Title: Casting method and casting mold
Abstract: A casting method and casting mold able produce a casting having an island and connecting portion is disclosed. A casting having a body, an opening provided so as to pass through the body, an island arranged separated from the body in the opening, and a connecting portion joining the island and body is cast using a casting mold. The casting mold is provided with a body gate connected to a body cavity for forming the body and an opening gate connected to an island/connecting portion cavity for forming the island and the connecting portion. The body gate and opening gate are connected to a runner through body pin gates and opening pin gates; in addition, a die casting mold able to suitably change between a three-part mold structure and a two-part mold structure to cast a die casting is disclosed. The three-part mold structure die casting mold, a movable mold, a first cavity, a connection sleeve, a first runner, a pin gate, and an extension sleeve. When forming the two-part mold structure die casting mold, the fixed mold is removed, the extension sleeve insert inserted in the extension sleeve is removed, and the pin gate is filled by a pin gate insert. Further, the intermediate mold insert and the movable mold insert are replaced to form the two-part mold structure die casting mold forming the second cavity and second runner moving the movable mold with respect to the intermediate mold.
Patent Number: 7,025,114 Issued on 04/11/2006 to Nagasaka, et al.
| Inventors:
|
Nagasaka; Takeshi (Kariya, JP);
Hatano; Tomoyuki (Nagoya, JP);
Takagi; Hiromi (Nagoya, JP);
Ozawa; Ikuo (Toyoake, JP);
Hibi; Yasushi (Kariya, JP);
Furuhata; Minoru (Osaka, JP);
Tsuboe; Koji (Osaka, JP);
Uenaka; Isao (Osaka, JP)
|
| Assignee:
|
DENSO Corporation (Kariya, JP)
|
| Appl. No.:
|
683477 |
| Filed:
|
October 10, 2003 |
Foreign Application Priority Data
| Jul 04, 2001[JP] | 2001-203913 |
| Oct 11, 2002[JP] | 2002-299477 |
| Current U.S. Class: |
164/113; 164/312; 164/121; 164/137 |
| Current Intern'l Class: |
B22D 17/10 (20060101) |
| Field of Search: |
164/113,121,137,135,339,312,296,340
|
References Cited [Referenced By]
U.S. Patent Documents
| 3137904 | Jun., 1964 | Steinman et al.
| |
| 3575233 | Apr., 1971 | Mahle et al.
| |
| 5323840 | Jun., 1994 | Usui et al.
| |
| 6460596 | Oct., 2002 | Yamaguchi et al.
| |
| Foreign Patent Documents |
| 58-199131 | Nov., 1983 | JP.
| |
| 3-136822 | Jun., 1991 | JP.
| |
Primary Examiner: Tran; Len
Attorney, Agent or Firm: Harness, Dickey & Pierce, PLC
Claims
The invention claimed is:
1. A casting method for casting a product having a body, an opening provided
so as to pass through the body, an island provided separated from the body in the
opening, and a connecting portion joining the island and body using a mold having
a cavity corresponding to the shape of the product,
the mold being provided with a body gate connected to a body cavity for forming
the body in the cavity and a separate opening gate connected to an island/connecting
portion cavity for forming the island and connecting portion in the opening in
the cavity;
the body gate and opening gate being connected to a runner for introducing a
melt into them; and
the melt fed into the runner being filled in the cavity through the body gate
and the opening gate; wherein
the sectional area of the connecting portion being smaller than that of the body
and a channel area of the island/connecting portion cavity being smaller than that
of the body cavity.
2. A casting method as set forth in the claim 1, wherein,
the mold has a three-part structure of a fixed mold, an intermediate mold, and
a movable mold;
the fixed mold and the intermediate mold are provided between them with said runner;
the intermediate mold and movable mold are provided between them with
said cavity, said body gate, and said opening gate;
the intermediate mold is provided with a body pin gate connecting the runner
and the body gate and an opening pin gate connecting the runner and the opening
gate; and
the melt sent into the runner is filled in the cavity through the body pin gate
and body gate and through the opening pin gate and opening gate.
3. A casting method as set forth in claim 2, comprising:
filling the melt, then moving said intermediate mold and movable mold to separate
said fixed mold and said intermediate mold;
moving said movable mold to separate said intermediate mold and movable mold,
cutting a runner casting formed in said runner from pin gate castings formed in
said body pin gate and said opening pin gate, and releasing said pin gate castings
from said intermediate mold;
then releasing the casting from said movable mold in the state with the pin gate
castings attached.
4. A casting method as set forth in claim 2, wherein said intermediate mold and
said movable mold have between them a balance runner provided at least at part
of the section between said body pin gate and said body gate and at least at part
of the section between said opening pin gate and said opening gate and wherein
at least part of said melt is supplied from said body pin gate through said balance
runner to said body gate and from said opening pin gate through said balance runner
to said opening gate.
5. A casting method as set forth in claim 1, wherein said product is a front
end panel for an automobile and has a body having a surround, an opening formed
inside said surround, a part mount as an island arranged in said opening, and stays
supporting said part mount as said connection portion.
6. A casting method as set forth in claim 5, wherein said part mount mounts a
motor, fan, or pulley.
7. A casting mold for casting a product having a body, an opening provided so
as to pass through the body, an island provided separated from the body in the
opening, and a connecting portion joining the island and body,
the mold having a three-part structure of fixed mold, an intermediate mold, and
a movable mold;
the intermediate mold and the movable mold being provided between them with a
cavity having a body cavity for forming the body and an island/connecting portion
cavity for forming the island and the connecting portion in the opening, a body
gate connected to the body cavity, and a separate opening gate connected to the
island/connecting portion cavity;
the fixed mold and the intermediate mold being provided between them with a runner
for introducing melt into the body gate and the opening gate;
the intermediate mold being provided with a body pin gate connecting the runner
and the body gate and an opening pin gate connecting the runner and the opening
gate; and
the mold sent into the runner being filled in the cavity through the body pin
gate and body gate and through the opening pin gate and opening gate; wherein
the sectional area of the connecting portion being smaller than that of the body
and a channel area of the island/connecting portion cavity being smaller than that
of the body cavity.
8. A casting mold as set forth in claim 7, wherein a plurality of at least one
of said body gate and said opening gate are provided.
9. A casting mold as set forth in claim 7, wherein said body pin gate and/or
said opening pin gate is reversely tapered to expand in channel area from said
fixed mold toward said movable mold or from said movable mold toward said fixed mold.
10. A casting mold as set forth in claim 7, wherein said body pin gate and/or
said opening pin gate is provided at a cavity insert detachably inserted in a cavity
insert setting hole provided in said intermediate mold.
11. A casting mold as set forth in claim 7, wherein a draft of a least part of
an inner wall of said cavity at said movable mold side is not more than 1°.
12. A casting mold as set forth in claim 7, wherein said movable mold is provided
with a plurality of ejector pins for pushing out the casting formed in the cavity
from said cavity.
13. A casting mold as set forth in claim 12, wherein said ejector pins are provided
to abut against said casting near body pin gates and/or opening pin gates.
14. A casting mold as set forth in claim 7, wherein said intermediate mold and
said movable mold have between them a balance runner provided at least at part
of the section between said body pin gate and said body gate and at least at part
of the section between said opening pin gate and said opening gate.
15. A casting mold as set forth in claim 14, wherein said movable mold is provided
with a plurality of ejector pins for pushing out the casting formed in the cavity
from said cavity and wherein said ejector pins are provided to abut against said
balance runner near the positions of body pin gates connected to said balance runner.
16. A casting mold as set forth in claim 15, wherein a projection projecting
out in the direction of the intermediate mold is provided near a joining portion
of said body pin gate and/or opening pin gate and said balance runner.
17. A casting mold as set forth in claim 7, wherein an end part formed at said
movable mold in said body pin gate and/or said opening pin gate is provided with
a distributor projecting out toward an inlet of said body pin gate and/or said
opening pin gate.
18. A casting mold as set forth in claim 17, wherein said distributor is shaped
with a draft of at least part of not more than 1°.
19. A casting mold as set forth in claim 7, wherein a portion where said body
pin gate and/or said opening pin gate connects with said runner and is provided
with a constricted part reduced in channel area.
20. A casting mold as set forth in claim 7, wherein said runner is branched into
a body runner for introducing said melt into said body pin gate and an opening
runner for introducing said melt into said opening pin gate.
21. A casting old as set forth in claim 20, wherein said body runner and said
opening runner are adjusted in inside diameter so that the rates of filling said
melt in them become substantially equal.
22. A casting mold as set forth in claim 20, wherein said opening runner has
a shape similar to the shape of said island.
23. A casting mold as set forth in claim 7, wherein said cavity is connected
to a pressure reducing means for reducing the pressure in said cavity.
24. A casting mold as set forth in claim 7, wherein said product is a front end
panel for an automobile and has a body having a surround, an opening formed inside
said surround, a part mount as an island arranged in said opening, and stays supporting
said part mount as said connecting portion.
25. A casting mold as set forth in claim 24, wherein said part mount mounts a
motor, fan, or pulley.
26. A casting method for casting a product having a body, an opening provided
so as to pass through the body, an island provided separated from the body in the
opening, and a connecting portion joining the island and body using a mold having
a cavity corresponding to the shape of the product,
the mold having a body cavity for forming the body in the cavity, an island/connecting
portion cavity for forming the island and the connecting portion in the opening
in the cavity, and a separate opening gate connected to the island/connecting portion
cavity, the opening gate being connected to a runner introducing melt into it;
the mold fed into the runner being filled in the cavity through the opening gate; wherein
the sectional area of the connecting portion being smaller than that of the body
and a channel area of the island/connecting portion cavity being smaller than that
of the body cavity.
27. A casting mold for casting a product having a body, an opening provided so
as to pass through the body, an island provided separated from the body in the
opening, and a connecting portion joining the island and body,
the mold having a three-part structure of a fixed mold, intermediate mold, and
movable mold;
the intermediate mold and movable mold being provided between them with a cavity
having a body cavity for forming the body and an island/connecting portion cavity
for forming the island and the connecting portion in the opening and a separate
opening cavity connected to the island/connecting portion cavity;
the fixed mold and the intermediate mold being provided between them with a runner
for introducing melt into the opening gate;
the intermediate mold being provided with an opening pin gate connecting the
runner and the opening gate; and
the melt sent into the runner being filled in the cavity through the opening
pin gate and opening gate; wherein
the sectional area of the connecting portion being smaller than that of the body
and a channel area of the island/connecting portion cavity being smaller than that
of the body cavity.
28. A three-part mold structure die casting mold having a fixed mold having a
connection sleeve connected to an ejection sleeve for injecting a melt, an intermediate
mold able to move with respect to said fixed mold, and a movable mold able to move
with respect to said intermediate mold, said intermediate mold and said movable
mold having between them a cavity for injection of said melt to form a die casting,
said fixed mold and said intermediate mold having between them a first runner connected
to said connection sleeve, and said intermediate mold having inside it a pin gate
connecting said first runner and said cavity, wherein,
said intermediate mold is formed with an extension sleeve provided on an extension
of said connection sleeve, said intermediate mold and said movable mold have formed
between them a second runner for connecting said extension sleeve and said cavity,
said extension sleeve has an extension sleeve insert inserted in it for filling
the same, and said second runner has a second runner insert inserted in it for
filling the same;
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold insert inserted detachably in said
movable mold; and
said die casting mold being adapted to form a two-part mold structure die casting
mold moving said movable mold with respect to said intermediate mold by removing
said fixed mold, removing said extension sleeve insert and said second runner insert
inserted in said extension sleeve and said second runner, or filling said pin gate
by a pin gate insert inserted into said intermediate mold and replacing at least
one of said intermediate mold insert and said movable mold insert with another
intermediate mold insert or another movable mold insert to form another cavity.
29. A die casting mold as set forth in claim 1, wherein:
said intermediate mold is formed with an extension sleeve provided on an extension
of said connection sleeve, and said extension sleeve has an extension sleeve insert
inserted in it for filling it;
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold insert inserted detachably in said
movable mold; and
said die casting mold is designed to be able to form a two-part mold structure
die casting mold moving said movable mold with respect to said intermediate mold
by removing said fixed mold, removing said extension sleeve insert inserted in
said extension sleeve, filling said pin gate by a pin gate insert to be inserted
into said intermediate mold, and replacing at least one of said intermediate mold
insert and said movable mold insert with another intermediate mold insert or another
movable mold insert to form another cavity and a second runner connecting this
and the above extension sleeve.
30. A die casting mold as set forth in claim 1, wherein:
said intermediate mold is formed with an extension sleeve provided on an extension
of said connection sleeve, said intermediate mold and said movable mold have formed
between them a second runner for connecting said extension sleeve and said cavity,
said extension sleeve has an extension sleeve insert inserted in it for filling
it, and said second runner has a second runner insert inserted in it for filling it;
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold insert inserted detachably in said
movable mold; and
said die casting mold is designed to be able to form a two-part mold structure
die casting mold moving said movable mold with respect to both said fixed mold
and said intermediate mold in a state with the two closed by removing said extension
sleeve insert and said second runner insert inserted in said extension sleeve and
said second runner, filling said first runner by a fixed mold insert to be inserted
in said fixed mold, filling said pin gate by a pin gate insert to be inserted into
said intermediate mold, and replacing at least one of said intermediate mold insert
and said movable mold insert with another intermediate mold insert or another movable
mold insert to form another cavity.
31. A die casting mold as set forth in claim 1, wherein:
said intermediate mold is formed with an extension sleeve provided on an extension
of said connection sleeve, and said extension sleeve has an extension sleeve insert
inserted in it for filling it;
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold inset inserted detachably in said
movable mold; and
said die casting mold is designed to be able to form a two-part mold structure
die casting mold moving said movable mold with respect to both said fixed mold
and said intermediate mold in a state with the two closed by removing said extensions
sleeve insert inserted in said extension sleeve, filing said first runner by a
fixed mold insert to be inserted in said fixed mold, filing said pin gate by a
pin gate insert to be inserted into said intermediate mold, and replacing at least
one of said intermediate mold insert and said movable mold insert with another
intermediate mold inset to another movable mold insert to form another cavity and
a second runner connecting this and the above extension sleeve.
32. A die casting mold as set forth in claim 1, wherein:
said intermediate mold and said movable mold have formed between them a second
runner for connecting said connection sleeve and said cavity, and said second runner
has a second runner insert inserted in it to fill it;
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold insert inserted detachably in said
movable mold, and said first runner is formed between a fixed mold insert inserted
detachably with respect to said fixed mold and said intermediate mold; and
said die casting mold is designed to be able to form a two-part mold structure
die casting mold moving said movable mold with respect to said fixed mold by removing
said intermediate mold, removing said second runner insert inserted in said second
runner, and replacing said fixed mold insert with another fixed mold insert or
replacing said fixed mold insert and said movable mold insert with other fixed
mold insert and movable mold insert.
33. A die casting mold as set forth in claim 1, wherein:
said cavity is formed between an intermediate mold insert inserted detachably
in said intermediate mold and a movable mold insert inserted detachably in said
movable mold, and said first runner is formed between a fixed mold insert inserted
detachably in said fixed mold and said intermediate mold; and
said die casting mold is designed to be able to form a two-part mold structure
die casting mold moving said movable mold with respect to said fixed mold by removing
said intermediate mold and replacing said fixed mold insert with another fixed
mold insert or replacing said fixed mold insert and said movable mold insert with
another fixed mold insert and another movable mold insert to fill said first runner
and form another cavity and a second runner connecting this and said extension sleeve.
34. A die casting mold as set forth in claim 28, wherein said movable mold is
provided with a plurality of ejector pins for ejecting a die casting formed in
said cavity from said cavity and a usage pin changing means for changing ejector
pins used among said plurality of ejector pins between when forming said three-part
mold structure and said two-part mold structure.
35. A die casting mold as set forth in claim 28, wherein said die casting mold
has a burner unit for adjusting a surface temperature in said cavity around said cavity.
36. A die casting mold as set forth in claim 28, wherein said cavity is formed
around it with a plurality of insertion and positioning holes enabling insertion
and positioning of said burner unit, and said burner unit can be changed in arrangement
among said insertion and positioning holes.
37. A die casting mold as set forth in claim 28, wherein said die casting mold
is provided with a pressurizing cylinder for pressurizing said casting to cut it
from a casting formed in said pin gate when separating a casting formed in said
first runner from said intermediate mold in the case of forming said three-part
mold structure.
38. A die casting mold as set forth in claim 28, wherein a die casting formed
in said cavity is a front end panel for attaching an auto part at the front of
an automobile and for supporting an engine.
39. A die casting mold as set forth in claim 1, wherein said movable mold is
provided with a plurality of ejector pins for ejecting a die casting formed in
said cavity from said cavity and a usage pin changing means for changing ejector
pins used among said plurality of ejector pins between when forming said three-part
mold structure and said two-part mold structure.
40. A die casting mold as set forth in claim 1, wherein said die casting mold
has a burner unit for adjusting a surface temperature in said cavity around said cavity.
41. A die casting mold as set forth in claim 1, wherein said cavity is formed
around it with a plurality of insertion and positioning holes enabling insertion
and positioning of said burner unit, and said burner unit can be changed in arrangement
among said insertion and positioning holes.
42. A die casting mold as set forth in claim 1, wherein said die casting mold
is provided with a pressurizing cylinder for pressurizing said casting to cut it
from a casting formed in said pin gate when separating a casting formed in said
first runner from said intermediate mold in the case of forming said three-part
mold structure.
43. A die casting mold as set forth in claim 1, wherein a die casting formed
in said cavity is a front end panel for attaching an auto part at the front of
an automobile and for supporting an engine.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a casting method and a casting mold for casting
a product having a body, an opening provided so as to pass through that body, an
island arranged inside the hollow away from the body, and a connecting portion
connecting the island and the body, in particular a case of casting a product with
thicknesses of the body, island, and connecting portion of 1.5 to 4 mm. Note that
here, the term "mold" is used in a sense including both "molds" and "dies".
Further, the present invention relates to a die casting mold of a three-part
mold structure using three molds to form a thin die casting or a complicatedly
shaped die casting.
2. Description of the Related Art
In the past, for example in the die casting method for casting a product used
for various parts, a cavity having the same shape as the product has been formed
between a pair of molds and a melt of metal has been filled in the cavity to cast
the product.
In this die casting method, a gate serving as an inlet for the melt in the cavity
and a runner for guiding the melt poured from a pouring portion into the gate are
provided between the pair of molds. Further, the melt is poured into a sleeve at
the pouring portion and the melt injected to the runner by a plunger to fill the
melt in the cavity from the runner through the gate.
With this conventional casting method, it was difficult to produce a casting
having a complicated shape or a thin casting. For example, it was difficult to
cast a part having an opening provided so as to pass through the body and having
inside that opening an island arranged separated from the body and a connection
portion joining the island and body.
That is, in a casting having such an island and connecting portion, the melt
flowing from the runner to the body has to flow to the island through the connecting
portion. It is however not easy to feed melt from the body to the connecting portion
and island. In many cases, the melt is not sufficiently filled there—resulting
in casting defects.
The problem of casting defects can be said to occur not only in the die casting
method, but also general casting methods. Therefore, a casting method able to produce
a casting having an island and connecting portion easily and with a high quality
has been desired.
In another respect, almost all die casting molds for forming the die castings
are of two-part mold structures having a fixed mold having a connection sleeve
for injection of the melt and a movable mold able to move relative to the fixed
mold and forming a die casting in a cavity formed between the fixed mold and movable
mold. As opposed to this, the inventors discovered a three-part mold structure
die casting mold provided with an intermediate mold between the fixed mold and
movable mold.
In this three-part mold structure die casting mold, the melt injected from the
connection sleeve is filled into a cavity formed between the intermediate mold
and movable mold through a runner formed between the fixed mold and movable mold
and a pin gate formed at the intermediate mold. Afterwards, the intermediate mold
is moved with respect to the fixed mold, then the movable mold is moved with respect
to the intermediate mold and the die casting formed in the cavity is taken out.
Note that as prior art documents related to the invention of this application,
there are Japanese Unexamined Patent Publication (Kokai) No. 58-199131 and Japanese
Unexamined Patent Publication (Kokai) No. 3-136822.
This three-part mold structure die casting mold can form a thin die casting
with a thickness of for example 1.5 to 4 mm or a die casting with a complicated
shape while prevent casting defects. Therefore it is not suitable for forming a
thick die casting with a thickness of for example over 4 mm or a die casing with
not that complicated a shape. Further, in this case, use of a conventional two-part
mold structure die casting mold facilitates handling and facilitates maintenance
etc. since it is simple in structure.
That is, the above two-part mold structure die casting mold and three-part mold
structure die casting mold each has its advantages and disadvantages. Therefore,
a die casting mold having the advantages of both has been desired.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a casting method and casting
mold able to easily produce a casting having an island and connecting portion in
a high quality state.
Another object of the present invention is to provide a die casting mold
able to be suitably changed between a three-part mold structure and two-part mold
structure in accordance with the shape of the individual die casting and therefore
able to optimally form a die casting.
According to a first aspect of the present invention, there is provided
a casting method for casting a product having a body, an opening provided so as
to pass through the body, an island provided separated from the body in the opening,
and a connecting portion joining the island and body using a mold having a cavity
corresponding to the shape of the product, the mold being provided with a body
gate connected to a body cavity for forming the body in the cavity and an opening
gate connected to an island/connecting portion cavity for forming the island and
connecting portion in the opening in the cavity; the body gate and opening gate
being connected to a runner for introducing a melt into them; and the melt fed
into the runner being filled in the cavity through the body gate and the opening gate.
That is, the present invention provides a casting method for a product having
a body forming the outer shape of the product as a whole and an island and connecting
portion formed in the opening passing through the body.
Further, in the present invention, use is made of a mold providing the body
gate and opening gate at a body cavity and island/connecting portion cavity and
connecting these gates to a runner.
Therefore, it is possible to easily produce a casting having a complicated
shape in a state with no casting defects.
That is, the melt introduced into the runner is divided between the body gate
and the opening gate. Further, the melt starts to be filled in the body cavity
from the body gate, while the melt starts to be filled in the island/connecting
portion cavity from the opening gate. That is, melt is directly sent through the
gates to the body cavity and the island/connecting portion cavity.
Accordingly, it is possible to prevent melt from being supplied later
to one cavity than the other cavity and possible to directly and quickly fill melt
to both cavities. For this reason, it is possible to prevent the delay of supply
of melt and the occurrence of casting defects.
In this way, it is possible to match as much as possible the ease of filling
of
melt between the body cavity and the island/connecting portion cavity even when
producing a casting having an island and connecting portion.
Accordingly, it is possible to easily produce a high quality casting
with almost no problem of casting defects even in a casting having an island and
connecting portion.
According to a second aspect of the present invention, there is provided
a casting mold for casting a product having a body, an opening provided so as to
pass through the body, an island provided separated from the body in the opening,
and a connecting portion joining the island and body, the mold having a three-part
structure of a fixed mold, intermediate mold, and movable mold; the intermediate
mold and movable mold being provided between them with a cavity having a body cavity
for forming the body and an island/connecting portion cavity for forming the island
and the connecting portion in the opening, a body gate connected to the body cavity,
and an opening cavity connected to the island/connecting portion cavity; the fixed
mold and the intermediate mold being provided between them with a runner for introducing
melt into the body gate and the opening gate; the intermediate mold being provided
with a body pin gate connecting the runner and the body gate and an opening pin
gate connecting the runner and the opening gate; and the melt sent into the runner
being filled in the cavity through the body pin gate and body gate and through
the opening pin gate and opening gate.
The structure of the casting mold of the present invention does not form the
cavity, gates, and runner at the interface of a pair of molds as in the past, but
forms them at other portions than the interface for a three-dimensional arrangement.
Due to this, it is possible to form the opening gate directly in the island/connecting
portion cavity where the melt has difficulty flowing to and introduce the melt
from the opening gate directly to the island/connecting portion cavity. Further,
to introduce melt directly to the body cavity and island/connecting portion cavity,
it is also possible to provide the above body pin gate and opening pin gate, respectively.
This structure of the mold can be realized by a three-part structure of a fixed
mold, intermediate mold, and movable mold as explained above.
That is, the runner is provided between the fixed mold and the intermediate
mold, and the cavity, body gate, and opening gate are provided between the intermediate
mold and movable mold. Further, the intermediate mold is provided with the body
pin gate for connecting the body cavity and body gate and the opening pin gate
for connecting the island/connecting portion cavity and the opening gate.
Due to this, it is possible to supply melt directly to the body cavity and the
island/connecting portion cavity and possible to easily release the product etc.
from the mold after the casting as explained above.
For this reason, if using the casting mold of the present invention, it is possible
to realize a casting method which enables the formation of a casting in a high
quality state free from casting defects even for a casting having the island and
connecting portion and which enables the casting to be easily taken out from the
casting mold after being shaped.
According to a third aspect of the present invention, there is provided
a casting method for casting a product having a body, an opening provided so as
to pass through the body, an island provided separated from the body in the opening,
and a connecting portion joining the island and body using a mold having a cavity
corresponding to the shape of the product, the mold having a body cavity for forming
the body in the cavity, an island/connecting portion cavity for forming the island
and the connecting portion in the opening in the cavity, and an opening gate connected
to the island/connecting portion cavity, the opening gate being connected to a
runner introducing melt into it; the melt fed into the runner being filled in the
cavity through the opening gate.
The melt fed into the runner starts to be filled in the island/connecting portion
cavity from the opening gate. Further, the melt flowing into the island/connecting
portion cavity then flows into the body cavity and fills the cavity as a whole.
In this way, since the melt is introduced into the cavity through the opening
gate, it is possible to prevent the problems of casting defects etc. in the island/connecting
portion cavity and possible to produce a high quality casting.
According to a fourth aspect of the present invention, there is provided
a casting mold for casting a product having a body, an opening provided so as to
pass through the body, an island provided separated from the body in the opening,
and a connecting portion joining the island and body, the mold having a three-part
structure of a fixed mold, intermediate mold, and movable mold; the intermediate
mold and movable mold being provided between them with a cavity having a body cavity
for forming the body and an island/connecting portion cavity for forming the island
and the connecting portion in the opening and an opening cavity connected to the
island/connecting portion cavity; the fixed mold and the intermediate mold being
provided between them with a runner for introducing melt into the opening gate;
the intermediate mold being provided with an opening pin gate connecting the runner
and the opening gate; and the melt sent into the runner being filled in the cavity
through the opening pin gate and opening gate.
By using this casting mold, it is possible to easily introduce a melt into the
cavity through the opening gate. Due to this, if using this casting mold, it is
possible to easily produce a high quality casting free of defects in the opening.
According to a fifth aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having connection sleeve connected
to an ejection sleeve for injecting a melt, an intermediate mold able to move with
respect to the fixed mold, and a movable mold able to move with respect to the
intermediate mold, the intermediate mold and the movable mold having between them
a cavity for injection of the melt to form a die casting, the fixed mold and the
intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the intermediate mold is formed with an extension
sleeve provided on an extension of the connection sleeve, the intermediate mold
and the movable mold have formed between them a second runner for connecting the
extension sleeve and the cavity, the extension sleeve has an extension sleeve insert
inserted in it for filling the same, and the second runner has a second runner
insert inserted in it for filling the same; the cavity is formed between an intermediate
mold insert inserted detachably in the intermediate mold and a movable mold insert
inserted detachably in the movable mold; and the die casting mold is designed to
be able to form a two-part mold structure die casting mold moving the movable mold
with respect to the intermediate mold by removing the fixed mold, removing the
extension sleeve insert and the second runner insert inserted in the extension
sleeve and the second runner, or filling the pin gate by a pin gate insert inserted
into the intermediate mold and replacing at least one of the intermediate mold
insert and the movable mold insert with another intermediate mold insert or another
movable mold insert to form another cavity.
The die casting mold of the present invention is designed to be able to be changed
between the three-part mold structure and the two-part mold structure in accordance
with the shape of the die casting to be formed. Further, to realize this, a insert
enabling a change of the cavity is formed when forming a three-part mold structure
and a insert structure is formed at a predetermined position used when forming
a two-part mold structure.
That is, the three-part mold structure die casting mold is comprised of the
fixed mold, intermediate mold, and movable mold and has an extension sleeve insert
and second runner insert inserted in the extension sleeve provided at the intermediate
mold and the second runner provided between the intermediate mold and movable mold.
Further, the cavity is formed between the intermediate mold insert and the movable
mold insert. In the three-part mold structure die casting mold, a path for the
melt communicating the connection sleeve with the cavity through the first runner
is formed.
Further, the die casting mold is designed to allow for the formation of
the above two-part mold structure by removing the fixed mold, removing the extension
sleeve insert and second runner insert, and filling the pin gate with the pin gate
insert. Further, at least one of the intermediate mold insert and movable mold
insert is replaced with another intermediate mold insert or another movable mold
insert to form another cavity. To form the above two-part mold structure die casting
mold, it is also possible to form a path for the melt communicating the extension
sleeve with the second cavity through the second runner.
In this way, it is possible to use the fixed mold and intermediate mold used
when
forming the above three-part mold structure to form a two-part mold structure for
forming a die casting different from the die casting formed when forming a three-part
mold structure. Therefore, it is possible to use the same die casting mold to form
die castings of different shapes.
When forming a thin die casting with a thickness of for example 1.5 to 4 mm
or a die casting with a complicated shape, in general casting is difficult. Therefore,
at this time, it is possible to form the above three-part mold structure die casting
mold and fill the melt directly into the parts of the difficult to cast casting
through the pin gate. At this time, it is possible to prevent casting defects and
form a high quality die casting.
On the other hand, when forming a thick die casting with a thickness of for example
over 4 mm or a die casting with not that complicated a shape, in general casting
is not that difficult. Therefore, at this time, it is possible to form the above
simple structure two-part mold structure die casting mold to facilitate the handling
and improve the maintenance ability etc.
In this way, the die casting mold of the present invention can combine the superior
features of the above three-part mold structure and the superior features of the
above two-part mold structure. That is, according to the die casting mold of the
present invention, it is possible to suitably switch between the three-part mold
structure and the two-part mold structure in accordance with the shape of the individual
die casting and form the best die casting mold for the individual die casting.
According to a sixth aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having a connection sleeve
connected to an ejection sleeve for injecting a melt, an intermediate mold able
to move with respect to the fixed mold, and a movable mold able to move with respect
to the intermediate mold, the intermediate mold and the movable mold having between
them a cavity for injection of the melt to form a die casting, the fixed mold and
the intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the intermediate mold is formed with an extension
sleeve provided on an extension of the connection sleeve, the intermediate mold
and the movable mold have formed between them a second runner for connecting the
extension sleeve and the cavity, the extension sleeve has an extension sleeve insert
inserted in it for filling the same, and the second runner has a second runner
insert inserted in it for filling the same; the intermediate mold is formed with
an extension sleeve provided on an extension of the connection sleeve, and the
extension sleeve has an extension sleeve insert inserted in it for filling it;
the cavity is formed between an intermediate mold insert inserted detachably in
the intermediate mold and a movable mold insert inserted detachably in the movable
mold; and the die casting mold is designed to be able to form a two-part mold structure
die casting mold moving the movable mold with respect to the intermediate mold
by removing the fixed mold, removing the extension sleeve insert inserted in the
extension sleeve, filling the pin gate by a pin gate insert to be inserted into
the intermediate mold, and replacing at least one of the intermediate mold insert
and the movable mold insert with another intermediate mold insert or another movable
mold insert to form another cavity and a second runner connecting this and the
above extension sleeve.
In the present invention, the second runner is formed at least at one of the
other
intermediate mold insert and other movable mold insert when forming the above two-part
mold structure die casting mold. That is, in the present invention, since no second
runner is formed directly between the intermediate mold and the movable mold as
in the three-part mold structure die casting mold, it is not necessary to provide
a second runner insert such as shown in the fifth aspect of the invention and the
insert structure is simple. In addition, in the present invention as well, it is
possible to obtain similar actions and effects as in the fifth aspect of the invention.
According to a seventh aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having a connection sleeve
connected to an ejection sleeve for injecting a melt, an intermediate mold able
to move with respect to the fixed mold, and a movable mold able to move with respect
to the intermediate mold, the intermediate mold and the movable mold having between
them a cavity for injection of the melt to form a die casting, the fixed mold and
the intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the intermediate mold is formed with an extension
sleeve provided on an extension of the connection sleeve, the intermediate mold
and the movable mold have formed between them a second runner for connecting the
extension sleeve and the cavity, the extension sleeve has an extension sleeve insert
inserted in it for filling it, and the second runner has a second runner insert
inserted in it for filling it; the cavity is formed between an intermediate mold
insert inserted detachably in the intermediate mold and a movable mold insert inserted
detachably in the movable mold; and the die casting mold is designed to be able
to form a two-part mold structure die casting mold moving the movable mold with
respect to both the fixed mold and the intermediate mold in a state with the two
closed by removing the extension sleeve insert and the second runner insert inserted
in the extension sleeve and the second runner, filling the first runner by a fixed
mold insert to be inserted in the fixed mold, filling the pin gate by a pin gate
insert to be inserted into the intermediate mold, and replacing at least one of
the intermediate mold insert and the movable mold insert with another intermediate
mold insert or another movable mold insert to form another cavity.
The die casting mold of the present invention can also be switched between the
above three-part mold structure and the above two-part mold structure in accordance
with the shape of the die casting formed.
Further, in the present invention, the above two-part mold structure is
formed using the above fixed mold, intermediate mold, and movable mold. Further,
the fixed mold and intermediate mold are fixed and the movable mold moved with
respect to them.
In the present invention, when forming the above two-part mold structure die
casting
mold, since the fixed mold, intermediate mold, and movable mold are used in the
same way as the above three-part mold structure die casting mold, it is easy to
change from the three-part mold structure to the two-part mold structure.
With the die casting mold of the present invention as well, it is possible to
suitably change between the three-part mold structure and two-part mold structure
in the same way as the above and possible to form the best die casting mold for
each die casting.
According to an eighth aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having a connection sleeve
connected to an ejection sleeve for injecting a melt, an intermediate mold able
to move with respect to the fixed mold, and a movable mold able to move with respect
to the intermediate mold, the intermediate mold and the movable mold having between
them a cavity for injection of the melt to form a die casting, the fixed mold and
the intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the intermediate mold is formed with an extension
sleeve provided on an extension of the connection sleeve, and the extension sleeve
has an extension sleeve insert inserted in it for filling it; the cavity is formed
between an intermediate mold insert inserted detachably in the intermediate mold
and a movable mold insert inserted detachably in the movable mold; and the die
casting mold is designed to be able to form a two-part mold structure die casting
mold moving the movable mold with respect to both the fixed mold and the intermediate
mold in a state with the two closed by removing the extension sleeve insert inserted
in the extension sleeve, filling the first runner by a fixed mold insert to be
inserted in the fixed mold, filling the pin gate by a pin gate insert to be inserted
into the intermediate mold, and replacing at least one of the intermediate mold
insert and the movable mold insert with another intermediate mold insert or another
movable mold insert to form another cavity and a second runner connecting this
and the above extension sleeve.
In the present invention, the second runner is formed from another intermediate
mold insert and another movable mold insert when forming the two-part mold structure
die casting mold. That is, in the present invention, since no second runner is
formed directly between the intermediate mold and the movable mold as in the three-part
mold structure die casting mold, it is not necessary to provide a second runner
insert such as shown in the seventh aspect of the invention and the insert structure
is simple. In addition, in the present invention as well, it is possible to obtain
similar actions and effects as in the seventh aspect of the invention.
According to a ninth aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having a connection sleeve
connected to an ejection sleeve for injecting a melt, an intermediate mold able
to move with respect to the fixed mold, and a movable mold able to move with respect
to the intermediate mold, the intermediate mold and the movable mold having between
them a cavity for injection of the melt to form a die casting, the fixed mold and
the intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the intermediate mold and the movable mold have
formed between them a second runner for connecting the connection sleeve and the
cavity, and the second runner has a second runner insert inserted in it to fill
it; the cavity is formed between an intermediate mold insert inserted detachably
in the intermediate mold and a movable mold insert inserted detachably in the movable
mold, and the first runner is formed between a fixed mold insert inserted detachably
with respect to the fixed mold and the intermediate mold; and the die casting mold
is designed to be able to form a two-part mold structure die casting mold moving
the movable mold with respect to the fixed mold by removing the intermediate mold,
removing the second runner insert inserted in the second runner, and replacing
the fixed mold insert with another fixed mold insert or replacing the fixed mold
insert and the movable mold insert with other fixed mold insert and movable mold insert.
The die casting mold of the present invention can also be switched between the
above three-part mold structure and the above two-part mold structure in accordance
with the shape of the die casting formed.
Further, in the present invention, the above two-part mold structure is
formed using the above fixed mold, intermediate mold, and movable mold. Further,
in the present invention, the first runner is formed using the fixed mold insert.
When forming the two-part mold structure, the fixed mold insert is switched with
another fixed mold insert.
Further, in the three-part mold structure die casting mold of the present
invention, the intermediate mold is not formed with the above extension sleeve
and the extension sleeve insert is not required. Therefore, according to the present
invention, it is possible to form the above two-part mold structure die casting
mold extremely easily.
With the die casting mold of the present invention as well, like with the fifth
aspect of the invention, it is possible to suitably change between the three-part
mold structure and two-part mold structure in the same way and possible to form
the best die casting mold for each die casting.
According to a 10th aspect of the invention, there is provided a three-part
mold structure die casting mold having a fixed mold having a connection sleeve
connected to an ejection sleeve for injecting a melt, an intermediate mold able
to move with respect to the fixed mold, and a movable mold able to move with respect
to the intermediate mold, the intermediate mold and the movable mold having between
them a cavity for injection of the melt to form a die casting, the fixed mold and
the intermediate mold having between them a first runner connected to the connection
sleeve, and the intermediate mold having inside it a pin gate connecting the first
runner and the cavity, wherein the cavity is formed between an intermediate mold
insert inserted detachably in the intermediate mold and a movable mold insert inserted
detachably in the movable mold, and the first runner is formed between a fixed
mold insert inserted detachably in the fixed mold and the intermediate mold; and
the die casting mold is designed to be able to form a two-part mold structure die
casting mold moving the movable mold with respect to the fixed mold by removing
the intermediate mold and replacing the fixed mold insert with another fixed mold
insert or replacing the fixed mold insert and the movable mold insert with another
fixed mold insert and another movable mold insert to fill the first runner and
form another cavity and a second runner connecting this and the extension sleeve.
In the present invention, the second runner is formed by another intermediate
mold insert and another movable mold insert when forming the two-part mold structure
die casting mold. That is, in the present invention, since no second runner is
formed directly between the intermediate mold and the movable mold as in the three-part
mold structure die casting mold, it is not necessary to provide a second runner
insert such as shown in the eighth aspect of the invention and the insert structure
is simple. In addition, in the present invention as well, it is possible to obtain
similar actions and effects as in the eighth aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clearer
from the following description of the preferred embodiments given with reference
to the attached drawings, in which:
FIG. 1 is a perspective view of the overall configuration of a casting in a
first embodiment;
FIG. 2 is a partial perspective view of the state where part of the casting
of the first embodiment and the casting portion formed at a runner at the time
of casting are connected;
FIG. 3 is a sectional view of the structure of a casting mold in the first embodiment;
FIG. 4 is a sectional view of the state of the casting mold in the first embodiment
being filled with a molten metal;
FIG. 5 is a sectional view of the opened state of a fixed mold and intermediate
mold of the casting mold in the first embodiment;
FIG. 6 is a sectional view of the opened state of an intermediate mold and movable
mold of the casting mold in the first embodiment;
FIG. 7 is a sectional view of the state of separation of the product from the
cavity in the first embodiment;
FIG. 8 is a partial sectional view of the structure of a body pin gate and opening
pin gate in the first embodiment;
FIG. 9 is a partial sectional view of a constricted parts of a body pin gate
and opening pin gate in the first embodiment;
FIG. 10 is a partial sectional view of end part of a body pin gate and opening
pin gate in the first embodiment;
FIG. 11 is a partial sectional view of a casting mold in the case of forming
a body pin gate and opening pin gate in the first embodiment reversely tapered
to expand in channel area from the movable mold toward the fixed mold;
FIG. 12 is an explanatory view of a three-part mold structure die casting mold
in a state with a melt injected in a second embodiment;
FIG. 13 is an explanatory view of a three-part mold structure die casting mold
in a state with a melt injected in the second embodiment;
FIG. 14 is an explanatory view of a three-part mold structure die casting mold
in a state with the intermediate mold and movable mold moved with respect to the
fixed mold in the second embodiment;
FIG. 15 is an explanatory view of a three-part mold structure die casting mold
in a state with a first runner sleeve casting cut and with the movable mold moved
with respect to the intermediate mold in the second embodiment;
FIG. 16 is an explanatory view of a three-part mold structure die casting mold
in a state with a first die casting ejected by ejector pins in the second embodiment;
FIG. 17 is an explanatory view of a three-part mold structure die casting mold
in a state with the parts disassembled in the second embodiment;
FIG. 18 is an explanatory view of a two-part mold structure die casting mold
in a state with the parts disassembled; in the second embodiment;
FIG. 19 is an explanatory view of a two-part mold structure die casting mold
in a state with the melt injected in the second embodiment;
FIG. 20 is an explanatory view of a two-part mold structure die casting mold
in a state with the melt injected in the second embodiment;
FIG. 21 is an explanatory view of a two-part mold structure die casting mold
in a state with the movable mold moved with respect to the intermediate mold;
FIG. 22 is an explanatory view of a two-part mold structure die casting mold
in a state with a second die casting ejected by ejector pins in the second embodiment;
FIG. 23 is an explanatory view of a first die casting in the second embodiment;
FIG. 24 is an explanatory view of a first die casting in the second embodiment;
FIG. 25 is a perspective explanatory view showing a first die casting and showing
a first cavity, connection sleeve, first runner, pin gate, etc. in the second embodiment;
FIG. 26 is a perspective explanatory view showing a second die casting and showing
a second cavity, extension sleeve, second runner, in the second embodiment;
FIG. 27 is an explanatory view of another three-part mold structure die casting
mold in the second embodiment;
FIG. 28 is an explanatory view of a three-part mold structure die casting mold
in a state in a third embodiment; and
FIG. 29 is an explanatory view of a three-part mold structure die casting mold
in a state in a fourth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Below, a preferred embodiment of the present invention will be described with
reference to the drawings.
In this case, the runner, pin gates, gates, and cavity may be arranged three-dimensionally.
Therefore, it is possible to easily secure a path of supply of the melt from the
runner to the body gate and opening gate.
Further, after filling the melt into the cavity and forming the casting,
it is possible to move the fixed mold, intermediate mold, and movable mold relative
to each other so as to release the castings formed in the cavity, pin gates, and
runner from the fixed mold, intermediate mold, and movable mold and enable them
to be easily removed.
Further, the method may comprise filling the melt, then moving the intermediate
mold and movable mold to release the fixed mold and the intermediate mold; moving
the movable mold to release the intermediate mold and movable mold, cutting the
runner casting formed in the runner from pin gate castings formed in the body pin
gate and the opening pin gate, and releasing the pin gate castings from the intermediate
mold; then releasing the casting in the state from the mold with the pin gate castings
attached from the movable m
