U.S. patent application number 14/368324 was filed with the patent office on 2015-02-26 for cast-in structure of vehicle component, and cast-in mold.
The applicant listed for this patent is Ahresty Corporation, Yorozu Corporation. Invention is credited to Shunzo Aoyama, Yasushi Kanno, Masaharu Matsumoto, Sadahiro Sekine.
Application Number | 20150056470 14/368324 |
Document ID | / |
Family ID | 48697179 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150056470 |
Kind Code |
A1 |
Aoyama; Shunzo ; et
al. |
February 26, 2015 |
CAST-IN STRUCTURE OF VEHICLE COMPONENT, AND CAST-IN MOLD
Abstract
An object of the present invention is to surely provide a
projection of burr by forming an appropriate gap needed to set a
cast-in member to a cast-in mold, and by completely closing the gap
when the cast-in mold is clamped, and to correct a cast-in
positioning (axis mating) to a die-cast component by a clamping
operation of the die-cast mold, regardless of a dimensional
precision of the cast-in member upon a manufacture. A steel plate
cast-in member 2, which is wrapped cast except for a bonding
portion 2b to a steel plate bonding member 3 upon molding a
die-cast component 1, has a mold contact portion A at a boundary
between a cast-in portion 2a wrapped cast with a die-cast component
1 and the bonding portion 2b. When a cast-in mold A is clamped, the
mold contact portion 4 is brought into intimate butting contact
with the cast-in mold A, whereby a gap S between the cast-in member
2 and the cast-in mold A, i.e., a cavity is closed. Thus, a
projection of burr is prevented.
Inventors: |
Aoyama; Shunzo;
(Toyohasi-shi, JP) ; Kanno; Yasushi;
(Toyohasi-shi, JP) ; Matsumoto; Masaharu;
(Yokohama-shi, JP) ; Sekine; Sadahiro;
(Yokohama-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ahresty Corporation
Yorozu Corporation |
Toyohashi-shi, Aichi
Yokohama-shi, Kanagawa |
|
JP
JP |
|
|
Family ID: |
48697179 |
Appl. No.: |
14/368324 |
Filed: |
December 18, 2012 |
PCT Filed: |
December 18, 2012 |
PCT NO: |
PCT/JP2012/082722 |
371 Date: |
June 24, 2014 |
Current U.S.
Class: |
428/684 ;
164/284 |
Current CPC
Class: |
B60G 2206/20 20130101;
B60G 2200/21 20130101; B60G 21/051 20130101; B60G 2200/20 20130101;
B32B 15/013 20130101; B32B 15/012 20130101; B22D 19/00 20130101;
B22D 17/002 20130101; Y10T 428/12972 20150115; B22D 19/04 20130101;
B22D 17/22 20130101; B60G 2206/81012 20130101; B22D 17/24 20130101;
B60G 2206/202 20130101 |
Class at
Publication: |
428/684 ;
164/284 |
International
Class: |
B22D 19/00 20060101
B22D019/00; B22D 17/22 20060101 B22D017/22; B32B 15/01 20060101
B32B015/01; B22D 17/24 20060101 B22D017/24 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 27, 2011 |
JP |
2011-286365 |
Claims
1.-7. (canceled)
8. A cast-in structure for a cast-in member, which is made of a
steel plate and which is wrapped cast upon molding a die-cast
component by means of a cast-in mold except for a bonding portion
to be bonded to a steel plate bonding member, wherein the cast-in
member includes a mold contact portion on both surfaces at a
boundary between a cast-in portion wrapped cast with the die-cast
component and the bonding portion, wherein the mold contact portion
is brought into intimate butting contact with the cast-in mold,
when the cast-in mold is clamped.
9. The cast-in structure for the cast-in member according to claim
8, wherein the mold contact portion of the cast-in member is formed
to have a taper shape.
10. The cast-in structure for the cast-in member according to claim
8, wherein the cast-in member is formed into a cylinder, internal
and external mold contact taper surface portions of the mold
contact portion, formed to have a taper shape and formed
consecutively on the entire circumference in an axial direction of
the cylinder, are formed on a boundary between the bonding portion
on one end of the cast-in member and the cast-in portion on the
other end of the cast-in member, and when the cast-in mold is
clamped, a tapered butting portion formed on the cast-in mold is
brought into intimate butting contact with the internal and
external mold contact taper surface portions.
11. A cast-in mold for a cast-in member, the cast-in mold being
configured to cast-in a steel plate cast-in member to a die-cast
component by setting a cast-in portion of the steel plate cast-in
member into a cavity except for a bonding portion to be bonded to a
steel plate bonding member, wherein the cast-in mold includes a
butting portion that is brought into intimate butting contact with
a mold contact portion upon mold clamping, the mold contact portion
being formed on both surfaces of the cast-in member at a boundary
between the cast-in portion and the bonding portion of the cast-in
member.
12. The cast-in mold for the cast-in member according to claim 11,
wherein the butting portion is formed into a taper shape, and is
brought into intimate butting contact with the mold contact
portion, which is similarly formed into a taper shape.
13. The cast-in mold for the cast-in member according to claim 11,
wherein the butting portion is provided with a biting projection
that bites the mold contact portion of the cast-in member.
14. The cast-in mold for the cast-in member according to claim 11,
comprising: a fixed mold and a movable mold, each having an
external butting taper surface portion of the butting portion that
is brought into intimate butting contact with an external mold
contact taper surface portion of the mold contact portion upon mold
clamping, the external mold contact taper surface portion being
formed on both the internal and external surfaces of the cylinder
to have a taper shape and formed consecutively on the entire
circumference in an axial direction of a cylinder of the cast-in
member formed into a cylindrical shape; and a movable core having
an internal butting taper surface portion of the butting portion,
the internal butting taper surface portion being brought into
intimate butting contact with an internal mold contact taper
surface portion of the mold contact portion upon mold clamping.
Description
TECHNICAL FIELD
[0001] The present invention relates to a cast-in structure for a
cast-in member and a cast-in mold, and more particularly to a
cast-in structure for a steel plate cast-in member and a cast-in
mold, the cast-in member being wrapped cast except for a bonding
portion bonded to a bonding member upon molding a die-cast
component, when the die-cast component casted by using a light
alloy metal such as aluminum and a steel plate bonding member are
bonded to each other, i.e., when different kind of metals are
bonded to each other.
BACKGROUND ART
[0002] When a member made of a light alloy metal such as aluminum,
magnesium, or zinc and a member made of an iron steel (iron metal),
i.e., members made of different kind of metals, are directly welded
and bonded to each other, a weak intermetallic compound is formed
between both members (on a bonding interface). Therefore, a weld
crack is generated, resulting in that reliability in bonding
strength (weld strength) is deteriorated. This has conventionally
been known.
[0003] As a method of solving the problem of deterioration in the
reliability of the bonding strength caused by the direct weld
bonding between the members made of different kind of metals, a
cast-in structure (cast enclosing structure) has been proposed (for
example, see patent literature 1). In the cast-in structure, a
cast-in member (joint member) made of a material same as a steel
plate bonding member (steel member) that is to be welded and bonded
is integrally wrapped cast and bonded upon molding an aluminum
die-cast component.
[0004] In the patent literature 1, the deterioration in the bonding
strength by the direct weld between the members made of different
kind of metals and the difficult welding between aluminum members
are avoided, and the aluminum die-cast component can be bonded to
the steel plate bonding member (steel member) made of a different
kind of metal via the steel plate cast-in member (steel joint
member) that can be welded and bonded without any troubles.
Specifically, since the bonding member and the cast-in member are
both made of steel plate, both members are bonded by welding with
sufficient bonding strength without any troubles, and the aluminum
die-cast component can be bonded by welding to the steel plate
bonding member that is made of a different kind of metal.
[0005] In the cast-in structure for the cast-in member that is
wrapped cast to an aluminum die-cast component only at the cast-in
portion of the steel plate cast-in member with the bonding portion
bonded to the steel plate bonding member by welding being left
(except for the bonding portion bonded to the steel plate bonding
member by welding), when a molten metal is casted in a die-cast
mold, a so-called cavity, burr (casting burr) is likely to project
toward the bonding portion of the cast-in member exposed to the
outside from the cast aluminum die-cast component. Therefore, a
countermeasure against the projection of burr has to be taken.
[0006] A gap needed to set the cast-in member to the die-cast mold
by a fitting method of fitting the cast-in member to the die-cast
mold is formed in a space between the cast-in member and the
die-cast mold. Therefore, a counter-measure against the projection
of burr from the gap has to be required.
[0007] The gap of settings between the cast-in member and the
die-cast mold is inevitable for promptly setting the cast-in member
to the die-cast mold by means of a carrier device such as a robot
hand. On the other hand, a dimensional error due to plastic
deformation (plastic strain) is likely to occur on the cast-in
member manufactured by machine working such as press working. A
cast-in member that is formed into a cylinder having a rectangular
(oblong) or elliptic cross-section by bending process is
particularly likely to have a dimensional error due to plastic
deformation. In addition, it is difficult to perform a process for
maintaining high dimensional precision. Therefore, burr is likely
to project.
[0008] When the burr (casting burr) projects up to the bonding
portion of the cast-in member bonded to the steel plate bonding
member by welding, the projecting burr might cause deterioration in
bonding strength to the bonding member.
[0009] When it is supposed that the aluminum die-cast component, to
which the steel plate cast-in member made of different kind of
metal from the aluminum die-cast component is wrapped cast and
bonded, is used for a body component or a suspension component of a
vehicle that is used under severe environment where the component
is easy to be corroded, galvanic corrosion generated between the
cast-in member and the aluminum die-cast component, which are made
of different kind of metals, becomes a problem. As a
counter-measure against the galvanic, corrosion, there have been
proposed a method of providing an insulating material for
preventing the galvanic corrosion between the cast-in member and
the aluminum die-cast member, and a method of applying a seal
material for preventing water content from entering the gap on the
cast-in portion wrapped cast with the aluminum die-cast member.
However, these methods cannot prevent the galvanic corrosion due to
the projecting burr, resulting in that the effect of these methods
is deteriorated.
CITATION LIST
Patent Literature
[0010] Patent Literature 1: JP-2010-194583 A (see [0026] to
[0011] , FIG. 4(b), and the like)
SUMMARY OF INVENTION
Technical Problem
[0012] In the prior art described in the patent literature 1, the
structure of preventing the projection of burr generated when the
steel plate cast-in member is wrapped, cast upon molding the
aluminum die-cast component is a dam formed by an acceleration of
solidification of a molten metal, by cooling, on a step formed on
the cast-in member (joint member) wrapped cast with the aluminum
die-cast component. This structure cannot prevent the projection of
burr with reliability.
[0013] Specifically, in this prior art, the gap needed to set the
cast-in member to the die-cast mold is not completely closed after
the die-cast mold is clamped, but still present in a curved (bent)
shape as illustrated in FIG. 4(b). Therefore, the molten metal cast
in the cavity with a predetermined casting pressure passes through
the step, which is formed between the mold and the cast-in member
(joint member) due to the presence of the gap, to project toward
the bonding portion of the cast-in member (joint member) with a
flow rate not reduced by the step. Accordingly, possibility of the
deposition of burr in a wide range from the peripheral edge of the
aluminum die-cast component to the bonding portion (welded surface)
still remains.
[0014] In view of this, the present invention is accomplished for
solving these problems. Specifically, the present invention aims to
appropriately form a gap needed to set the cast-in member into a
mold, e.g., a gap that can absorb a dimensional tolerance of
.+-.1.0 mm by press working of the cast-in member between the
cast-in member and the mold, to surely prevent the projection of
burr by closing the gap at the point when the mold is clamped, to
take a countermeasure against the galvanic corrosion, and to
automatically correct the positional deviation of the cast-in
member into the mold by the clamping operation of the mold.
Solution to Problem
[0015] In order to attain the foregoing objects, a cast-in
structure for a cast-in member and a cast-in mold according to the
present invention has at least features described below.
[0016] Specifically, the present invention provides a cast-in
structure for a cast-in member, which is made of a steel plate and
which is wrapped cast upon molding a die-cast component by means of
a cast-in mold except for a bonding portion bonded to a steel plate
bonding member, wherein the cast-in member includes a mold contact
portion on both surfaces at a boundary between a cast-in portion
wrapped cast with the die-cast component and the bonding portion,
wherein the mold contact portion is brought into intimate butting
contact with the cast-in mold, when the cast-in mold is
clamped.
[0017] Specifically, the mold contact portion of the cast-in member
is formed to have a taper shape, and the mold contact portion is
brought into intimate butting contact by the taper structure with
the cast-in mold, when the cast-in mold is clamped. The cast-in
member is formed into a cylinder. The cast-in member includes
internal and external mold contact taper surface portions of the
mold contact portion, formed to have a taper shape and formed
consecutively on the entire circumference in an axial direction of
the cylinder, The internal and external, mold contact taper surface
portions are formed on a boundary between the bonding portion on
one end. of the cast-in member and the cast-in portion on the other
end of the cast-in member, and when the cast-in mold is clamped, a
tapered butting portion formed on the cast-in mold is brought into
intimate butting contact with the internal and external mold
contact taper surface portions,
[0018] According to these configurations, when the cast-in mold is
clamped, the cast-in mold is in intimate butting contact with the
mold contact portions on both surfaces of the cast-in member,
whereby the gap on both surfaces at the casting boundary of the
cast-in member (the boundary between the cast-in portion and the
bonding portion) are closed. This structure prevents the molten
metal cast in the mold from projecting on both surfaces of the
bonding portion, bonded to the steel plate bonding member, of the
cast-in member. In other words, the projection of burr toward the
bonding port ion can be prevented.
[0019] The cast-in member is formed into a cylinder, and the mold
contact portion is formed to have a taper shape and formed
consecutively on the entire circumference in an axial direction of
the cylinder. With this configuration, when the cast-in mold is
clamped, the gap on both surfaces on the casting boundary of the
cast-in member can be closed, and at the same time, the cast-in
member can be positioned to the cast-in mold.
[0020] Specifically, in a case where the cast-in member is
positionally shifted with respect to the cast-in mold when the
cast-in member is carried and set to the cast-in mold, the cast-in
member can automatically be corrected to be positioned on a correct
set position (posture) of the cast-in mold by the clamping
operation of the cast-in mold that is brought into intimate butting
contact with the internal and external mold contact taper surface
portions of the mold contact portion, which are formed to have a
taper shape and formed consecutively on the entire circumference in
an axial direction of the cylinder.
[0021] The present invention also provides a cast-in mold being
configured to cast-in a steel plate cast-in member to a die-cast
component by setting a cast-in portion of the steel plate cast-in
member into a cavity except for a bonding portion to be bonded to a
steel plate bonding member, wherein
[0022] the cast-in mold includes a butting portion that is brought
into intimate butting contact with a mold contact portion upon mold
clamping, the mold contact portion being formed on both surfaces of
the cast-in member at a boundary between the cast-in portion and
the bonding portion of the cast-in member.
[0023] In this case, it is preferable that the butting portion is
formed into a taper shape, and is brought into intimate butting
contact with the mold contact portion, which is similarly formed
into a taper shape. It is also preferable that the butting portion
is provided with a biting projection that bites the mold contact
portion of the cast-in member. In this case, it is preferable that
hardness (Hv) of the biting projection is more than three times the
hardness (Hv) of the steel plate cast-in member. For example, when
the hardness (Hv) of the steel plate cast-in member is 140 or
lower, the hardness (Hv) of the biting projection is preferably 420
or higher, more preferably 500 or higher.
[0024] The cast-in mold includes a fixed mold and a movable mold,
each having an external butting taper surface portion of the
butting portion that is brought into intimate butting contact with
an external mold contact taper surface portion of the mold contact
portion, the external mold contact taper surface portion being
formed on both the internal and external surfaces of the cylinder
to have a taper shape and formed consecutively on the entire
circumference in an axial direction of a cylinder of the cast-in
member formed into a cylindrical shape; and a movable core having
an internal butting taper surface portion of the butting portion,
the internal butting taper surface portion being brought into
intimate butting contact with the internal mold contact taper
surface portion of the mold contact portion.
[0025] According to this configuration, when the cast-in mold is
clamped, the butting portion is brought into intimate butting
contact with the mold contact portions on both surfaces of the
cast-in member, whereby the gap on both surfaces at the casting
boundary of the cast-in member (the boundary between the cast-in
portion and the bonding portion) are closed. This structure
prevents the molten metal cast in the cavity from projecting of the
bonding portion, bonded to the steel plate bonding member, of the
cast-in member. In other words, the projection of burr toward the
bonding portion can surely be prevented.
[0026] The cast-in member is formed into a cylinder, and the mold
contact portion is formed to have a taper shape and formed
consecutively on the entire circumference in an axial direction of
the cylinder. With this configuration, when the cast-in mold is
clamped, the gap on both surfaces on the casting boundary of the
cast-in member can be closed, and at the same time, the cast-in
member can be positioned to the cast-in mold.
[0027] Specifically, in a case where the cast-in member is
positionally shifted with respect to the mold when the cast-in
member is set to the cast-in mold, the gap on both surfaces on the
casting boundary of the cast-in member can be closed, and at the
same time, the cast-in member can automatically be corrected to be
positioned on a correct set position (posture) of the cast-in mold
by the clamping operation of the internal and external butting
portion of the cast-in mold that is brought into intimate butting
contact with the internal and external mold contact taper surface
portions of the mold contact portion of the cast-in member.
[0028] When the butting portion is brought into intimate butting
contact with the mold contact portion of the cast-in member by the
mold clamping, the biting projection bites the mold contact
portion. Thus, the gap at the casting boundary (boundary between
the cast-in portion and the bonding portion) of the cast-in member
can be closed by a synergic action of the intimate butting-contact
and the biting projection biting the mold contact portion. It can
be expected that this structure can surely prevent the burr from
projecting toward the bonding portion of the cast-in member.
Advantageous Effect of the Invention
[0029] According to the cast-in structure for a cast-in member of
the present invention, when a cast-in mold is clamped, the cast-in
mold is brought into intimate butting contact with the mold contact
portion of the steel plate cast in member, whereby the gap on both
surfaces at the casting boundary of the cast-in member (the
boundary between the cast-in portion and the bonding portion) are
closed. This structure can surely prevent the projection of burr
from casting boundary.
[0030] Accordingly, the deposition of burr on the bonding portion
of the steel plate cast-in member can be prevented. Therefore, a
deburring work that is troublesome and burdensome is not at all
needed. Accordingly, productivity is enhanced, and sufficient
bonding strength (weld strength) is attained, and with this state,
the bonding portion of the cast-in member can be bonded to the
steel plate bonding member by welding. In addition, burr is not
deposited on the bonding portion of the cast-in member. Therefore,
an effect of a countermeasure against a galvanic corrosion, caused
by corrosion due to a contact of different kind of metals, can also
be expected.
[0031] In the cast-in structure, the cast-in member is formed into
a cylinder, and the mold contact portion, is formed to have a taper
shape and formed consecutively on the entire circumference in an
axial direction of the cylinder. With this configuration, when the
cast-in mold is clamped, the cast-in mold is brought into intimate
butting contact with the internal and external mold contact taper
surface portions of the mold contact portion. According to this
structure, the cast-in member can be positioned into the cast-in
mold, and can be wrapped cast with the die-cast component.
[0032] Specifically, in a case where the cast-in member is
positionally shifted with respect to the mold when the cast-in
member is set to the cast-in mold, the cast-in member can
automatically be corrected to be positioned on a correct set
position of the cast-in mold by the clamping operation of the
cast-in mold that is brought into intimate butting contact with the
internal and external mold contact taper surface portions of the
mold contact portion, particularly is brought into intimate butting
contact with the internal mold contact taper surface portion. With
this process, the cast-in member is wrapped cast with the die-cast
component. Accordingly, the cast-in member can be wrapped cast and
bonded to the die-cast, component with high strength, whereby the
die-cast component with reliable quality can be cast.
[0033] According to the cast-in mold of the present invention, when
the cast-in mold is clamped, the tapered butting portion is brought
into intimate butting contact with the tapered mold contact portion
of the cast-in member, so that the gap on both surfaces at the
casting boundary of the cast-in member (the boundary between the
cast-in portion and the bonding portion) are closed. With this
state, the molten metal can be cast into the cavity. The gap on
both surfaces can more surely be closed by a synergic action of the
intimate butting-contact and the biting projection biting the mold
contact portion. With this state, the molten metal can be cast into
the cavity.
[0034] The cast-in member can be wrapped cast to the die-cast
component with the cast-in structure (structure for preventing the
projection of burr) that perfectly prevents the projection of burr
from the casting boundary of the cast-in member.
BRIEF DESCRIPTION OF DRAWINGS
[0035] FIG. 1 is a sectional view illustrating one example of a
die-cast component that is wrapped cast by means of a cast-in
structure and a cast-in mold according to an embodiment of the
present invention, wherein the die-cast component is bonded to a
steel plate bonding member by welding.
[0036] FIG. 2 is a view illustrating one example of a cast-in
member wrapped cast and bonded to the die-cast component, wherein
(a) is a sectional view, and (b) is a side view viewed from a
bonding portion bonded to the steel plate bonding member by
welding.
[0037] FIG. 3 is an operation explanatory view illustrating a
section of one example of a cast-in mold according to the
embodiment of the present invention, wherein (a) illustrates a mold
opening state, and (b) illustrates that a cast-in member is carried
to a movable mold.
[0038] FIG. 4 is also an operation explanatory view, wherein (a)
illustrates that a movable core is inserted into a cylinder of the
cast-in member carried to the movable mold, and (b) illustrates
that a carrier device is returned to a stand-by position outside
the mold, and the movable mold starts clamping relative to a fixed
mold.
[0039] FIG. 5 is also an operation explanatory view, wherein (a)
illustrates a state just before the movable mold is clamped
relative to the movable mold, and (b) illustrates the state in
which the mold clamping of the movable mold relative to the fixed
mold is completed, and the movable core starts to move to a slide
forward limit in the cylinder of the cast-in member.
[0040] FIG. 6 is also an operation explanatory view, wherein (a)
illustrates the state of completing the mold clamping operation in
which the movable core moves to the slide forward limit in the
cylinder of the cast-in member, and (b) illustrates a state in
which a molten metal is cast in a cavity after a series of mold
clamping operation is completed.
[0041] FIG. 7 is a schematic explanatory view illustrating a
dimensional tolerance upon press working of the cast-in member,
wherein (a) is a perspective view, and (b) is an enlarged viewing
the mold clamping state.
[0042] FIG. 8 is an explanatory view illustrating a section of a
cast-in mold according to another embodiment of the present
invention.
[0043] FIG. 9 is an explanatory view illustrating the mold clamping
state of the cast-in mold.
[0044] FIG. 10 is a schematic perspective view illustrating a
torsion beam suspension to which a die-cast component obtained by
the cast-in structure and the cast-in mold according to the
embodiment of the present invention is applied.
[0045] FIG. 11 is a schematic plan view of the suspension.
[0046] FIG. 12 is a schematic perspective view illustrating a
trailing arm at one end of the suspension, the trailing arm being
partially enlarged.
[0047] FIG. 13 is a sectional view illustrating one example of
another die-cast component wrapped cast by the cast-in structure
and the cast-in mold according to another embodiment of the present
invention.
[0048] FIG. 14 is a perspective view illustrating one example of a
cast-in member wrapped cast and bonded to the die-cast
component.
[0049] FIG. 15 is an explanatory view illustrating a section of a
cast-in mold according to another embodiment of the present
invention, wherein (a) illustrates that a cast-in member is carried
to a fixed mold, and (b) illustrates a mold clamping state of a
movable mold relative to the fixed mold.
DESCRIPTION OF EMBODIMENTS
[0050] A cast-in structure of a cast-in member and a cast-in mold
according to an embodiment of the present invention will be
described below in detail with reference to the accompanying
drawings. It is to be noted that the present invention is not
limited by the embodiment.
[0051] FIG. 1 is a sectional view illustrating one example of a
die-cast component cast by the cast-in structure and the cast-in
mold according to the embodiment of the present invention, wherein
the die-cast component is bonded to a steel plate bonding member by
welding.
Description of Cast-In Structure
[0052] The cast-in structure is a structure in which the steel
plate cast-in member 2 is wrapped cast and bonded, with a bonding
portion 2b being left (except for the bonding portion 2b), to the
steel plate bonding member 3 upon molding a die-cast component 1.
When a later-described cast-in mold A is clamped, latter-described
butting portions 9 and 11 of the cast-in mold A are brought into
intimate butting contact with a later-described mold contact
portion 4 of the cast-in member 21 whereby a gap S between the
cast-in member 2 and the cast-in mold A within an intimate
butting-contact portion (range) is closed. This structure prevents
a projection of burr toward the bonding portion 2b of the cast-in
member 2 set on a position outside a cavity a as illustrated in
later-described FIG. 6 (see FIG. 6(a) described later).
[0053] The die-cast component 1 is cast by using a molten metal
mainly including a light alloy metal such as aluminum, magnesium,
or zinc.
<<Structure of Cast-In Member>>
[0054] FIG. 2 is a sectional view and a side view illustrating one
example of the cast-in member. The structure will be described with
reference to FIG. 1, according to need.
[0055] The cast-in member 2 includes a cast-in portion 2a that is
wrapped cast upon molding the die-cast component 1, and the bonding
portion 2b that is bonded to the steel plate bonding member 3 by
welding, such as resistance spot welding or stud welding. The
cast-in member 2 also includes a mold contact-portion 4 on the
boundary between the cast-in portion 2a and the bonding portion
2b.
[0056] The cast-in member 2 is made of a steel plate (iron-based
metal) with a material same as the material of the bonding member 3
with a desired thickness, e.g., about 3 mm. This steel plate
undergoes a press bending process, and then, butt bonding portions
are bonded (fixed) by welding, whereby the cast-in member 2 is
formed into a cylinder with a desired length (mm).
[0057] Specifically described, the cast-in member 2 is formed into
substantially a rectangular cylinder in which short sides on both
sides are bent in an arc shape in a plan view as illustrated in
FIG. 2. The bonding portion 2b on one end of the opening is bonded
to the bonding member 3 by welding, while the cast-in portion 2a on
the other end of the opening is integrally wrapped cast upon
molding the die-cast component 1 as illustrated in FIG. 1.
<<Structure of Mold Contact Portion>>
[0058] The mold contact portion 4 is a portion with which a butting
portion 9 of a cast-in mold A is brought into intimate butting
contact, when the cast-in member 2 is set to the cast-in mold A for
mold clamping.
[0059] As illustrated in FIG. 2, the portion between the cast-in
portion 2a and the bonding portion 2b of the cast-in member 2 is
narrowed (the diameter of the cylinder is reduced) almost parallel
to the axis of the cast-in member 2 except for the ends of the
cast-in portion 2a and the bonding portion 2b. Thus, the mold
contact portion 4 is formed on the boundary between the cast-in
portion 2a and the bonding portion 2b so as to be consecutive in
the whole circumference along the axial direction of the cylinder
of the cast-in member 2 with a taper shape having a predetermined
tilt angle.
[0060] As illustrated in FIG. 2(b), the mold contact portion 4
formed to be consecutive in the entire circumferential direction
with the taper shape at the boundary between the cast-in portion 2a
and the bonding portion 2b includes an external mold contact taper
surface portion 4a and an internal mold contact taper surface
portion 4b. Butting portions 9 of both of later-described fixed and
movable molds A1 and A2, out of butting portions 9 and 11 provided
respectively to the fixed and movable molds A1 and A2 and a
later-described movable core A3 of the cast-in mold A, are brought
into intimate butting contact with the external mold contact taper
surface portion 4a, when, the cast-in mold A is clamped. The
butting portion 11 of the movable core A3 is brought into intimate
butting contact with the internal mold contact taper surface
portion 4b, when the cast-in mold A is clamped.
[0061] Specifically, the cast-in member 2 is set and held such that
the cast-in member 2 is sandwiched and pressed by both of the fixed
mold A1 and the movable mold A2, which are brought into intimate
butting contact with the external mold contact taper surface
portions 4a of the mold contact portion 4, and the movable core A3
that is brought into intimate butting contact with the internal
mold contact taper surface portion 4b from both of the inner and
outer surfaces of the cylinder, when the cast-in mold A is clamped.
In this state, the cast-in portion 2a is inserted into a cavity a
(see FIG. 6(a) described later).
[0062] The tilt angles (taper angle) .theta. of the external mold
contact taper surface portion 4a and the internal mold contact
taper surface portion 4b of the cast-in member 2 in the axial
direction of the cylinder are not particularly limited, but they
are preferably set to be about 27.degree..
[0063] As illustrated in FIGS. 1 and 2, a constricted portion 5 is
formed on the cast-in portion 2a of the cast-in member 2 in the
present embodiment. The constricted portion 5 is formed to be
consecutive on the whole circumference of the cast-in member 2.
With this structure, the cast-in bonding strength at the cast-in
portion 2a of the cast-in member 2, which is wrapped cast with the
die-cast component 1, is strengthened by the constricted portion 5.
Therefore, the cast-in member 2 is wrapped cast and bonded with
high strength and high rigidity with no chance of being slipped
from the die-cast component 1.
[0064] Although not illustrated, the shape of the constricted
portion 5 is not particularly limited. Specifically, any shape can
be employed, so long as the constricted portion 5 can increase the
cast-in bonding strength to the die-cast component 1 with high
strength and high rigidity for preventing the cast-in member 2 from
slipping from the die-cast component 1.
[0065] According to the cast-in structure of the present embodiment
described above in detail, when the cast-in mold A is clamped, the
cast-in mold A is brought into intimate butting contact with the
internal and external mold contact taper surface portions 4a and
'3b of the mold contact portion 4 of the cast-in member 2, whereby
a gap S on both surfaces at the boundary between the cast-in
portion 2a and the bonding portion 2b of the cast-in member 2 is
sealed.
[0066] This structure surely prevents molten metal, which is cast
in the cast-in mold A (cavity a) with the cast-in portion 2a of the
cast-in member 2 being wrapped cast, from projecting toward the
bonding portion 2b of the cast-in member 2 that is bonded to the
steel plate bonding member 3 by welding. In other words, projection
of burr toward the bonding portion 2b can surely be prevented.
<<Structure of Cast-In Mold>>
[0067] Subsequently, the cast-in mold A according to the embodiment
of the present invention will be described. FIGS. 3 to 6 are
explanatory sectional views illustrating an operation of the
cast-in mold according to the embodiment of the present invention.
The structure will be described with reference to FIG. 2, according
to need.
[0068] The cast-in mold A is a die-cast mold formed such that the
cast-in portion 2a of the cast-in member 2 is wrapped cast and
bonded to the die-cast component 1 with the bonding portion 2b that
is bonded to the steel plate bonding member 3 being left (except
for the bonding portion 2b that is bonded to the steel plate
bonding member 3 by welding).
[0069] The cast-in mold A has a structure including a fixed mold
A1, the movable mold A2 that can perform mold clamping and mold
opening relative to the fixed mold A1, and the movable core
(pull-out core) A3 that is assembled to the movable mold A2 so as
to be capable of advancing and retreating (moving vertically) and
forms the cavity a with both of the fixed mold A1 and the movable
mold A2.
[0070] As illustrated in FIGS. 3 to 6, the cast-in mold A is formed
as described below. Specifically, the cast-in member 2 is set and
held such that the cast-in portion 2a of the cast-in member 2 faces
the cavity a formed by the slidable advancing movement (descending
movement) of the movable core A3 and the mold clamping of the
movable mold A2 relative to the fixed mold A1, and with this state,
molten metal such as aluminum, magnesium, or zinc is cast in the
cavity a.
[0071] The fixed mold A1 and the movable mold A2 respectively
include a cavity surface 6 forming the cavity a, a core slide
concave, cutout portion 7 formed on the cavity surface 6 such that
the core slide concave cutout portion 7 go through toward the
outside of the mold, and an insert holding portion 8 and the
butting portion (press-contact portion) 9 formed on the boundary
between the core slide concave cutout portion 7 and the cavity
surface 6.
[0072] The core slide concave cutout portion 7 is formed on mold
parting surfaces (mating surfaces) of the fixed mold A1 and the
movable mold A2. The planar shape of the core slide concave cutout
portion 7 matches the cross-section of the movable core A3 split
into two in the longitudinal direction in order that the movable
core A3 can freely slide during the mold clamping operation and
mold opening operation.
[0073] The insert holding portion 8 formed on the movable mold A2
has a function of temporarily holding the cast-in member 2 in
cooperation with the movable core A3 in order to prevent the
cast-in member 2 from falling until the mold clamping of the
movable mold A2 relative to the fixed mold A1 is completed.
[0074] More specifically described, as illustrated in FIG. 3(b),
the cast-in member 2 is gripped by a carrier device B, such as a
hand robot, and conveyed to the movable mold A2. The insert holding
portion 8 has a function of receiving and holding the cast-in
member 2, in cooperation with the movable core A3 inserted into the
cylinder of the cast-in member 2 during the period from when the
grip of the cast-in member 2 by the carrier device B is canceled
and the carrier device B is returned to a stand-by position, not
illustrated, at the outside of the mold from the portion between
the fixed mold A1 and the movable mold A2 till when the mold
clamping of the movable mold A2 relative to the fixed mold A1 is
completed as illustrated in FIG. 6(a).
[0075] As illustrated in FIG. 3, the insert holding portion 8 is
formed on the core slide concave cutout portion 7 at the boundary
of the cavity surface 6, and is formed to have, a hollow shape,
matching the shape of the longitudinal surface of the bonding
portion 2b of the cast-in member 2, with a depth (step)
corresponding to the thickness (plate thickness) of the cylinder of
the cast-in member 2.
[0076] Although not illustrated, the insert holding portion 8 is
formed on the core slide concave cutout portions 7 of the fixed
mold A1 and the movable mold A2 to have a planar shape, which is
formed by splitting the cast-in member 2 into two in the
longitudinal direction, along the outer surface of the bonding
portion 2b of the cast-in member 2. The cast-in member 2 is formed
to have a rectangular shape by bending both short sides into an arc
shape as illustrated in FIG. 2.
<<Structure of Butting Portion>>
[0077] When the cast-in member 2 is carried to the movable mold A2
for mold clamping relative to the fixed mold A1, the butting
portion 9 is brought into intimate butting contact with the
external mold contact taper surface portion 4a of the mold contact
portion 4 of the cast-in member 2, thereby closing the gap S
between the cast-in mold and the cast-in member 2. The butting
portion 9 also has a function of setting and holding the cast-in
member 2 immovable in the cavity a in cooperation with the butting
portion 11 of the movable core A3.
[0078] As illustrated in FIG. 3, the butting portion 9 is an
external butting taper surface portion 9a formed to have a taper
shape with the tilt angle (taper angle) .theta. of the external
mold contact taper surface portion 4a of the cast-in member 2. The
butting portion 9 tilts toward the direction from the insert
holding portion 8 of the fixed mold A1 and the movable mold A2
toward the cavity surface a (in the axial direction of the cylinder
of the cast-in member 2).
[0079] The external butting taper surface portion 9a is formed to
have a length shorter than the length of the taper (the length of
the taper of the cast-in member 2 in the axial direction of the
cylinder) of the external mold contact taper surface portion 4a in
the axial direction of the cylinder of the cast-in member 2. For
example, the external butting taper surface portion 9a is formed to
be shorter by about 1 to 2 mm.
[0080] According to this configuration, when the movable mold A2 is
clamped relative to the fixed mold A1, the external butting taper
surface portion 9a is surely brought into intimate butting contact
with the external mold contact taper surface portion 4a of the mold
contact portion 4 of the cast-in member 2, whereby the gap 3
between the cast-in mold A and the cast-in member 2 can surely be
closed. In addition, the external butting taper surface portion 9a
holds the cast-in member 2 by press-contact from the inner surface
and the outer-surface of the cast-in member 2 with the butting
portion 11 of the movable core A3.
<<Structure of Movable Core>>
[0081] The movable core A3 is assembled and supported to the core
slide concave cutout portion 7 on the movable mold A2 so as to be
capable of advancing and retreating (moving vertically) by a
driving unit, not illustrated, such as a core puller.
[0082] The movable core A3 is formed into a block having a
predetermined height, e.g., a height equal to the cast-in depth of
the cast-in member 2, in a cross section of the inner surface of
the cylinder of the cast-in member 2 (the rectangular shape in
which both short sides are consecutive in an arc shape) and in a
cross section of the core slide concave cutout portions 7 on the
fixed mold A1 and the movable mold A2.
[0083] As illustrated in FIG. 6(a), the movable core A3 has a
cavity forming surface portion 10. The cavity forming surface
portion 10 is formed on a lower half portion (leading end) that is
inserted into the cast-in portion 2a of the cast-in member 2, when
the movable core A3 slidably advances into (move down into) the
cylinder of the cast-in member 2 up to a slide forward limit. The
cavity forming surface portion 10 is formed to be slightly smaller
than an upper half portion of the movable core A3. The movable core
A3 also has the butting portion 11 formed to be continuous with the
cavity forming surface portion 10 on the upper half portion at the
boundary with the cavity forming surface portion 10.
<<Structure of Butting Portion>>
[0084] The butting portion 11 is brought into intimate butting
contact with the internal mold contact taper surface portion 4b of
the mold, contact portion 4 of the cast-in member 2 by the
mold-clamping operation of the movable core A3 that moves into the
cylinder of the cast-in member 2 up to the slide forward limit,
after the mold-clamping of the movable mold A2 relative to the
fixed mold A1 is completed. Thus, the butting portion 11 closes the
gap 3 between the butting portion 11 and the internal mold contact
taper surface portion 4b. The butting portion 11 also has a
function of setting and holding the cast-in member 2 immovable with
the external butting taper surface portion 9a of the butting
portion 9 on each of the fixed mold A1 and the movable mold A2.
[0085] The butting portion 11 is an internal butting taper surface
portion 11a formed into a taper shape with the tilt angle (taper
angle) .theta. of the internal, mold contact taper portion 4b of
the mold contact portion 4 of the cast-in member 2 as illustrated
in FIG. 3. The butting portion 11 has a sectional shape matching
the inner surface of the cylinder of the cast-in member 2 at the
side of the bonding portion 2b and the concave cutout inner
surfaces of the slide concave cutout portions 7 on both the fixed
mold A1 and the movable mold A2. The butting portion 11 is formed
(in the axial direction of the cylinder of the cast-in member 2)
from the cavity forming surface portion 10 toward the upper half
portion of the movable core A3, which is larger (wider) than the
cavity forming surface portion 10.
[0086] The internal butting taper surface portion 11a is formed to
have a length shorter than the length of the taper (the length of
the taper of the cast-in member 2 in the axial direction of the
cylinder) of the internal mold contact taper surface portion 4b in
the axial direction of the cylinder of the cast-in member 2. For
example, the internal butting taper surface portion 11a is formed
to be shorter by about 1 to 2 mm.
[0087] According to this configuration, when the movable core A3
slidably advances into the cylinder of the cast-in member 2 up to
the slide forward limit (when the movable core A3 slidably moves
down), the internal butting taper surface portion 11a is surely
brought into intimate butting contact with the internal mold
contact taper surface portion 4b of the mold contact portion 4 of
the cast-in member 2, whereby the gap S between the internal
butting taper surface portion 11a and the cast-in member 2 can
surely be closed. In addition, the internal butting taper surface
portion 11a holds the cast-in member 2 by press-contact from the
inner surface and the outer surface of the cast-in member 2 with
the external butting taper surface portion 9a of each of the fixed
mold A1 and the movable mold A2.
[0088] In the present embodiment, as illustrated in FIG. 6(a), the
intimate butting-contact between the internal butting taper surface
portion 11a of the movable core A3 and the internal mold contact
taper surface portion 4b of the cast-in member 2 and the intimate
butting-contact between the external butting taper surface portions
9a of the fixed mold A1 and the movable mold A2 and the external
mold contact taper surface portion 4a of the cast-in member 2 are
achieved with the intimate-contact range L from both the inside and
outside of the cylinder. Specifically, the present embodiment
provides the intimate butting-contact structure from both the inner
surface and the outer surface of the cylinder, and this structure
can surely prevent the burr from projecting on the inner surface
and the outer surface of the cylinder of the cast-in member 2 at
the bonding portion 2b.
[Operation]
[0089] A cast-in operation of the cast-in member 2 by using the
cast-in mold A configured as described above will briefly be
described. The operation will be described with reference to FIGS.
3 to 6, according to need.
[0090] A mold opening state illustrated in FIG. 3(a) where the
fixed mold A1, the movable mold A2, and the movable core A3 are
opened will firstly be described. In this mold opening state, the
cast-in member 2 gripped, by the carrier device B such as a hand
robot is carried to the movable mold A2 as illustrated in FIG.
3(b). In this case, the cast-in member 2 is carried to the movable
mold A2 such that the bonding portion 2b of the cast-in member 2 is
located to be in contact with the insert holding portion 8 of the
movable mold A2.
[0091] After the cast-in member 2 is carried to the movable mold A2
by the carrier device B, the movable core A3 starts to slidably
advance (slidably moves down), as illustrated in FIGS. 3(b) to
4(a), whereby the movable core A3 is inserted into the cylinder of
the cast-in member 2. In this case, the movable core A3 slidably
advances into the cylinder before the slide forward limit in the
cylinder of the cast-in member 2 (the state illustrated in FIG.
6(a)). Specifically, as illustrated in FIG. 4, the movable core A3
is temporarily stopped at the slide advancing position with the
bonding portion 2b of the cast-in member 2 being held by the insert
holding portion 8 of the movable mold A2 in order to prevent the
cast-in member 2 from falling or from being positionally shifted.
The movable core A3 waits on this slide advancing position.
[0092] When the cast-in member 2 carried to the movable mold A2 is
held (nipped) by the insert holding portion 8 of the movable mold
A2 due to the slidable advancing motion of the movable core A3, the
gripped state of the cast-in member 2 by the carrier device B is
canceled. Then, the carrier device B is returned to the stand-by
position at the outside of the mold, not illustrated, from the
portion between the fixed mold A1 and the movable mold A2.
[0093] When the cast-in member 2 is held by the movable mold A2 and
the movable core A3, and the carrier device C is returned to the
stand-by position at the outside of the mold, the mold-clamping of
the movable mold A2 relative to the fixed mold A1 is started as
illustrated in FIGS. 4(b) to 5(b). In this case, as illustrated in
FIGS. 5(a) and 5(b), the mold-clamping of the movable mold A2
relative to the fixed mold A1 is completed in a state in which the
bonding portion 2b of the cast-in member 2 is located to be in
contact with the insert holding portion 8 of the fixed mold A1.
After the mold-clamping is completed, the external butting taper
surface portions 9a of the fixed mold A1 and the movable mold A2
are brought into intimate butting contact with the external mold
contact taper surface portions 4a of the cast-in member 2, as
illustrated in FIGS. 5(b).
[0094] After the mold-clamping of the movable mold A2 relative to
the fixed mold A1 is completed, the movable core A3, which is
stopped before the slide forward limit in the cylinder of the
cast-in member 2 illustrated in FIGS. 4(a) to 5(b), slidably
advances (moves) to the slide forward limit in the cylinder of the
cast-in member 2 as illustrated in FIG. 6(a). With this, as
illustrated in FIG. 6(a), the internal butting taper surface
portions 11a of the movable core A3 are brought into intimate
butting contact with the internal mold contact taper surface
portions 4b of the cast-in member 2.
[0095] The order of the mold-clamping operation of the cast-in mold
A described above is only one example, and the order is not limited
to this order of the mold-clamping operation. A general
mold-clamping operation may be employed. Specifically, at a point
when the cast-in member 2 is carried to the movable mold A2 that is
opened, the movable core A3 can slidably advance (slidably move
down) to the slide forward limit in the cylinder of the cast-in
member 2, and at the point when the carrier device B is returned to
the stand-by position, not illustrated, at the outside of the mold,
the mold-clamping operation of the movable mold A2 can be started,
and then, the mold-clamping of the movable mold A2 relative to the
fixed mold A1 can be completed.
[0096] As described above, according to the cast-in mold A
including the fixed mold A1, the movable mold A2, and the movable
core A3 according to the present embodiment, the gap S on both
surfaces at the boundary between the cast-in portion 2a and the
bonding portion 2b of the cast-in member 2 is closed by the
intimate butting-contact between the cast-in member 2 and the fixed
mold A1, the movable mold A2, and the movable core A3 from the
inner surface and the outer surface of the cylinder, after a series
of the mold-clamping operation starting from the carrier of the
cast-in member 2 to the movable mold A2 is completed, as
illustrated in FIGS. 6(a) and 6(b).
[0097] Specifically, as illustrated in an enlarged view in FIG. 6,
the gap S is formed on the inner surface and the outer surface of
the cylinder at the bonding portion 2b of the cast-in member 2 that
is inserted into the insert holding portions 8 of the fixed mold A1
and the movable mold A2, but the gap S is closed within the
intimate-contact range L on the inner surface and the outer surface
of the cylinder at the mold contact portion 4 of the cast-in member
2 with which the butting portions 9 and 11 of the fixed mold A1,
the movable mold A2, and the movable core A3 are brought into
intimate butting contact. This structure can surely prevent the
burr from projecting toward the bonding portion 2b, when the molten
metal is cast in the cavity a. In other words, the projection of
the burr toward the bonding portion 2b can surely be prevented.
[0098] The gap S on both surfaces between the cast-in member 2, and
the fixed mold A1, the movable mold A2, and the movable core A3 are
closed to prevent the projection of the burr by the intimate
butting-contact by means of the taper structure composed of the
external mold contact taper surface portion 4a and the internal
mold contact taper surface portion 4b of the mold contact portion 4
formed on the cast-in member 2, the external butting taper surface
portion 9a of the butting portion 9 formed on each of the fixed
mold A1 and the movable mold A2, and the internal butting taper
surface portion 11a of the butting portion 11 formed on the movable
core A3. Therefore, the gap 3 on both surfaces can be closed, and
at the same time, the cast-in member 2 can be re-positioned to a
correct set position (correct set posture) in the cavity a, even
when the positional deviation is generated in a set including the
inside of the cavity a of the cast-in member 2.
[0099] Subsequently, a process of setting a cylindrical cast-in
member 2 having a dimensional tolerance of .+-.1.0 mm in press
working into the cavity a by means of the taper structure will be
described with reference to a schematic explanatory view of FIG. 7.
In the description of the setting process, the tilt angle (taper
angle) .theta. of the external mold contact taper surface portion
4a and the internal mold contact taper surface portion 4b of the
cast-in member 2, the external butting taper surface portions 9a of
the fixed mold A1 and the movable mold A2, and the internal butting
taper surface portion 11a of the movable core A3 is 27.degree..
[0100] In X and Y directions and Z direction (axial direction of
the cylinder) in FIG. 7(a), a cast-in member 2 having the
dimensional tolerance of .+-.0 mm (the size in the figure) in the Y
direction is illustrated by a solid line, a cast-in member 2 having
the dimensional tolerance smaller by a maximum of -1.0 mm is
illustrated, by a one-dot chain line, and a cast-in member 2 having
the dimensional tolerance larger by a maximum of +1.0 mm is
illustrated by a two-dot chain line in FIG. 7(b).
[0101] When the cast-in member 2 having the dimensional tolerance
smaller by a maximum of -1.0 mm is set into the cavity a, the
cast-in portion 2a is inserted into the cavity a with an excess of
1.0 mm, compared to the cast-in member 2 having the dimensional
tolerance of .+-.0 mm as illustrated in FIG. 7(b). When the cast-in
member 2 having the dimensional tolerance larger by a maximum of
+1.0 mm is set into the cavity a, the bonding portion 2b is
inserted into the insert holding portion 8 with an excess of 1.0
mm, compared to the cast-in member 2 having the dimensional
tolerance of .+-.0 mm as illustrated in FIG. 7(b). Even if such
positional deviations occur, the intimate butting-contact is surely
achieved similarly with the case of the cast-in member 2 having the
dimensional tolerance of .+-.0 mm, and the axial line of the
cylinder of the cast-in member 2 (crossing axial lines in X and Y
directions) can be made concentric with the axial lines of the
movable core A3, by the taper structure composed of the external
mold contact, taper surface portion 4a and the internal mold
contact taper surface portion 4b of the mold contact portion 4
formed on the cast-in member 2, the external butting taper surface
portion 9a of the butting portion 9 formed on the fixed mold A1 and
the movable mold A2, and the internal butting taper surface portion
11a of the butting portion 11 formed on the movable core A3, during
the clamp-molding operation.
[0102] With this configuration, even if the cast-in member 2 having
the dimensional tolerance of .+-.1.0 mm is used, the gap S on both
surfaces can surely be closed within the intimate-contact range L
(see FIG. 6(a)) by the taper structure.
Description of Cast-In Mold According to Another Embodiment
[0103] FIG. 8 is an explanatory view illustrating a cast-in mold
according to another embodiment of the present invention, and FIG.
9 is an explanatory view illustrating a state in which a series of
mold-clamping operation of the cast-in mold is completed.
[0104] The cast-in mold in the present embodiment is basically the
same as the cast-in mold A described above in detail, except that a
biting projection 12 is formed on the butting portion 9 of each of
the fixed mold A1 and the movable mold A2. The same components are
identified by the same numerals, and the redundant description will
not be made.
[0105] Specifically, as illustrated in FIGS. 8 and 9, a cast-in
mold A0 has a mold structure including a fixed mold A1, a movable
mold A2 that can perform a mold-clamping process and mold-opening
process relative to the fixed mold A1, and a movable core A3 that
is assembled to the movable mold A2 so as to be capable of slidably
advancing and retreating (moving up and down) to form a cavity a
with both of the fixed mold A1 and the movable mold A2.
[0106] As illustrated in FIG. 8, the biting projection 12 is formed
on the butting portion 9 of each of the fixed mold A1 and the
movable mold A2.
<<Structure of Biting Projection>>
[0107] As illustrated in FIG. 9, the biting projection 12 has a
function of closing the gap S between the cast-in mold A0 and the
cast-in member 2 in cooperation with the butting portion 9 that is
brought into intimate butting contact with the mold contact portion
4 of the cast-in member 2, when the movable mold A2 is clamped
relative to the fixed mold A1.
[0108] As illustrated in FIG. 8, the biting projection 12 is formed
on the external butting taper surface portion 9a of the butting
portion 9 at the side of the cavity surface 6, and to have an
appropriate projecting shape and projecting height. Thus, as
illustrated in FIG. 9, the biting projection 12 bites the external
mold contact taper surface portion 4a, when the external butting
taper surface portion 9a is brought into intimate butting contact
with the external mold contact taper surface portion 4a of the mold
contact portion 4 of the cast-in member 2.
[0109] It is preferable that hardness (Hv) of the biting projection
12 is set to be more than three times the hardness of the steel
plate cast-in member. For example, when the hardness (Hv) of the
steel plate cast-in member is 140 or lower, the hardness (Hv) of
the biting projection 12 is preferably 420 or higher, more
preferably 500 or higher. With this configuration, the biting
projection 12 surely bites the cast-in member 2, every time the
die-cast component 1 is cast, without causing pressure loss by a
casting mold (casting shot) of the die-cast component 1, which is
repeated several tens of thousands of times to hundreds of
thousands of times. Accordingly, the biting projection 12 can close
the gap S between the cast-in member 2 and the cast-in mold,
[0110] As described above, according to the cast-in mold A0
including the fixed mold A1, the movable mold A2, and the movable
core A3, and having the biting projection 12 on the butting portion
9 of each of the fixed mold A1 and the movable mold A2, according
to another embodiment, the gap S on both surfaces at the boundary
between the cast-in portion 2a and the bonding portion 2b of the
cast-in member 2 is closed by the intimate butting-contact between
the cast-in member and the fixed mold A1, the movable mold A2, and
the movable core A3 from the inner surface and the outer surface of
the cylinder and the biting projection 12 biting the mold contact
portion 4, after a series of the mold-clamping operation starting
from the carrier of the cast-in member 2 to the movable mold A2 is
completed, as illustrated in FIG. 9.
[0111] Specifically, as illustrated in an enlarged view in FIG. 9,
the gap 3 on both surfaces is formed on the inner surface and the
outer surface of the cylinder at the bonding portion 2b of the
cast-in member 2 that is inserted into the insert holding portions
8 of the fixed mold A1 and the movable mold A2, but the gap S is
closed by the intimate butting-contact of the butting portions 9
and 11 of the fixed mold A1, the movable mold A2, and the movable
core A3, and further, the gap 5 is closed by a synergic action of
the intimate-contact and biting at the inside and outside of the
mold contact portion 4 of the cast-in member 2 bit by the biting
projection 12, particularly on the external mold contact taper
surface portion 4a. This structure can surely prevent the burr from
projecting, when the molten metal is cast in the cavity a.
[0112] Although not illustrated, the projection shape of the biting
projection 12 is not particularly limited. The projection shape may
be a shape by which the biting projection 12 can bite the mold
contact portion 4 when the butting portion 9 is brought into
intimate butting contact with the mold contact portion 4 of the
cast-in member 2. The biting amount (depth) of the biting
projection 12 biting the mold contact portion 4 is preferably about
0.03 mm, when the plate thickness (wall thickness) of the cast-in
member 2 is defined as 3 mm, for example.
[0113] The biting projection 12 may be detachably provided to the
butting portion 9 with a packing structure in order to facilitate a
maintenance operation.
[0114] The die-cast component 1 cast by the cast-in structure and
the cast-in molds A and A0 according to the present embodiments
described above in detail can be applied as a trailing arm C1 of a
torsion beam suspension C illustrated in FIGS. 10 to 12 as one
example of a vehicle component (automobile component).
[0115] FIG. 10 is a schematic perspective view of a torsion beam
suspension to which the die-cast component formed by the cast-in
mold a cast-in structure according to the present embodiments is
applied, FIG. 11 is a schematic plan view of the torsion beam
suspension, and FIG. 12 is a schematic perspective view in which a
trailing arm is enlarged.
[0116] Specifically, the bonding portion 2b, which is exposed to
the outside, of the steel plate cast-in member 2 wrapped cast with
the trailing arm C1 that is the die-cast component 1 is bonded to
an end of a torsion beam C2, which is a steel plate bonding member
3 made of the same material, by welding.
[0117] Specifically described, as illustrated in FIGS. 10 to 12,
the bonding portion 2b of the cast-in member 2 is externally fitted
to the end of the steel plate torsion beam C2, having the same
sectional shape, and with this state, the bonding portion 2b of the
cast-in member 2 is bonded to the torsion beam C2 by welding. In
this case, no burr is generated and deposited on the bonding
portion 2b of the cast-in member 2. Therefore, the trailing arm C1
can be bonded to the end of the torsion beam C2 with high rigidity
by welding.
[0118] According to this structure, the trailing arm C1, which is
cast by using aluminum, can be bonded to the steel plate torsion
beam C2, which is made of a different kind of metal, by welding
without any problem.
Description of Cast-In Structure and Cast-In Mold According to
Another Embodiment
[0119] A cast-in structure and a cast-in mold using a sheet-type
cast-in member 20 will be described next.
[0120] FIG. 13 is a sectional view illustrating one example of
another die-cast component cast by using the cast-in structure and
the cast-in mold according to another embodiment of the present
invention.
Description of Cast-In Structure
[0121] As in the embodiment described above in detail, the cast-in
structure closes the gap S between a cast-in member 20 and a
later-described cast-in mold A4 by the structure in which butting
portions 22 and 23 of the cast-in mold A4 are brought into intimate
butting contact with a mold contact portion 21 of the cast-in
member 20, when the cast-in mold A4 is clamped. In other words, a
cavity al of the cast-in mold A4 is closed by the intimate
butting-contact of the butting portions 22 and 23 of the cast-in
mold A4 to the mold contact portion 21 of the cast-in member 20.
This structure prevents burr from projecting toward the bonding
portion 20b of the cast-in member 20, which is set to be located
outside of the cavity a1 (see FIG. 15(b) described later).
<<Structure of Cast-In Member>>
[0122] FIG. 14 is a perspective view illustrating one example of
the cast-in member bonded to the die-cast component by wrapping
cast. The structure will be described with reference to FIG. 13,
according to need.
[0123] For example, the cast-in member 20 is formed into a sheet
shape with a desired size by press-cutting and bending a steel
plate with a thickness of about 3 mm as illustrated in FIG. 14. As
illustrated in FIG. 13, one side of the cast-in member 20 is
defined as a cast-in portion 20a that is wrapped cast upon molding
the die-cast component 100, and the other side is defined as a
bonding portion 20b bonded to a steel plate bonding member, not
illustrated.
[0124] As illustrated in FIG. 14, the cast-in member 20 thus
configured has a tapered mold contact portion 21 on the boundary
between the cast-in portion 20a and the bonding portion 20b.
<<Structure of Mold Contact Portion>>
[0125] The mold contact portion 21 includes a fixed mold contact
taper surface portion 21a and a movable mold contact taper surface
portion 21b. When the cast-in mold A4 is clamped, a butting portion
22 on a fixed mold A5 of the cast-in mold A4 are brought into
intimate butting contact with the fixed mold contact taper surface
portion 21a, and a butting portion 23 on a movable mold A6 of the
cast-in mold A4 is brought into intimate butting contact with the
movable mold contact taper surface portion 21b. Specifically, the
mold contact portion 21 is brought into intimate butting contact
with the butting portions 22 and 23 of the fixed mold A5 and the
movable mold A6 from both surfaces. The intimate butting-contact
described above is achieved from both surfaces within an
intimate-contact range L in FIG. 15(b).
<<Structure of Cast-In Mold>>
[0126] FIG. 15 is an explanatory sectional view illustrating the
cast-in mold according to another embodiment of the present
invention.
[0127] The cast-in mold A4 includes the fixed mold A5 and the
movable mold A6 that can perform mold clamping and mold opening
relative to the fixed mold A5.
[0128] An insert holding portion 25 is provided on a mold parting
surface (mating surface) consecutive to a cavity surface 24a of the
fixed mold A5f out of cavity surfaces 24a and 24b, forming the
cavity a1, of the fixed mold A5 and the movable mold A6. The
butting portion 22 is provided on the boundary between the insert
holding portion 25 and the cavity surface 24a. The butting portion
23 is provided on a mold parting surface of the movable mold A6
opposite to the butting portion 22.
<<Structure of Butting Portion>>
[0129] As illustrated in FIG. 15, the butting portions 22 and 23
are respectively a fixed butting taper surface portion 22a and a
movable butting taper surface portion 23a. Each of the fixed
butting taper surface portion 22a and the movable butting taper
surface portion 23a is formed into a taper shape toward the cavity
surface 24a or 24b on each of the fixed mold A5 and the movable
mold A6 with a tilt angle of the fixed mold contact taper surface
portion 21a and the movable mold contact taper surface portion 21b
of the cast-in member 20.
[0130] With this structure, when the movable mold A6 is clamped
relative to the fixed mold A5, the fixed butting taper surface
portion 22a is brought into intimate butting contact with the fixed
mold contact taper surface portion 21a of the cast-in member 20,
while the movable butting taper surface portion 23a is brought into
intimate butting contact with the fixed mold contact taper surface
portion 21b of the mold contact portion 21 of the cast-in member
20. Accordingly, the fixed mold A5 and the movable mold A6 hold the
cast-in member 20 in the state in which the cast-in member 20 is
sandwiched from both surfaces within the intimate-contact range L
illustrated in FIG. 15(b).
[0131] Specific examples of the embodiments of the present
invention have been described above. However, the embodiments
described above in detail are only illustrative, and not intended
to limit the scope of the claims. The technical matter described in
the claims includes those modified within a scope not departing
from the spirit of the present invention.
[0132] For example, the cast-in structure of the cast-in member 2
can be configured as described below. Specifically, when the
cast-in member 2 is carried to the movable mold A2 by the carrier
device 3, mold clamping to the fixed mold A1 is performed with the
cast-in member 2 being adsorbed and held to the movable mold A2 by
magnetic force, and with this state, molten metal is cast. In this
case, it is preferable that a magnet is embedded in a portion apart
from the cavity a, such as the insert holding portion 8 of the
movable mold A2 into which the bonding portion 2b of the cast-in
member 2 is inserted. With this structure, the deposition of the
molten metal cast in the cavity or deterioration of the magnetic
force of the magnet due to thermal influence can be prevented.
[0133] Since the cast-in structure for the cast-in member 2 that is
adsorbed and held by the movable mold A2 by magnetic force is
employed, the following operation can be realized. Specifically,
after the cast-in member 2 is carried to the movable mold A2, the
mold clamping of the movable mold A2 to the fixed mold A1 is
started. Immediately before or after the movable mold A2 is clamped
relative to the fixed mold A1, the slidable advancing motion of the
movable core A3 is started from the stand-by position (slide
retreating limit), and the movable core A3 is moved to the slide
forward limit in the cylinder of the cast-in member 2. With this, a
series of the mold-clamping operation of the cast-in mold A is
completed. Then, the internal butting taper surface portion 11a of
the butting portion 11 of the movable core A3 is brought into
intimate butting contact with the internal mold contact taper
surface portion 4b of the cast-in member 2 at once, whereby the gap
S on both surfaces can be closed.
[0134] The biting projection 12 may be provided on the butting
portion 11 (the internal butting taper surface portion 11a) of the
movable core A3. It may be configured such that, when the butting
portion 11 is brought into intimate butting contact with the
internal mold contact taper surface portion 4b of the mold contact
portion 4 of the cast-in member 2, the biting projection 12 bites
the internal mold contact taper surface portion 4b, as in the
external mold contact taper surface portion 4a of the mold contact
portion 4.
[0135] Although the detailed description is not made, plastic
deformation (plastic strain) of the cast-in member 2 during a
manufacture by press molding or machine working can be corrected by
the mold clamping for closing the gap S by the structure in which
the external butting taper surface portions 9a of the butting
portions 9 of the fixed mold A1 and the movable mold A2 and the
internal butting taper surface portion 11a of the butting portion
11 of the movable core A3 are brought into intimate butting contact
with the internal and external taper surface portions 4a and 4b of
the mold contact portion 4 of the cast-in member 2.
[0136] For example, in the case where plastic strain is caused such
that the long side of the cylindrical wail of the cast-in member 2,
which is press-molded into a general rectangular cylinder in a plan
view, is curved toward the inside of the cylinder, this plastic
strain can be linearly corrected by press-contact from both the
inner surface and the outer surface of the cylinder with
mold-clamping force (pressing force) from a die-cast machine.
[0137] Specifically, the plastic strain remaining on the cylinder
wall of the cast-in member 2 after the machining work (pressing) is
corrected by the mold clamping force and the taper structure in
which the fixed and movable molds A1 and A2 and the movable core A3
are brought into intimate butting contact with the cast-in member 2
upon the mold clamping. Accordingly, it is expected that the
cast-in member 2 is returned to the correct cylindrical shape
illustrated in the figure, and with this state, bonded to the
die-cast component 1 by the casting-in.
[0138] The cast-in structure of the cast-in member 2 and the
cast-in mold A according to the present embodiment can be applied
to an injection molding field in which a steel plate cast-in member
is bonded to a resin component by casting-in, as well as a die-cast
field in which a steel plate cast-in member is bonded by casting-in
upon molding a die-cast component.
REFERENCE SIGNS LIST
[0139] A, A0, A4: Cast-in mold
[0140] A1, A5: Fixed mold
[0141] A2, A6: Movable mold
[0142] A3: Movable core
[0143] a, a1: Cavity
[0144] 1, 100: Die-cast component
[0145] 2: Cast-in member
[0146] 2a: Cast-in portion
[0147] 2b: Bonding portion
[0148] 3: Bonding member
[0149] 4, 21: Mold contact portion
[0150] 4a: External mold contact taper surface portion
[0151] 4b: Internal mold contact taper surface portion
[0152] 5: Constricted portion
[0153] 9, 11, 22, 23: Butting portion
[0154] 9a; External butting taper surface portion
[0155] 11a: Internal butting taper surface portion
[0156] 12: Biting projection
[0157] S: Gap
* * * * *