Divided Mold Device for Semi-Solid Casting Method of Large Materials

Abstract

The objective of the present invention is to enable the casting of large materials using existing equipment by manufacturing a large aluminum casting mold with a segmented structure, and to improve the quality of the casting by applying independent cooling and temperature control systems to each segmented mold. In accordance with the above purpose, the present invention provides a large material casting mold in a 2-part or 4-part structure, and each part mold is integrally aligned with the mold base through a key and a keyway.

Description

Technology Field

[0001] The present invention relates to the configuration of a split mold for large-scale aluminum casting and a control and adjustment device thereof. Background Technology

[0002] Large-scale molds are essential for casting large aluminum materials. However, as mold sizes increase, the processing equipment required to manufacture them must also become larger, presenting the problem of requiring massive investment costs. Therefore, while single molds were traditionally manufactured and used, the split mold method is gradually being introduced to accommodate the casting of large materials. Split molds offer the advantage of enabling the realization of large molds using existing equipment by being manufactured in two or four sections. However, using split molds presents a critical disadvantage: even slight interference or misalignment between the molds can render the process impossible. Precise positional control of the mold is particularly critical in processes where the molten metal is in a jelly-like state, such as semi-solid casting. Furthermore, in semi-solid casting, cylinders for driving core pins are placed inside the mold; since these cylinders are sensitive to the temperature of the molten metal, direct exposure to the high temperatures of the mold can lead to performance degradation and damage. To prevent this, structural improvements are required, such as installing a partition between the mold and the cylinder to block heat transfer. Therefore, while existing technology allowed for the reduction of equipment investment costs during the production of large molds through a segmented structure, sufficient technical means were not provided to simultaneously resolve the issues of alignment between segmented molds and cylinder protection. Accordingly, there is a need for the development of a new segmented mold device suitable for the large-scale semi-solid casting method.

[0003] US 2020 / 0038946 A1 discloses a configuration that divides the mold into layers. However, this configuration still retains the difficulty of machining large molds. The problem to be solved

[0004] The present invention aims to provide a split mold device suitable for a semi-solid casting method for large materials. Specifically, the invention aims to resolve the issues of super-large processing equipment and massive investment costs required for conventional single mold production, enable the production of molds for casting large materials using existing equipment through a split mold structure, structurally prevent problems where process execution becomes impossible due to misalignment or interference between split molds, integrate each split mold into a plate using a key groove and key device so that the process can be performed stably like a single mold even if thermal deformation occurs, and provide a structure that blocks heat transfer by installing a partition so that the cylinder for driving the core pin used in the semi-solid method is not directly exposed to the high temperature of the mold, while simultaneously serving as a support for the cylinder, thereby improving the precision, durability, and reliability of the mold, increasing productivity, and reducing maintenance costs in the semi-solid casting process for large materials. means of solving the problem

[0005] In accordance with the above purpose, the present invention provides a large material casting mold in a 2-part or 4-part structure.

[0006] In addition, the present invention machines and arranges a key groove on the rear surface of each divided cavity (core) mold. By inserting and engaging a key device into the key groove, the divided mold is seated in the correct position on the bottom plate of the mold base. The key device is designed with a bolt fastening method, allowing for simple installation and removal. Furthermore, by fixing the divided molds as a single unit, the process can be performed stably as if it were a single mold, even if thermal deformation occurs during the process.

[0007] The combination of the key groove and the key device maintains precise positional alignment between the split dies. It structurally blocks misalignment of some of the split dies to prevent disruption to the process, thereby preventing process failures.

[0008] Since the reactive solid process proceeds with the molten metal in a jelly-like state, performance degradation may occur if the cylinder driving the core pin is directly exposed to the high temperature of the mold. To prevent this, a partition is installed between the mold and the cylinder to block heat transfer. The partition is designed to perform both heat blocking and cylinder support functions, thereby ensuring both structural stability and functionality.

[0009] By integrating the split molds into a key device to operate as a single mold, problems such as misalignment, thermal deformation, and interference are fundamentally resolved in the large-scale material casting process. As a result, the precision and durability of the mold can be improved during large-scale material casting, productivity can be increased, and maintenance costs can be reduced.

[0010] That is, the present invention is,

[0011] As a split mold for casting large materials,

[0012] A splitting mold comprising two or more split bodies;

[0013] A mold base on which the above-mentioned split mold is aligned and seated; and

[0014] A fixing member for aligning and fixing the above-mentioned split mold to a mold base; is included,

[0015] The back surface of the above-mentioned split mold has one or more keyways formed therein, and

[0016] One or more keys that are coupled to the above keyway and align the position of the split mold are arranged on the mold base, and

[0017] The present invention provides a split mold characterized by, when the split mold is placed on a mold base, the key is inserted into a keyway, and the key is fixed by the fixing member to align and fix the mold base and the split mold.

[0018] In the above, the key is characterized by having a hole into which a fixing member can be inserted.

[0019] In the above, when a core pin is inserted into a split mold,

[0020] Core pin;

[0021] A cylinder controlling the core pin above; and

[0022] It is characterized by including a partition wall disposed between the cylinder and the split mold to block heat transfer.

[0023] In the above, the fixing member includes a bolt, characterized in that the bolt tightens the key to fix it. Effects of the invention

[0024] According to the present invention, the responsiveness to casting large materials is improved.

[0025] By manufacturing the mold with a segmented structure, it is possible to cast large aluminum materials using existing equipment.

[0026] Economic feasibility can be ensured as large molds can be manufactured without the need for separate investment in extra-large processing equipment.

[0027] The split molds are seated precisely on the mold base plate via the key groove and key mechanism on the rear of each split mold, fundamentally preventing interference or misalignment. The split molds are integrated by the key mechanism, enabling stable process execution as if they were a single mold.

[0028] The key device is designed with a bolt-fastening method, making installation and removal simple and improving work efficiency during mold maintenance and reassembly. By fixing the split molds as a single unit, precision and repeatability can be ensured.

[0029] The bulkhead installed between the mold and the cylinder blocks the high temperature of the mold from being transferred to the cylinder, thereby preventing damage to temperature-sensitive components. The bulkhead performs heat insulation and simultaneously acts as a support for the cylinder, ensuring both structural stability and functionality.

[0030] Despite its split mold structure, it ensures process reliability by maintaining the same level of position control and precision as a single mold. Precise position control enables improved productivity and quality in the large-scale semi-solid casting process. Brief explanation of the drawing

[0031] FIG. 1 is a drawing illustrating the overall structure of a divided mold device for a large-scale material reaction casting method according to the present invention, showing that when the divided mold is seated on the mold base plate, it can be aligned by a key and a keyway. FIG. 2 is a drawing illustrating the combined state of the Key groove (200) and Key device (100) of a split mold device according to the present invention. Specific details for implementing the invention

[0032] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

[0033] The present invention relates to a split mold control and adjustment device for large-scale aluminum casting. Large molds are required for casting large-scale materials. In particular, the novel semi-solid process is advantageous for improving the mechanical properties (physical properties) of the casting material.

[0034] The present invention reduces the production costs and effort associated with processing large molds by configuring a mold for large materials as a divided mold comprising a plurality of divided parts. The divided production of the mold has the advantage of enabling the creation of large molds corresponding to large materials using existing equipment. In particular, the present invention achieves both casting quality and economic efficiency by adjusting the number of divisions according to the shape and size of the material, such as 2 divisions or 4 divisions, and by varying the number of divisions between the movable mold and the fixed mold.

[0035] The disadvantage of such split molds is that if there is a problem with interference or positional alignment between the split molds, the process cannot be performed. To resolve this disadvantage, the present invention forms a key groove in each split mold and designs it to be coupled with a bottom plate of the mold base, thereby fundamentally preventing factors that interfere with the process, such as when the position of any one of the split molds is misaligned during the process.

[0036] In addition, since the process using the reactive solidification method is carried out in a jelly-like state with a low molten metal temperature, the use of cylinder-based core pins is sensitive to temperature; therefore, it is necessary to install a partition to prevent the mold temperature from reaching the cylinder.

[0037] A structure is designed and manufactured to simultaneously serve as a bulkhead and a support for the cylinder.

[0038] FIG. 1 shows a key (100) that is coupled to a key groove (200) formed on the back of a split mold (exemplified by a two-part mold) of the present invention. The key (100) has a hole into which a fixing member, such as a bolt, can be inserted.

[0039] In addition, a groove pattern and side grooves are formed on the back of the split mold to utilize the thermal insulation of the air layer.

[0040] The key (100) is fixed in advance to the bottom surface of the mold base (300) where the split molds are arranged using a bolt (10), which is a fixing member. At this time, the bolt is not tightened completely but is connected with a slight looseness. The purpose is to guide the key (100) to be naturally inserted into the key groove (200) when the split mold is placed.

[0041] The divided mold bodies are placed one by one on the mold base (300), and the rear keyway (200) of each mold is positioned so that it fits precisely into the key (100) of the mold base. During this process, the key is naturally inserted into the keyway of the mold and alignment is achieved.

[0042] Once all the split molds are engaged with the key and alignment is complete, the bolt (10) of the key device is finally tightened to secure it. This firmly connects the key (100) and the keyway (200), thereby integrating the entire split mold. FIG. 2 shows the key (100), the keyway (200), the mold base (300), and the bolt (10) that secures the key in a cross-sectional view and a schematic view. It is preferable to make the key out of hot-worked tool steel or pre-hardened mold steel (P20, 718, NAK80).

[0043] Meanwhile, since the process using the reactive solidification method proceeds in a jelly-like state with a low molten metal temperature, the use of cylinder-based core pins is sensitive to temperature; therefore, it is necessary to install a partition to prevent the mold temperature from reaching the cylinder.

[0044] The structure is designed and manufactured to simultaneously serve as a bulkhead and a support for the cylinder.

[0045] FIG. 3 schematically shows a core pin (30) located in a mold, a cylinder (40) for controlling it, and a partition (50) for blocking the mold temperature for the cylinder (40).

[0046] That is, in the reaction process, the shape formation by the core pin is performed faster than in the molten metal, and the position control of the core pin must be performed quickly and accurately. Accordingly, a partition (50) is installed to provide thermal insulation so that the cylinder for controlling the core pin position does not experience errors due to the temperature transfer of the mold. It is preferable to install a composite material partition combining ceramic insulation and high-temperature alloy steel.

[0048] Unless otherwise defined in the foregoing, all technical and scientific terms used in this specification have the same meaning as commonly understood by a skilled expert in the art to which the present invention pertains. Furthermore, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless explicitly and specifically defined otherwise. Throughout the specification, when a part is described as having, possessing, or including a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components. Additionally, the singular form may include the plural form depending on the context.

[0049] In addition, in this specification, the term "on or above" means being located above or below the target part, and does not necessarily mean being located on the upper side with respect to the direction of gravity. Furthermore, when a part such as a region or plate is said to be "on or above" another part, this includes not only cases where it is in contact with or spaced apart from "immediately above or above" another part, but also cases where there is another part in between.

[0050] Furthermore, the terms used in this invention are used merely to describe specific embodiments and are not intended to limit the invention.

[0052] The rights of the present invention are not limited to the embodiments described above but are defined by the claims, and it is obvious that a person skilled in the art may make various modifications and adaptations within the scope of the rights described in the claims. Explanation of the symbols

[0053] Key (100), keyway (200), mold base (300), bolt (10), core pin (30), cylinder (40), bulkhead (50)

Claims

Claim 1 A split mold for casting large materials, comprising: a split mold including two or more split bodies; a mold base on which the split mold is aligned and seated; one or more keyways formed on the back surface of the split mold to align the split mold with the mold base; one or more keys coupled to the keyways to align the position of the split mold; and a fixing member that can be inserted into the key; wherein the key has a hole into which the fixing member can be inserted, and the fixing member includes a bolt, and the key is fixed to the bottom surface of the mold base in advance with a bolt that is the fixing member, but the bolt is not fully tightened and is coupled loosely, and when the split mold is placed on the mold base, the key is inserted into the keyway and the bolt is tightened to fix the key and the keyway, thereby aligning and fixing the mold base and the split mold. Claim 2 delete Claim 3 A split mold according to claim 1, characterized in that when a core pin is inserted into the split mold, it comprises: a core pin; a cylinder for controlling the core pin; and a partition disposed between the cylinder and the split mold to block heat transfer. Claim 4 delete

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