A METHOD AND A DEVICE FOR PRESS CASTING

Abstract: A method and a device (1) respectively of press casting, a liquid metal (49) being poured into a filling chamber (20) to be influenced in this chamber by a lower piston (43) and an upper piston (18), which are mounted on a lower machine table (5) and an upper machine table (10) respectively, which tables (5 and 10 respectively) support a lower mold part (24) and an upper mold part (22) respectively. According to the invention the filling chamber (20) is disposed in or at the lower mold part (24) and receives, as regards the poured-in amount of metal, said lower piston (43), which is adjustable as to its elevational level and can be adjusted to make said amount of metal reach a level somewhat below the casting system (51) between the mold parts (22, 24). The lower piston (43) has a larger diameter than the upper piston (18), which, in connection with the filling of the metal (41), is designed to be lowered to a central position in a guiding and feeding sleeve (19) in the upper mold part (22) and is retained in this position by means of an adjustable holding force. The lower piston (43) is subsequently designed to be pressed upwards and carry out the basic feeding into the casting system (51), counteracted up to said holding force by the upper piston (18), which is designed to, in the final phase of the basic feeding, be actuated by a larger force and be lifted somewhat to an upper holding position. The upper piston (18) is designed to, subsequent to the pressing movement of the lower piston (43), be activated and lowered to a lower position, the final pressing being done, subsequent to which the mold parts (22, 24) are designed to be opened up and to release the casting.

Description: A METHOD AND A DEVICE FOR PRESS CASTING The present invention relates to a method of press cas¬ ting of the type described in more detail in the preamble of patent claim 1. The invention also relates to a device, designed for a press casting according to the first de¬ vice claim. In order to in a rational way utilize the capacity of a press casting machine it is in most cases used to cast different objects. In order to cast these different ob¬ jects, i.e. to change from a casting of a certain type of object to a certain other type of object, the lower pis¬ ton as well as the upper piston are usually exchanged as well as the sleeve which constitutes the filling cham¬ ber and of course the mold as well as the sleeve, which surrounds the lower piston. These measures are of course always time-consuming and expensive processes and there¬ fore objectionable. Also, the casting process is made more difficult in this way, since e.g. constantly changed diameters of casting pistons, used a little while, lead to varying pressures, which in practice is not acceptable on indeed not feasible. Consequently, a change as regards the casting piston diameter, i.e. an exchange of a cas¬ ting piston, must be accompanied by a corresponding change of the compression pressure of the machine. This implies auto aticly a substant al risk of having the personnel make miscalculations or wrong adjustments of the pressure, resulting i.ϊ a worse quality or actually a rejection of castings. Particularly when the casting is done under relatively low pressures, e.g. between 1 and 200 bars, a few problems, so far unsolved, will appear. The rationale of such a low pres¬ sure casting is to make possible a use of sand mold cores, which in its turn makes possible a production of more comp¬ licated products or products, which are to meet highqua¬ lity requirements, e.g. car rims, sand mold cores however not being absolutely required. The particular complex of problems of a low pressure casting comprises partly the necessity of continuously using strongly heated molds and a superheated metal and partly prolonged cycle periods, since the solidification times are absurdly prolonged,e.g. between 100 and 300 seconds. Thanks to the comparatively slow solidification the metal structure will be coarse and have a low strength. In case a blacking occurs, it is true that it is advantageuous during the filling of the li¬ quid metal, but it is a drawback during the ensuing soli¬ dification, because it prolongs the cycle periods and cont¬ ributes to a larger grain size and hence a coarser struc¬ ture and a lower strength. Thus, it has so far been neces- ary in many cases to oversize the products. JP 59-130688 relates to already known techniques in this field. The lower piston according to this specification has a larger diameter than the upper piston, but no speci¬ fic reasons or explanations are mentioned why this is or must be the case. The activation of the initiation of the movement of the upper piston is done, when a pressure in¬ fluence has been obtained from the melt via the movement upwards of the lower piston. As regards the lower piston only a general movement upwards is mentioned. As regards the upper piston only a general movement downwards is men¬ tioned. The object of the present invention is to, in the above- mentioned respects, improve and develop the already known method and devices of press casting. Also, another object is to, in this field, develop the state of the art in va¬ rious respects and create opportunities fo a rationally useful technique and products having a high and uniform quality. One particular object of the present invention is to im¬ prove the casting when relatively low pressures are used by achieving shorter cycle periods, improved product qua¬ lity, particularly as regards a higher strength, a lower porosity and a finer material structure, namely a material structure having finer grains. Blacking normally is to be avoided and a surface with finer grains obtained, if pos¬ sible. These objects are achieved by carrying out a method of the type mentioned in the introduction mainly as set forth in the characterizing clause of patent claim 1, as well as by designing a device for press casting mainly as is set forth in the first device claim. It is particularly advantageous according to the inven¬ tion, if the lower piston is moved upwards to a mechani¬ cal stop element in its upmost position, the upper end sur¬ face of the lower piston, when necessary, forming the lower surface of the object or objects to be molded. Also, the upper piston must be able to be moved upwards with a small counter pressure, in case the space in the mold and bet¬ ween the pistons is completely utilized and consequently allow the lower piston to reach its uppermost position. Also, the actuation of the upper piston is to be complete¬ ly programmable, as regards time as well as speed. Additional characteristics and advantages of the inven¬ tion are set forth in the following description, reference being made to the accompanying drawings, which partly sche- maticly show three non-limiting embodiments of a device for press casting according to the present invention. The drawings show in detail in: Fig. 1 the device according to the invention in its cas¬ ting position, i.e. subsequent to the closing of themolds and the pouring in of liqui '* metal but before the actual casting; Fig. 2 the device according to Fig. 1 subsequent to the lowering of the upper piston into its holding position; Fig. 3 the device according to Figs. 1 and 2 subsequent to the movement of the lower piston and the filling of the mold with the upper piston displaced upwards carried out; Fig. 4 the device according to Figs. 1-3 in connection with a movement of the upper piston subsequent to the af¬ terfeeding carried out; Fig. 5 the device according to Figs. 1-4, the mold being open and the upper piston being moved downwards completely and the product being ready to be ejected; Fig. 6 the device according to Figs. 1-5 subsequent to an ejection/release of the molded product and a pulling in¬ wards of the upper piston to the starting position for a new casting cycle; Figs. 7-12 a modified device according to the invention, the injection system being displaced from the central area but for the rest corresponding to the device according to Figs. 1-6; and Fig. 13 a third embodiment according to the invention in¬ cluding an selectable system placed in the central area, and Fig. 14 a fourth embodiment according to the inventionwith a mainly modified feeding and pouring in of the liquid metal. In the drawings a device according to the present inven¬ tion in its entirety is designated 1. This device compri¬ ses a machine frame 2, which mainly comprises an upper base plate 3, from which machine bearers 4, e.g. four, pro¬ ject downwards, the lower ends of which support a lower machine table 5, which rests on feet 6. Upper base plate 3 supports hydraulicly form cylinders 7, e.g. four, which are designed to open up and close a cas¬ ting mold, which will be described below, by means of an already known control system (not shown) . From form cy¬ linders 7 piston rods 9 project downwards through bores 8 in the base plate. An upper machine table 10 is suspen¬ ded at the lower ends of said piston rods 9 and* is dis- placeable along machine bearers 4 by means of guide bush¬ ings 11. Preferably in a central position on top of upper machine table 10 a yoke 13 is disposed, at a distance from this machine table by means of spacing rods 12, and this yoke 13 supports a cylinder 14 for an upper piston, which cy¬ linder projects upwards through an opening 15 in the base plate, which opening is wide enough to also allow the passage of the yoke therethrough, in a position according to Fig. 3. Through an opening 16 in yoke 13 a piston rod 17 with an upper piston 18 projects downwards, which upper piston can be introduced into a filling funnel 21, mounted in upper machine table 10, which funnel leads to a feeding and guiding sleeve 19 in the upper mold part. Said sleeve leads in its turn to a filling chamber 20 designed to fill a certain adjusted or predetermined amount of a liquid metal. Said filling chamber i._ mounted in the lower mold part och extends a small distance below this mold part, preferably having an enlarged diameter in order to allow a position fixation between the lower mold part and the lower machine table. On the lower side of the upper machine table an uppermold part 22 is fastened, the lower side of which is provided with an upper mold cavity 23. On machine table 5 a lower mold part 24 rests, the upper side of which in an analogous way is provided with a lower mold cavity 25. Below machine table 5 a holder plate 27 is mounted by means of spacing rods 26, at a distance from the machine tuble, the holder plate 27 being designed to hold ejec¬ tion cylinders 28 mounted below it. Corresponding piston rods 29 extend upwards through openings 30 in holder plate 27 and are designed to in unison support a bridge 31, which is displaceably mounted between machine table 5 and hol¬ der plate 27. Bridge 31 supports in its turn e.g. 2-12 ejection rods 32, which extend upwards through holes 33 in machine table 5 and are designed to, above this machine table, support a common connection plate 34 with upper ejec¬ tion plates 35, ejection pins 37 projecting from these ejec¬ tion plates into said lower mold part 24 in guiding holes 36 in this mold part, by means of which ejection pins 37 the casting, subsequent to its completed molding, can be ejected, when the mold has been opened up. In the middle of and below bridge 31 a cylinder 38 of a lower piston is mounted , in which cylinder 38 a piston 39 is disposed, from which a piston rod 40 extends, which ex¬ tends through openings 41 och 42 respectively in bridge 31 and machine table 5 respectively in order to, with its free end, support a lower piston 43. Sleeve 19 and bushing 45 may also be designed as one unit. Also, the bushings can be cooled directly or indirectly in a way known per se, not shown in detail in this connection. However, cooling conduits are collectively designed by the reference nu¬ merals 46 in Fig. 1. Lower piston 43 and piston rod 40 suitably are cooledtoo, in which case from piston 39 a connection 47 for a cooling equipment, not shown, may extend downwards through cy¬ linder 38. The device now described can be used in the followingway: Fig. 1 shows, as was mentioned above, this device in its molding position, the molds being closed e.g. around an encased mold insert 48. A certain adjusted amount of li¬ quid metal, preferably belonging to the group of non-iron- alloys, has already been filled in chamber 20 and is de¬ signated 49. The surface of the filled-in metal suitably will reach a level which is slightly below the lower edge of the molding system. In order to obtain this precise adjustment one not only start with a predetermined amount of metal but above all from the level of the lower piston, which according to the invention is adjusted to a desired elevational posi¬ tion, which actually allows an exact computable filling of metal, designed to carry out the casting in an optimal way and with the least possible excess amount. The posi¬ tion of the lower piston is adjusted and indicated in a suitable way, e.g. by means of a programmable display pa¬ nel in an electronic fashion. As appears from the figure, the lower piston has a larger diameter, e.g. between 10 and 300 %, than the upper piston, which means that small pis¬ ton movements result in larger volume changes. The ratio between the diameters of the lower piston and the length of the filling chamber ought to be between 1:1 and 1:4, preferably about 1:2.5. Another important advantage of a lower piston and then also a filling chamber with a lar¬ ger diameter than the coaxially disposed upper piston and feeding and guiding sleeve respectively is that the down¬ wardly running liquid metal is not allowed to splash into the molding system and be solidifi-- in it prematurely. An additional advantage, thanks to tnese characteristics of the invention is that the inner wall of the filling chamber, which is provided with a lubricant, will not be sprayed with running metal, which otherwise would result in an uneven distribution of the lubricant and risks of biting and other drawbacks as a consequence. Now the fil¬ ling chamber wall will instead be exposed to the liquid metal in a quiter way, which rises successively in the chamber, an even distribution of the lubricant being se¬ cured. In addition to a liquid metal filling through a funnel and a sleeve into the filling chamber, it is also possible to feed the liquid metal in a lateral direction through a tube or a conduit or channel from a storage container. Subsequently the upper piston will be lowered according to Fig. 2 into a predetermined or programmed holding po¬ sition, preferably roughly in the middle of sleeve 19. This position is designed to allow a displacement, when a pressure is exerted, to a higher level and a displace¬ ment subsequent to the metal feeding to an even higher le¬ vel. In a practical embodiment the upper piston is designed to, in said normal holding position, resist upwardly di¬ rected metall pressures of e.g. 1-20 bars without a posi¬ tion alteration. According to Fig. 3 the liquid metal has been fed into the molding system by the lower piston, which thanks to its com¬ paratively large diameter exerts an adequate or limited compression pressure, through which the mold in a relati¬ vely quiet way is filled with metal, at the same time as, thanks to the more compact design, a considerable amount of centrally stored heat is retained and transmitted to the center of the molding system. Themovement of the low¬ er piston is preferably adjustable as regards the speed in the various sections, and it is suitably programmed. In the final phase of the upward movement of the lower pis¬ ton the upper piston is influenced by a metal column, formed below it, its pressure finally exceeding the adjustedhol¬ ding pressure and from then on resulting in a limited lif¬ ting of the upper piston to an upper holding position. All the time the upper piston continues acting with an adjus¬ ted pressure on the metal column. The lower piston finally stops in an upper end position, preferably against a sta¬ tionary stop element. In the functional positions between Figs. 3 and 4 the up¬ per piston has been activated, possibly with a time delay, to move further downwards, excercising an afterfeeding movement, which preferably is adjustable and programmable. During this movement the upper piston, which has a smal¬ ler diameter, acts on the central, superheated area above the lower piston and influences there the central metal portion, which is somewhat more mobile and substantially easier than the outer metal portion can be compressed, said central metal portion being compressed from within. Addi¬ tional heat is thereby evolved, which enhances the flow characteristics of the metal and its workability. Thanks to the smaller diameter of the upper piston the afterfee- ding can be done efficiently, the porosity being lowered to a minimum, because the porosity mainly is developed in the central thick-walled portions , which according to the description above are influenced primarily. Finally, the upper piston will stop in its lower holding position ac¬ cording to Fig. 4. During the transition from the functional position accor¬ ding to Fig. 4 to the position shown in Fig. 5 the upper pis¬ ton continues first of all to exercise a high compression pressure against the metal column and consequently increa¬ singly projects out of the lifting upper mold part, until e.g. a stationary stop position according to Fig. 5 has been reached, and simultaneously the upper mold part con¬ tinues its movement upwards to the starting position shown in Fig. 5. When the metal has been solidified in the mold, after e.g. 2-20 seconds, form cylinders 7 are activated and in this way piston rods 9 will pull upper machine table 10 upwards with upper mold part 22, and the upper side of the casting will be free. In order to entirely eject the pressed piece 50 from filling chamber 20 cylin¬ der 14 of the upper piston remains activated and conse¬ quently it pushes the piston rod .outwards successively, when machine table 10 is moved upwards, the upper piston continuously being pressed against the pressed piece, un¬ til the upper machine table has reached its upper star¬ ting position according to Fig. 3, in which the cylinder of the upper piston is activated in order to pull the pis¬ ton inwards to the position shown in Fig. 3. Of course, piston rod 17 can be pulled inwards somewhat earlier, e.g. as soon as a relative position has been reached, in which the pressed piece has left the filling chamber. Cylinders 28 are activated now, which results in a lifting of bridge 31 and finally in an activation of ejection pins 37, the casting being freed completely also from the lower mold part. The lower piston contributes to this also, since its cylinder is fastened to the bridge, resulting in a movementof also the lower piston besides the ejection pins in relation to the lower mold part. When cylinders 28 have returned to their starting position according to Fig. 1, cylinder 38 will be activated, its piston 39 lifting the lower piston to the position shown in Fig. 3, which is the same position as the position shown in Fig. 2, and in this way a new molding cycle can be initiated. The free end surface of the lower piston and preferably al¬ so its mantle surface are according to a preferred embodi¬ ment of the invention provided with a ceramic coating in order to prevent a wear and/or obtain a limited heat in¬ sulation. The wall of the filling chamber can also be made of a ceramic material. In this way the metal will be cooled to a minimal extent in the filling chamber, which is de¬ sirable, and at the same time the thermal expansion of sleev 19 and the lower piston respectively will also be relative¬ ly limited, which is desirable to preserve the basic tole¬ rances. Also, the upper piston can be cooled in order to achieve a quicker solidification and its mantle surface can, in order to prevent a wear, be provided with a cera¬ mic coating. Whereas the transition time from one type of coating to another type is between 3 and 4 hours in a conventional press casting machine, the corresponding transition time of a device or machine according to the invention can be lowered to 10-15 minutes. This shows that substantial time savings and rationalization gains are possible according to the invention. In accordance with the design shown in Fig. 14 the lower mold part can be moved upwards and downwards by means of four cylinders 3', fastened to the upper, movable machine plate. The ejection device has been moved from the lower machine plate to the upper one. The lower injection cylin¬ der is fastened to the lower machine table by means of a fastening flange. The advantage of this design is that the metal can be poured in to an as low filling level as possible, a froth¬ ing and an oxidation being avoided in this way or these effects at least being thoroughly counteracted. This is particularly true as regards aluminum alloys at elevated temperatures and during a low pressure molding. The defi¬ nitely lowest filling level is obtained, when the filling is done below the mold, as is depicted in the drawing. This could be done in this embodiment by moving the lif¬ ting device for the lower mold part as well as the ejec¬ tion device. This embodiment will function in the following way: During the filling of the metal the lower piston is pulled down¬ wards successively, and in this way the metal surface will continuously appear adjacent the upper edge of the cylinder or the filling chamber, formed in this way. Subsequently the casting ladle will be removed and upper machine table 10 moved downwards. Thanks to this movement the mold parts can be united by cylinders 3". Cylinders 3" as well as the ejection device are fastened to the move- able machine plate. The recess in the middle of mold 24 matches cylinder 44. Lower mold 24 now will rest on lower machine plate 5. The casting is done in the same way as has been described above. During the mold opening two things are activated simultaneously: a) an opening (cylinder 7) of upper ma¬ chine plate 6" + 4' + 2"; b) an activation outwards of cylinders 2" of the lower mold part, i.e. they work tore- tain lower mold part 24 on machine table 5 and in this way divide the mold into parts 22 and 24. When the mold has been opened up sufficiently, the mold opening process is terminated and cylinders 3" and 7 cease working. The casting has, thanks to the mold opening and a suitable mold construction, been retained in the upper mold part. A suitable device, designed in a way known per se, is int¬ roduced between the mold parts in order to receive the cas¬ ting, which is ejected by means of cylinders 28. The cas¬ ting can now be removed by means of said device. The lower mold part is now moved upwards to close the mold. Cylinders 3 ^ are activated and in this way they will in unison pull the lower mold part towards mold part 22. The machine cycle has been concluded and a new such cycle can be initiated with a filling of liquid metal etc.

Claims: CLAIMS 1. A method of press casting, a liquid metal (49) being poured into a filling chamber (20) to be influenced in this chamber by a lower piston (43) and an upper piston (18) respectively, which are mounted at a lower machine table (5) and an upper machine table (10) respectively, which tables support a lower mold part (24) and an upper mold part (22), said filling chamber being disposed in or at said lower mold part and receiving as regards the poured-in metal amount said lower piston in an adjustable height level, which lower piston is adjusted ~-_> allow said metal amount to reach a level somewhat below the molding system between the mold parts and which has a larger dia¬ meter than the upper piston, c h a r a c t e r i z e d in that the upper riston is lowered in connection with the filling of th-^ metal downwards to a central position in a guiding and feeding sleeve (19) in the upper mold part, retained in this position by means of an adjustable holding force, in that the lower piston subsequently is pressed upwards in order to carry out the basic feeding into the casting system, counteracted up to said holding force by the upper piston, which in the final phase of the basic feeding is influenced by a larger force and is lif¬ ted somewhat to an upper holding*position, and in that the upper piston subsequent to the pressing movement of the lower piston carried out is activated and lowered to a lower position, the final pressing being done, subsequent to which the mold parts are opened up in order to re¬ lease the casting. 2. A method according to claim 1, c h a r a c t e ¬ r i z e d in that in the casting position, when themolds are closed or open for e.g. an encased mold insert (48) , a certain predetermined amount of liquid me+-al (49), pre¬ ferably belonqing to the group of non-iron-alloys, is poured into tne chamber (20) , the surface of the filled metal suitably being allowed to reach a small distance be- low the lower edge of the casting system, and in that, in order to obtain this exact adjustment, the lower piston is adjusted into its desired elevational level, which prefe¬ rably is indicated in a suitable way, e.g. by means of a programmable display panel in an electronic way. 3. A method according to claim 2, c h a r a c t e r i z e d in that, when the filling of the amount of liquid metal has been completed, the upper piston is lowered to a pre¬ determined or programmed holding position, preferably roughly at the center of the guiding and feeding sleeve (19) , which position is designed to allow a displacement due to a pressure to a higher position and a movement af¬ ter the feeding to an even higher level, in a practical embodiment the upper piston in said normal holding posi¬ tion being designed to resist upwardly directed metal pres¬ sures of e.g. 1-20 bars without a position alteration. 4. A method according to claim 3, c h a r a c t e r i z e d in that subsequent to the lowering of the upper piston to said first holding position the liquid metal is fed into the casting system by means of the lower piston, which, thanks to its larger diameter, 1-4 times, as compared to the upper piston, renders possible an adequate or limited compression pressure, by means of • which the mold is filled with metal in a relatively quiet way, a considerable amount of centrally accumulated heat, thanks to the compact de¬ sign, at the same time being retained and transmitted to the center of the casting system. 5. A method according to claim 4, c h a r a c t e r i z e d in that the movement of the lower piston is adjusted as re¬ gards the speed in the various sections, which suitably is done in a programmed way, in that in the final phase ofthe movement upwards of the lower piston the upper piston is influenced by a metal column, formed below it, the pressure of which finally surmounts the adjusted holding pressure and from then on renders possible a limited raising of the upper piston to an upper holding position, and in that the upper piston continuously acts with its adjusted pressure on the metal column, whereas the lower piston finally stops in an upper end position, preferably against a stationary stop element. 6. A method according to claim 5, c h a r a c t e ¬ r i z e d in that when the lower piston has reached its upper end position, the upper piston is activated, pos¬ sibly with a time delay, to be moved further downwards with a movement after the feeding, which preferably is cont¬ rolled and can be programmed, during which movement the up¬ per piston, which has a smaller diameter, acts on the cent¬ ral superheated area above the lower piston and influen¬ ces in this area the somewhat more mobile central metal portion, which is compressed substantially easier than the outer metal portion and from within pressurizes said metal portion, additional heat being generated, which increases the flow and workability of the metal, and in that the up¬ per piston finally is stopped in its lower holdingposition. 7. A method according to claim 6, c h a r a c t e ¬ r i z e d in that, when the casting has been completed, the upper piston, to start with, is made to continue ex¬ erting its high compression pressure against the metal co¬ lumn and to an increasing extent project out of the lif¬ ting upper mold part, until e.g. a stationary stop posi¬ tion has been reached, the upper mold part simultaneously being made to continue its movement upwards to its upper end position, and in that, when the metal has been solidi¬ fied in the mold, after .g. 2-20 seconds, form cylinders (7) are activated, piston rods (9) pulling the upper ma¬ chine table (10) upwards with the upper mold part (22) and the upper side of the casting being uncovered, as well as in that, in order to make the obtained small piece (50) leave the filling chamber (20) completely, the upper pis¬ ton cylinder (14) is kept activated to push the piston rod outwards successively, when the upper machine table (10) is moved upwards, the upper piston continuously being pressed against said small piece, until the upper machine table has reached its upper starting position, in which the upper piston cylinder is activated to pull the piston inwards to its upper starting position, or that the upper piston is pulled inwards somewhat earlier, e.g. as soon as a relative position has been reached, in which said small piece has left the filling chamber. 8. A method according to claim 7, c h a r a c t e ¬ r i z e d in that, when the mold has been opened up, the ejection device is activated with an activation of cylin¬ ders (28) and a lifting of a bridge (31) and finally an activation of the ejection pins (37) as a result, the cas¬ ting being released completely also from the upper mold part, with the assistance of the upper piston, its cylin¬ der being fastened to the bridge, with the reuslt that al¬ so the upper piston in addition to the ejection pins moves in relation to the upper mold part, and in that, when the cylinders (28) of the ejection pins have returned to their starting position, the cylinder (38) of the upper piston (18) is activated, the upper piston being raised to its upper starting position. 9. A method according to any of claims 1-8, c h a r a c ¬ t e r i z e d in that the lower mold part is moved upwards and is lowered by means of four cylinders (3") , fastened to the upper movable machine table, and in that the ejec¬ tion is done from the upper machine table, whereas the pouring-in of metal is done in a filling chamber in the lower stationary machine table. 10. A method according to claim 9, c h a r a c t e ¬ r i z e d in that during the metal filling the lower piston is pulled downwards successively, the metal sur¬ face continuously being positioned adjacent the upper edge of the cylinder or the filling chamber formed in this way, in that, when the metal filling has been completed, the upper machine table (10) is mo ad downwards, duringwhich movement the mold parts (22,24) preferably are united by means of said four cylinders (3'), in that the upper ma¬ chine table in the final phase of said movement is moved with a recess in the central area over the projecting end of the filling chamber, until the lower mold part rests on the lower machine table (5) , subsequent to which the casting is done. 11. A device designed to carry out the method according to claim 1, in which liquid metal (49) is to be poured into a filling chamber (20) in order to be influenced in this filling chamber by a lower piston (43) and an upper pis¬ ton (18) respectively, which are mounted at a lower machine table (5) and an upper machine table (10) respectively, which tables support a lower mold part (24) and an upper mold part (22) respectively, the filling chamber being dis¬ posed in or at the lower mold part and receiving said low¬ er piston, the elevational level of which is adjustable as regards the filled amount of metal and which lower piston is adjusted to make said amount of metal reach a level some¬ what below the casting system between the mold parts and which has a larger diameter than the upper piston, c h a ¬ r a c t e r i z e d in that the upper piston is designed to, in connection with the filling of the metal, be low¬ ered to a central position in a guiding and feeding sleeve (19) in the upper mold part and be retained in this posi¬ tion by means of an adjustable holding force, in that the lower piston subsequently is designed to be pressed up¬ wards and to carry out the basic feeding into the casting system, counteracted up to said holding rce by the upper piston, which is designed in the final . se of the basic feeding to be influenced by a larger force and be lifted somewhat to an upper holding position, and in that the up¬ per piston, when the press movement of the lower piston has been completed, is designed to be actuated and be low¬ ered to a lower position, in which the final pressing will be done, subsequent to which the mold parts are designed to be opened up and to release the casting. 12. A device according to claim 11, c h a r a c t e ¬ r i z e d in that it comprises a machine frame (2) , which mainly comprises an upper base plate (3) , from which ma¬ chine bearers (4) , e.g. four, project downwards, the lower ends of which support a lower machine table (5) , which rests on feet (6) , in that the upper base plate (3) sup¬ ports hydraulic form cylinders (7) , e.g. four, designed to open up and close a casting mold (22,24) by means of a guiding system, known per se, in that piston rods (9) pro¬ ject from the form cylinders (7) downwards through bores (8) in the base plate, at the lower ends of which piston rods on upper machine table (10) is suspended, which by means of guide bushings (11) is displaceable along thema¬ chine bearers (4) , in that preferably in a central area above the upper machine table (10) , by means of spacing rods (12) , a yoke (13) is mounted at a distance from the machine table, said yoke (13) supporting an upper piston cylinder (14) , which projects upwards through an opening (15) in the base plate, which opening has such a width, that even the yoke can pass through the same, in that through an opening (16) in the yoke (13) a piston rod (17) projects with said upper piston (18) , which can be intro¬ duced into a filling funnel (21), ' mounted in the upperma¬ chine table (10) and leading to said feeding and guiding sleeve (19) in the upper mold part, in that the sleeve in its turn leads to said filling chamber (20) and is de¬ signed to pour a certain adjusted or predetermined amount of a liquid metal in the filling chamber, in that the fil¬ ling chamber is disposed in the lower mold part and ex¬ tends somewhat below the same, preferably with an enlarged diameter for a position fixation between the lower mold part and the lower machine table, in that on the lower side of the upper machine table said upper mold part (22) is fastened, the lower side of which is provided with an upper mold cavity (23), and in that on the machine table (5) said lower mold part (24) rests, the upper side of whic- in an analoguous way is provided with a lowermold cavity (25) . 13. A device according to claim 12, c h a r a c t e ¬ r i z e d in that below the machine table (5) by means of spacing rods (26) a holder plate (27) is mounted, at adis¬ tance from the machine table and designed for ejection cy¬ linders (28) , mounted below the holder plate and the pis¬ ton rods (29) of which extend upwards through openings (30) in the holder plate (27) , designed to, in unison, support a bridge (31), which is displaceably mountedbet¬ ween the lower machine table (5) and the holder plate (27) , in that the bridge (31) in its turn supports ejection rods (32) , e.g. 2-12, which extend upwards through holes (33) in the lower machine table (5), designed to, above thema¬ chine table, support a common connection plate (34) having upper ejection plates (35) and ejection pins (37) , which project from the ejection plates and into the lower mold part (24) in guide holes (36) in the mold part, by means of which ejection pins the casting subsequent to the comp¬ leted molding, will be ejected, when the mold is opened up, in that a lower piston cylinder (38) is mounted in a central area below the bridge (31) , in which a piston (39) is mounted, from which a piston rod (40) extends through openings (41 and 42 respectively)' in the bridge (31) and the lower machine table (5) respectively, designed to, with its free end, support said lower piston (43) . 14. A device according to any of claims 11-13, c h a ¬ r a c t e r i z e d in that the lower piston is adjust¬ able in such c*-* elevational position, that the filling chamber mainly is filled with a predetermined amount of liquid metal and with the least possible excess amount, the position of the lower piston being adjusted and indi¬ cated in a suitable way, e.g. via a programmable display panel in an electronic way. 15. A device according to claim 14, c h a r a c t e ¬ r i z e d in that the lower piston (43) and/or the pis- ton rod (40) are cooled, in which case a connection (47) for a cooling equipment extends from the piston (39) down¬ wards through the cylinder (38) and/or in that the lower piston has a larger, diameter, e.g. between 10 and 300 %, than the upper piston, designed to obtain minor piston movements resulting in larger volume changes, and/or in that the ratio between the lower piston diameter and the filling chamber length is between 1:1 and 1:4, preferably about 1:2.5. 16. A device according to any of claims 11-15, c h a ¬ r a c t e r i z e d in that the upper piston is designed to be lowered to a predetermined or programmed holding po¬ sition, preferably roughly at the center of the sleeve (19) , which position is designed to allow a displacement under pressure to a higher position and a movement after the fee¬ ding to an even lower level, the upper piston, in a normal holding position, resisting upwardly directed metal pres¬ sures of e.g. 1-20 bars without a position alteration. 17. A device according to any of claims 11-16, c h a ¬ r a c t e r i z e d in that the lower piston movement is adjustable as regards the speed in the various sections, which suitably is programmed, in that the upper piston, in the final phase of the movement upwards of the lower piston, is actuated by a metal column, formed below the upper piston, the pressure of which finally surmounts the adjusted holding pressure and from then on results in a limited lifting of the upper piston to an upper holding position, the upper piston continuously influencing the metal column with an adjusted pressure, and in that the lower piston finally stops in an upper end position, pre¬ ferably against a stationary stop element. 18. A device according to any of claims 11-17, c h a ¬ r a c t e r i z e d in that the upper piston, subsequent to a terminated feeding movement of the lower piston up¬ wards, is designed to be activated, possibly with a time delay, to be moved further downwards, exercising a move¬ ment, after the feeding, which preferably is adjustable and programmable, during which movement the upper piston, which has a smaller diameter, acts on the central super¬ heated area above the lower piston and influences in this area the central metal portion, which is somewhat more mo¬ bile, and in that the upper piston finally stops in its lower holding position. 19. A device according to any of claims 11-18, c h a ¬ r a c t e r i z e d in that the upper piston, when the molding has been completed, is designed to first of all continue exerting a high compression pressure against the metal column and increasingly being pushed out of the lif¬ ting upper mold part, until e.g. a stationary stop posi¬ tion has been reached, the upper mold part simultaneously continuing its movement upwards to its starting position, in that, when the metal has been solidified in the mold, after e.g. 2-20 seconds, the form cylinders (7) are ac¬ tivated, the piston rods (9) pulling the upper machine table (10) upwards with the upper mold part (22) and the upper surface of the casting being uncovered, in that, in order to make said small piece (50) leave the filling chamber (20) completely, the upper piston cylinders (14) remain activated and push the piston rod outwards suc¬ cessively, when the machine table (10) is moved upwards, the upper piston continuously being pressed against said small piece, until the upper machine table has reached its upper starting position, in which the upper piston cylinder is activated to pull the piston inwards to its upper casting position, or the piston rod (17) being de¬ signed to be pulled inwards somewhat earlier, e.g. as soon as a relative position has been reached, in which said small piece has left the filling chamber. 20. A device according to any of claims 11-19, c h a ¬ r a c t e r i z e d in that, subsequent to a completed molding and subsequent to a lifting upwards of the upper machine table,the cylinders (28) are activated with a lif¬ ting of the bridge (31) and finally an activation of the ejection pins (37) as a consequence, the casting being re¬ leased completely also from the lower mold part, the lower piston also interacting, since its cylinder is fastened to the bridge, the lower piston in addition to the ejection pins also being moved in relation to the lower mold part, and in that, when the cylinders (28) have returned to their starting position the cylinder (38) is activated, the piston (39) of which lifts the lower piston, and in this way a new molding cycle can be initiated. 21. A device according to any of claims 11-20, c h a ¬ r a c t e r i z e d in that the free end surface of the lower piston and preferably also its mantle surface are provided with a ceramic coating, designed to preventwear and/or provide a limited heat insulation, and/or in that the wall of the filling chamber is made of a ceramic ma¬ terial, and/or in that the upper piston is cooled to achieve a faster solidification and its mantle surface is provided with a ceramic coating. 22. A device according to any of claims 11-21, c h a ¬ r a c t e r i z e d in that the lower mold part is de¬ signed to be moved upwards and lowered by means of four cylinders (3~) , fastened to the upper moveable machine plate, in that the ejection device is mounted on the up¬ per machine table, in that the filling chamber is fastened to the lower machine table by means of a fastening flange, and in that, in addition to the lifting device for the lower mold part, also the ejection device is mounted on the upper machine table. 23. A device according to claim 22, c h a r a c t e ¬ r i z e d in that, during the metal filling, the lower piston is designed to be pulled downwards successively, the metal surface continuously being present adjacent the upper edge of the cylinder-shaped filling chamber, in that, subsequent to the metal filling, the upper machine table is designed to be moved downwards, during whichmove¬ ment the mold parts preferably are united by the cylinders (3') , in that the cylinders (3") as well as the ejection device are fastened to the moveable machine plate, and in that the upper machine plate in the final phase of said movement is moved with a recess in the central area over the upwardly projecting end of the filling chamber, until the lower mold part rests on the lower machine table (5) , subsequent to which the molding is done.

Inventors: IVANSSON HANS, IVANSSON, HANS
Applicants: TOUR & ANDERSSON AB
Application year: 1991
Main classification: B22D17
IPC codes: B22D18