JPH0323253B2 - - Google Patents
Info
- Publication number
- JPH0323253B2 JPH0323253B2 JP58080943A JP8094383A JPH0323253B2 JP H0323253 B2 JPH0323253 B2 JP H0323253B2 JP 58080943 A JP58080943 A JP 58080943A JP 8094383 A JP8094383 A JP 8094383A JP H0323253 B2 JPH0323253 B2 JP H0323253B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- suction
- firing
- molding
- iron
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 57
- 239000000843 powder Substances 0.000 claims description 49
- 238000010304 firing Methods 0.000 claims description 42
- 238000000034 method Methods 0.000 claims description 31
- 239000000919 ceramic Substances 0.000 claims description 25
- 229910052742 iron Inorganic materials 0.000 claims description 24
- 239000002245 particle Substances 0.000 claims description 21
- 230000008569 process Effects 0.000 claims description 15
- 239000002002 slurry Substances 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 230000001590 oxidative effect Effects 0.000 claims description 6
- 238000007605 air drying Methods 0.000 claims description 2
- 238000000465 moulding Methods 0.000 description 39
- 238000005266 casting Methods 0.000 description 26
- 239000000463 material Substances 0.000 description 23
- 239000000835 fiber Substances 0.000 description 18
- 239000002131 composite material Substances 0.000 description 15
- 239000011797 cavity material Substances 0.000 description 14
- 238000002156 mixing Methods 0.000 description 13
- 229910000831 Steel Inorganic materials 0.000 description 12
- 239000010959 steel Substances 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 10
- 239000002184 metal Substances 0.000 description 10
- 239000004033 plastic Substances 0.000 description 9
- 229920003023 plastic Polymers 0.000 description 9
- 239000011148 porous material Substances 0.000 description 9
- 230000035699 permeability Effects 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 239000011230 binding agent Substances 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 229910000838 Al alloy Inorganic materials 0.000 description 5
- 229910001018 Cast iron Inorganic materials 0.000 description 5
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000005060 rubber Substances 0.000 description 5
- -1 Al alloys Chemical class 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000001704 evaporation Methods 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 230000005484 gravity Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 230000003746 surface roughness Effects 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000004512 die casting Methods 0.000 description 3
- 230000008020 evaporation Effects 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 229910000861 Mg alloy Inorganic materials 0.000 description 2
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 2
- 229910001297 Zn alloy Inorganic materials 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000007872 degassing Methods 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 238000009423 ventilation Methods 0.000 description 2
- 229910001141 Ductile iron Inorganic materials 0.000 description 1
- 229910000915 Free machining steel Inorganic materials 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000001476 alcoholic effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000008119 colloidal silica Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000005350 fused silica glass Substances 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 150000002505 iron Chemical class 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 238000004421 molding of ceramic Methods 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000004439 roughness measurement Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 229910052851 sillimanite Inorganic materials 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000007779 soft material Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 229910052845 zircon Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B19/00—Other methods of shaping glass
- C03B19/02—Other methods of shaping glass by casting molten glass, e.g. injection moulding
- C03B19/025—Other methods of shaping glass by casting molten glass, e.g. injection moulding by injection moulding, e.g. extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/061—Materials which make up the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/261—Moulds therefor
- B28B1/262—Mould materials; Manufacture of moulds or parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
- B29C33/3814—Porous moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
- B29C51/365—Porous moulds
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B19/00—Other methods of shaping glass
- C03B19/02—Other methods of shaping glass by casting molten glass, e.g. injection moulding
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B9/00—Blowing glass; Production of hollow glass articles
- C03B9/30—Details of blowing glass; Use of materials for the moulds
- C03B9/34—Glass-blowing moulds not otherwise provided for
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B9/00—Blowing glass; Production of hollow glass articles
- C03B9/30—Details of blowing glass; Use of materials for the moulds
- C03B9/48—Use of materials for the moulds
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Organic Chemistry (AREA)
- Ceramic Engineering (AREA)
- Dispersion Chemistry (AREA)
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
Description
ãçºæã®è©³çŽ°ãªèª¬æã
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ã§ãããDETAILED DESCRIPTION OF THE INVENTION The present invention relates to a suction mold, and particularly to a method for manufacturing a durable suction mold that has good air permeability throughout the mold and is highly effective in removing air and gas from the cavity.
AlåéãZnåéãMgåéãCuåéãªã©ã®æº¶
èéå±ããã©ã¹ããã¯ããŽã ãã¬ã©ã¹ãããã¯ã¢
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åŸæ¥ããåºãè¡ãããŠããã Molten metals such as Al alloys, Zn alloys, Mg alloys, and Cu alloys, plastics, rubber, glass, or molten or softened plastic materials such as mortar and wax are poured by gravity into a mold with a cavity and then pressurized. Methods of forming (including casting, the same shall apply hereinafter) by methods involving inflow or plastic flow have been widely used in the past.
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åçš®èŠæ±ãæºè¶³ã§ããå®çšçãªæ圢åããªãã€
ãã Generally, it is desirable that the mold used in this molding method satisfy the following requirements, but hitherto there has been no practical mold that can satisfy these various requirements.
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ã©ãè¡ãå Žåã«åé¡ãšãªãããŸãããŽã çã®ç«äœ
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ãã It has sufficient strength characteristics to withstand the desired molding, can be used many times instead of requiring molding each time as is typical with sand molds, and has good transferability, making it possible to mold complex shapes and It is possible to handle thin-walled shapes, the mold can be easily enlarged and large molded products can be obtained, the mold does not produce pinholes or cavities on the surface or inside the molded product, and the mold is easy to manufacture and can be obtained at low cost. For example, a die-casting mold is used as a casting mold for forming (casting) molten metal such as Al alloy, and although this mold can satisfy the following conditions,
cannot meet the conditions. In particular, in die casting, molten metal is forced into a mold at high pressure and high speed, and the mold has no air permeability, resulting in porosity.
This tends to cause problems when performing airtightness, heat treatment, surface treatment, etc. Fixed molds and movable molds are also used to produce three-dimensional products such as rubber, and liquid or softened materials are charged into the mold and pressurized at a predetermined pressure to form them. However, it is difficult to meet the conditions because the air inside the cavity and the air trapped in the material cannot be removed, resulting in problems such as a decrease in the yield of good products and the need for complicated deburring work. Because the mold is made of metal, the following conditions cannot be met.
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補äœæ³ãæäŸããããšãããã®ã§ããã The present invention solves the above-mentioned problems of conventional molds, has sufficient strength and can be used many times, has good transferability and reproducibility, and is easily applicable to complex shapes, thin-walled shapes, and large shapes. In addition, the entire mold is breathable, and by applying suction force from desired locations, air and gas within the cavity and molding material can be effectively removed, and manufacturing is simple and inexpensive. The present invention aims to provide a method for manufacturing this type of durable mold.
ãã®ç®çãéæããããæ¬çºæã¯ãç²åŸ500ÎŒ
ïœä»¥äžã®éç³»ç²æ«ãšç²åŸ300ÎŒïœä»¥äžã®ã»ã©ãã
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ïŒã50æéçŒæããææ³ãšãããã®ã§ããã To achieve this objective, the present invention has a particle size of 500 ÎŒm.
The aggregate is iron-based powder with a particle size of 300 ÎŒm or less and ceramic powder with a particle size of 300 ÎŒm or less, and a caking agent containing components that evaporate during the hardening process is mixed in a weight ratio of (1 to 5): (1 to 5).
5): 1 is mixed to make a slurry mixture, this slurry mixture is poured and solidified to form a mold surface, and after air drying and/or primary firing, the firing temperature is 600 ~ 600 in an oxidizing atmosphere. This method involves firing at 1000°C for 1 to 50 hours.
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ãã Embodiments of the present invention will be described below with reference to the accompanying drawings.
第ïŒå³ãªãã第ïŒå³ã¯åžåŒæ圢åãäŸç€ºããã
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ã³ã°å±€ïŒãæããŠããã 1 to 3 illustrate a suction molding mold, which is made up of a composite fired body 1 made of iron-based powder and ceramic powder (refractory powder) as aggregates. This composite fired body 1 has a dense hardened layer 2 on the outer periphery including an arbitrary mold surface 11 such as a concave or convex shape, and has a backing layer 3 made of an unfired mixed structure inside this hardened layer 2. ing.
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ã®ããã®å°ç®¡ãããŒã¿ïŒïŒãåèšãããŠããã Figure 2 shows an example of a separate mold, where the mold surface 1
A runner 12 leading to the backing layer 1 is made of a hardened layer, and a pin hole 13 is formed through the hardened layer 2 and the backing layer 3. Further, if necessary, conduits and heaters 14 for mold cooling and heat retention are buried.
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匷ããŠããã FIG. 3 shows another example of the present invention, which consists of a composite fired body 1 made of iron-based powder, ceramic powder (refractory powder), and steel fibers 4 as aggregates. Similar to the previous embodiment, this composite fired body 1' has a dense hardened layer 2 on the outer periphery and a backing layer 3 made of an unfired mixture inside the hardened layer 2. Steel fibers 4 are almost uniformly dispersed within each layer and at the boundaries between both layers, and these dispersed steel fibers 4 strengthen the unfired mixed structure constituting the backing layer 3 and also strengthen the hardened layer 2. By being passed between the backing layers 3, the adhesion between both layers is strengthened.
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ãç·»å¯ã§å¹³æ»ãªé¢æ§ç¶ãæ§æããã The hardened layer 2 is made of modified iron particles (a-Fe 2 O 3 ) 2 of iron-based powder dispersed in ceramic powder as shown in FIG. 4a.
0 and fired ceramic grains 21. The formation mechanism of this hardened layer 2 is not necessarily clear, but in general, the iron-based powder greatly increases in volume due to oxidation, and is sintered in a manner that envelops the ceramic particles, while the firing of the ceramic particles also progresses. This is thought to be the result of diffusion bonding at the interface. This hardened layer 2 has fine pores 22 (approximately 5 to 10 ÎŒm) due to evaporation of evaporation components contained in the binder during the drying process, primary firing process, and secondary firing process. These fine pores 22 form a porous yet dense and smooth surface.
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KgïŒcm2ã®ç¹æ§ãåããã On the other hand, the bucking layer 3 inside the hardened layer 2 is made of a mixed structure of unfired iron-based powder particles 20' and ceramic powder particles 21', as shown in FIG. 4b. Coarse pores 22' are formed at the interface of the grains 20' due to the previous evaporation of the caking agent. These pores 22' are the pores 2 of the hardened layer 2.
2, therefore, the composite fired body 1 has a porous ventilation structure as a whole. The pores 22, 2
2' is characterized by no cracks. The porosity depends on the composition and firing conditions described below, but it is generally between 1 and 2'.
The compressive strength is approximately 200 to 900.
Kg/cm 2 characteristics.
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å·¥çšãæ¡çšãããã®ã§ããã Therefore, in order to obtain a suction molding mold as shown in FIGS. 1 to 4, the present invention mixes and kneads aggregate and caking material to form a slurry sample 5, and pours this slurry sample 5. The process of molding;
This method employs a process of drying or primary firing the mixed molded body, and a process of firing the product that has gone through this process under oxidizing atmosphere conditions.
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ãã First, the step of obtaining slurry sample 5 is to thoroughly mix and stir iron-based powder and ceramic powder or steel fibers, add a caking agent containing components that evaporate during the curing process, and thoroughly mix and stir. It consists of things.
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is used in the present invention to bond iron-based particles and ceramic particles and to create fine pores in the composite fired body. Specific examples include colloidal silica and ethyl silicate. The former is a stabilized silica colloidal liquid, in which water is the evaporated component. Also,
The latter is a mixture of a low condensate of orthoethyl silicate (approximately 40-42% effective silica), an alcoholic solvent (e.g., ethanol, isoprepanol), water, and an acid catalyst to accelerate the reaction and stabilize the sol. (for example, hydrochloric acid), mixed and hydrolyzed, and the evaporated component in this case is mainly alcohol.
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The weight ratio is preferably (1-5):(1-5):1, and this blending ratio improves strength, air permeability, thermal conductivity,
Various properties such as surface texture can be obtained in a well-balanced manner. Here, the lower limit of the blending ratio was defined as
This is because it is necessary to obtain the minimum strength that can be used as a mold, and the reason why the upper limit was specified is that too much aggregate will reduce the covering ability of the caking material from the aspect of moldability, resulting in a decrease in strength. This is because it causes deterioration of the stability of the mold surface. The upper limit for iron-based powder was stipulated by
Even if the blend of ceramic powder and binder is appropriate, if iron-based powder is used in excess, sufficient strength will not be obtained, and the surface quality will deteriorate due to excessive porosity, which will impair transferability. It is. The reason why the upper limit of ceramic powder is limited is that the strength will be impaired if excessively blended. Caking agents are necessary for bonding aggregates together and are necessary to provide air permeability.
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It should be 10vol%. If it is less than 1%, effects such as improved strength and dimensional stability cannot be expected. but
Addition of more than 10% tends to cause fiber balls and reduces moldability. In addition, excessive precipitation on the surface of the hardened layer results in poor skin quality and is also disadvantageous in terms of cost.
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é©åœã«éžæããã°ããã The particle size of the iron-based powder is preferably 500 ÎŒm or less, and the particle size of the ceramic powder is preferably 300 ÎŒm or less. If the maximum dimension exceeds 500 ÎŒm for iron-based powders and 300 ÎŒm for ceramic powders, the strength, that is, the bucking effect, will decrease and the mold surface will become excessively porous, resulting in a rough surface. Impairs transferability. Therefore, it has sufficient strength and durability and good transferability, and can be used for molding complex shapes, thin-walled shapes, and large shapes.Moreover, it has good air permeability throughout the mold, so it can be easily used inside the cavity or during molding. This makes it impossible to achieve the purpose of producing a mold that allows gas and air in the material to be easily removed by suction. Therefore, the upper limit of particle size was specified. Under the conditions of this maximum particle size, the particle size may be selected so that strength, transferability, and porosity can be obtained according to the purpose and application of the mold. From the viewpoint of mold surface roughness, which affects transferability, the finer the particle size, the better; however, if it is extremely fine, cracks are likely to occur during the drying and firing processes. Therefore, the minimum grain size may be appropriately selected to avoid the occurrence of cracks during actual mold manufacturing. The steel fibers may be appropriately selected, for example, from a length of 1 to 30 mm and a thickness of 20 to 400 ÎŒm depending on the size of the mold.
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When using a suction mold as shown in the figure, this can be easily carried out by inserting pins and pipes into the mold during the casting process.
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The baking time should be at least 1 hour.
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ãæé·ã§ã50æéãé床ãšãã¹ãã§ããã The lower limit of firing temperature is 600â, the lower limit of firing time is 1
The reason why the time is set is because the firing is insufficient and a dense hardened layer, which is a feature of the present invention, is not formed, and the strength necessary for a durable type cannot be obtained. The reason why the upper limit of the firing temperature was set at 1000°C is that although a hardened layer is formed, the surface becomes rough and transferability is impaired. The longer the firing time, the higher the strength.
The hardened layer does not grow beyond its limit, and instead causes surface roughness and reduced productivity. Although it depends on the mold dimensions, etc., the maximum time should be 50 hours.
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ããããã In this secondary firing step in an oxidizing atmosphere, firing of the ceramic powder and oxidation sintering of the iron-based powder dispersed in the molded body proceed, and as shown in Figure 6, a dense hardened layer is formed from the surface to the inside. 2 is gradually produced, and at the same time, the volatile components of the caking agent remaining in the molded body are burned and removed, so that the formation of porosity is promoted.
Upon completion of the secondary firing, a durable suction mold made of the composite fired body 1 as shown in FIGS. 1 to 3 is obtained. .
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æã«èšå®ããã°ããã In addition, in the present invention, in order to adjust the air permeability (porosity), the type, particle size, blending ratio of iron powder and ceramic powder, vibration and squeezing conditions during pour molding, firing conditions, etc. are adjusted by adjusting the required strength, etc. It may be set arbitrarily while taking into consideration.
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ããã Figure 16 shows the relationship between the mixing ratio of iron-based powder (for example, cast iron powder) and ceramic powder (iron-based powder/ceramic powder) and porosity. To increase the porosity, increase the mixing ratio of iron-based powder. I know it's good. 17th
The figure shows the relationship between the blending ratio of binder and aggregate (iron powder + ceramic powder) and porosity, and it can be seen that the lower the aggregate blending ratio, the higher the porosity tends to be.
次ã«åžåŒæ圢åã®äœ¿çšç¶æ³ãšäœçšã説æããã Next, we will explain how the suction molding mold is used and how it works.
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䌎ãå å§åžåŒæ圢ããå Žåã«é©çšããäŸã瀺ãã Figures 7 to 9 show examples of how the suction molding mold manufactured according to the present invention is used.
Applied when forming liquid or slurry material W such as refractories by non-pressure suction method, No. 8
The figure is applied to molding a liquid or slurry material W, typically molten metal, using a low-pressure suction method. Figure 9 shows rubber, glass, plastic,
An example in which this method is applied to pressurized suction molding of liquid or soft material W' such as metal with plastic flow will be shown.
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ãã Molding by the non-pressure suction method shown in FIG. 7, for example, is divided into a fixed mold 1a and a movable mold 1b,
1 and 11 are coated with a mold coating agent and a mold release agent, and incorporated into a molding device to perform pouring and mold release.For this molding, suction parts are placed in advance at desired locations on the fixed mold 1a and the movable mold 1b. 8, 8 are provided, and the suction parts 8, 8 are connected to a pressure reducing device 9 such as a vacuum pump via a hose or the like, and a suction force is applied from the time of injection of the material W to the time of molding.
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äœçšããããã®ã§ããã In the case of molding by the low pressure suction method, a fixed mold 1a and a movable mold 1b made of the composite fired body 1 are used instead of the molds in a known vacuum casting apparatus as illustrated in FIG. and suction parts 8, 8 are provided at desired locations on the movable mold 1b, and the suction parts 8,
8 to the pressure reducing device 9 as in the case of FIG. 7,
The piston rod 16 of the mold opening/closing cylinder 15 may be connected to the movable mold 1b. For molding, the material W is charged into the crucible 17, a molten metal is made in the holding furnace 18, and the material W is inserted into hot water by pressurizing gas through the air introduction hole 25 provided in the airtight lid 19 above the crucible. The fixed mold 1a and the movable mold 1b are connected through the conduit 26
The hot water is pushed up into the cavity 10 of the hot water tank, and at the same time, a suction force is applied through the suction parts 8, 8 by the pressure reducing device 9.
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As shown in Fig. 9, suction molding molds 1a and 1b of the composite fired body produced according to the present invention are used instead of the conventional male mold, and a fixed mold 1a corresponding to the female mold is fixed to the pressbed side. However, the movable mold 1b corresponding to the male mold is attached to the press slide side, and the suction parts 8, 8 are provided at desired parts of both molds 1a, 1b and connected to a pressure reducing device. For molding, fill the mold surface of the fixed mold 1a with material W',
Next, the movable die 1b is operated to apply the necessary pressure to the material W' while sucking air through the suction parts 8, 8.
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転åæ§ãšååçŸæ§ãåããŠããã In each of the above-mentioned moldings, according to the present invention, the mold is composed of a composite fired body 1 made of iron-based powder and ceramic powder as aggregates, and this composite fired body 1 is made of a hardened layer 2 made of oxidized iron-based powder. Because it forms the outer periphery, the mold has a strength of 200 kg/cm 2 or more, which is necessary for a durable mold, and there is no cracking, chipping, or crumbling even after repeated rapid heating and cooling. In this case, important corner chipping does not occur. In particular, when steel fibers are used as an aggregate, characteristics such as high bending strength and little dimensional change can be obtained.
Moreover, in addition to having the strength as a durable type, the outer hardened layer 2 and the inner backing layer 3 that make up the composite fired body 1 are porous, consisting of fine pores 22, 22'. It consists of
The entire mold has good ventilation. Furthermore, although the cured layer 2 that constitutes the mold surface has suction holes, it is dense and has small surface roughness, and since it is made by pour molding, it has good transferability and mold reproducibility. ing.
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æ圢ããããšãã§ãããã®ã§ããã Therefore, as shown in FIGS. 7 to 9, by applying suction from a desired location during the molding process, the entire cavity or mold surface can be made to have a uniform negative pressure. It is possible to fill the material evenly and provide good transferability, and at the same time, it is possible to quickly and reliably eliminate air in the cavity, air caught in when filling the material, or gas released from the material. Moreover, the mold manufactured according to the present invention has a lower thermal conductivity than a metal mold, and has a low velocity of molten metal.
Even with low-pressure inflow, hot water flows well. For these reasons, molded products with complex shapes and thin shapes without pinholes or cavities on the surface or inside can be molded very easily.
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çŒæäœãšããããçæ¹ã®ã¿ãåžæ°ããŠãããã In addition, the suction parts 8, 8 in the above example may be obtained by inserting an intake pipe into a mold during casting molding, or may be provided after secondary firing. For the outer surface other than the suction part, methods such as applying a sealing material as appropriate, attaching it to an airtight casing, or joining a planar body may be used. Of course, the entire mold can also be used as a suction part. In the above example, both of the split molds are composed of composite fired bodies, and each mold is inhaled, but in some cases, only one of the divided molds may be made of a composite fired body, or only one of them may be inhaled. .
次ã«æ¬çºæã®å ·äœçãªå®æœäŸã瀺ãã Next, specific examples of the present invention will be shown.
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ãŒç¶è³æãåŸããExample: Cast iron powder (particle size under 100 ÎŒm) was used as the iron-based powder, synthetic mullite powder (particle size under 100 ÎŒm) was used as the ceramic powder, and ethyl silicate was used as the binder, with a weight mixing ratio of 3:3:1. A slurry-like material A was obtained by uniformly mixing and stirring the mixture.
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A slurry sample B was obtained.
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åžåŒæ圢åAâ²ïŒBâ²ãåŸãã Next, slurry samples A and B were respectively poured into molds containing models (sewing machine parts, automobile parts), and the solidified molded bodies were removed from the molds, ignited, and subjected to primary firing for 0.5 hours, and then loaded into a firing furnace. Then, secondary firing was performed at a firing temperature of 900â under air conditions.
Suction molding molds Aâ² and Bâ² were obtained.
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As shown in the figure. Compressive strength and weight increase with increasing firing time. This is due to the formation of a hardened layer due to oxidation of the iron-based powder.
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ããŠå©çšããã®ã«å¥œé©ã§ããããšããããã The results of a bending strength test and measurements of dimensional changes for the suction mold B' are shown in FIGS. 12 and 13. From FIG. 12 and FIG. 13, it can be seen that when steel fibers are added, the bending strength is significantly improved and changes in mold dimensions are suppressed, and therefore it is suitable for use as a large mold. Recognize.
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ã©ã®çºçã¯ã¿ãããªãã€ãã In order to examine the effects of rapid heating and cooling on suction molding molds A' and B', repeated heating and cooling tests were conducted using a cycle of heating at 800°C for 5 minutes and cooling at room temperature for 5 minutes. As a result, no cracks or chips were observed even after 100 cycles.
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以äžã®æ°åçãæããŠããããšããããã FIG. 14 shows the results of examining the relationship between firing time, hardened layer thickness, and porosity under conditions of constant firing temperature for suction molding molds A' and B'. In the case of the present invention, the entire mold has at least 5
% or more.
æ°åç20ïŒ
ã®åžåŒæ圢åAâ²ãçšããåé¢ã«
ã°ã©ãã¢ã€ãã¢ã«ã³ãŒã«æº¶æ¶²ã§å¡åãè¡ããå
åŽéšã«åžåŒç®¡ãåä»ãä»ã®é¢ãç®ã©ãããŠé³é
è£
眮ã«çµèŸŒã¿ãã¢ã«ãããŠã åéADCâ12ã®
éåé³é ãè¡ãã€ã€ãåžåŒç®¡ãéããŠ700mmHg
ã®åžåŒãè¡ã€ããé³èŸŒã¿æ¡ä»¶ã¯ãé³èŸŒã¿æž©åºŠ
700âãé³èŸŒã¿æéïŒãïŒç§ãé¢åæé15ã50
ç§ã§è¡ã€ãã Using a suction molding mold Aâ² with a porosity of 20%, coat the mold surface with graphite alcohol solution, attach a suction pipe to the side of the mold, select the other surface, and assemble it into the casting machine to form the aluminum alloy ADC. -700 mmHg through the suction tube while performing gravity casting of -12
suction was performed. The casting conditions are the casting temperature
700â, casting time 3-5 seconds, mold release time 15-50
I was there in seconds.
ãã®çµæ湯æµããè¯å¥œã§ã²ãããªãè¯å¥œãªé³
é ãè¡ããã ãã§ãªããåçŽãªéåé³é ã«ãã
ã¹é³ç©ã®è»¢åæ§ïŒé³èïŒãèãããè¯ããªãé³
åºã粟床ãåäžããããããšå
±ã«è¡šé¢éšã¯å¿è«
å
éšã«ãå·£ã®ãªãå°å¯ã§è¯å¥œãªé³ç©ãåŸãã
ããããããŠãèåã1.5mmã®é³é ãè¡ã€ããã
ãã¿ãã¿ãŸã§æ¹¯ãåããæ¬ é¥ã®ãªãè¯å¥œãªèè
é³é åãåŸããããèä¹
æ§ã¯70åã®é³é åŸãå
ã®æå·ã¯å
šãèŠãããããªãçžåœåæ°ã®é³é ã
å¯èœã§ãã€ãã As a result, not only was it possible to perform good casting with good melt flow and no sinkage, but the transferability (casting surface) of the casting was significantly better than with simple gravity casting, and casting accuracy was improved. At the same time, a good casting with low density and no cavities was obtained not only on the surface but also inside. At the same time, we performed casting with a wall thickness of 1.5 mm.
The hot water spread to every corner, and a good thin-walled cast product with no defects was obtained. As for durability, no damage to the mold was observed even after 70 castings, and a considerable number of castings were still possible.
æ°åç25ïŒ
ã®åžåŒæ圢åBâ²ãçšããäœå§é³
é æ³ã«ããAlåéã®é³é ãè¡ãããã®ãšãã«
å¯ååããã³åºå®åã®åŽéšã«åä»ããåžåŒç®¡ã
éããŠ700mmHgã®åžåŒåãäœçšãããããã®çµ
æäœå§é³é ã®ç¹åŸŽã«å ããŠãé³åºã粟床ããã€
ã«ã¹ãé³é 䞊ã¿ã«åäžããã Using a suction mold Bâ² with a porosity of 25%, an Al alloy was cast by a low-pressure casting method, and at this time a suction force of 700 mmHg was applied through suction pipes attached to the sides of the movable mold and the fixed mold. As a result, in addition to the characteristics of low-pressure casting, casting accuracy has been improved to the same level as die casting.
ãªãããã®ä»åžåŒæ圢åAâ²ïŒBâ²ãçšããŠã
éŽé¡ã®åºæãã¯ãããšãããŽã 補åãã¬ã©ã¹è£œ
åããã©ã¹ããã¯è£œåã®å å§æ圢çšåãšããŠçš
ãããšãããè¯å¥œãªèä¹
æ§ãåŸããããšå
±ã«ã
ãã€ããã€ã«åäžãªåžåŒåãäœçšãããã転å
æ§ãåãžã®å¯çæ§ãéåžžã«è¯ããªãããã€ãŸã
ãã€ããã€ãŒå
ã®ç©ºæ°ãã¬ã¹ãå¹æçã«é€å»ã
ããããæ°æ³¡ãªã©ã®ãªãè¯åã®åŸãããããšã
ããã€ããåæã«åŸæ¥ã®ããã«ããªãçºçãã
ãªãã§æžãããææå¹çãè¯ããªã€ãã第ïŒïŒ
å³ã«ãã¹ã¿ãŒã¢ãã«ãšåžåŒæ圢åããã³æ圢å
ã®è¡šé¢ããã枬å®çµæã瀺ãããã®ç¬¬ïŒïŒå³ã
ãæ¬çºæã¯ãããã転åæ§ã®åŸãããããšãã
ããã In addition, using other suction molding molds A' and B',
When used as a mold for pressure molding of rubber products, glass products, and plastic products, including shoe sole materials, good durability was obtained, and
Uniform suction force acts on the cavity, resulting in very good transferability and adhesion to the mold, and since air and gas inside the cavity are effectively removed, good quality products without air bubbles can be obtained. I understand. At the same time, material efficiency has been improved because burrs do not need to be generated as in the conventional method. 15th
The figure shows the surface roughness measurement results of the master model, suction molding mold, and molded product. It can be seen from FIG. 15 that the present invention provides excellent transferability.
以äžèª¬æããæ¬çºæã®ç¬¬ïŒçºæã«ãããšãã«
ã¯ã倧éçç£çšã®åŒ·åºŠãšèä¹
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±ã«ã
è¯å¥œãªè»¢åæ§ãå
·åãããããåå
šäœã«éæ°æ§ã
æã¡ããã€ããã€å
šåã«ããããŠç°¡åãã€å¹æç
ã«è±æ°å¹æãäžããããšãã§ãããã€ãŸã倧åå
ã容æã§ãããšå
±ã«ãç°¡åãªå·¥çšãšçã補é æé
åã³äœã³ã¹ãã§è£œé å¯èœãªåžåŒæ圢åã®è£œäœæ³ã
æäŸã§ããã According to the first aspect of the present invention explained above, it has strength and durability for mass production, and
It has good transferability, has air permeability throughout the mold, can provide an extremely simple and effective deaeration effect to the entire cavity, is easy to upsize, and has a simple and short process. It is possible to provide a method for manufacturing a suction molding mold that can be manufactured in short manufacturing time and at low cost.
æ¬çºæã«ãã補äœãããåžåŒæ圢åã¯ã¢ã«ãã
ãŠã åéãZnåéãMgåéãCuåéãæ®éé³
éããã¯ã¿ã€ã«é³éãªã©ã®éååžåŒé³é ãäœå å§
åžåŒé³é ã«å¥œé©ã§ããã»ããããŠããŽã ãã¬ã©
ã¹ããã©ã¹ããã¯ãéå±ãªã©ã®å¡æ§æµåã䌎ãå
å§åžåŒæ圢åãªã©è±æ°ãèŠæ±ãããããããåæ
圢ã«çšããããšãã§ããããŸããã»ã©ããã¯ãã¢
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ã®é«ãæ圢åãšããŠãé©çšã§ããããããã«ãã
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ãæ圢åãå®äŸ¡ã«éç£ããããšãã§ãããã The suction molding mold produced according to the present invention is suitable for gravity suction casting and low pressure suction casting of aluminum alloys, Zn alloys, Mg alloys, Cu alloys, ordinary cast iron, ductile cast iron, etc., as well as wax, rubber, glass, etc. It can be used for any type of molding that requires degassing, such as pressurized suction molding that involves plastic flow, such as plastics and metals. It can also be used as a mold with high degassing and dehydration properties in the molding of ceramics, mortar, refractories, etc. In each of these molds, it is possible to inexpensively mass-produce molded products with complex shapes, thin walls, and tightness and precision. can. .
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ïŒïŒå³ã¯ç²çµæãšéªšæã®é
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瀺ãã°ã©ãã§ããã
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Figures 1 to 3 are cross-sectional views showing examples of durable molds, Figures 4 a and b are cross-sectional views schematically showing the structure of durable suction molds, and Figures 5 and 6 are suction molds. 7 to 9 are cross-sectional views showing examples of the use of the suction molding mold. FIG. 10 is a graph showing the relationship between the strength and firing time of the suction molding mold according to the present invention. The figure is a graph showing the relationship between firing time and weight increase, Figure 12 is a graph showing the relationship between fiber inclusion rate and bending strength, Figure 13 is a graph showing the relationship between fiber inclusion rate and dimensional change, and Figure 14 is a graph showing the relationship between fiber inclusion rate and dimensional change. Graph showing the relationship between time, porosity, and hardened layer, 1st
Figure 5 is a graph showing the transferability of the suction mold, No. 16
The figure is a graph showing the relationship between the blending ratio of aggregate and porosity, and FIG. 17 is a graph showing the relationship between the blending ratio of caking material and aggregate and porosity. 1... Composite fired body, 2... Hardened layer, 3... Unfired backing layer.
Claims (1)
äžã®ã»ã©ããã¯ç²æ«ã骚æãšãããã«ç¡¬åéçšã§
èžçºããæåãå«ãç²çµæãééé åæ¯ã§ïŒïŒã
ïŒïŒïŒïŒïŒãïŒïŒïŒïŒã«æ··åããŠã¹ã©ãªãŒç¶æ··åç©
ãäœãããã®ã¹ã©ãªãŒç¶æ··åç©ãæµã蟌ã¿åºåã
ããŠåé¢ãé 圢ãããããèªç¶ä¹Ÿç¥åã¯ïŒåã³äž
次çŒæããã®ã¡ãé žåæ§é°å²æ°äžã§çŒæ枩床600
ã1000âã§ïŒã50æéçŒæããããšãç¹åŸŽãšãã
èä¹ æ§åžåŒæ圢åã®è£œäœæ³ã1 Iron-based powder with a particle size of 500 ÎŒm or less and ceramic powder with a particle size of 300 ÎŒm or less are used as aggregates, and a caking agent containing components that evaporate during the hardening process is mixed in a weight ratio of (1 to 30 ÎŒm).
5): (1 to 5): 1 is mixed to make a slurry mixture, this slurry mixture is poured and solidified to form a mold surface, and after air drying and/or primary firing, it is placed in an oxidizing atmosphere. Firing temperature in 600
A method for producing a durable suction mold, characterized by firing at ~1000°C for 1 to 50 hours.
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP58080943A JPS606243A (en) | 1983-05-11 | 1983-05-11 | Durable suction forming mold |
MX200937A MX161282A (en) | 1983-04-09 | 1984-04-06 | FORMING, COMPOSITE AND DURABLE MODEL TO MANUFACTURE THREE-DIMENSIONAL PRODUCTS |
CA000451448A CA1266159A (en) | 1983-04-09 | 1984-04-06 | Composite and durable forming model with permeability |
SU843725402A SU1632366A3 (en) | 1983-04-09 | 1984-04-06 | Wear-resistant split moulding pattern |
AT84103966T ATE64876T1 (en) | 1983-04-09 | 1984-04-09 | TRANSLUCENT FORM. |
EP84103966A EP0121929B1 (en) | 1983-04-09 | 1984-04-09 | Permeable mold |
IN247/MAS/84A IN160636B (en) | 1983-04-09 | 1984-04-09 | |
DE8484103966T DE3484752D1 (en) | 1983-04-09 | 1984-04-09 | PERMANENT SHAPE. |
AU26640/84A AU566385B2 (en) | 1983-04-09 | 1984-04-09 | Permeable moulds |
KR1019840001857A KR910000953B1 (en) | 1983-04-09 | 1984-04-09 | Composite and durable forming model with permability |
BR8401651A BR8401651A (en) | 1983-04-09 | 1984-04-09 | COMPOSITE AND DURABLE SHAPE |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP58080943A JPS606243A (en) | 1983-05-11 | 1983-05-11 | Durable suction forming mold |
Publications (2)
Publication Number | Publication Date |
---|---|
JPS606243A JPS606243A (en) | 1985-01-12 |
JPH0323253B2 true JPH0323253B2 (en) | 1991-03-28 |
Family
ID=13732568
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP58080943A Granted JPS606243A (en) | 1983-04-09 | 1983-05-11 | Durable suction forming mold |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPS606243A (en) |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS4838288A (en) * | 1971-09-20 | 1973-06-05 |
-
1983
- 1983-05-11 JP JP58080943A patent/JPS606243A/en active Granted
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS4838288A (en) * | 1971-09-20 | 1973-06-05 |
Also Published As
Publication number | Publication date |
---|---|
JPS606243A (en) | 1985-01-12 |
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