Automated variable dimension mold and bottom block system

Abstract

A molten metal mold and bottom block system, including apparatus and method embodiments, which may include a mold cavity framework with a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity, and wherein one or more of the sides are movably mounted relative to the second side, and are controllably moved during the casting. This system may also include embodiments wherein the castpart produced has a tapered form at one or both of the castpart ends. Aspects of this invention may be considered to be a castpart shrinkage management system or a castpart form or profile control system due to the advantage of increased controls of castpart form during the casting process.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application does not claim priority from any other application.TECHNICAL FIELD[0002]This invention pertains to an automated variable dimension mold and bottom block system, resulting in a desired castpart taper or configuration.BACKGROUND OF THE INVENTION[0003]Metal ingots, billets and other castparts may be formed by a casting process which utilizes a vertically oriented mold situated above a large casting pit beneath the floor level of the metal casting facility, although this invention may also be utilized in horizontal molds. The lower component of the vertical casting mold is a starting block. When the casting process begins, the starting blocks are in their upward-most position and in the molds. As molten metal is poured into the mold bore or cavity and cooled (typically by water), the starting block is slowly lowered at a pre-determined rate by a hydraulic cylinder or other device. As the starting block is lowered, solidified m...

AI Technical Summary

Benefits of technology

The patent describes an automated system for producing cast parts with a desired taper or configuration. The system uses a vertical mold and a starting block that is lowered at a controlled rate to allow the metal to solidify in the mold. The starting block is raised and lowered using a hydraulic cylinder. The system can produce various cast parts, such as ingots, billets, and cast parts with complex tapers or configurations. The bottom block, which holds the cast part, can be raised and lowered to facilitate the casting process. The system is controlled by a computer and can produce cast parts with high efficiency and accuracy.

Problems solved by technology

One of the problems associated with this process is that a portion of the rolling ingot is wasted due to a phenomenon sometimes referred to as alligatoring.

During the rolling process, the ends of the ingots which exhibit alligatoring are cut off, thereby resulting in a substantial amount of waste of aluminum which must be reheated and re-cast, in addition to the expense of doing so.

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