U.S. patent application number 17/036335 was filed with the patent office on 2022-03-31 for modular mold design for casting a vehicle frame and components.
The applicant listed for this patent is GM Global Technology Operations LLC. Invention is credited to Garrold A. DeGrace, David D. Goettsch, Gregory T. Naismith, Madhusudhan Raju Nannapuraju, Anil K. Sachdev.
Application Number | 20220097127 17/036335 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-31 |
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United States Patent
Application |
20220097127 |
Kind Code |
A1 |
Goettsch; David D. ; et
al. |
March 31, 2022 |
MODULAR MOLD DESIGN FOR CASTING A VEHICLE FRAME AND COMPONENTS
Abstract
A modular casting mold for casting an automotive component
includes a plurality of die portions defining a mold cavity
corresponding to an automotive component, at least one of the
plurality of die portions is an active die portion adapted to
control the temperature of the modular casting mold throughout the
casting process and including features for ejecting an automotive
component cast within the modular casting mold, and the modular
casting mold adapted to be attached to another modular casting mold
for casting a single automotive component.
Inventors: |
Goettsch; David D.; (Shelby
Township, MI) ; DeGrace; Garrold A.; (Frankenmuth,
MI) ; Naismith; Gregory T.; (Clarkston, MI) ;
Nannapuraju; Madhusudhan Raju; (Farmington Hills, MI)
; Sachdev; Anil K.; (Rochester Hills, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GM Global Technology Operations LLC |
Detroit |
MI |
US |
|
|
Appl. No.: |
17/036335 |
Filed: |
September 29, 2020 |
International
Class: |
B22D 17/22 20060101
B22D017/22 |
Claims
1. A modular casting mold for casting an automotive component,
comprising: a plurality of die portions defining a mold cavity
corresponding to the automotive component; the plurality of die
portions including at least one active die portion adapted to
control the temperature of the modular casting mold throughout the
casting process and including features for ejecting the automotive
component cast within the modular casting mold; and the modular
casting mold adapted to be attached to another modular casting mold
for casting the automotive component.
2. The modular casting mold of claim 1, wherein the at least one
active die portion includes burners for heating the active die
portion.
3. The modular casting mold of claim 1, wherein the at least one
active die portion includes cooling jets for cooling a casted
component within the modular casting mold.
4. The modular casting mold of claim 1, wherein the at least one
active die portion includes air jets for injecting air between an
inner surface of the active die portion and a casted automotive
component within the modular casting mold to free the casted
automotive component from the modular casting mold.
5. The modular casting mold of claim 1, wherein the at least one
active die portion includes jets for injecting pressurized fluid
between an inner surface of the active die portion and a casted
automotive component within the modular casting mold to free the
casted automotive component from the modular casting mold.
6. The modular casting mold of claim 1, wherein the at least one
active die portion is adapted to selectively vibrate to free a
casted automotive component within the modular casting mold from
the modular casting mold.
7. The modular casting mold of claim 1, wherein the at least one
active die portion includes mechanical features adapted to push a
casted automotive component from the modular casting mold.
8. A modular casting mold assembly for casting an automotive
component, comprising: a plurality of modular casting molds adapted
to be modularly connected to one another, each of the plurality of
modular casting molds including: a plurality of die portions
defining a modular mold cavity corresponding to a portion of the
automotive component, modular mold cavities of the plurality of
modular casting molds being in fluid communication with one another
when the plurality of modular casting molds are connected to define
a mold cavity corresponding to the automotive component; and the
plurality of die portions of each of the plurality of modular
casting molds including at least one active die portion adapted to
individually control the temperature of each of the plurality of
modular casting molds throughout a casting process and including
features for ejecting the automotive component cast within the
modular casting mold.
9. The modular casting mold assembly of claim 8, wherein the at
least one active die portion includes burners for heating the
active die portion and the modular casting mold assembly.
10. The modular casting mold assembly of claim 8, wherein the at
least one active die portion includes cooling jets for cooling a
casted automotive component within the modular casting mold
assembly.
11. The modular casting mold assembly of claim 8, wherein the at
least one active die portion includes air jets for injecting
pressurized air between an inner surface of the at least one active
die portion and a casted automotive component within the modular
casting mold assembly to free the casted automotive component from
the modular casting mold assembly.
12. The modular casting mold assembly of claim 8, wherein the at
least one active die portion includes jets for injecting
pressurized fluid between an inner surface of the active die
portion and a casted automotive component within the modular
casting mold assembly to free the casted automotive component from
the modular casting mold assembly.
13. The modular casting mold assembly of claim 8, wherein the at
least one active die portion is adapted to selectively vibrate to
free a casted automotive component from the modular casting mold
assembly.
14. The modular casting mold assembly of claim 8, wherein the at
least one active die portion includes mechanical features adapted
to push a casted automotive component from the modular casting mold
assembly.
15. A method of forming an automotive component, comprising:
assembling a plurality of modular casting molds, each of the
plurality of modular casting molds including a plurality of die
portions defining a modular mold cavity corresponding to a portion
of the automotive component, modular mold cavities of the plurality
of modular casting molds being in fluid communication with one
another when the plurality of modular casting molds are connected
to define a mold cavity corresponding to the automotive component;
pre-heating the modular casting mold assembly by actuating burners
included within at least one active die portion of each of the
plurality of modular casting molds; filling the mold cavity with
molten material; de-activating the burners included within the at
least one active die portion of each of the plurality of modular
casting molds; cooling the modular casting mold assembly and the
molten material within the mold cavity by actuating cooling jets
included within the at least one active die portion of each of the
plurality of modular casting molds to solidify the molten material
within the mold cavity; de-activating the cooling jets included
within the at least one active die portion of each of the plurality
of modular casting molds; opening the modular casting mold
assembly; and ejecting the automotive component from the plurality
of modular casting molds.
16. The method of claim 15, wherein ejecting the automotive
component from the plurality of modular casting molds includes
actuating air jets included within the at least one active die
portion of each of the plurality of modular casting molds and
injecting pressurized air between the at least one active die
portion of each of the plurality of modular casting molds and the
casted automotive component.
17. The method of claim 15, wherein ejecting the automotive
component from the plurality of modular casting molds includes
actuating jets included within the at least one active die portion
of each of the plurality of modular casting molds and injecting
pressurized fluid between the at least one active die portion of
each of the plurality of modular casting molds and the automotive
component.
18. The method of claim 15, wherein ejecting the automotive
component from the plurality of modular casting molds includes
vibrating the at least one active die portions of each of the
plurality of modular casting molds.
19. The method of claim 15, wherein ejecting the automotive
component from the plurality of modular casting molds includes
actuating mechanical features within the at least one active die
portion of each of the plurality of modular casting molds.
20. The method of claim 15, wherein opening the modular casting
mold assembly and ejecting the automotive component from the
plurality of modular casting molds includes one of: opening each of
the plurality of modular casting molds and ejecting the automotive
component from each of the plurality of modular casting molds
simultaneously, and sequentially opening each of the plurality of
modular casting molds and ejecting the automotive component from
each of the plurality of modular casting molds, one at a time.
Description
INTRODUCTION
[0001] The present disclosure relates generally to manufacturing an
automotive component, and more particularly to a modular casting
mold and method thereof for casting large automotive
components.
[0002] Conventional die casting, also known as high-pressure die
casting (HPDC), is a commonly used metal casting process. Die
casting typically includes forcing or injecting molten metal under
high pressure into a mold cavity. The mold cavity is formed using
two or more die portions which have been machined into a shape of
the desired casting cavity. Depending on the type of metal material
being used, a hot or cold chamber die casting machine may be used,
as well as squeeze casting methods, in addition to over-molding,
where alloy is casted over/around existing substrates in order to
achieve higher structural properties of an end product. One die
portion is called a "cover die portion" and the other die portion
an "ejector die portion", and where they meet "the parting line".
Conventionally, the cover die portion includes an attached shot
sleeve cylinder that is gravity filled and in a second metal
transport, a plunger injects the molten metal at great velocity
into the casting cavity formed by the cover and ejector die. The
two-step metal flow process and high velocities needed to reduce
temperature loss during injection can cause damage to the metal
that weakens the final casting.
[0003] When the casting has sufficiently cooled and acquired the
strength to be handled, the ejector die is withdrawn from the cover
die bringing the casting with it. The ejector die portion typically
includes ejector pins and/or a plate to push the casting out of the
ejector die. These ejector pins are attached to a movable platen of
the casting machine.
[0004] High pressure die casting is a cyclic process were the
molten metal loses heat to the colder mold as it is injected and
solidified. Controlled coolant flow is used to control the
temperature distribution across the mold body and the range of the
temperature highs and lows. A high mold temperature reduces metal
filling temperature loses that may hinder filling out cavity
features. A cool mold temperature reduces solidification time of
the casting and increases casting production rate of the machine.
Thermal management of these two conflicting goals is challenging
with the large thermal inertia of a typical automotive HPDC
die.
[0005] Typically, in the context of automotive component
manufacturing and the die casting process, multiple die casting
machines are each used to cast different automotive components. For
example, a single die casting machine cell in a factory may be
dedicated to casting a single automotive component. These
components from each casting machine are then assembled or secured
together by factory workers or robotic systems to form or partially
form a more complicated automotive component, such as the
automotive chassis or frame.
[0006] Die casting generally involves higher capital costs, long
lead times and limited supply base relative to other casting and
manufacturing processes. Generally, larger automotive components
are made in multiple pieces, and then assembled later. Die molds
large enough to make such components in a single piece are
expensive, have the complexity of multiple pull components, are
difficult to achieve a uniform temperature, too large and heavy to
transport efficiently, and are dedicated to a single component,
thus multiple large dies molds must be kept on hand, adding
tremendous expense. Further, current high pressure die casting
molds and processes depend on great injection pressures, and low
vacuum levels to achieve required filling and solidification
rates.
[0007] Thus there is a need for an improved modular die casting
mold and associated methods thereof, particularly as related to
casting large automotive components, that use low velocity filling,
low pressures, active thermal management and low thermal inertia
modular thin walled mold construction.
SUMMARY
[0008] According to several aspects of the present disclosure, a
modular casting mold for casting an automotive component includes a
plurality of die portions defining a mold cavity corresponding to
an automotive component, at least one of the plurality of die
portions being an active die portion adapted to control the
temperature of the modular casting mold throughout the casting
process and including features for ejecting an automotive component
cast within the modular casting mold, and the modular casting mold
adapted to be attached to another modular casting mold for casting
a single automotive component.
[0009] According to another aspect, each active die portion
includes burners for heating the active die portion.
[0010] According to another aspect, each active die portion
includes cooling jets for cooling a casted component within the
modular casting mold.
[0011] According to another aspect, each active die portion
includes air jets for injecting air between an inner surface of the
active die portion and a casted automotive component within the
modular casting mold to free the casted automotive component from
the modular casting mold.
[0012] According to another aspect, each active die portion
includes jets for injecting pressurized fluid between an inner
surface of the active die portion and a casted automotive component
within the modular casting mold to free the casted automotive
component from the modular casting mold.
[0013] According to another aspect, each active die portion is
adapted to selectively vibrate to free the casted automotive
component from the modular casting mold.
[0014] According to another aspect, each active die portion
includes mechanical features adapted to push the casted automotive
component from the modular casting mold.
[0015] According to several aspects of the present disclosure, a
modular casting mold assembly for casting an automotive component
includes a plurality of modular casting molds adapted to be
modularly connected to one another, each of the plurality of
modular casting molds including a plurality of die portions
defining a mold cavity corresponding to a portion of the automotive
component, the mold cavities of the plurality of modular casting
molds being in fluid communication with one another when the
plurality of modular casting molds are connected to define a mold
cavity corresponding to the automotive component, and at least one
of the plurality of each of the plurality of modular casting molds
being an active die portion adapted to individually control the
temperature of each of the plurality of modular casting molds
throughout a casting process and including features for ejecting
the automotive component cast within the modular casting mold.
[0016] According to another aspect, each active die portion
includes burners for heating the active die portion and the
plurality of modular casting molds.
[0017] According to another aspect, each active die portion
includes cooling jets for cooling a casted automotive component
within the modular casting mold assembly.
[0018] According to another aspect, each active die portion
includes air jets for injecting pressurized air between an inner
surface of the active die portion and the casted automotive
component within the modular casting mold assembly to free the
casted automotive component from the modular casting mold
assembly.
[0019] According to another aspect, each of the active die portions
includes jets for injecting pressurized fluid between an inner
surface of the active die portion and the casted automotive
component within the modular casting mold assembly to free the
casted automotive component from the modular casting mold
assembly.
[0020] According to another aspect, each of the plurality of active
die portions is adapted to selectively vibrate to free the casted
automotive component from the modular casting mold assembly.
[0021] According to another aspect, each of the active die portions
includes mechanical features adapted to push the casted automotive
component from the at least one ejector die portion of the modular
casting mold.
[0022] According to several aspects of the present disclosure, a
method of forming an automotive component includes assembling a
plurality of modular casting molds, each of the plurality of
modular casting molds including a plurality of die portions
defining a mold cavity corresponding to a portion of the automotive
component, the mold cavities of the plurality of modular casting
molds being in fluid communication with one another when the
plurality of modular casting molds are connected to define a mold
cavity corresponding to the automotive component, pre-heating the
modular casting mold assembly by actuating burners included within
at least one active die portion of each of the plurality of modular
casting molds, filling the mold cavity with molten material,
de-activating the burners included within the active die portions,
cooling the modular casting mold assembly and the molten material
within the mold cavity by actuating cooling jets included within
the active die portions of each of the plurality of modular casting
molds to solidify the molten material within the mold cavity,
de-activating the cooling jets included within the active die
portions, opening the modular casting mold assembly, and ejecting
the casted automotive component from the plurality of modular
casting molds.
[0023] According to another aspect, ejecting the casted automotive
component from the plurality of modular casting molds includes
actuating air jets included within the active die portions and
injecting pressurized air between the active die portions and the
casted automotive component.
[0024] According to another aspect, ejecting the casted automotive
component from the plurality of modular casting molds includes
actuating jets included within the active die portions and
injecting pressurized fluid between the active die portions and the
casted automotive component.
[0025] According to another aspect, ejecting the casted automotive
component from the plurality of modular casting molds includes
vibrating each of the active die portions.
[0026] According to another aspect, ejecting the casted automotive
component from the plurality of modular casting molds includes
actuating mechanical features within each of the active die
portions.
[0027] According to another aspect, opening the modular casting
mold assembly and ejecting the casted automotive component from the
plurality of modular casting molds includes one of opening each of
the plurality of modular casting molds and ejecting the casted
automotive component from each of the plurality of modular casting
molds simultaneously, and sequentially opening each of the
plurality of modular casting molds and ejecting the casted
automotive component from each of the plurality of modular casting
molds, one at a time.
[0028] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0030] FIG. 1 is a perspective exploded view of a modular casting
mold according to an exemplary embodiment of the present
disclosure;
[0031] FIG. 2 is a perspective view of a modular casting mold
according to another exemplary embodiment of the present
disclosure;
[0032] FIG. 3 is a sectional view of FIG. 2, taken along line
3-3;
[0033] FIG. 4 is an exploded perspective view of a modular casting
mold assembly according to an exemplary embodiment of the present
disclosure; and
[0034] FIG. 5 is a flow chart illustrating a method incorporating
the modular casting mold and modular casting mold assembly of the
present disclosure.
DETAILED DESCRIPTION
[0035] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses.
[0036] Referring to FIG. 1, a modular casting mold 10 for casting
an automotive component includes a plurality of die portions 12.
The plurality of die portions 12 define a mold cavity 16, shown in
FIG. 4, corresponding to an automotive component 13. As shown in
FIG. 1, in an exemplary embodiment, an exploded view of the modular
casting mold 10 includes ten die portions 12. One of the die
portions 12 includes an inlet 18 configured to allow molten
material to flow into the mold cavity 16 from a source of molten
material 19.
[0037] Referring to FIG. 2 and FIG. 4, in another exemplary
embodiment, the modular casting mold 10' includes two die portions
12' that define a mold cavity 16'. Referring to FIG. 1 and FIG. 4,
at least one of the die portions 12' is an active die portion 14,
14'. The active die portion 14, 14' is adapted to control the
temperature of the modular casting mold 10, 10' throughout the
casting process. Active thermal management of the modular casting
mold 10, 10' allows the molten material injected into the mold to
completely fill the mold cavity 16 under low pressure, and high
cooling rates reduces the solidification time. The active die
portion 14 further includes features for ejecting an automotive
component 13 cast within the modular casting mold 10, 10'.
[0038] The ability to fill the mold cavity 16 with molten material
under low pressure allows the modular casting mold 10, 10' to be
adapted to be attached to another modular casting mold 10, 10' for
casting a single automotive component 13. It is to be understood
that a modular casting mold 10, 10' of the present disclosure
includes at least one active die portion 14, 14'. More than one
active die portion 14, 14' may be present, or, all of the die
portions 12, 12' can be active die portions 14, 14'. The modular
casting mold 10, 10', as shown in FIG. 2 and FIG. 3, includes a
frame 20 that supports the active die portion 14, 14' and
accompanying elements thereon.
[0039] In an exemplary embodiment, each active die portion 14, 14'
includes burners 22 for heating the active die portion 13. The
burners 22 may use direct flame, or radiant heat to heat up the
active die portion 14, 14', and the die portions 12, and to
actively control the temperature of the modular casting mold 10,
10' during filling of the mold cavity 16.
[0040] In another exemplary embodiment, each active die portion 14,
14' includes cooling jets 24 for cooling a casted component within
the modular casting mold 10, 10'. The cooling jets 24 are adapted
to cool the molten material within the mold cavity 16 to solidify
the automotive component being cast therein. The cooling jets 24
are controllable to allow active control of the cooling of the
molten material to accommodate casting solidification contraction
and mold to mold interferences when the modular casting mold 10,
10' is attached to another modular casting mold 10, 10'.
[0041] In another exemplary embodiment, each active die portion 14,
14' includes air jets 26 for injecting air between an inner surface
28 of the active die portion 14, 14' and a casted automotive
component within the modular casting mold 10, 10'. The air jets 26
are adapted to pressurize the air in the frame 20. Vent plugs
placed in the active die portion 14' allow the pressured air to act
on the solidified cast automotive component 13 and free the casted
automotive component 13 from the modular casting mold 10, 10'.
[0042] In another exemplary embodiment, each active die portion 14,
14' includes jets 30 for injecting pressurized fluid between the
inner surface 28 of the active die portion 13 and the casted
automotive component within the modular casting mold 10, 10'. The
pressurized fluid may be water or lubricant, or a combination of
the two, and may be directed to targeted, high contact pressure
surfaces between the casted automotive component and the mold
cavity 16 to free the casted automotive component from the modular
casting mold 10, 10'.
[0043] In another exemplary embodiment, each active die portion 14,
14' is adapted to selectively vibrate to free the casted automotive
component from the modular casting mold 10.
[0044] In another exemplary embodiment, each active die portion 14,
14' includes mechanical features adapted to push the casted
automotive component from the modular casting mold 10. The
mechanical features may be ejector pins, or a moveable plate
adapted to selectively push the casted automotive component.
[0045] Referring to FIG. 4, the modular casting mold 10 is adapted
to be attached to other modular casting molds 10 to create a single
casted automotive component. A modular casting mold assembly 40 for
casting an automotive component 42 includes a plurality of modular
casting molds 10A, 10B, 10C adapted to be modularly connected to
one another. In the exemplary embodiment shown in FIG. 4, the
modular casting mold assembly 40 includes a first modular casting
mold 10A, a second modular casting mold 10B and a third modular
casting mold 100.
[0046] Each of the first, second and third modular casting molds
10A, 10B, 100 includes a plurality of die portions 12A, 12B, 12C,
12D, 12E, 12F defining first, second and third mold cavities 16A,
16B, 16C respectively. Each of the first, second and third mold
cavities 16A, 16B, 16C corresponds to a portion of the automotive
component 42. The first, second and third mold cavities 16A, 16B,
16C of the first, second and third modular casting molds 10A, 10B,
100 are in fluid communication with one another when the first,
second and third modular casting molds 10A, 10B, 10C are connected
to define a single mold cavity 16ABC corresponding to the
automotive component 42. Each of the first, second and third
modular casting molds 10A, 10B, 10C of the modular casting mold
assembly 40 includes features substantially identical to the
modular casting mold 10 shown in FIG. 3.
[0047] At least one of the die portions 12A, 12B, 12C, 12D, 12E,
12F of each of the first, second and third modular casting molds
10A, 10B, 10C is an active die portion 14A, 14B, 14C that is
adapted to individually control the temperature of each of the
first, second and third modular casting molds 10A, 10B, 100
throughout a casting process and includes features for ejecting the
automotive component 42 cast within the modular casting mold
assembly 40.
[0048] Referring again to FIG. 4 for reference, in an exemplary
embodiment, each of the active die portions 14A, 14B, 14C include
burners 22 for heating the die portions 12A, 12B, 12C, 12D, 12E,
12F and the active die portions 14A, 14B, 14C of each of the first,
second and third modular casting molds 10A, 10B, 10C. The burners
22 may use direct flame, or radiant heat to heat up the active die
portions 14A, 14B, 14C and the die portions 12A, 12B, 12C, 12D,
12E, 12F and to actively control the temperature of the active die
portions 14A, 14B, 14C and the die portions 12A, 12B, 12C, 12D,
12E, 12F during the filling of the mold cavity 16ABC.
[0049] In another exemplary embodiment, each active die portion
14A, 14B, 14C includes cooling jets 24 for cooling the casted
automotive component 42 within the modular casting mold assembly
40. The cooling jets 24 are adapted to cool the molten material
within the mold cavity 16ABC to solidify the automotive component
42 being cast therein. The cooling jets 24 are controllable to
allow active control of the cooling of the molten material to
accommodate casting solidification contraction and mold to mold
interferences between the first, second and third modular casting
molds 10A, 10B, 100.
[0050] In another exemplary embodiment, each active die portion
14A, 14B, 14C includes air jets 26 for injecting air between the
inner surface 28 of the active die portion 14A, 14B, 14C and the
casted automotive component 42 within the modular casting mold
assembly 40. The air jets 26 are adapted to pressurize the air
injected between the inner surfaces 28 of the active die portion
14A, 14B, 14C and the casted automotive component 42 within the
modular casting mold assembly 40 to free the casted automotive
component 42 from the first, second and third modular casting molds
10A, 10B, 100.
[0051] In another exemplary embodiment, each active die portion
14A, 14B, 14C includes jets 30 for injecting pressurized fluid
between the inner surfaces 28 of the active die portion 14A, 14B,
14C and the casted automotive component 42 within the modular
casting mold assembly 40. The pressurized fluid may be water or
lubricant, ora combination of the two, and may be directed to
targeted, high contact pressure surfaces between the casted
automotive component 42 and the mold cavity 16ABC to free the
casted automotive component 42 from the modular casting mold
assembly 40.
[0052] In another exemplary embodiment, each active die portion
14A, 14B, 14C is adapted to selectively vibrate to free the casted
automotive component 42 from the modular casting mold assembly
40.
[0053] In another exemplary embodiment, each active die portion
14A, 14B, 14C includes mechanical features adapted to push the
casted automotive component 42 from the modular casting mold
assembly 40. The mechanical features may be ejector pins, or a
moveable plate adapted to selectively push the casted automotive
component
[0054] Referring to FIG. 5, a method 110 of forming an automotive
component incorporating the modular casting mold 10 and modular
casting mold assembly 40 of the present disclosure includes, moving
to block 112, assembling a plurality of modular casting molds 10A,
10B, 100 each of the plurality of modular casting molds 10A, 10B,
100 including a plurality of die portions 12A, 12B, 12C, 12D, 12E,
12F defining a mold cavity 16A, 16B, 16C corresponding to a portion
of the automotive component 42, the mold cavities 16A, 16B, 16C of
the plurality of modular casting molds 10A, 10B, 100 being in fluid
communication with one another when the plurality of modular
casting molds 10A, 10B, 100 are connected to define a mold cavity
16ABC corresponding to the automotive component 42.
[0055] Moving on to block 114, after the modular casting mold
assembly 40 is assembled, the method includes heating the modular
casting mold assembly 40 by actuating burners 22 included within
active die portions 14A, 14B, 14C of each of the plurality of
modular casting molds 10A, 10B, 10C.
[0056] Moving on to block 116, the mold cavity 16ABC is filled with
molten material. The material may be any suitable material
depending on the automotive component 42 that is being cast. In an
exemplary embodiment, the mold cavity is filled with molten
aluminum or magnesium. In a variation of this embodiment, the
entire modular casting mold assembly 40 may be placed within a
furnace to provide added ability to heat and control the
temperature of the modular casting mold assembly 40 before and
during filling of the mold cavity 16ABC.
[0057] Moving on to block 118, once the mold cavity is filled, the
burners 22 within the active die portions 14A, 14B, 14C are
de-activated. Moving on to block 120, the modular casting mold
assembly 40 and the molten material within the mold cavity 16ABC is
cooled by actuating cooling jets 24 included within active die
portions 14A, 14B, 14C of each of the plurality of modular casting
molds 10A, 10B, 10C. Cooling the modular casting molds 10A, 10B,
100 and the molten material helps to solidify the molten material
within the mold cavity 16ABC. By actively controlling the
temperature of the modular casting molds 10A, 10B, 100, both when
heating and cooling, casting solidification contraction and mold to
mold interferences between the modular casting molds 10A, 10B, 100
is accounted for.
[0058] Moving to block 122, the cooling jets 22 are deactivated.
Moving to block 124, the modular casting mold assembly 40 is
opened, and at block 126, the casted automotive component 42 is
ejected from the modular casting molds 10A, 10B, 100.
[0059] In an exemplary embodiment, ejecting the casted automotive
component 42 from the modular casting molds 10A, 10B, 100, shown at
block 126, includes actuating air jets 26 included within the
active die portions 14A, 14B, 14C and injecting pressurized air
between the active die portions 14A, 14B, 14C and the casted
automotive component 42.
[0060] In another exemplary embodiment, ejecting the casted
automotive component 42 from the modular casting molds 10A, 10B,
100, shown at block 126, includes actuating jets 30 included within
the active die portions 14A, 14B, 14C and injecting pressurized
fluid between the active die portions 14A, 14B, 14C and the casted
automotive component 42.
[0061] In another exemplary embodiment, ejecting the casted
automotive component 42 from the modular casting molds 10A, 10B,
100, shown at block 126, includes vibrating each of the active die
portions 14A, 14B, 14C.
[0062] In still another exemplary embodiment, ejecting the casted
automotive component 42 from the modular casting molds 10A, 10B,
100, shown at block 126, includes actuating mechanical features
within each active die portion 14A, 14B, 14C.
[0063] In one exemplary embodiment, opening the modular casting
mold assembly 40 and ejecting the casted automotive component 42
from the modular casting molds 10A, 10B, 100, shown at blocks 124
and 126, includes opening each of the plurality of modular casting
molds 10A, 10B, 100 and ejecting the casted automotive component 42
from the modular casting molds 10A, 10B, 10C simultaneously.
Alternatively, opening the modular casting mold assembly 40 and
ejecting the casted automotive component 42 from the modular
casting molds 10A, 10B, 100, shown at blocks 124 and 126, includes
sequentially opening each of the plurality of modular casting molds
10A, 10B, 100 and ejecting the casted automotive component 42 from
the modular casting molds 10A, 10B, 100, one at a time.
[0064] The modular casting mold assembly 40 and associated method
110 of the present disclosure offers the advantage of producing
relatively large cast automotive components at reduced cycle times
and reduces overall mass and cost. Actively managing the
temperature of the modular casting mold assembly 40 allows the
molten material injected therein to remain liquified long enough to
flow throughout the mold cavity 16ABC. This in turn, allows the
molten material used for the cast component to be injected at low
pressure, rather than being injected at high pressures and
velocities. Because the molten material is injected at low
pressures it is possible to use a modular design that allows
smaller individual molds 10 to be assembled modularly to create
larger parts. In high pressure applications, the structure needed
to keep modular parts assembled correctly during casting would be
prohibitive. At low pressures, modular molds can be fastened
together with lower risk of distortion or molds becoming detached,
as with high pressure methods. Using modular molds allows different
molds to be used for different components, saving overall tooling
costs and storage. Finally, the end result is a single casted
component that is stronger, cheaper and weighs less than a similar
component, made piecemeal and attached together. Bolting or welding
individual components together adds mass to the final product, and
junctures between attached components may result in stress
concentrations or weakness resulting in potential failure.
[0065] A thin walled modular casting mold design enables the
construction of complex cavity geometries while still allowing for
the mold piece removal from the casting surface including, most
notably, the interior casting surfaces. Low pressure or gravity
pour filling of casting cavity is used in conjunction with back
wall applied mold heating for fluidity length and containment
requirements of cavity. Back wall applied coolant time and
intensity profile can be specified for casting porosity, material
property and cycle time requirements. Casting release from
individual mold pieces is aided by applied gas pressure, lubricant
and mold vibration.
[0066] The description of the present disclosure is merely
exemplary in nature and variations that do not depart from the gist
of the present disclosure are intended to be within the scope of
the present disclosure. Such variations are not to be regarded as a
departure from the spirit and scope of the present disclosure.
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