U.S. patent application number 14/793906 was filed with the patent office on 2017-01-12 for cast molding method and devices thereof.
The applicant listed for this patent is HER CHANG TECHNOLOGY CO., LTD.. Invention is credited to CHUN-YUNG HUANG, TIEN-KEN LIANG, MING-CHIA TSAI, WEIDONG XING, NING ZHANG.
Application Number | 20170008079 14/793906 |
Document ID | / |
Family ID | 57730474 |
Filed Date | 2017-01-12 |
United States Patent
Application |
20170008079 |
Kind Code |
A1 |
LIANG; TIEN-KEN ; et
al. |
January 12, 2017 |
CAST MOLDING METHOD AND DEVICES THEREOF
Abstract
A cast molding method accomplishes the cast molding by a
smelting chamber, a casting chamber, a hinge press system and a
vacuum system. First, a metallic die is assembled in the casting
chamber and then a metallic material is put in the smelting
chamber. Next, the metallic material is heated up in a vacuum state
and the casting chamber is pre-heated at a same time. After the
metallic material in the smelting chamber has been melted down and
the casting chamber has been vacuumized, the melted metallic
material is filled into the metallic die, and then the hinge press
system is turned on to cast mold the metallic die, resulting in a
semi-solid product. After the semi-solid product has been cooled
down, the product of cast molding is accomplished according to the
present invention.
Inventors: |
LIANG; TIEN-KEN; (Tainan
County, TW) ; HUANG; CHUN-YUNG; (Tainan County,
TW) ; TSAI; MING-CHIA; (Tainan County, TW) ;
XING; WEIDONG; (Tainan County, CN) ; ZHANG; NING;
(Tainan County, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HER CHANG TECHNOLOGY CO., LTD. |
Tainan County |
|
TW |
|
|
Family ID: |
57730474 |
Appl. No.: |
14/793906 |
Filed: |
July 8, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21J 5/004 20130101;
B22D 37/005 20130101; B22D 27/15 20130101; B22D 21/005 20130101;
B22D 21/022 20130101; B22D 17/14 20130101; B22D 17/2015 20130101;
B21J 5/002 20130101; B22D 21/04 20130101; B22D 17/28 20130101; B22D
23/02 20130101 |
International
Class: |
B22D 17/14 20060101
B22D017/14; B22D 21/02 20060101 B22D021/02; B22D 27/15 20060101
B22D027/15; B22D 21/04 20060101 B22D021/04; B22D 17/20 20060101
B22D017/20; B22D 17/28 20060101 B22D017/28 |
Claims
1. A cast molding method accomplishing the cast molding by a
smelting chamber, a casting chamber, a hinge press system and a
vacuum system, and the cast molding method comprising following
steps: providing a metallic die and assembling the metallic die in
the casting chamber; providing a crucible and assembling the
crucible in the smelting chamber, then loading a metallic material
in the crucible and vacuumizing the smelting chamber using the
vacuum system; heating up the metallic die to 40.degree. C. to
500.degree. C.; heating up the crucible to the melting point of the
metallic material to melt down the metallic material; vacuumizing
the metallic die in the casting chamber using the vacuum system;
filling the metallic die with the melted metallic material in the
crucible; turning on the hinge press system to forge the metallic
die, accomplishing a semi-solid product; and accomplishing the
product after the semi-solid product has been cooled down.
2. The cast molding method according to claim 1, further including
a gas supply system to provide an anaerobic gas into the
crucible.
3. The cast molding method according to claim 2, wherein the
anaerobic gas supplied by the gas supply system is argon or
nitrogen.
4. The cast molding method according to claim 1, wherein the vacuum
system vacuumizes the crucible to a vacuum degree of
0.3.times.10.sup.-1 Pa.about.1.0.times.10.sup.-1 Pa.
5. The cast molding method according to claim 1, wherein the vacuum
system vacuumizes the metallic die to a vacuum degree of
0.3.times.10.sup.-1 Pa.about.1.0.times.10.sup.-1 Pa.
6. The cast molding method according to claim 4, wherein the vacuum
system is provided with at least a vacuum pump.
7. The cast molding method according to claim 6, wherein the vacuum
system is provided with a first vacuum pump and a second vacuum
pump.
8. The cast molding method according to claim 7, wherein the first
vacuum pump is a mechanical pump which forms low vacuum in the
smelting chamber and the casting chamber.
9. The cast molding method according to claim 7, wherein the second
vacuum pump is a Root's pump which forms high vacuum in the
smelting chamber and the casting chamber.
10. The cast molding method according to claim 1, wherein the
metallic material is Titanium, Titanium alloy, aluminum alloy or
stainless steel.
11. The cast molding method according to claim 1, wherein the
metallic material is Titanium alloy and the crucible is heated up
until the Titanium alloy reaches 1600.degree. C. to 1800.degree.
C.
12. Devices of the cast molding method, comprising: a smelting
chamber, the smelting chamber being provided with a roof, a
crucible and a first heating unit, with the first heating unit
heating up the crucible and the roof being covered on a top of the
smelting chamber; a casting chamber, the casting chamber being
disposed at a side of the smelting chamber and being provided with
a holding space to accommodate the metallic die, with the casting
chamber also being provided with a guide tube connecting the
crucible and the holding space; a hinge press system, the hinge
press system being disposed at a side of the casting chamber and
being provided with a control unit, a second piping, a power unit
and a hinge press bar, with the second piping being connected
respectively to the control unit and the power unit, the hinge
press bar being connected with the power unit to provide power to
the hinge press bar to move toward the holding space; and a vacuum
system, the vacuum system vacuumizing the smelting chamber and the
casting chamber respectively, and being provided with at least a
vacuum pump.
13. The devices of the cast molding method according to claim 12,
further including a gas supply system, with the gas supply system
being disposed at a side of the smelting chamber and being provided
with a storage tank and a first piping, with the first piping being
connected to the storage tank and the smelting chamber to supply an
anaerobic gas into the crucible.
14. The devices of the cast molding method according to claim 12,
wherein the vacuum system is provided with a first vacuum pump and
a second vacuum pump.
15. The devices of the cast molding method according to claim 14,
wherein the first vacuum pump is a mechanical pump which forms low
vacuum in the smelting chamber and the casting chamber.
16. The devices of the cast molding method according to claim 14,
wherein the second vacuum pump is a Root's pump which forms high
vacuum in the smelting chamber and the casting chamber.
17. The devices of the cast molding method according to claim 12,
wherein the hinge press system is a hydraulic oil pressure
system.
18. The devices of the cast molding method according to claim 12,
wherein the power unit is a hydraulic pressure boosting
cylinder.
19. The devices of the cast molding method according to claim 12,
wherein the casting chamber further includes a second heating
unit.
20. The devices of the cast molding method according to claim 19,
wherein the second heating unit is a heating coil or heating
resistor.
21. The devices of the cast molding method according to claim 12,
wherein the first heating unit is a heating coil and is wrapped
outside of the crucible.
22. The devices of the cast molding method according to claim 12,
wherein the hinge press bar is disposed below the holding space or
is disposed next to the holding space.
Description
BACKGROUND OF THE INVENTION
a) Field of the Invention
[0001] The present invention relates to a cast molding method and
devices thereof, and more particularly to a cast molding method and
devices thereof, which combine a casting process with a forging and
stamping process for a metal to implement the metal forming once
and for all, thereby shortening the forming process considerably
and reducing the production cost.
b) Description of the Prior Art
[0002] A conventional small metal fitting, such as sport equipment
(Golf head, striking surface), a housing structure (housing of an
electronic part, housing of a watch), a small hardware fitting or
an automobile part, will be manufactured by a technology of
precision casting or precision die forging. For the precision
casting, a casting mold is prepared first. The casting mold is
provided with a mold cavity in a pre-determined specification of a
product. Next, liquid wax is poured into the mold cavity of the
casting mold to form a wax mold. The wax mold is then taken out of
the mold cavity and submerged in a loam to form a polymer loam
shell mold. After that, the shell mold is heated up to melt down
the wax mold. The wax mold flows out of the ceramic shell mold, and
a melted liquid metal is poured into the ceramic shell mold to form
an embryo. Finally, the embryo is undergone with a few times of
surface machining and then the product in the pre-determined
specification can be made.
[0003] In the precision casting process, the production cycle of
the shell mold is long and the technology is complicated.
Furthermore, a loose and heavy resultant (.alpha.-Ti) will be
created on the metal surface after casting. Therefore, the metal
will have a poor mechanical strength and the shell mold can be used
only once.
[0004] On the other hand, for the precision die forging process, a
metal block made of carbon steel or alloy steel is first chosen for
forging. The metal block is then undergone with a few times of
forging and stamping process in a few forging dies. In the forging
process, as the mold cavity of each forging die changes the shape
orderly in a series, the outline of the metal block can be forged
and stamped gradually and simultaneously into the embryo in the
corresponding shape. Finally, the embryo is undergone with a few
times of surface machining, and then the product in the
pre-determined specification can be made.
[0005] Although the product of the forging formation is provided
with the advantages of uniformity and high structural strength, as
too many forging dies are used in the forging process, it can
easily result in the shortcomings that the cost of die sinking and
manufacturing can be too high, the forging process is not suitable
for mass production, it is not easy to make complex shapes and the
forging dies need to be replaced frequently due to deformation by
pressure.
SUMMARY OF THE INVENTION
[0006] To solve this issue, the present invention provides a
technical means which is able to combine the casting process with
the forging and stamping process for a metal to implement the metal
forming once and for all, thereby shortening the forming process
considerably and reducing the production cost.
[0007] To achieve the abovementioned object, the present invention
discloses a cast molding method which accomplishes the cast molding
by a smelting chamber, a casting chamber, a hinge press system and
a vacuum system. First, a metallic die is assembled in the casting
chamber and then a metallic material is put in the smelting
chamber. Next, the metallic material is heated up in a vacuum state
and the casting chamber is pre-heated at a same time. After the
metallic material in the smelting chamber has been melted down and
the casting chamber has been vacuumized, the melted metallic
material is filled into the metallic die, and then the hinge press
system is turned on to cast mold the metallic die, resulting in a
semi-solid product. After the semi-solid product has been cooled
down, the product of cast molding is accomplished according to the
present invention.
[0008] To achieve the abovementioned object, the present invention
also discloses the devices of cast molding, including a smelting
chamber, a casting chamber, a hinge press system and a vacuum
system. The smelting chamber is provided with a roof, a crucible
and a first heating unit. The first heating unit heats up the
crucible and the roof is covered on a top of the smelting chamber.
The casting chamber is disposed at a side of the smelting chamber
and is provided with a holding space to accommodate the metallic
die. The casting chamber is also provided with a guide tube which
is connected to the crucible and the holding space. The hinge press
system is disposed at a side of the casting chamber and is provided
with a control unit, a second piping, a power unit and a hinge
press bar. The second piping is connected respectively to the
control unit and the power unit. The hinge press bar is connected
with the power unit which provides power to the hinge press bar to
move toward the holding space. The vacuum system vacuumizes
respectively the smelting chamber and the casting chamber, and is
provided with at least a vacuum pump.
[0009] To enable a further understanding of the said objectives and
the technological methods of the invention herein, the brief
description of the drawings below is followed by the detailed
description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a schematic view of structures of devices of
cast molding, according to the present invention.
[0011] FIG. 2 shows a block diagram of steps in the cast molding
method, according to the present invention.
[0012] FIG. 3 shows a schematic view of metallographic structures
of a product made of the cast molding method, according to the
present invention.
[0013] FIG. 4 shows a schematic view of metallographic structures
of a product made of the conventional precision casting
process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to FIG. 1, it shows a schematic view of structures
of devices of the cast molding method, according to the present
invention. The cast molding method accomplishes the cast molding
with the cast molding devices including a smelting chamber 1, a
casting chamber 2, a gas supply system 3, a hinge press system 4
and a vacuum system 5.
[0015] The smelting chamber 1 is provided with a roof 11, a
crucible 12 and a first heating unit 13. The first heating unit 13
heats up the crucible 12 and the roof 11 is covered on a top of the
smelting chamber 1 to seal the crucible 12. The first heating unit
13 can be a heating coil and is wrapped outside of the crucible
12.
[0016] The casting chamber 2 is disposed at a side of the smelting
chamber 1. In the embodiment as shown in the drawing, the casting
chamber 2 is located below the smelting chamber 1. The casting
chamber 2 is provided with a holding space 21 to accommodate a
metallic die 6, and a guide tube 22 which is connected to the
crucible 12 and the holding space 21. The casting chamber 2 is
further provided with a second heating unit (not shown in the
drawing) to heat up the casting chamber 2. The second heating unit
can be a heating coil or heating resistor.
[0017] The gas supply system 3 is disposed at a side of the
smelting chamber 1 and is provided with a storage tank 31 and a
first piping 32. The first piping 32 is connected to the storage
tank 31 and the smelting chamber 1 to supply an anaerobic gas into
the crucible 12, and the anaerobic gas is argon or nitrogen.
[0018] The hinge press system 4 is disposed at a side of the
casting chamber 2 and is provided with a control unit 41, a second
piping 42, a power unit 43 and a hinge press bar 44. The second
piping 42 is connected respectively to the control unit 41 and the
power unit 43; whereas, the hinge press bar 44 is connected to the
power unit 43. The power unit 43 provides power to the hinge press
bar 44 to move toward the holding space 21. The hinge press system
4 can be a hydraulic oil pressure system and the power unit 43 is a
hydraulic pressure boosting cylinder. Moreover, in the embodiment
as shown in the drawing, the hinge press bar 44 is located below
the holding space 21. Naturally, the hinge press bar 44 can be also
located next to the holding space 21.
[0019] The vacuum system 5 vacuumizes respectively the smelting
chamber 1 and the casting chamber 2, and the vacuum system 5 is
provided with at least a vacuum pump. In the embodiment as shown in
the drawing, the vacuum system 5 is provided with a first vacuum
pump 51 and a second vacuum pump 52. The first vacuum pump 51 is a
mechanical pump and can form low vacuum in the smelting chamber 1
and the casting chamber 2. The second vacuum pump 52 is a Root's
pump and can form high vacuum in the smelting chamber 1 and the
casting chamber 2. By serially connecting the first vacuum pump 51
with the second vacuum pump 52, a system of large gas exhaust rate
and high vacuum degree can be achieved.
[0020] Referring to FIG. 2, the cast molding method of the present
invention includes following steps:
[0021] The metallic die 6 is provided and assembled into the
holding space 21 of the casting chamber 2.
[0022] The crucible 21 is provided and assembled into the smelting
chamber 1. A metallic material (not shown in the drawing) is loaded
into the crucible 12 and the roof 11 is covered on the top of the
smelting chamber 1 to seal the crucible 12. The crucible 12 is then
vacuumized by the vacuum system 5 to the vacuum degree of
0.3.times.10.sup.-1 Pa.about.1.0.times.10.sup.-1 Pa. The present
invention utilizes at least a vacuum pump (such as mechanical pump
and Root's pump) and can combine the vacuumizing abilities of
different vacuum pumps to achieve the requirement of high vacuum or
low vacuum. On the other hand, the metallic material that is loaded
into the crucible 12 can be Titanium, Titanium alloy (such as
Ti-6Al-4V), aluminum alloy or stainless steel.
[0023] The metallic die 6 is heated up to 40.degree. C. to
500.degree. C. by the second heating unit.
[0024] When the vacuum degree in the crucible 12 reaches
0.3.times.10.sup.-1 Pa.about.1.0.times.10.sup.-1 Pa, the
vaccumizing to the crucible 12 by the vacuum system 5 is
stopped.
[0025] The gas supply system 3 supplies an anaerobic gas into the
crucible 12. At this time, when the crucible 12 reaches the vacuum
degree of 0.3.times.10.sup.-1 Pa.about.1.0.times.10.sup.-1 Pa, the
crucible 12 is filled with the anaerobic gas (can be argon or
nitrogen) and an anoxic environment is formed inside the crucible
12. Therefore, in the subsequent heating step, the metallic
material in the crucible 12 can be prevented from oxidation.
[0026] The crucible 12 is heated up to the melting point of the
metallic material by the first heating unit 13 to melt down the
metallic material. For example, if the metallic material that is
put in the crucible 12 is Titanium alloy, then the heating
temperature should reach 1600.degree. C. to 1800.degree. C. that
the metallic material can be melted down completely.
[0027] The metallic die 6 in the casting chamber 2 is vacuumized to
the vacuum degree of 0.3.times.10.sup.-1
Pa.about.1.0.times.10.sup.-1 Pa by the vacuum system 5, forming an
anoxic environment inside the metallic die 6.
[0028] The melted metallic material in the crucible 12 is filled
into the metallic die 6 through the guide tube 22. At this time,
the melted metallic material is at higher temperature (if the
metallic material is Titanium alloy, then the temperature will
reach about 1600.degree. C. to 1800.degree. C.), and as the
metallic die 6 is at temperature of 40.degree. C. to 500.degree.
C., it is equipped with a cooling function; therefore, after the
melted metallic material has been filled into the metallic die 6, a
semi-solid state can be formed to the metallic material, thereby
accomplishing the casting procedure.
[0029] After that, the hinge press system 4 is turned on to forge
the metallic die 6. By using the control unit 41 to control the
power unit 43, the hinge press bar 44 will move toward the metallic
die 6 and provide pressure to accomplish the semi-solid product.
The control unit 41 can control and adjust the setting of pressure
and time that the power unit 43 provides.
[0030] The product is accomplished after the semi-solid product has
been cooled down. The product to which the present invention
applies includes sport equipment (Gold head, striking surface), a
housing structure (housing of an electronic part, housing of a
watch), a small hardware fitting and an automobile part. By the
forming method and the devices of the present invention, an anoxic
environment is provided when the metallic material is melted and
cooled down in the casting procedure, and an anoxic environment is
also provided during forging formation. Therefore, it can assure
that the metallic material will not be oxidized in the casting and
forging procedures, so that the product will not form a loose
resultant easily by oxidation, thereby improving the mechanical
strength and extensibility of the product.
[0031] Referring to FIG. 3, it shows a schematic view of
metallographic structures of a product made of the cast molding
method, according to the present invention; whereas, FIG. 4 shows a
schematic view of metallographic structures of a product made of
the conventional precision casting process. The product of cast
molding of the present invention is constituted by complex
structures which are all formed by non-isometric columnar crystal
structures 71 and isometric crystal structures 73. On the other
hand, in the product of the conventional precision casting process,
the distribution area of the resultants (.alpha.-Ti) 72 that are
all made of the isometric crystal structures 73 is larger and
heavier. In addition, the product of the cast molding of the
present invention and the product of the conventional precision
casting process are tested for tensile strength, yield strength and
strain respectively. The results of test are shown in the following
table.
TABLE-US-00001 TABLE 1 Tensile Strength Yield Strength Strain
(RmMPa) (Rp0.2 MPa) A(%) Product of Cast 983.3 866 11.83 Molding of
the Present Invention Product of 951.6 848.3 7.67 Conventional
Precision Casting Process Rate of Increase +3.3% +2.1% +54.2%
[0032] From the test results in Table 1, it is known that in
comparison with the product of the conventional precision casting
process, the tensile strength, yield strength and strain are all
improved for the product of the cast molding of the present
invention.
[0033] It is of course to be understood that the embodiments
described herein is merely illustrative of the principles of the
invention and that a wide variety of modifications thereto may be
effected by persons skilled in the art without departing from the
spirit and scope of the invention as set forth in the following
claims.
* * * * *