U.S. patent application number 10/993819 was filed with the patent office on 2006-05-25 for method of making a casting assembly.
Invention is credited to Casee Michele Eisele, Michael Carl Harting, Michael Dean Kollath, Edwin Roy Kreis, Robert Lee JR. Wood.
Application Number | 20060108085 10/993819 |
Document ID | / |
Family ID | 36423688 |
Filed Date | 2006-05-25 |
United States Patent
Application |
20060108085 |
Kind Code |
A1 |
Eisele; Casee Michele ; et
al. |
May 25, 2006 |
METHOD OF MAKING A CASTING ASSEMBLY
Abstract
A method of making an investment or lost foam casting assembly
of a first part movable with respect to a second part includes
making first and second separate wax or foam patterns of portions
of the first part. Then, a third wax or foam pattern of the second
part is made. Next, ceramic core pieces are made. At least one of
the core pieces is mounted on the first pattern to form a
subassembly. The subassembly is combined with the third pattern so
that the core pieces maintain a separation between the third
pattern and the first pattern. The first and second patterns are
bonded together to trap the subassembly and to form a complete
casing assembly.
Inventors: |
Eisele; Casee Michele;
(Mannheim, DE) ; Kollath; Michael Dean;
(Dunkerton, IA) ; Wood; Robert Lee JR.; (Waterloo,
IA) ; Kreis; Edwin Roy; (Waterloo, IA) ;
Harting; Michael Carl; (La Porte City, IA) |
Correspondence
Address: |
DEERE & COMPANY
ONE JOHN DEERE PLACE
MOLINE
IL
61265
US
|
Family ID: |
36423688 |
Appl. No.: |
10/993819 |
Filed: |
November 19, 2004 |
Current U.S.
Class: |
164/34 ; 164/35;
164/90 |
Current CPC
Class: |
B22C 9/04 20130101; B22C
9/108 20130101; B22C 7/02 20130101 |
Class at
Publication: |
164/034 ;
164/035; 164/090 |
International
Class: |
B22C 9/04 20060101
B22C009/04; B22D 19/12 20060101 B22D019/12 |
Claims
1. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making first and
second separate patterns of portions of the first part; making a
third pattern of the second part; making a plurality of ceramic
core pieces; and mounting at least one of the core pieces on the
first pattern to form a subassembly; combining the subassembly with
the third pattern so that the core pieces maintain a separation
between the third pattern and the first pattern; attaching the
first and second patterns together to trap the third pattern and
form a complete casting assembly.
2. The method of claim 1, wherein: the third pattern is hollow; and
the subassembly is received by and inserted through the third
pattern.
3. The method of claim 1, wherein: the at least one of the core
pieces is hollow and receives the first pattern; the third pattern
is hollow; and the at least one of the core pieces and the first
pattern are received by the third pattern.
4. The method of claim 1, wherein: the patterns are formed out of
wax and the assembly is used in an investment casting process.
5. (canceled)
6. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third pattern of
another portion of the second part; making at least one ceramic
core pieces; mounting the core piece on the first pattern to form a
subassembly; combining the subassembly with the second pattern so
that the core pieces maintain a separation between the second
pattern and the first pattern; and bonding the third pattern to the
second pattern and around the subassembly to trap the subassembly
and form a complete casting assembly.
7. The method of claim 6, characterized by: openings are formed
between the second pattern and the third pattern, and the
subassembly is received by said openings.
8. The method of claim 6, wherein: the patterns are formed out of
wax and the assembly is used in an investment casting process.
9. (canceled)
10. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third and fourth
patterns of other portions of the second part; making a pair of
ceramic core pieces; mounting the core pieces on the first pattern
to form a subassembly; combining the subassembly with the second
pattern so that the core pieces maintain a separation between the
second pattern and the first pattern; and bonding the third and
fourth patterns to the second pattern and around the subassembly to
trap the subassembly and form a complete casting assembly.
11. The method of claim 10, characterized by: openings are formed
between the second pattern and the third and fourth patterns, and
the subassembly is received by said openings.
12. The method of claim 10, wherein: the patterns are formed out of
wax and the assembly is used in an investment casting process.
13. (canceled)
14. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third pattern of
another portion of the second part; coating at least a portion of
the first pattern with a ceramic coating; combining the coated
first pattern with the second pattern so that the ceramic coating
maintains a separation between the second pattern and the first
pattern; and bonding the third pattern to the second pattern and
around the subassembly to trap the subassembly and form a complete
casting assembly.
15. The method of claim 14, characterized by: an opening is formed
between the second pattern and the third pattern, and the coated
first pattern is received by said opening.
16. The method of claim 14, wherein: the patterns are formed out of
wax and the assembly is used in an investment casting process.
17. (canceled)
18. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making first and
second separate patterns of portions of the first part; making a
third pattern of the second part; making a plurality of ceramic
core pieces; mounting at least one of the core pieces on the first
pattern to form a subassembly; combining the subassembly with the
third pattern so that the core pieces maintain a separation between
the third pattern and the first pattern; and attaching the first
and second patterns together to trap the third pattern and form a
complete casting assembly, and the patterns are formed out of foam
and the assembly is used in a lost foam casting process.
19. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third pattern of
another portion of the second part; making at least one ceramic
core pieces; mounting the core piece on the first pattern to form a
subassembly; combining the subassembly with the second pattern so
that the core pieces maintain a separation between the second
pattern and the first pattern; and bonding the third pattern to the
second pattern and around the subassembly to trap the subassembly
and form a complete casting assembly, and the patterns are formed
out of foam and the assembly is used in a lost foam casting
process.
20. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third and fourth
patterns of other portions of the second part; making a pair of
ceramic core pieces; mounting the core pieces on the first pattern
to form a subassembly; combining the subassembly with the second
pattern so that the core pieces maintain a separation between the
second pattern and the first pattern; and bonding the third and
fourth patterns to the second pattern and around the subassembly to
trap the subassembly and form a complete casting assembly, and the
patterns are formed out of foam and the assembly is used in a lost
foam casting process.
21. A method of making a casting assembly for casting a first part
movable with respect to a second part, comprising: making a first
pattern of the first part; making a second pattern of a first
portion of the second part; making separate third pattern of
another portion of the second part; coating at least a portion of
the first pattern with a ceramic coating; combining the coated
first pattern with the second pattern so that the ceramic coating
maintain a separation between the second pattern and the first
pattern; and bonding the third pattern to the second pattern and
around the subassembly to trap the subassembly and form a complete
casting assembly, and the patterns are formed out of foam and the
assembly is used in a lost foam casting process.
Description
BACKGROUND
[0001] The present invention relates to a method of making a
casting part assembly for casting parts such as by an investment or
lost foam casting process.
[0002] Some part assemblies with multiple cast parts have one cast
part which is separate, but coupled to and movable with respect to
a second cast part. Such an assembly may require that three
separate parts be made by a lengthy casting process, then welding
two of the parts together around the movable part. A simpler method
of making such a part assembly is desired.
SUMMARY
[0003] Accordingly, an object of this invention is to provide a
method of casting a multiple part assembly where one part is
received by and movable with respect to a second part.
[0004] These and other objects are achieved by the present
invention, which is a method of making a casting assembly of a
first part movable with respect to a second part. First, first and
second separate wax or foam patterns of portions of the first part
are made. Then, a third wax or foam pattern of the second part is
made. Next, ceramic core pieces are made. At least one of the core
pieces is mounted on the first pattern to form a subassembly. The
subassembly is combined with the third pattern so that the core
pieces maintain a separation between the third pattern and the
first pattern. The first and second patterns are bonded together to
trap the subassembly and to form a complete casting assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1-3 are perspective views of patterns used with a
first embodiment of the present invention;
[0006] FIGS. 4 and 5 are perspective views of ceramic cores used
with the first embodiment of the present invention;
[0007] FIGS. 6-9 are perspective views showing the steps of the
first embodiment of the present invention;
[0008] FIGS. 10-12 are perspective views of patterns used with a
second embodiment of the present invention;
[0009] FIG. 13 is a perspective view of the ceramic cores used with
a second embodiment of the present invention;
[0010] FIGS. 14 and 15 are perspective views showing the steps of
the second embodiment of the present invention; and
[0011] FIGS. 16 and 17 are perspective views relating to a third
embodiment of the present invention.
DETAILED DESCRIPTION
[0012] According to a first embodiment of the present invention, a
wax or foam pattern 10 is formed as shown in FIG. 1. Pattern 10 is
a portion of a first investment or lost foam cast part, and
includes a cylindrical shaft 12 with a cylindrical ring 14 formed
on one end thereof.
[0013] Another wax or foam pattern 16 is formed as shown in FIG. 2.
Pattern 16 is a cylindrical wax or foam ring and comprises a
remaining portion of the first part.
[0014] A wax or foam pattern 18 is formed as shown in FIG. 3.
Pattern 18 is in the shape of the second part which is a hollow
sleeve.
[0015] A ceramic core 20 is formed as shown in FIG. 4. Ceramic core
20 is in the form of a hollow cylindrical sleeve.
[0016] A pair of ceramic cores 22 are formed as shown in FIG. 5.
Ceramic cores 22 are in the form of a hollow annular ring. In place
of ceramic cores to separate parts, parts could be coated with a
refractory coating which could be either sprayed on, brushed on, or
dipped.
[0017] Referring now to FIG. 6, one of the cores 22 is mounted on
the shaft 12 of pattern 10 next to ring 14. Next, as shown in FIG.
7, core 20 is mounted on the shaft 12 of pattern 10 next to core
22. Next, as shown in FIG. 8, pattern 18 is mounted over the core
20 with one end next to core 22. Finally, as shown in FIG. 9,
another ceramic core ring 22 is mounted on the shaft 12 of pattern
10 next to the other end of core 20, and pattern ring 16 is bonded
or attached, such as by gluing or wax or foam welding, to the upper
end of shaft 12.
[0018] This results in an investment or lost foam casting assembly
26 wherein the patterns 10 and 16 of the first part are separate
and spaced apart from the pattern 18 of the second part. This
assembly 26 may then be used in a known standard investment or lost
foam casting process, and the result will be a first inner metal or
cast part received by and rotatable with respect to a second outer
metal or cast part.
[0019] A second embodiment of the invention is illustrated by FIGS.
10-15 which relate to an investment casting assembly for a wheel
sleeve assembly having a sleeve, a pinion and a retaining
bracket.
[0020] A wax or foam pattern 30 is formed as shown in FIG. 10.
Pattern 30 is a portion of a first investment or lost foam cast
part, and includes a cylindrical shaft 32 with a gear piece 34
formed on one end thereof.
[0021] Another wax or foam pattern 36 is formed as shown in FIG.
11. Pattern 36 is a housing 38 which forms a slot or recess 40.
[0022] A pair of wax or foam patterns 42 are formed as shown in
FIG. 12. Patterns 42 are in the shape of the U-shaped brackets.
[0023] A pair of ceramic ring cores 44 are formed as shown in FIG.
13. Ceramic cores 44 have a hollow cylindrical sleeve 46 with a
flange 48 at one end.
[0024] Referring now to FIG. 14, the cores 44 are mounted on the
shaft 32 of pattern 30 on either side of the gear piece 34 with
flanges 48 next to the ends of the gear piece 34, and this
subassembly is mounted in the recess 40 of pattern 36.
[0025] Next, as shown in FIG. 15, a wax or foam pattern 42 is
mounted over each of the cores 44 and is glued to the pattern 36,
trapping the pinion gear. This casting assembly 50 may then be
coated, fired, poured, and cleaned as in the known standard
investment casting process, or processed according to the known
lost foam casting process. The result will be an inner metal shaft
and gear part received by and rotatable with respect to a metal
housing/bracket part. Each separate piece of the assembly 50 will
require its own attachment point to a casting tree.
[0026] A third embodiment of the invention is illustrated by FIGS.
16 and 17 together with FIGS. 10, 11 and 12, and also relates to an
investment or lost foam casting assembly for a wheel sleeve
assembly having a sleeve, a pinion and a retaining bracket.
[0027] As in the second embodiment, a wax or foam pattern 30 is
formed as shown in FIG. 10. Pattern 30 is a portion of a first cast
part, and includes a cylindrical shaft 32 with a gear piece 34
formed on one end thereof.
[0028] Another wax or foam pattern 36 is formed as shown in FIG.
11. Pattern 36 is a housing 38 which forms a slot or recess 40.
[0029] A pair of wax or foam patterns 42 are formed as shown in
FIG. 12. Patterns 42 are in the shape of the U-shaped brackets.
[0030] Then, the gear piece 34 and the portions of shaft 32 next to
gear piece 34 are coated with a ceramic coating 60 as shown in FIG.
16.
[0031] Referring now to FIG. 17, the subassembly of FIG. 16 is
mounted in the recess 40 of pattern 36, and the patterns 42 are
glued or wax-welded to the pattern 36 so as to trap a portion of
pattern 30 and ceramic coating 60 therebetween.
[0032] The third embodiment also produces an investment or lost
foam casting assembly wherein the wax or foam pattern 30 of a first
part is separate and spaced apart from the wax or foam patterns 36
and 42 of the second part. When these patterns are replaced by
metal during the investment or lost foam casting process, the
result will be an inner metal shaft and gear part received by and
rotatable with respect to a metal housing/bracket part.
[0033] Thus, an investment or lost foam cast assembly with loose
pieces is made with ceramic cores and patterns which are glued or
wax or foam welded together. The loose piece is fitted with
pre-formed ceramic cores or should be partially coated before
assembly. This new process will allow assemblies to be formed
earlier in the process, thereby shortening lead times. It will also
eliminate strength concerns that are caused by other assembly
methods, such as fasteners, welding, etc.
[0034] With this method, the assembly operations can be performed
on patterns which can be much lighter than the cast metal parts
would be. This avoids a need for special lifting equipment,
fixtures, etc. For example, if a very light foam pattern will
become a 100 lb. iron part, the assembly could be easily done by
hand with the present invention, whereas traditional processes
would involve handling the 100 lb. part while assembling other
pieces.
[0035] While the present invention has been described in
conjunction with a specific embodiment, it is understood that many
alternatives, modifications and variations will be apparent to
those skilled in the art in light of the foregoing description.
Accordingly, this invention is intended to embrace all such
alternatives, modifications and variations which fall within the
spirit and scope of the appended claims.
* * * * *