 2 vollständig geschlossen ist und eine beinahe Füllung von 100% erreicht wird. In diesem Zustand wird die Giesskammer 2 bzw. der Bolzen 5 mittels dem Induktionsheizelement 3 erwärmt, wobei die Erwärmung bis nahe unterhalb der Liquidustemperatur vor der Einwechslung in die Druckgiessmaschine 10 erfolgt, vorzugsweise während der Zuführung 11 der Giesskammer 2 an die Druckgiessmaschine 10, siehe Fig. 3 und 4. Durch den Wechsler (nicht dargestellt) wird die Giesskammer 2 in die Druckgiessmaschine 10 eingewechselt bzw. die davor in der Druckgiessmaschine 10 angeordnete Giesskammer 2 ausgewechselt. Stellung C zeigt die Position in der die Giesskammer 2 bereits in der Druckgiessmaschine 10 angeordnet ist und das Metall flüssig ist und die gewünschte Temperatur zum Vergiessen aufweist. Das Verschlusssystem 6 gibt die Ausgussöffnung 8 frei und der Giesskolben 4, welcher über das Kolbenkupplungssystem 7 mit einem Antrieb verbunden ist presst das flüssige Metall über die Ausgussöffnung 8 in die Kavitäten, was aus der Abbildung D zu entnehmen ist. Fig. 2 shows a step-by-step representation of the process in a casting chamber 2 of the device 1, with the bolt 5 made of the metal to be cast being inserted into the casting chamber 2 in position A and the casting piston 4 moves up to the bolt 5 in order to close the casting chamber 2. In position B it can be seen that the casting chamber 2 is completely closed and that it is almost 100% full. In this state, the casting chamber 2 or the bolt 5 is heated by means of the induction heating element 3, the heating being carried out to just below the liquidus temperature before the transfer to the die casting machine 10, preferably during the supply 11 of the casting chamber 2 to the die casting machine 10, see Figs. 3 and 4 . By means of the changer (not shown) the casting chamber 2 is changed into the die casting machine 10 or the casting chamber 2 arranged in front of it in the die casting machine 10 is exchanged. Position C shows the position in which the casting chamber 2 is already arranged in the die casting machine 10 and the metal is liquid and has the desired temperature for casting. The closure system 6 releases the pouring opening 8 and the pouring piston 4, which is connected to a drive via the piston coupling system 7, presses the liquid metal through the pouring opening 8 into the cavities, which can be seen from FIG.

Fig. 3 und 4 zeigen mögliche Zuführungen 11 der Giesskammern 2 zur Druckgiessmaschine 10. Fig. 3 zeigt eine horizontale Zuführung 11, wobei auch eine vertikale Zuführung von Giesskammern 2 denkbar ist. Die Anzahl der Giesskammern 2 ist auf die Vorrichtung 1 bzw. Geschwindigkeit und Kapazität abzustimmen, wobei mindestens zwei Giesskammern 2 in einer erfindungsgemässen Vorrichtung 1 angeordnet sein müssen um ein Vorwärmen bis nahe unter die Liquidustemperatur und ein anschliessendes Erwärmen in der Druckgiessmaschine 10 bis das Metall flüssig ist durchzuführen bzw. um einen optimalen und wirtschaftlichen Prozess zu gewährleisten. Fig. 4 zeigt eine alternative Anordnung der Giesskammern 2, welche konzentrisch um ein Zentrum angeordnet sind und eine Art Revolver darstellen. Die Übergabe der Giesskammern 2 aus der Zuführung 11 an die Druckgiessmaschine 10 erfolgt mittels eines Wechslers (nicht dargestellt). Figs. 3 and 4 show possible infeeds 11 of the casting chambers 2 to the die casting machine 10. Fig. 3 shows a horizontal feed 11, whereby a vertical feed of casting chambers 2 is also conceivable. The number of casting chambers 2 is to be matched to the device 1 or speed and capacity, with at least two casting chambers 2 having to be arranged in a device 1 according to the invention in order to preheat to just below the liquidus temperature and subsequent heating in the die casting machine 10 until the metal is liquid is to be carried out or to ensure an optimal and economical process. Fig. 4 shows an alternative arrangement of the casting chambers 2, which are arranged concentrically around a center and represent a kind of revolver. The transfer of the casting chambers 2 from the feeder 11 to the die casting machine 10 takes place by means of a changer (not shown).

BezugszeichenlisteList of reference symbols

11
Vorrichtungcontraption
22
GiesskammerCasting chamber
33rd
InduktionsheizelementInduction heating element
44th
GiesskolbenPouring flask
55
Bolzen aus zu vergiessendem MaterialBolts made of material to be cast
66th
VerschlusssystemLocking system
77th
KolbenkupplungssystemPiston clutch system
88th
AusgussöffnungPouring opening
99
EinführöffnungInsertion opening
1010
DruckgiessmaschineDie casting machine
1111
ZuführungFeed

Claims (7)

  1. Method for casting metals, preferably lightweight metals, under pressure by the cold-chamber process, comprising the steps of:
    • placing a bolt (5) of the metal to be cast into one of at least two casting chambers (2),
    • feeding and introducing a selected casting chamber (2) into a diecasting machine (10), the casting chamber (2) having in each case an outlet opening (8), wherein the feeding and changing over of the casting chambers (2) is carried out alternately from at least two available casting chambers (2),
    • heating the bolt (5) by means of induction (3), wherein the melting of the bolt (5) in the casting chamber (2) is carried out after the feeding and introducing of the selected casting chamber (2) into the diecasting machine (10) but before the opening of the outlet opening (8) of the casting chamber (2) for filling the cavities is completed, characterized in that, after the placing in of the bolt (5), the casting chamber (2) is closed completely by the casting piston (4).
  2. Method according to Claim 1, characterized in that the complete melting of the bolt (5) is carried out inductively.
  3. Method according to either of Claims 1 and 2, characterized in that the heating of the bolt (5) up until the feeding and introducing of the selected casting chamber into the diecasting machine (10) is carried out to below the liquidus temperature of the bolt (5).
  4. Method according to one of Claims 1 to 3, characterized in that, before the pouring of the metal to be cast into the cavities to be filled, a closure system opens the outlet opening (8) in the casting chamber (2).
  5. Apparatus (1) for casting metals, preferably lightweight metals, under pressure by the cold chamber process, preferably for carrying out the method according to one of the preceding claims, comprising a diecasting machine (10), a feed (11) and a changer, wherein that the apparatus (1) has at least two casting chambers (2), wherein the casting chambers (2) are fed to the diecasting machine (10) by means of the feed (11) and the casting chambers (2) are changed over between the feed (11) and the diecasting machine (10), preferably alternately, by means of the changer, wherein the casting chambers (2) have an induction heating element (3), characterized in that the apparatus (1) has a piston coupling system (7) and the casting chambers (2) have in each case a casting piston (4), wherein, during the changing over of the casting chamber (2) from the feed (11) into the diecasting machine (10) by means of the changer, the casting piston (4) is connected to the diecasting machine (10) by the piston coupling system (7).
  6. Apparatus (1) according to Claim 5, characterized in that the casting chambers (2) have in each case a closure system (6) which closes the outlet opening (8) in the casting chamber (2) and opens it before the filling of the cavities.
  7. Apparatus according to either of Claims 5 and 6, characterized in that the casting chambers (2) are arranged in relation to one another in a closed circuit and are fed alternately to the diecasting machine (10).
EP18189842.0A 2018-08-21 2018-08-21 Method and appartus for casting metals under pressure using a cold chamber Active EP3613520B1 (en)

Priority Applications (4)

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EP18189842.0A EP3613520B1 (en) 2018-08-21 2018-08-21 Method and appartus for casting metals under pressure using a cold chamber
JP2019150210A JP2020028918A (en) 2018-08-21 2019-08-20 Metal casting
US16/544,951 US11040394B2 (en) 2018-08-21 2019-08-20 Casting of metals
CN201910774807.3A CN110842170B (en) 2018-08-21 2019-08-21 Casting of metals

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DE3640370A1 (en) * 1985-11-26 1987-05-27 Ube Industries INJECTION METHOD OF AN INJECTION MOLDING MACHINE
US5660223A (en) * 1995-11-20 1997-08-26 Tht Presses Inc. Vertical die casting press with indexing shot sleeves
US5787959A (en) * 1996-12-02 1998-08-04 General Motors Corporation Gas-assisted molding of thixotropic semi-solid metal alloy
EP0936010A1 (en) 1998-02-12 1999-08-18 Didier-Werke Ag Method and apparatus for pressure casting metals
EP1046444B1 (en) * 1999-04-20 2002-03-06 Ritter Aluminium Giesserei Gmbh Pressure diecasting method
EP1110643A1 (en) * 1999-12-22 2001-06-27 Alusuisse Technology & Management AG Pretreatment of thixotropic metal billets
DE10043717A1 (en) 2000-09-04 2002-03-14 Buehler Druckguss Ag Uzwil Process for compressive reforming of aluminum or magnesium alloys comprises conveying the liquid or liquid material from a preparation chamber into a casting chamber of a die casting machine
DE10047735A1 (en) * 2000-09-27 2002-04-11 Rauch Fertigungstech Gmbh Process for die casting and filling sleeve therefor as well as die casting machine
JP2003290900A (en) * 2002-04-02 2003-10-14 Sanpo:Kk Injection device in cold-chamber type die casting machine
JP3993813B2 (en) * 2002-10-31 2007-10-17 有限会社リムテック Molten metal material injection equipment
CN1539576A (en) * 2003-04-23 2004-10-27 山田藤夫 Appts and method for smelting material
US20050067131A1 (en) * 2003-09-29 2005-03-31 Spx Corporation Semi-solid metal casting process
CN1640586A (en) * 2004-01-17 2005-07-20 镁联科技（香港）有限公司 Metal alloy thixotropic forming process and equipment thereof
JP4516535B2 (en) * 2006-02-13 2010-08-04 東洋機械金属株式会社 Molten metal forming equipment

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CN110842170B (en) 2023-02-21
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US11040394B2 (en) 2021-06-22
CN110842170A (en) 2020-02-28
JP2020028918A (en) 2020-02-27

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