Method and apparatus for shaping hardenable shaping material

Abstract

The invention relates to a device (10) and a method for shaping a hardenable shaping material (202), comprising the following steps:-accommodating the hardenable shaping material (202) in a fluid state in a cavity (14) delimited by a first mould part (100) and at least a second mould part (101) of a shaping tool (12); generating at least one first relative movement between the first and the second mould part (100, 101) such that the cavity (14) becomes smaller; and hardening the molding material (202).

Description

[0001] The invention relates to a method and a device for shaping a hardenable shaping material. This allows the production of components, in particular by one-shot shaping.

[0002] As is known, by using a forming tool, a hardenable forming material can be made into any desired shape and it can harden into that shape, or in other words, solidify or fuse into that shape. In this way, a component of the desired shape can be produced from the initial amorphous forming material. This can also be called a primary forming of the component.

[0003] Casting is a typical method of primary molding. In this case, the molding material is filled into a molding tool, solidified in the mold, and can then be removed from the molding tool. There are various different casting methods, for example, which differ in the type of molding tool, the molding material and / or the way in which the molding material is filled into the molding tool.

[0004] One disadvantage of previous casting methods is that the required components, in particular the component dimensions, cannot always be produced with the required quality. This applies in particular to components with thin-walled areas. In the context of the present disclosure, thin-walled areas are generally understood to be areas with a material thickness of at most 3 mm or even at most 5 mm. In such thin-walled areas, there is a risk of so-called cold overlap during the casting process. This can be understood to mean that parts of the molding material harden too early, for example while the molding material is still filling and before the molding material has achieved the desired positioning in the molding tool.

[0005] Therefore, the minimum wall thickness usually depends on the method of manufacturing the casting and the material of the molding material, not on the function of the component. The closer you get to the method-specific minimum possible wall thickness, the greater the process-related rejection.

[0006] Furthermore, various metal alloys with inherently favorable properties cannot be processed into thin-walled products. Examples include wrought aluminum alloys and steel. Plastics also present problems when filling forming tools with thin-walled areas, especially when using high-viscosity forming materials. Furthermore, not all polymers are reliably viable (e.g. Teflon). When using ceramic pressure slip casting, problems arise with premature water removal and premature curing, and the achievable material structure is generally not very dense. Due to its low fluidity, concrete can only be used as a forming material for thick-walled components. When combined with steel reinforcement, it is also generally difficult to form filled concrete.

[0007] As a result, potential manufacturing component designs have so far been limited or, for example, complex additional measures have been required to limit the risk of cold laps. These additional measures can include, for example, specially designed gating systems that maintain a high proportion of fluid molding material near thin-walled areas. Insulated and / or heated molds can also be used. Die casting methods can also be used. However, the achievable component sizes are limited and filling the molding material under pressure can lead to turbulence and air inclusions in the melt, which can impair the quality of the metal structure. Cores used to produce hollow structures cannot be used for die casting.

[0008] It is therefore an object of the present invention to improve the production of components, in particular components having thin-walled regions, from hardenable molding materials, in particular with regard to costs, effort and / or quality.

[0009] This object is achieved by the subject matter of the attached independent claim. Advantageous embodiments are given in the dependent claims and in the description.

[0010] Therefore, a method for shaping a hardenable shaping material is proposed, the method comprising:

[0011] - receiving (or in other words arranging) a hardenable molding material in a fluid state (in particular a fluid or molten state) in a molding cavity delimited by a first mold part and at least one second mold part of a molding tool;

[0012] - generating at least a first relative movement between the first and second mould parts, so that the moulding cavity becomes smaller, in particular if the moulding material is still fluid at this stage;

[0013] - Hardening the moulding material, which may in particular involve allowing a defined period of time to expire, during which the mould parts are not moved and / or the mould cavity is not changed.

[0014] This process differs from known casting methods in that the size of the cavity filled with molding material changes and becomes smaller, in particular, when the molding material has not yet hardened. The cavity in the prior art does not change in this way after the injection of the fluid molding material, but remains unchanged until the molding material solidifies. The mold is then opened to remove the finished part, i.e. the cavity is enlarged and dissolved.

[0015] On the other hand, according to the invention, it has been recognized that the proposed method enables the heating of the mold part by the molding material after the molding material has been filled into the cavity or at least one mold part (see below). Only in this way can the cavity become smaller, the wall thickness or volume of the cavity be reduced, and thus the static fluid molding material contained in the cavity be locally reduced, in particular when forming thin-walled areas of the type disclosed in this article. However, since the mold part in this state has already been heated to a certain extent by the molding material previously absorbed, the heat that this mold part absorbs from the molding material is limited. This means that the parts of the molding material located in the thin-walled areas of the cavity harden more slowly, thereby reducing the risk of cold overlap.

[0016] Furthermore, regardless of the risk of cold laps (i.e. even with molding materials such as concrete at room temperature), reliable and high-quality forming of thin-walled areas can be achieved by the disclosed relative movement. For example, according to the invention, molding material can enter the thin-walled areas in a less turbulent manner, but rather in a laminar flow and / or in a more uniform manner than in previous die casting methods, which avoids casting defects.

[0017] Reducing the cavity due to the first relative movement may involve reducing the volume of the cavity. As a result, the cavity and the molding material contained therein can achieve a so-called target geometry. Additionally or alternatively, the distance between at least one pair of relative regions of the mold parts can be reduced by the first relative movement (e.g., viewed along the axis of movement of the first relative movement). This may also be accompanied by a reduction in the size of the cavity, in particular a reduction in the size of the cavity corresponding to the distance.

[0018] The cavity can define the shape of the part to be manufactured. The mold parts can together define the volume and / or surface area of ​​the cavity, or in other words, limit it by at least 80% or at least 90%. Each mold part can define or limit at least 15% or at least 25% of the volume and / or surface area of ​​the cavity. In addition to the mold parts, no movable parts are provided to define the cavity. Otherwise, these movable parts can only define a corresponding small part of the surface area and / or volume of the cavity. For example, these movable parts can only be used to locally and limitedly press the molding material into the cavity defined by the first and second mold parts. Such movement of additional parts cannot be included in the first and second relative movements of the mold parts of the present disclosure.

[0019] Containing the molding material in the cavity can include:

[0020] - Filling the molding material into the cavity defined by the first and second mold parts, or in other words, filling the molding material into the molding tool when the first and second mold parts are already arranged in a way to form the cavity (at least in an enlarged initial state, or also as a pre-cavity).

[0021] Alternatively, this can include containing the molding material in the cavity:

[0022] - Filling the molding tool in the open state with molding material and arranging the first mold part and the second mold part relative to each other to form a cavity containing (filled with) molding material.

[0023] In the open state, the first and second mold parts can be lifted against each other, in particular in such a way that the first and second mold parts do not jointly delimit any wall area of ​​the cavity and / or the mold parts do not substantially touch each other. Thus, in this case, molding material can be filled into only one mold part, for example into a recess present in this mold part. The mold parts can then be arranged relative to each other in such a way that a cavity is formed, and the already filled molding material is contained between these mold parts and the cavity.

[0024] A further improvement provides that the first relative movement is only produced when the entire molding material is contained in the mold cavity. For example, a certain volume of molding material may be required to produce a certain component. Only when this molding material is completely filled into the molding tool and is therefore contained in the mold cavity can the mold cavity be reduced by means of the first relative movement (in particular by defining thin-walled areas). This increases the extent to which the mold part is heated by the incorporated molding material.

[0025] In principle, the molding material can be filled into the molding tool in a manner (particularly unique) that generates a laminar flow in the molding material. For example, a suitable filling speed can be selected for the molding material for this purpose.

[0026] According to a variant, the molding material is filled into the molding tool by gravity die casting. Alternatively, the molding material can be filled into the molding tool by die casting or low-pressure casting. In this context, when the first relative movement is generated, the pressure applied for filling can be at least partially maintained or increased (for example by at least 10%). This can reduce turbulence in the molding material.

[0027] On the other hand, in order to avoid turbulence, any pressure exerted on the molding material during and / or resulting from the first relative movement (in particular independently of any method used for filling the molding material) must not increase by more than 25% or even by more than 10%, or can remain substantially constant. It can be assumed that at least atmospheric pressure or a defined negative pressure acts on the molding material before the first relative movement is generated.

[0028] After the first relative movement is complete, there may still be a fluid connection from the interior of the cavity to the exterior (in other words, to an area outside the cavity). For example, a fluid connection to an overflow area of ​​any molding material discharged from the cavity and / or a fluid connection of the cavity to the exterior can be maintained through a vent. This limits any pressure buildup within the molding material.

[0029] The first relative movement enables the molding material to move under essentially laminar flow conditions, in particular to force the molding material to be layered into thin-walled areas. To this end, for example, the force and / or the speed of movement of the first relative movement can be appropriately selected. In particular, the first relative movement can be essentially force-free. This can be understood as the force that produces this relative movement being limited, by which the relative movement can be achieved (for example by overcoming inertia or friction), but without generating a force that significantly exceeds this force to affect the molding material, and the force that significantly exceeds this force is necessary to significantly (for example, more than 20 percent) and / or permanently increase the pressure of the molding material.

[0030] Generally speaking, no pressure casting occurs before and / or during or after the first relative movement.The molding material can withstand a pressure greater than 0.2 MPa or even greater than 1 MPa in at least one of the above conditions and preferably in none of the above conditions.

[0031] After the first relative movement, and optionally after allowing the molding material to harden, one embodiment provides for the following:

[0032] - applying a closing force to at least one of the first and second mould parts, whereby a feed force presses the mould parts against each other.

[0033] Between the first relative movement and the application of the closing force, it may be necessary to wait for a defined period of time, for example at least 2 seconds, but preferably not more than 60 seconds, or generally until the molding material begins to solidify. During this period of time, the mold cavity can maintain its reduced state, which is achieved due to the first relative movement. This can be achieved by applying an appropriate holding force, or even by not applying any force. The closing force can correspond to a subsequent increase (in particular a further increase) of the force applied to the at least one molded part.

[0034] This additional closing force allows the forming material to be formed into the final shape with greater precision. In addition, it has been shown that this can improve the material structure, for example by achieving a preferred particle size in the metal forming material.

[0035] Optionally, the closing force can be used to generate a further relative movement between the first and second mold parts, by which the size of the cavity is reduced, in particular a further reduction in size based on the state after the first relative movement. This reduction in size can be smaller than the first relative movement. For example, the reduction in size can be less than 50% of the size during the first relative movement, or even less than 10%. This takes into account the fact that the molding material can no longer flow as it did during the first relative movement, but has, for example, at least partially solidified. After the further relative movement, the cavity and the molding material contained therein may have reached its final target geometry.

[0036] Additionally or alternatively, the closing force can only be generated when the molding material is no longer fluid, at least in certain areas. This may mean that the molding material has hardened at least partially and / or in certain areas. The molding material may also be completely hardened.

[0037] The at least partially hardened molding material can thus be formed, in particular finalized, by the closing force to produce a final component shape and / or a final material structure.

[0038] According to another aspect, the closing force is at least 10% higher than the force applied to produce the first relative movement. This enables the molding material to be shaped particularly reliably and precisely by the closing force. The closing force and the force applied to produce the first relative movement can be generated by means of the same movement device, which simplifies the method and the device for this purpose.

[0039] The mold can form a lost mold (i.e. a mold that is damaged by the casting process) or a permanent mold. In the case of lost molds in particular, the relative movement of the mold parts has been unusual so far that thin-walled areas cannot be manufactured with the reliability that can be achieved according to the invention.

[0040] According to a variant, one of the mold parts is a lost foam part and the corresponding other mold part is a permanent mold part. This can be provided in particular in any variant of the present disclosure, in which a further relative movement occurs while the closing force is generated. The lost foam part increases the freedom of forming, since the component can be removed by destroying the mold part. In particular, there is greater freedom in the arrangement of overflow areas or collecting cavities. For example, these can be arranged outside the parting surface of the mold part, in particular completely within the lost foam part. However, since only one of the mold parts (i.e. the lost foam part) needs to be remade before each casting process, the workload can be reduced by arranging the additional mold part as a permanent mold part.

[0041] Further improvements to the method also provide:

[0042] -During the first relative movement (and / or during any other relative movement, for example due to the application of the above-mentioned closing force) part of the molding material is discharged from the mold cavity, that is, the part of the molding material that is forced to leave the mold cavity due to the reduction in the size of the mold cavity.

[0043] This enables a significant travel path within the relative range of motion and a significant reduction in cavity size. The cavity can initially be defined to have a correspondingly large volume to accommodate a large volume of molding material to effectively heat the mold part.

[0044] In this context, discharge may include at least one of the following:

[0045] - Partial discharge of the molding material into at least one collecting cavity which is delimited by at least one mold part. The collecting cavity can, for example, be at least partially unfilled beforehand and / or cannot define components to be retained in the component to be produced (i.e., the molding material solidified therein can subsequently be removed from the component). The collecting cavity can also be referred to as overflow. Alternatively or additionally, a general overflow region can be provided in the molding tool.

[0046] - discharge part of the molding material through the filling channel for filling the molding material. This may include, for example, pressing part of the molding material back into a molding material container connected to the filling channel and / or into a melt generator connected to the filling channel and / or into a gate system connected to the filling channel.

[0047] - Expelling the molding material through a (fluid) channel, which is formed or opened by destroying a defined area of ​​the molding tool. For example, at least one of the mold parts or the molding tool can generally include at least one predetermined breaking point, which breaks in a certain way due to the pressure applied by the molding material. The predetermined breaking point can form a defined area of ​​the molding tool, which is opened and therefore destroyed. The defined area and / or the predetermined breaking point can be, for example, a wall area of ​​a lost foam with a locally reduced material thickness. The wall area can separate the cavity from the discharge channel and can be penetrated by the molding material, thereby establishing a fluid connection between the cavity and the discharge channel. Due to the first or any other relative movement of the mold parts, the pressure effect of the molding material can increase above a threshold value, whereupon the predetermined breaking point breaks.

[0048] In a further development, at least one core is arranged in the mold cavity, which core is embedded in the molding material. At least one mold part, in particular the mold part that actively moves during the first or any other relative movement, can be moved relative to the core. The core can generally be stationary. For example, the core can be positioned in the mold cavity by means of a rod or a bar, whereby at least one (in particular actively moving) mold part can be moved relative to the core. In this context, the mold part can also be penetrated by a rod or a web. For example, the rod or the web can protrude into the mold cavity through a recess in the mold part.

[0049] The invention also relates to an apparatus for shaping a hardenable shaping material, comprising, inter alia:

[0050] a molding tool comprising a first mold part and at least one second mold part, the first mold part and the second mold part together defining a molding cavity in which a hardenable molding material can be accommodated;

[0051] - a movement device arranged to generate a relative movement between the first and second mould parts;

[0052] - a control device configured to control the movement device to generate at least a first relative movement between the first and second mold parts when the mold cavity is at least partially filled with hardenable molding material, the first relative movement reducing the size of the mold cavity.

[0053] The device can be configured to perform the method according to any variant of the present disclosure.In particular, the control device can be arranged to initiate any required measures and / or perform any necessary actuations.

[0054] Further optional features and specific embodiments of the general features of the method and apparatus of the present disclosure are explained below. These features and embodiments can be provided in any number and combination.

[0055] For example, according to one general aspect, the forming tool and / or mold parts may include at least one of the following materials: plastic, wood, ceramic, glass, microcrystalline glass, concrete, cement, gypsum, composite and / or synthetic materials, sand / binder mixture, molding sand, metal, steel, in particular hot-working steel.

[0056] The forming tool and / or its parts may be non-heatable or heatable (i.e. temperature controlled). The latter can be achieved by means of at least one of the following variants: hot air preheating, radiant heating, convection heating, heat conduction, electric heating by resistive heating, electric heating by induction, electric heating by electric current heating, near-contour heating / cooling by heating / cooling circuits, water temperature control, oil temperature control, fluid metal temperature control, heating by chemical reaction.

[0057] The number of mold parts is not limited to two, i.e. the molding tool is not necessarily limited to two mold halves formed by mold parts. On the contrary, a greater number of mold parts can be provided. Typically, the mold parts can include mold tilts and / or rounded corners.

[0058] The forming tool may comprise at least one of the following as at least one of the forming parts or as an additional tool part: a punch, a die, a retaining clamp, a slide, an undercut die part and / or an undercut tool part, a mandrel, a core.

[0059] The molding tool may include at least one of any number of the following features, which may also be referred to as auxiliary parts of the tool: runners, venting ducts, overflow areas, ejector pins, guides or guide structures, temperature sensors, pressure sensors, material detectors, hot runners, seals, valves for controlling the flow of molding material, predetermined breaking points and / or diaphragms, overflow or backflow guide structures, temperature sensors, pressure sensors, material detectors, hot runners, seals, molding material flow control valves, predetermined breaking points and / or diaphragms, overflow or backflow resistance (for example, including geometric flow resistance, cross-sectional transitions, porous structures; specifically induced cold laps; extended flow paths; roughening).

[0060] The working direction of the mold part can be linear and / or can include only one direction of movement. Alternatively, several working directions and / or complex movements can occur in several continuous working directions.

[0061] The molding material can include at least one of the following materials:

[0062] Thermoplastics, thermosets, fiber-reinforced composites, ceramic casting materials, gypsum, concrete, in particular ultra-high performance concrete (UHPC), polymer concrete, metals such as magnesium, aluminum, copper, zinc, tin, iron, nickel, lead, titanium and its alloys, wrought aluminum alloys, cast iron, steel.

[0063] Material feeding, or in other words, filling with molding material, can be carried out according to one of the following variants: the mold part can be completely immersed in the fluid molding material and closed in the fluid molding material; gravity casting can be carried out in an open molding tool; one of the mold parts can include a filling channel, in particular a mold part formed as a punch, which is moved into the mold part formed as a die; a transverse hot channel can be provided; the molding material can be fed vertically from below through one of the mold parts, in particular a mold part designed as a die using the low pressure principle; the molding material can be contained in the cavity and then only heated there, in particular melted there.

[0064] Additionally or alternatively, any of the following adjuvants may be used alone or in any combination: lubricating oils or lubricants, mold release agents, chemical protective coatings, coatings that accommodate heat transfer, coatings that modify surface composition / particle morphology.

[0065] In the following, examples of embodiments of the present invention are explained with reference to the accompanying drawings. In all the drawings, similar or similarly acting features may be denoted by the same reference numerals.

[0066] Figure 1 Operating states a)-d) of a device according to the first embodiment example are shown, the device performing the method according to the first embodiment example.

[0067] Figure 2 Operation states a)-b) of an apparatus according to the second embodiment example are shown, the apparatus performing the method according to the second embodiment example.

[0068] Figure 3 Operation states a)-b) of a device according to the third embodiment example are shown, the device performing the method according to the third embodiment example.

[0069] Figure 4 Operation states a)-b) of an apparatus according to a fourth embodiment example are shown, the apparatus performing a method according to a fourth embodiment example.

[0070] Figure 5 Operation states a)-d) of a device according to a fifth embodiment example are shown, the device performing a method according to a fifth implementation example.

[0071] Figure 6 Operation states a)-b) of an apparatus according to the sixth embodiment example are shown, the apparatus performing the method according to the sixth embodiment example.

[0072] Figure 1 The device 10 is shown comprising a forming tool 12. The forming tool 12 has two mold parts 100, 101. One mold part 100 is designed as a punch and the other mold part 101 is designed as a die. The forming tool 12 can be designed as a lost mold, for example made of sand, or as a die.

[0073] The mold part 101 is fixed. The mold part 100 is movable. For this purpose, the mold part 100 is mechanically coupled to a schematically shown direction of movement 18, in particular to an actuator of a movement device 18, for example a hydraulic cylinder.

[0074] The apparatus 10 further comprises a control device 16, such as a computer and / or comprising at least one processor. The control device 16 is arranged to control the direction of movement 18 via a wired or wireless data connection shown in dashed lines to move the mold part 100 as desired.

[0075] The control device 16 and the direction of movement 18 are only shown in state a), but are also present in the other states b)-d). Figure 2-6 The device 10 shown in FIG. 1 is shown in FIG. 1 , but still exists.

[0076] The mold part 101 has a recess 20 into which the mold part 100 can be moved. The space between the recess 20 and the opposing surface of the part 100 that can be moved into the recess 20 forms a cavity 14 for accommodating a molding material (not shown).

[0077] Figure 1 A succession of operating states a)-d) is shown, each operating state corresponding to a method step of a method performed by the device 10 .

[0078] In state a), the molding tool 12 is shown in an open state. The mold part 100 has been clearly moved out of the recess 20 of the mold part 101, and the cavity 14 is not completely surrounded by the mold parts 100, 101, or in other words, is not completely defined by the mold parts 100, 101. In this state, the cavity 14 can be described as open, dissolved, or not yet fully formed.

[0079] For example, in gravity casting, a molding material not shown is filled into the recess 20 in a fluid, particularly molten state. The molding material is heated to a temperature higher than room temperature, for example, more than 100° C. The molding material can include any material example disclosed herein, and may particularly be molten metal.

[0080] In state b), mold part 100 has been partially lowered into recess 20 of mold part 101 by movement direction 18. As a result, cavity 14 is formed and / or completely closed by mold parts 100, 101 and is completely confined between mold parts 100, 101. This can be described as forming an enlarged pre-cavity. The molding material, not shown, completely fills cavity 14 and thereby heats mold parts 100, 101. Features known to those skilled in the art, such as vents that allow molding material to pass through mold parts 100, 101, are not shown.

[0081] Then, the mold part 100 is further lowered to reach state c). It should be noted that, starting from state a), lowering the mold part 100 can occur as part of a continuous first relative movement. This first continuous relative movement can include state b) as an intermediate stage and end with state d) in which the target geometry is reached. In this case, state c) represents an intermediate stage, which can also be described as achieving a pre-geometry.

[0082] However, the first relative movement (especially continuous relative movement) of the type disclosed herein can also only occur in state b). For example, after reaching state b), a defined time can be waited for the mold parts 100, 101 to heat up.

[0083] In state c), the cavity 14 is significantly smaller than the cavity in state b), i.e., the volume of the cavity 14 has been reduced. This reduction in size is also achieved by forming thin-walled areas, because the distance between the opposing areas and surfaces of the mold parts 100, 101 is reduced. The material thickness of these thin-walled areas may not exceed 5 mm or not exceed 3 mm. In other words, this thin-walled material thickness can be formed or predetermined by the cavity.

[0084] In state c), the still fluid molding material penetrates into the thin-walled areas without forming cold overlaps and completely fills these thin-walled areas. This occurs under laminar flow conditions, which significantly improve the quality of the cast product compared to turbulent die casting, for example.

[0085] During the transition from state b) to state c), excess molding material flows back into the filler channel (not shown). As described above, while the molding material is still fluid, the size of the mold cavity 14 is reduced until state d), in which the size of the mold cavity 14 can be further reduced before the molding material solidifies (i.e. until the target geometry is reached).

[0086] In summary, starting from state b) (pre-cavity), via state c) (pre-geometry), state d) (target geometry) can be achieved in a continuous relative movement, and only then can the molding material be hardened.

[0087] Alternatively, starting from state c), state d can only be approached after a defined period of time. During this period of time, the molding material begins to harden at least partially and / or in certain areas and is no longer completely fluid. A closing force is then generated via the direction of movement 18, which pushes the mold part 100 further into the recess 20 of the mold part 101 to reach state d). As a result, the already partially or completely solidified molding material forms the final component geometry. In this case, the molding tool 12 is advantageously designed as a permanent mold in order to withstand the closing force.

[0088] Finally, the state a) of the molding tool 12 or an even more open state of the molding tool 12 can be changed (not shown) in order to remove the component formed from the hardened molding material from the molding tool 12 .

[0089] Figure 2 A modification of the first embodiment is shown in which a filler channel 201 is formed in the first mold part 101 to perform a gravity casting method. Figure 2The state a) corresponds largely to Figure 1 2 ) and shows the initial filling of the molten molding material 200 through the filling channel 201. Thus, the mold parts 100, 101 are heated by the molding material 200.

[0090] Figure 2 The state b) corresponds to the state according to Figure 1 The target geometry of state d) is achieved by relative movement of mold part 100 into mold part 101 (see movement arrow in state b). The cavity 14 defined between these mold parts 100, 101 becomes smaller, forming a thin-walled area. The molding material, which is still fluid, penetrates into these mold parts along the heated adjacent surfaces of mold parts 101, 100 under laminar flow conditions without any casting defects.

[0091] Figure 3 Shows something like Figure 2 The present invention is a process different from that of the present invention, but for low-pressure casting. In this case, according to a low-pressure casting method known per se, the molding material 200 is filled into the mold cavity 14 between the mold parts 100, 101 from vertically below through a filling channel 300. In other words, the molding material 200 rises under pressure into the mold cavity 14, see flow direction 301. The mold parts 100, 101 can form a permanent mold and are made, for example, of hot-working steel.

[0092] In state a) (pre-cavity), in order to achieve heating of mold parts 100, 101, the molding material then at least partially, in particular completely fills the mold cavity 14. Then, mold part 100 is lowered relative to mold part 101 (see movement arrow in state b), which corresponds to the target geometry. Then, the mold cavity 14 is reduced, thin-walled areas are formed and filled with stationary, fluid molding material 200. Excess molding material 200 is squeezed out of the mold cavity 14 back into the filling channel 300, see flow direction 302.

[0093] Alternatively, something like Figure 1 In the state d), after the molding material hardens, the solidified part can be further formed by means of an additional closing force, thereby further reducing the size of the cavity 14. In this case, before applying the closing force, the filling channel 300 can be closed, for example, by a valve not shown.

[0094] Figure 4 Shows something like Figure 3The process is not limited to the die casting method, but is suitable for the transverse feeding of the molding material 200. More precisely, the molding material 200 is laminated and filled into the cavity 14 between the mold parts 100, 101 by means of the slide 400 in the state a) (enlarged pre-cavity), and the mold parts 100 and 101 are heated.

[0095] In state b) (target geometry), the cavity 14 becomes smaller due to the displacement of the mold part 100 into the mold part 101 (see displacement arrow). Excess molding material is squeezed out of the cavity 14 by pushing back the slide 401.

[0096] Figure 5 An apparatus 10 is shown, wherein the stationary mold part 101 comprises at least one collecting cavity 500 (eg formed as a circumferential ring). The collecting cavity 500 may also be referred to as an overflow.

[0097] In state a) (pre-cavity), use something like Figure 4 The low-pressure method fills the molding material through the filling channel 504 and increases (see the flow direction indicated by the arrow) the molding material in the cavity 14. The molding material then heats the mold parts 100, 101. In state b) (pre-geometry), the mold part 100 is lowered into the mold part 101, squeezing out the excess molding material from the cavity 14 (see the flow direction indicated by the arrow below). As shown by the deviated shading or filling, the molding material 501 then begins to solidify and becomes viscous and / or hardens. After a corresponding hardening time, a closing force is applied to reach state d) (target geometry), whereby the mold part 100 is further lowered and the size of the cavity 14 is further reduced. The molding material 501 then enters the collecting cavity 500, where an excess component area 502 is formed, which can then be removed.

[0098] In the state of FIG. d), the filling channel 504 can be closed by a valve (not shown) and / or the filling channel 504 can be closed by the solidified molding material.

[0099] Figure 6 A variant is shown with an additional core 600 for defining a hollow structure in the manufactured component. The mold part 100 has a recess into which a rod 601 is inserted. The rod 601 serves as a holding and positioning device for positioning the core 600 in the cavity 14.

[0100] In state a), the molding material 200 is again filled into the mold cavity 14 via the filling channel 300 using a low-pressure method (see flow direction 301 ). The molding material 200 is embedded in the mold core 600 , or in other words, surrounds the mold core 600 .

[0101] The core 600 initially has a defined gap 610 relative to the mold part 100, in particular when viewed along the axis of movement of the mold part 100. By means of this gap, the extent of movement of the core 600 relative to the mold parts 100, 101 can be adjusted. To reach state b), the mold part 100 is lowered into the mold part 101 relative to the initially fixed rod 601 (see movement arrow). Only after the gap 610 has been bridged, the movement forces are transmitted from the mold part 101 to the core 600, so that the core 600 can be lowered together with the mold part 100.

[0102] When state b) is reached, the target geometry is achieved, wherein the cavity 14 is reduced in size and has thin-walled areas. As indicated by flow arrows 302 , excess molding material can be squeezed out of the cavity 14 through the filler channel 300 .

[0103] In the following table, the states of the input molding material are shown as a function of the positions of the mold parts 100, 101 according to an embodiment of the method of the present invention. The "open" state corresponds to Figure 1 a) is shown in the state shown in the figure. The "pre-cavity" state corresponds to Figure 1 b) The state of the initial enlarged cavity shown.

[0104] The “pre-geometry” state corresponds to a cavity whose dimensions have been reduced compared to the “pre-cavity” but have not yet been explicitly reduced, e.g. Figure 1 c), for example, the "target geometry" state corresponds to the maximum reduction in volume of the cavity; see Figure 1 d) as an example.

[0105] For example, by selecting suitable time intervals between the individual movement states of the molding tool and / or by selecting the molding material and / or by selecting its filling temperature, the following states of the molding material can be achieved.

[0106] When poured into a sand mold (optionally, as Figure 6 As shown, with a moving core package), one embodiment shows the following sequence, where "X" represents the state of the molding material in the corresponding state of the molding tool:

[0107] Forming tool status Molding material fluid Molding material paste Molding material solid Open X Pre-cavity X Pre-geometry X Target geometry X cool down X

[0108] In another exemplary process, the following method is used, which corresponds to a thixoforming process due to the molding of the sludge-like substance. For example, the molding material is not filled before the pre-cavity is formed, for example, using a low-pressure method:

[0109] Forming tool status Molding material fluid Molding material paste Molding material solid Open Pre-cavity X Pre-geometry X Target geometry X cool down X

[0110] In another exemplary process, once the pre-geometry exists, the forming material has solidified, and then the target geometry is formed by applying further closing forces, the following process occurs. This may also be referred to as casting forging:

[0111] Forming tool status Molding material fluid Molding material paste Molding material solid Open X Pre-cavity X Pre-geometry X Target geometry X cool down X

[0112] Reference numerals list

[0113] 10. Equipment

[0114] 12 Forming tools

[0115] 14 Cavity

[0116] 16 Control Equipment

[0117] 18 Sports Equipment

[0118] 20 concavity

[0119] 100 Mould parts

[0120] 101 mold parts

[0121] 201 Filling channel

[0122] 202 Molding material

[0123] 300 Filling channel

[0124] 301-302 Flow direction

[0125] 500 Collection Cavity

[0126] 501 Hardened molding material

[0127] 502 Extra Component Area

[0128] 504 Filling channel

[0129] 600 core

[0130] 601 bars

[0131] 610 Gap

Claims

1. A method for shaping a hardenable shaping material (202), the method comprising: - receiving a hardenable molding material (202) in a fluid state in a molding cavity (14) defined by a first mold part (100) and at least a second mold part (101) of a molding tool (12); - after a defined period of time has expired during which the mould parts (100, 101) have been heated with the moulding material (202): causing at least a first relative movement between the first and second mould parts (100, 101) to reduce the mould cavity (14) and form a thin-walled area, wherein the material thickness of the thin-walled area does not exceed 5 mm or does not exceed 3 mm; - Hardening the molding material (202).

2. The method according to claim 1, The first relative movement takes place in such a way that the molding material enters the thin-walled region essentially in a laminar flow.

3. The method according to claim 1 or 2, The first relative movement occurs when the molding material (202) is still in a fluid state.

4. The method according to any one of the preceding claims, The method of containing the molding material (202) comprises: - filling the molding material (202) into the cavity (14) defined by the first and second mold parts (100, 101); or - Filling the molding material (202) into the molding tool (12) in an open state, and arranging the first mold part (100) and the second mold part (101) relatively to form a cavity (14) for accommodating the molding material (202).

5. The method according to any one of the preceding claims, The first relative movement occurs only when all the molding material (202) is contained in the mold cavity (14).

6. The method according to any one of the preceding claims, in, The molding material (202) is filled into the molding tool (12) by means of pressure casting or low-pressure casting, wherein the pressure applied for filling is at least partially maintained or increased when the first relative movement occurs.

7. The method according to any one of claims 1 to 5, When the first relative movement occurs, the pressure acting on the molding material (202) increases by no more than 25% or by no more than 10%.

8. The method according to any one of the preceding claims, The time period for heating the mold parts (100, 101) is at least 2 seconds.

9. The method according to any one of the preceding claims, further comprising, after the first relative movement: - applying a closing force to at least one of the first and second mould parts (100, 101), said closing force pressing the mould parts (100, 101) against each other.

10. The method according to claim 9, in, By means of the closing force, a further relative movement between the first and second mold parts (100, 101) is generated, by means of which the mold cavity (14) becomes smaller.

11. The method according to claim 9 or 10, The closing force is only generated when the molding material (202) is no longer fluid, at least in certain areas.

12. The method according to any one of claims 9 to 11, The closing force is at least 10% higher than the force applied to generate the first relative movement.

13. The method according to any one of the preceding claims, The molding tool (12) is formed into a lost mold or a permanent mold.

14. The method according to any one of claims 1 to 11, in, One of the mold parts (100, 101) is a lost foam part, and the corresponding other of the mold parts (100, 101) is a permanent mold part.

15. The method according to any one of the preceding claims, further comprising: - during the first relative movement, ejecting a portion of the molding material (202) from the molding cavity (14).

16. The method according to claim 15, The discharge comprises at least one of the following: - partially discharging the molding material into at least one collecting cavity (500) delimited by at least one of the mold parts (100, 101); - discharging a portion of the molding material through a filling channel (300, 504) for filling the molding material; - Expelling the molding material through channels formed or opened by destroying defined areas of the mold.

17. A method according to any one of the preceding claims, At least one core (600) is arranged in the cavity (14) and embedded in the molding material (202).

18. An apparatus for shaping a hardenable shaping material (202), the apparatus comprising: a molding tool (12) having a first mold part (100) and at least one second mold part (101), the first mold part and the second mold part jointly delimiting a mold cavity (14) in which a hardenable molding material (202) can be accommodated; - a movement device (18) configured to generate a relative movement between the first and second mould parts (100, 101); a control device (16) configured to control the movement device (18) to generate at least one first relative movement between the first and second mold parts (100, 101) when the mold cavity (14) is at least partially filled with a hardenable molding material (202) and after expiration of a defined period of time for heating the mold parts (100, 101) with the molding material (202), thereby reducing the size of the mold cavity (14); Wherein, the control device (16) is also configured to control the first movement device (18) in such a manner that the size of the cavity (14) is reduced through the first relative movement while forming a thin-walled area, wherein the material thickness of the thin-walled area does not exceed 5 mm or does not exceed 3 mm.

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