U.S. patent application number 15/036585 was filed with the patent office on 2016-10-13 for pulling-up-type continuous casting apparatus and pulling-up-type continuous casting method.
This patent application is currently assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA. The applicant listed for this patent is TOYOTA JIDOSHA KABUSHIKI KAISHA. Invention is credited to Hiroyuki IKUTA, Naoaki SUGIURA.
Application Number | 20160296998 15/036585 |
Document ID | / |
Family ID | 51866291 |
Filed Date | 2016-10-13 |
United States Patent
Application |
20160296998 |
Kind Code |
A1 |
IKUTA; Hiroyuki ; et
al. |
October 13, 2016 |
PULLING-UP-TYPE CONTINUOUS CASTING APPARATUS AND PULLING-UP-TYPE
CONTINUOUS CASTING METHOD
Abstract
A pulling-up-type continuous casting apparatus according to an
aspect of the present invention includes a molten-metal holding
furnace that holds molten metal, a shape defining member disposed
in a vicinity of a molten-metal surface in the molten-metal holding
furnace, the shape defining member being configured to define a
cross-sectional shape of a cast-metal article to be cast as the
held molten metal passes through the shape defining member, and an
actuator that applies a pressure to the molten metal held in the
molten-metal holding furnace and thereby makes the held molten
metal pass through the shape defining member.
Inventors: |
IKUTA; Hiroyuki;
(Nisshin-shi, JP) ; SUGIURA; Naoaki;
(Takahama-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TOYOTA JIDOSHA KABUSHIKI KAISHA |
Toyota-shi, Aichi |
|
JP |
|
|
Assignee: |
TOYOTA JIDOSHA KABUSHIKI
KAISHA
Toyota-shi, Aichi
JP
|
Family ID: |
51866291 |
Appl. No.: |
15/036585 |
Filed: |
October 9, 2014 |
PCT Filed: |
October 9, 2014 |
PCT NO: |
PCT/JP2014/005156 |
371 Date: |
May 13, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22D 11/0403 20130101;
B22D 11/041 20130101; B22D 11/0406 20130101; B22D 11/006 20130101;
B22D 11/145 20130101; B22D 11/08 20130101; B22D 11/1246 20130101;
B22D 18/04 20130101 |
International
Class: |
B22D 11/00 20060101
B22D011/00; B22D 11/041 20060101 B22D011/041; B22D 11/14 20060101
B22D011/14; B22D 11/04 20060101 B22D011/04 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 15, 2013 |
JP |
2013-236639 |
Claims
1. A pulling-up-type continuous casting apparatus comprising: a
holding furnace that holds molten metal; a shape defining member
disposed in a vicinity of a molten-metal surface of the molten
metal, the shape defining member being configured to define a
cross-sectional shape of a cast-metal article to be cast as the
molten metal passes through the shape defining member; and a
pressurization device that applies a pressure to the molten metal
held in the holding furnace and thereby makes the molten metal pass
through the shape defining member.
2. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the pressurization device applies a pressure to
the molten metal held in the holding furnace by moving the shape
defining member into the molten metal held in the holding
furnace.
3. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the pressurization device comprises: an enclosed
vessel that hermetically encloses the molten metal held in the
holding furnace; and a pressurization unit that feeds a fluid into
the enclosed vessel and thereby applies a pressure to the molten
metal held in the holding furnace.
4. The pulling-up-type continuous casting apparatus according to
claim 3, wherein the pressurization device further comprises a
stalk extending from the shape defining member to the molten-metal
surface of the molten metal held in the holding furnace, and the
pressurization device applies a pressure to the molten metal held
in the holding furnace and thereby makes the molten metal pass
through the stalk and the shape defining member.
5. The pulling-up-type continuous casting apparatus according to
claim 1, further comprising a drawing section that grasps and pulls
up the cast-metal article and thereby draws the molten metal held
in the holding furnace through the shape defining member, the
cast-metal article being formed as the molten metal that has passed
through the shape defining member solidifies.
6. A pulling-up-type continuous casting method comprising:
disposing a shape defining member in a vicinity of a molten-metal
surface of molten metal held in a holding furnace, the shape
defining member being configured to define a cross-sectional shape
of a cast-metal article to be cast as the molten metal passes
through the shape defining member; and applying a pressure to the
molten metal held in the holding furnace and thereby making the
molten metal pass through the shape defining member.
7. The pulling-up-type continuous casting method according to claim
6, wherein a pressure is applied to the molten metal held in the
holding furnace by moving the shape defining member into the molten
metal held in the holding furnace.
8. The pulling-up-type continuous casting method according to claim
6, further comprising an enclosed vessel that hermetically encloses
the molten metal held in the holding furnace, wherein the pressure
is applied to the molten metal held in the holding furnace by
feeding a fluid into the enclosed vessel.
9. The pulling-up-type continuous casting method according to claim
8, further comprising a stalk extending from the shape defining
member to the molten-metal surface of the molten metal held in the
holding furnace, and the molten metal is made to pass through the
stalk and the shape defining member by applying a pressure to the
molten metal held in the holding furnace.
10. The pulling-up-type continuous casting method according to
claim 6, further comprising grasping and pulling up the cast-metal
article and thereby drawing the molten metal held in the holding
furnace through the shape defining member, the cast-metal article
being formed as the molten metal that has passed through the shape
defining member solidifies.
Description
TECHNICAL FIELD
[0001] The present invention relates to a pulling-up-type
continuous casting apparatus and a pulling-up-type continuous
casting method.
BACKGROUND ART
[0002] The inventors of the present application have proposed, in
Patent Literature 1, a free casting method as a revolutionary
continuous casting method that does not requires any mold. As shown
in Patent Literature 1, after a starter is submerged under the
surface of a melted metal (molten metal) (i.e., molten-metal
surface), the starter is pulled up, so that some of the molten
metal follows the starter and is drawn up by the starter by the
surface film of the molten metal and/or the surface tension. Note
that it is possible to continuously cast a cast-metal article
having a desired cross-sectional shape by drawing the molten metal
and cooling the drawn molten metal through a shape defining member
disposed in the vicinity of the molten-metal surface.
[0003] In the ordinary continuous casting method, the shape in the
longitudinal direction as well as the shape in cross section is
defined by the mold. In the continuous casting method, in
particular, since the solidified metal (i.e., cast-metal article)
needs to pass through the inside of the mold, the cast-metal
article has such a shape that it extends in a straight-line shape
in the longitudinal direction. In contrast to this, the shape
defining member used in the free casting method defines only the
cross-sectional shape of the cast-metal article, while it does not
define the shape in the longitudinal direction. Further, since the
shape defining member can be moved in the direction parallel to the
molten-metal surface (i.e., in the horizontal direction),
cast-metal articles having various shapes in the longitudinal
direction can be produced. For example, Patent Literature 1
discloses a hollow cast-metal article (i.e., a pipe) having a
zigzag shape or a helical shape in the longitudinal direction
rather than the straight-line shape.
CITATION LIST
Patent Literature
[0004] [PTL 1]: Japanese Unexamined Patent Application Publication
No. 2012-61518
SUMMARY OF INVENTION
Technical Problem
[0005] The present inventors have found the following problem.
Namely, in the free casting method disclosed in Patent Literature
1, there is a problem that since the starter has to be replaced
every time a new cast-metal article is cast, the productivity of
cast-metal articles cannot be improved.
[0006] The present invention has been made in view of the
above-described problem, and an object thereof is to provide a
pulling-up-type continuous casting apparatus and a pulling-up-type
continuous casting method capable of improving the productivity of
cast-metal articles by applying a pressure to molten metal and
thereby making the molten metal pass through a shape defining
member without using a starter.
Solution to Problem
[0007] A pulling-up-type continuous casting apparatus according to
an aspect of the present invention includes: a holding furnace that
holds molten metal; a shape defining member disposed in a vicinity
of a molten-metal surface of the molten metal, the shape defining
member being configured to define a cross-sectional shape of a
cast-metal article to be cast as the molten metal passes through
the shape defining member; and a pressurization device that applies
a pressure to the molten metal held in the holding furnace and
thereby makes the molten metal pass through the shape defining
member. As a result, since a cast-metal article can be cast without
using a starter, the productivity of cast-metal articles can be
improved.
[0008] The pressurization device preferably applies a pressure to
the molten metal held in the holding furnace by moving the shape
defining member into the molten metal held in the holding
furnace.
[0009] The pressurization device preferably includes an enclosed
vessel that hermetically encloses the molten metal held in the
holding furnace, and a pressurization unit that feeds a fluid into
the enclosed vessel and thereby applies a pressure to the molten
metal held in the holding furnace.
[0010] The pressurization device preferably further includes a
stalk extending from the shape defining member to the molten-metal
surface of the molten metal held in the holding furnace, and the
pressurization device preferably applies a pressure to the molten
metal held in the holding furnace and thereby makes the molten
metal pass through the stalk and the shape defining member.
[0011] The pulling-up-type continuous casting apparatus preferably
further includes a drawing section that grasps and pulls up the
cast-metal article and thereby draws the molten metal held in the
holding furnace through the shape defining member, the cast-metal
article being formed as the molten metal that has passed through
the shape defining member solidifies.
[0012] A pulling-up-type continuous casting method according to an
aspect of the present invention includes: disposing a shape
defining member in a vicinity of a molten-metal surface of molten
metal held in a holding furnace, the shape defining member being
configured to define a cross-sectional shape of a cast-metal
article to be cast as the molten metal passes through the shape
defining member; and applying a pressure to the molten metal held
in the holding furnace and thereby making the molten metal pass
through the shape defining member. As a result, since a cast-metal
article can be cast without using a starter, the productivity of
cast-metal articles can be improved.
[0013] It is preferable to apply a pressure to the molten metal
held in the holding furnace by moving the shape defining member
into the molten metal held in the holding furnace.
[0014] The pulling-up-type continuous casting method preferably
further includes an enclosed vessel that hermetically encloses the
molten metal held in the holding furnace, and the pressure is
preferably applied to the molten metal held in the holding furnace
by feeding a fluid into the enclosed vessel.
[0015] The pulling-up-type continuous casting method preferably
further includes a stalk extending from the shape defining member
to the molten-metal surface of the molten metal held in the holding
furnace, and the molten metal is preferably made to pass through
the stalk and the shape defining member by applying a pressure to
the molten metal held in the holding furnace.
[0016] The pulling-up-type continuous casting method preferably
further includes grasping and pulling up the cast-metal article and
thereby drawing the molten metal held in the holding furnace
through the shape defining member, the cast-metal article being
formed as the molten metal that has passed through the shape
defining member solidifies.
Advantageous Effects of Invention
[0017] According to the present invention, it is possible to
provide a pulling-up-type continuous casting apparatus and a
pulling-up-type continuous casting method capable of improving the
productivity of cast-metal articles by applying a pressure to
molten metal and thereby making the molten metal pass through a
shape defining member without using a starter.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a cross section showing a configuration example of
a free casting apparatus according to a first exemplary
embodiment;
[0019] FIG. 2 is a plane view of a shape defining member 102
provided in the free casting apparatus shown in FIG. 1;
[0020] FIG. 3A is a figure for explaining an operation of a free
casting apparatus according to a first exemplary embodiment;
[0021] FIG. 3B is a figure for explaining an operation of the free
casting apparatus according to the first exemplary embodiment;
[0022] FIG. 3C is a figure for explaining an operation of the free
casting apparatus according to the first exemplary embodiment;
[0023] FIG. 3D is a figure for explaining an operation of the free
casting apparatus according to the first exemplary embodiment;
[0024] FIG. 3E is a figure for explaining an operation of the free
casting apparatus according to the first exemplary embodiment;
[0025] FIG. 4 is a cross section showing a configuration example of
a free casting apparatus according to a second exemplary
embodiment;
[0026] FIG. 5 is a cross section showing a configuration example of
a free casting apparatus according to a third exemplary
embodiment;
[0027] FIG. 6 is a cross section showing another configuration
example of a free casting apparatus according to the present
invention; and
[0028] FIG. 7 is a plane view of a shape defining member 102
provided in the free casting apparatus shown in FIG. 6.
DESCRIPTION OF EMBODIMENTS
[0029] Specific exemplary embodiments to which the present
invention is applied are explained hereinafter in detail with
reference to the drawings. However, the present invention is not
limited to exemplary embodiments shown below. Further, the
following descriptions and the drawings are simplified as
appropriate for clarifying the explanation.
First Exemplary Embodiment
[0030] Firstly, a free casting apparatus (pulling-up-type
continuous casting apparatus) according to a first exemplary
embodiment is explained with reference to FIG. 1. FIG. 1 is a cross
section showing a configuration example of a free casting apparatus
according to the first exemplary embodiment. As shown in FIG. 1,
the free casting apparatus according to the first exemplary
embodiment includes a molten-metal holding furnace (holding
furnace) 101, an outer-shape defining member 102a, a support rod
103, an actuator 104, a cooling nozzle (cooling unit) 105, and a
drawing section 106.
[0031] The molten-metal holding furnace 101 contains molten metal
M1 such as aluminum or its alloy, and maintains the molten metal M1
at a predetermined temperature. In the example shown in FIG. 1,
since the molten-metal holding furnace 101 is not replenished with
molten metal M1 during the casting process, the surface of molten
metal M1 (i.e., molten-metal surface) is lowered as the casting
process advances. Alternatively, the molten-metal holding furnace
101 may be replenished with molten metal as required during the
casting process so that the molten-metal surface is kept at a fixed
level. Needless to say, the molten metal M1 may be a metal other
than aluminum or an alloy thereof.
[0032] The outer-shape defining member 102a is made of ceramic or
stainless, for example, and disposed in the vicinity of the
molten-metal surface. In the example shown in FIG. 1, the
outer-shape defining member 102a is positioned in a place lower
than the molten-metal surface. Further, in the example shown in
FIG. 1, a sidewall W that extends vertically upward from the outer
edge of the outer-shape defining member 102a is integrally formed
with the outer-shape defining member 102a in order to prevent the
molten metal M1 from flowing over the outer edge of the outer-shape
defining member 102a into the upper main surface thereof.
[0033] The outer-shape defining member 102a defines the outer shape
of a cast metal M3 to be cast. The cast metal M3 shown in FIG. 1 is
a cylindrical solid cast-metal article having a circular shape in a
horizontal cross section (hereinafter referred to as "lateral cross
section"). That is, more specifically, the outer-shape defining
member 102a defines the outer diameter on the lateral cross section
of the cast metal M3.
[0034] FIG. 2 is a plane view of the outer-shape defining member
102a. Note that the cross section of the outer-shape defining
member 102a shown in FIG. 1 corresponds to a cross section taken
along the line I-I in FIG. 2. As shown in FIG. 2, the outer-shape
defining member 102a has, for example, a rectangular shape as
viewed from the top, and has a circular opening at the center. This
opening serves as a molten-metal passage section 102b through which
molten metal passes. In this manner, the outer-shape defining
member 102a and the molten-metal passage section 102b constitute a
shape defining member 102.
[0035] The support rod 103 supports the outer-shape defining member
102a. Note that the support rod 103 is connected to the actuator
104.
[0036] The actuator 104 has a function of moving the outer-shape
defining member 102a in the up/down direction (vertical direction)
and in the horizontal direction through the support rod 103. In
this manner, it is possible to move the outer-shape defining member
102a downward as the molten-metal surface is lowered due to the
advance of the casting process. Further, since the outer-shape
defining member 102a can be moved in the horizontal direction, the
shape in the longitudinal direction of the cast metal M3 can be
freely changed.
[0037] In the example shown in FIG. 1, the actuator 104 also has a
function as a pressurization device that applies a pressure to the
molten metal M1. Specifically, the actuator 104 moves the
outer-shape defining member 102a into the molten metal M1
(downward) and thereby applies a pressure to the molten metal M1.
Then, when the outer-shape defining member 102a moves to a position
lower than the molten-metal surface of the molten metal M1, the
molten metal M1 is pushed up from the molten-metal surface through
the molten-metal passage section 102b (the molten metal M1 passes
through the molten-metal passage section 102b). Note that the part
of the molten metal M1 that is pushed up from the molten-metal
surface by applying a pressure to the molten metal M1 (or pulled up
by the drawing section 106 after that) but has not solidified yet
is called "held molten metal M2". Further, the interface between
the held molten metal M2 and the cast metal M3, which is formed as
the held molten metal M2 solidifies, is called "solidification
interface".
[0038] The cooling nozzle 105 sprays a cooling gas (such as air,
nitrogen, and argon) on the held molten metal M2 that has passed
through the molten-metal passage section 102b and/or the cast metal
M3 that is formed as the held molten metal M2 solidifies, and
thereby cools the held molten metal M2 and/or the cast metal M3.
The held molten metal M2, which has been made to pass through the
molten-metal passage section 102b by applying a pressure to the
molten metal M1, is cooled by the cooling gas and solidifies, thus
forming the cast metal M3.
[0039] The drawing section 106 includes a grasping section 1061, a
connecting member 1062, and a pulling-up machine 1063. The grasping
section 1061 grasps the cast metal M3 that is formed as the held
molten metal M2 that has passed through the molten-metal passage
section 102b solidifies. The connecting member 1062 connects the
grasping section 1061 with the pulling-up machine 1063. The
pulling-up machine 1063 drives the grasping section 1061 in the
up/down direction (vertical direction).
[0040] As the drawing section 106 pulls up the cast metal M3 that
is formed as the held molten metal M2 solidifies, the molten metal
M1 follows the pulled-up cast metal M3 and is also pulled up. As a
result, the molten metal M1 passes through the molten-metal passage
section 102b as the held molten metal M2.
[0041] As described above, the free casting apparatus according to
this exemplary embodiment makes the held molten metal M2 pass
through the molten-metal passage section 102b by applying a
pressure to the molten metal M1. Further, the free casting
apparatus according to this exemplary embodiment grasps and pulls
up the cast metal M3 that is formed as the held molten metal M2
that has passed through the molten-metal passage section 102b
solidifies, and thereby also pulls up the molten metal M1 that
follows the pulled up cast metal M3. That is, the free casting
apparatus according to this exemplary embodiment uses the cast
metal M3, which is formed as the held molten metal M2 solidifies,
as a substitute for the starter. As a result, the free casting
apparatus according to this exemplary embodiment can eliminate the
need for replacing the starter every time a new cast-metal article
is cast, thereby making it possible to reduce the time necessary
for the replacement of the starter and reduce the cost. That is,
the free casting apparatus according to this exemplary embodiment
can improve the productivity of cast-metal articles.
[0042] Next, a free casting method according to this exemplary
embodiment is explained with reference to FIGS. 1, 2 and 3A-3E.
FIGS. 3A to 3E are figures for explaining an operation of a free
casting apparatus according to the first exemplary embodiment.
[0043] Firstly, the outer-shape defining member 102a is disposed in
the vicinity of the molten-metal surface of the molten metal M1
held in the molten-metal holding furnace 101 (FIG. 3A).
[0044] Next, a pressure is applied to the the molten metal M1 by
moving the outer-shape defining member 102a into the molten metal
M1 (FIG. 3B). As the outer-shape defining member 102a moves to a
place lower than the molten-metal surface of the molten metal M1,
the molten metal M1 passes through the molten-metal passage section
102b as held molten metal M2.
[0045] Next, the held molten metal M2 that has passed through the
molten-metal passage section 102b is cooled by a cooling gas
sprayed from the cooling nozzle 105. As a result, the held molten
metal M2 solidifies and forms cast metal M3 (FIG. 3C).
[0046] By further moving the outer-shape defining member 102a into
the molten metal M1 and cooling the held molten metal M2 that has
passed through the molten-metal passage section 102b, the cast
metal M3 grows (FIG. 3D). Then, when the cast metal M3 grows to
such a length that the grasping section 1061 can grasp the cast
metal M3, the movement of the outer-shape defining member 102a into
the molten metal M1 is stopped (that is, the application of a
pressure to the molten metal M1 is stopped). After that, the
outer-shape defining member 102a may be kept in the molten metal M1
or may be moved to the vicinity of the molten-metal surface of the
molten metal M1. Note that when the outer-shape defining member
102a is kept in the molten metal M1, the molten metal M1 is
continuously kept in a pressurized state. Therefore, the drawn-up
property of the molten metal M1 improves.
[0047] Next, the cast metal M3 is pulled up by the drawing section
106 (FIG. 3E). Note that even when the cast metal M3 is pulled away
from the molten-metal surface, the molten metal M1 follows the cast
metal M3 and is pulled up from the molten-metal surface by the
surface film and/or the surface tension. The pulled-up molten metal
M1 forms held molten metal M2. As shown in FIG. 1, the held molten
metal M2 is formed in the molten-metal passage section 102b. In
other words, the held molten metal M2 is shaped into a given shape
by the outer-shape defining member 102a.
[0048] The held molten metal M2 that has pulled up by the drawing
section 106 is cooled by a cooling gas sprayed from the cooling
nozzle 105. As a result, the held molten metal M2 that has pulled
up by the drawing section 106 successively solidifies from its
upper side toward its lower side and hence the cast metal M3 grows.
In this manner, it is possible to continuously cast the cast metal
M3.
[0049] As described above, the free casting apparatus according to
this exemplary embodiment makes the held molten metal M2 pass
through the molten-metal passage section 102b by applying a
pressure to the molten metal M1. Further, the free casting
apparatus according to this exemplary embodiment grasps and pulls
up the cast metal M3 that is formed as the held molten metal M2
that has passed through the molten-metal passage section 102b
solidifies, and thereby pulls up the molten metal M1 that follows
the pulled up cast metal M3. That is, the free casting apparatus
according to this exemplary embodiment uses the cast metal M3 that
is formed as the held molten metal M2 solidifies as a substitute
for the starter. As a result, the free casting apparatus according
to this exemplary embodiment can eliminate the need for replacing
the starter every time a new cast-metal article is cast, thereby
making it possible to reduce the time necessary for the replacement
of the starter and reduce the cost. That is, the free casting
apparatus according to this exemplary embodiment can improve the
productivity of cast-metal articles.
Second Exemplary Embodiment
[0050] FIG. 4 is a cross section showing a configuration example of
a free casting apparatus according to a second exemplary
embodiment. The free casting apparatus shown in FIG. 4 includes a
pressurization device having a configuration different from that of
the pressurization device of the free casting apparatus shown in
FIG. 1.
[0051] Specifically, in comparison to the free casting apparatus
shown in FIG. 1, the free casting apparatus shown in FIG. 4 further
includes a lid 107 for hermetically enclosing the molten metal M1
and a fluid supply unit (pressurization unit) 108 that feeds a
fluid into the hermetically enclosed area. Further, in the example
shown in FIG. 4, a tubular stalk S that extends from the inner edge
of the outer-shape defining member 102a (that is, from the
molten-metal passage section 102b ) to the molten-metal surface of
the molten metal M1. Note that in the example shown in FIG. 4, the
sidewall W that extends vertically upward from the outer edge of
the outer-shape defining member 102a does not have to be provided
because no molten metal M1 flows over the outer edge of the
outer-shape defining member 102a into the upper main surface
thereof. The other configuration of the free casting apparatus
shown in FIG. 4 is similar to that of the free casting apparatus
shown in FIG. 1, and therefore its explanation is omitted.
[0052] The lid 107 closes the opened section of the molten metal
holding furnace 101. That is, the molten metal holding furnace 101
and the lid 107 constitute an enclosed vessel that hermetically
encloses the molten metal M1. However, the lid 107 includes an
opened section having such a size that the stalk S can pass through
the opened section. The stalk S extends from the inner edge of the
outer-shape defining member 102a (that is, from the molten-metal
passage section 102b) to the molten-metal surface of the molten
metal M1 through the opened section.
[0053] The fluid supply unit 108 applies a pressure to the molten
metal M1 by feeding a fluid such as atmospheric air into the
enclosed vessel. As a result, the molten metal M1 passes through
the stalk S and the molten-metal passage section 102b. Therefore,
the free casting apparatus shown in FIG. 4 can produce advantageous
effects equivalent to those of the free casting apparatus shown in
FIG. 1.
Third Exemplary Embodiment
[0054] FIG. 5 is a cross section showing a configuration example of
a free casting apparatus according to a third exemplary embodiment.
The free casting apparatus shown in FIG. 5 includes a
pressurization device having a configuration different from that of
the pressurization device of the free casting apparatus shown in
FIG. 1.
[0055] Specifically, in comparison to the free casting apparatus
shown in FIG. 1, the free casting apparatus shown in FIG. 5 further
includes an object 109 and a drive unit 110 that drives the object
109 in the up/down direction (vertical direction). The other
configuration of the free casting apparatus shown in FIG. 5 is
similar to that of the free casting apparatus shown in FIG. 1, and
therefore its explanation is omitted.
[0056] The object 109 is formed of material having a melting point
higher than that of the molten metal M1. The drive unit 110 moves
the object 109 from outside of the molten metal M1 into the molten
metal M1 and thereby applies a pressure to the molten metal M1. As
a result, the free casting apparatus shown in FIG. 5 can produce
advantageous effects equivalent to those of the free casting
apparatus shown in FIG. 1.
[0057] As described above, the free casting apparatuses according
to the above-described first to third exemplary embodiments apply a
pressure to the the molten metal M1 and thereby make the molten
metal M1 pass through the shape defining member 102 without using a
starter. As a result, the free casting apparatuses according to the
first to third exemplary embodiments can eliminate the need for
replacing the starter every time a new cast-metal article is cast,
thereby making it possible to reduce the time necessary for the
replacement of the starter and reduce the cost. That is, the free
casting apparatuses according to the first to third exemplary
embodiments can improve the productivity of cast-metal
articles.
[0058] Although example cases where a cast-metal article having a
cylindrical shape (cylindrical cast-metal article) is cast are
explained in the above-described exemplary embodiments, the present
invention is not limited to such examples. The present invention
can also be applied to cases where a cast-metal article having a
tubular shape, a square pillar shape, a square tubular shape, or
other shapes is cast. A case where a cast-metal article having a
tubular shape is cast is briefly explained hereinafter with
reference to FIGS. 6 and 7.
[0059] FIG. 6 is a cross section showing another configuration
example of a free casting apparatus according to the present
invention. The free casting apparatus shown in FIG. 6 includes an
inner-shape defining member 102c in addition to the outer-shape
defining member 102a.
[0060] The inner-shape defining member 102c defines the inner shape
of a cast metal M3 to be cast and the outer-shape defining member
102a defines the outer shape of the cast metal M3 to be cast. The
cast metal M3 shown in FIG. 6 is a hollow cast-metal article having
a ring shape in a horizontal cross section (hereinafter referred to
as "lateral cross section") (that is, the cast metal M3 shown in
FIG. 6 is a pipe). That is, more specifically, the inner-shape
defining member 102c defines the inner diameter on the lateral
cross section of the cast metal M3 and the outer-shape defining
member 102a defines the outer diameter on the lateral cross section
of the cast metal M3.
[0061] The inner-shape defining member 102c is supported by a
support rod 111. The support rod 111 is connected to the actuator
104. The actuator 104 has a function of moving the outer-shape
defining member 102a and the inner-shape defining member 102c in
the up/down direction (vertical direction) and in the horizontal
direction through the support rods 103 and 111, respectively.
[0062] FIG. 7 is a plane view of the inner-shape defining member
102c and the outer-shape defining member 102a. Note that the cross
section of the inner-shape defining member 102c and the outer-shape
defining member 102a in FIG. 6 corresponds to a cross section taken
along the line II-II in FIG. 7. As shown in FIG. 7, the outer-shape
defining member 102a has, for example, a rectangular shape as
viewed from the top, and has a circular opening at the center. The
inner-shape defining member 102c has a circular shape as viewed
from the top and is disposed at the center of the opening of the
outer-shape defining member 102a. The gap between the inner-shape
defining member 102c and the outer-shape defining member 102a
serves as the molten-metal passage section 102b through which the
molten metal passes. In this manner, the inner-shape defining
member 102c, the outer-shape defining member 102a, and the
molten-metal passage section 102b constitute a shape defining
member 102. With this configuration, a cast-metal article having a
tubular shape is cast.
[0063] Note that the present invention is not limited to the
above-described exemplary embodiments, and various modifications
can be made without departing the spirit and scope of the present
invention. For example, the above-described configuration examples
may be combined and used at the same time.
[0064] This application is based upon and claims the benefit of
priority from Japanese patent application No. 2013-236639, filed on
Nov. 15, 2013, the disclosure of which is incorporated herein in
its entirety by reference.
REFERENCE SIGNS LIST
[0065] 101 MOLTEN METAL HOLDING FURNACE
[0066] 102 SHAPE DEFINING MEMBER
[0067] 102a OUTER-SHAPE DEFINING MEMBER
[0068] 102b MOLTEN-METAL PASSAGE SECTION
[0069] 102c INNER-SHAPE DEFINING MEMBER
[0070] 103 SUPPORT ROD
[0071] 104 ACTUATOR
[0072] 105 COOLING NOZZLE
[0073] 1061 GRASPING SECTION
[0074] 1062 CONNECTING MEMBER
[0075] 1063 PULLING-UP MACHINE
[0076] 106 DRAWING SECTION
[0077] 107 LID
[0078] 108 FLUID SUPPLY UNIT
[0079] 109 OBJECT
[0080] 110 DRIVE UNIT
[0081] 111 SUPPORT ROD
[0082] M1 MOLTEN METAL
[0083] M2 HELD MOLTEN METAL
[0084] M3 CAST METAL
[0085] W SIDEWALL
[0086] S STALK
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