US3459256A - Casting apparatus - Google Patents

Description

Aug. 5, 1969 l.. `w. JEFFREYS CASTING APPARATUS med April 13, 196e United States Patent O 3,459,256 CASTING APPARATUS Lyman W. Jeffreys, Mount Prospect, Ill., assignor to Amsted Industries Incorporated, Chicago, Ill., a corporation of New Jersey Filed Apr. 13, 1966, Ser. No. 542,335 Int. Cl. B28b 7/02; B22d 17/26; B411) 11/68 U.S. Cl. 164-342 8 Claims ABSTRACT F THE DISCLOSURE An adjustable slab mold has a plurality of inner blocks interposed between opposed main side blocks to define a longitudinal casting cavity. An end block of the mold is biased away from an adjacent bottom block during loose engagement of the inner blocks and is movable on rollers across the cavity defining surface of the bottom block. Upon tight engagement of the inner blocks the end block is forced into contact with the bottom block.

This invention relates generally to the casting of metal articles and more particularly to a mold apparatus for the pressure casting of molten metal.

It is the present practice in the steel industry to cast ingots which are subsequently processed through various preliminary conditioning operations such as cropping, grinding and/0r scarfing in order to prepare such ingots for subsequent rolling operations which form the ingots into slabs, blooms or billets. These rolled products are then used to form finished mill products such as beams, plates, sheets or rails.

It has been proposed to cast slabs, billets or blooms in a chill mold by pressure casting. To overcome the necessity for multiple molds to produce the various sizes of slabs, blooms and billets, an adjustable mold was proposed. The mold is made up of a pair of opposed main blocks which are moved toward and away from each other for closing and opening the mold. Adjustable inner blocks are interposed between the main mold blocks for forming cavities of different sizes and proportions by relatively adjusting the inner blocks.

The inner blocks comprise a top block, a rear end block and bottom block. These inner blocks with the main side blocks define a cavity therebetween which is open at the front end. An ingate assembly closes the front end to complete the definition of the cavity.

Experience indicates that such a mold has been highly successful. One drawback does exist in the use of such a mold. The rear end or back block is arranged to rest on the top surface of the bottom block and is movable thereon. Since these molds are used to produce very large slabs, etc., the back block must of necessity be relatively large. The continued movement of the back block along the top of the bottom block tends to wear away this top surface. Since the mold parts are usually constructed of graphite, this wearing away may take place rather rapidly.

As the surface wears away it changes the linear configuration of the mold with the result that non-rectangular slabs may be produced which may require some finishing before they are suitable for forming into beams, plates, etc. In addition, the bottom surface of the back block may wear away with the result that the cavity adjustments based on the height of the back block will not be accurate.

It is therefore an object of this invention to provide an improved mold apparatus for casting metal articles.

Another object of this invention is to provide an ad- 3,459,256 Patented Aug. 5, 1969 ICC justable mold apparatus wherein wear of the mold surfaces is reduced.

A further object of this invention is the provision of a mold apparatus having an adjustable cavity wherein the tendency of the mold parts to wear is substantially reduced.

These and other objects and advantages of this invention will become apparent from a reading of the following detailed description of this invention when taken in conjunction with the accompanying drawing wherein:

FIGURE l is a partial cross sectional View in elevation of the mold apparatus of this invention, and

FIGURE 2 is a cross sectional view of the mold lifting apparatus of this invention.

The mold apparatus of this invention is especially suitable for the pressure pouring of slabs, billets and blooms.

Referring now to the drawings, reference number 10 denotes an adjustable slab mold mounted on a carriage 12. The mold 10 is made up of two main side blocks 14, only one of which is shown in the drawing, and a plurality of inner blocks. The two side blocks 14 are identical in configuration.

The inner blocks are a top block 16, a bottom block 18 and a rear end block 20. The two main side blocks are fitted together and engage inner blocs 16, 18 and 20 therebetween, defining a mold cavity 22 which is open at its front end. The open end of the cavity 22 is closed by a conventional ingate assembly 24. The blocks of the mold 10 are preferably constructed of graphite.

The top and bottom blocks 116 and 18 are preferably substantially the same length as the main side blocks 14. The bottom block 18 extends below the main side blocks 14 throughout most of its length, but it has a reduced end portion 2'5 which may be approximately ush with the lower surface of the main side blocks 14. The bottom block 18 normally remains fixed on the carriage 12. It is mounted on a rail 26 supported on transverse beams 28' of carriage 12.

The top block '16 is supported by a plurality of hangers or supports 30 which are adjustable in order that the position of top block 16 with respect to the main side blocks 14 may be adjustable for different sizes of slabs, etc. Reference may be had to the above-identified application for further details of the mounting and adjustment of the side blocks 14 and the inner blocks 16 and 1S.

The top, bottom and rear end blocks are selected as to size from the standpoint of the thickness of the slab to be cast. For example, customary slabs may be 5, 6 or 7 inches in thickness and for each of these thicknesses, a corresponding set of blocks is utilized in the mold.

The rear end block 20 is preferably formed of graphite and it is provided on its upper surface 32 with a vent block 34. The vent block 34 is provided with apertures 36 which permit gas to escape therethough during the pouring of molten metal into the assembled mold 10. The rear block 20 is provided with a backing plate 38 secured by conventional means, such as screws (not shown), to the block. The plate 3-8 provides means for attaching the adjusting mechanism 40 to the rear end block 20.

The adjusting mechanism 40 is provided with power means which comprises a pair of hydraulic or air cylinders 44. These cylinders 44 are mounted on brackets 46 which are mounted on support `48 incorporated in the structure of the mold carriage 12. Secured to each cylinder 44 is a piston rod 50 which extends from cylinders 44 through bushings 52 in support 48 to threaded sockets 54 of the lifting mechanism 56 for rear end block 20. Rearward movement of the lifting mechanism 56 which is supported on bracket 58 secured to support 48 is limited by stops 60, also secured to support 48.

The lifting mechanism 56 comprises a plate member 62 to which the threaded sockets 54 are welded or otherwise secured. The sockets 54 are on the side of the plate member 62 opposite that of the rear end block 20. yOn the other side of plate member 62, a bracket 64 is formed or secured. The bracket 64 is formed of two side plates 66 which extend outwardly from the surface of the plate member 62 in the direction of the rear end block 20. On the lower ends of the side plates, an ear 68 is formed, the purpose of which will be explained hereinbelow. The two side plates 66 are joined by joining members 70, each of which is provided with a vertical bore 72 in vertical alignment with each other. The three joining members 70 are spaced from each other to provide open areas between the two side plates 66. In the illustrated embodiment, one member 70 is near the top of the side plates 66, another near the bottom and the third, intermediate the other two, thereby providing a space 74 in the upper half of the lifting mechanism 56 and a space 76 in the lower half of the same.

The vertical bores 72 of joining members 70 are provided with sleeve bushings 78 which are utilized to retard movement of rod 80 which is retained in place by screw 81. The rod '80 extends from above the uppermost joining member 70 down through the middle member 70 and into the lowermost member 70. Rod 80 is utilized to retain connecting member 82 in vertically movable relationship to the lifting mechanism 56. Connecting member 82 may be of any suitable configuration. In the illustrated embodiment, it includes a flat side 84 joined to backing plate 38 of rear end block 20 by any suitable means as by welding or by screws (not shown). A side plate 86 is secured to the flat side `84 which at its end remote from side 84 is provided with two ears `88. The ears 88 are provided with vertical bores 90 which receive therein sleeve bushings 92. The bushings 92 are constructed and arranged to receive in sliding relationship rod 80 in order that connector `82 is movable vertically with respect to lifting mechanism 56.

The ears 88 are constructed and arranged to be received in open spaces 74 and 76 of `bracket `64. The ears 88 are supported for vertical movement on springs 94. The springs 94 are placed around rod l80. The lowermost spring 94 rests on lowermost joining member 70 and the second spring 94 rests on the middle joining member 70, thereby urging ears y88 and connector 82 upwardly. The springs 94 are sufliciently strong to support rear end block and its associated mechanism.

As indicated above, an ear 68 is formed on the lower end of each of the side plates 66. An axle 96 extends between the two ears 68 and the -axle 96 has a roller 98 mounted thereon in rotary relationship. The roller 98 is adapted to roll along the upper surface 100 of the bracket 58 and the upper surface 104 of the bottom block 18 which is in alignment with the top surface 100 of the bracket 58. -If desired, a sliding plate may be substituted for roller 98, which roller, however, is the preferred embodiment.

In operation, the bottom block 18 is placed in position. The rear end block is then moved to the desired position by activating the two cylinders 44. Pressure applied to the cylinders moves piston rods 50 to their right, thereby moving lifting mechanism 56 to its right. Since there is no weight added to the rear block 20` at this point, it is lifted out of contact with the top of the bottom block 18 by the springs 94 pushing up on the ears 88. This lifts connecting member and the rear end block. The roller 98 remains in contact with the bracket 58 and rolls along its top surface 100 to the desired position for rear end block 18 on the top surface 104 of the bottom block. The top block 16 is then lowered by supports 30 until it contacts the vent block 34 and forces the same along with rear block 20 downwardly until rear block 20 contacts the bottom block 18. The main side blocks 14 are then closed to form the cavity 22 which is then closed by ingate assembly 24. The assembled mold 10 is now rolled into place over the pouring tube 102 of a conventional pressure pouring tank where air tight connection is made between the ingate assembly 24 and the pouring tube 102 for the pressure pouring of the slab.

Following casting of the slab, the mold 10 is opened by reversing the steps for assembling the mold. As soon as the top block 1'6 is lifted out of contact with the vent block 34, the springs 94 lift the connector 82, thereby lifting rear end block 20 out of contact with the bottom block 18. The rear end block 20 may then be moved out of the mold or otherwise moved to adjust the size of the cavity 22.

It can be seen from the foregoing that by lifting the rear end block 20 out of contact with the bottom block 18 during adjustment of the cavity of the mold, the tendency of the top surface of the bottom block to wear is substantially, if not completely, eliminated. Wear of the bottom of the rear end block is also substantially eliminated.

While one embodiment of this invention has been described hereinbefore, it should be understood that various modilications may be made in this apparatus without departing from the spirit and scope of the annexed claims. For example, the power means may comprise a motor having a rotary connection with screws substituted for the two piston rods 50 thereby rotating the screws in order that the back block may be suitably positioned. The roller 98 may be replaced by a spring biased slide.

I claim:

1. An adjustable mold apparatus having a plurality of mold blocks, at least one of said blocks being movable relative to the molding position of said other blocks, said movable block in its molding position resting on the top of one of said other blocks, means for lifting said movable block out of contact with said other block during movement of said movable block relative to Said -other block, and roller means supporting said lifting means for rolling engagement with said other block during said relative movement.

2. An adjustable mold apparatus according to claim 1 wherein said lifting means is secured to said movable block.

3. In an adjustable mold having a plurality of mold blocks defining a casting cavity and at least one block movable in a horizontal direction relative to said other blocks to vary the size of the cavity, said movable block in its cavity-defining position being in contact with an upper surface of one of said other blocks, means for lifting said movable block vertically out of contact with said surface of the other block and maintaining it in said lifted position during movement to said movable block relative to said other block, whereby to reduce wear of said movable and other blocks.

4. The invention set out in claim 3 wherein said lifting means is secured to said movable block and said movable block is resiliently supported.

5. The invention set out in claim 4 including means for supporting said lifting means for gliding movement across the surface of said other block.

6. The invention set out in claim 3 wherein said lifting means is secured to said movable block and includes means for moving said movable `block relative to said other block.

7. The invention set out in claim 3 wherein said adjustable mold comprises side block and adjustable inner blocks interposed between the side blocks to define a longitudinal casting cavity, said movable block is an inner end block usable t-o vary the cavity size longitudinally, said other block is an inner bottom block; and said lifting means is secured to said inner end block.

8. The invention set out in claim 7 including roller means secured to said lifting means for supporting said lifting means for rolling engagement with said inner bottom block, and spring means engaged with said lifting 3,459,256 .5 6 means for resiliently supporting said inner end block rela- FOREIGN PATENTS tive to said roller means. 899,292 5/1945 France.

J. SPENCER OVERHOLSER, Primary Examiner 5 R. SPENCER ANNEAR, Assistant Examiner References Cited UNITED STATES PATENTS 2,289,928 7/ 1942 yParker 164-342 3,263,277 8/ 1966 -Ohlendorf etal. 164--343 X U.S. C1. X.R. 3,340,926 9/ 1967 Sylvester 249--158 X 249-158 3,340,798 9/1967 Winger 249-158 X

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