Patent Application
20180345358
The present disclosure relates to a molding machine for forming a mold by squeezing molding sand filled in a molding flask.
Conventionally, there is publicly known a molding machine for foaming a mold by filling a molding flask with molding sand by aeration and squeezing the filled molding sand (e.g., refer to Japanese Unexamined Patent Publication No. 2002-1491).
The molding machine described in Patent Document 1 includes a portion that wears in accordance with a period of use and a frequency of use. The worn portion may affect quality of a mold or a cast product. In this technical field, there is desired a molding machine for forming an excellent mold.
A molding machine according to an aspect of the present invention font's a mold by using a transferred molding flask and pattern plate, and comprises: a filling frame provided with a lower opening connectable to an upper opening of the molding flask and a side portion opened; a squeeze head mechanism including a squeeze board movable into and out from the filling frame, and a plurality of squeeze feet passing through the squeeze board, being able to move up and down with respect to the squeeze board; a sand injection hopper including at least one sand injection port for injecting molding sand into a molding space defined by the molding flask, the filling frame, the squeeze head mechanism, and the pattern plate; and a sand injection nozzle provided in a component detachably attached to an opening of the side portion of the filling frame to enable the sand injection port and the molding space to communicate with each other.
According to the molding machine according to the aspect of the present invention, even when the sand injection nozzle wears, only the component provided with the sand injection nozzle can be exchanged. Thus, the molding machine is excellent in maintenance and availability.
A molding machine according to another aspect of the present invention forms a mold by using a transferred molding flask and pattern plate, and comprises: a filling frame provided with a lower opening connectable to an upper opening of the molding flask; an injection frame disposed above the filling frame, being provided with a lower opening connectable to an upper opening of the filling fame; a squeeze head mechanism including a squeeze board movable into and out from the injection frame, and a plurality of squeeze feet passing through the squeeze board, being able to move up and down with respect to the squeeze board; a sand injection hopper including at least one sand injection port for injecting molding sand into a molding space defined by the molding flask, the filling frame, the injection frame, the squeeze head mechanism, and the pattern plate; and a sand injection nozzle provided in a side portion of the injection frame to enable the sand injection port and the molding space to communicate with each other.
According to the molding machine according to the other aspect of the present invention, even when the sand injection nozzle wears, only the filling frame provided with the sand injection nozzle can be exchanged. Thus, the molding machine is excellent in maintenance and availability.
In an embodiment, the molding machine may comprise a frame defining a part of the molding space and surrounding an outer periphery of the pattern plate to be slid up and down, and a liner detachably formed in an inner portion of the frame. In this case, the liner disposed between the frame and the pattern plate can reduce abrasion of the frame and the pattern plate.
In an embodiment, the liner may have an upper end surface and an inward surface, made of urethane rubber. In this case, the abrasion can be further reduced.
In an embodiment, the urethane rubber may have a heat-resistant temperature of 70 to 90° C. In addition, in an embodiment, the urethane rubber also may have a heat-resistant temperature of 110 to 130° C.
According to various aspects of the present invention, it is possible to provide a molding machine for forming an excellent mold.
Hereinafter, a molding machine according to each of the present embodiments will be described with reference to drawings.
As illustrated in
The pattern changer 5 transfers a pattern plate 8. The pattern changer 5 includes a plurality of support units (not illustrated) such as a main shaft, a turn table 7, and pattern carriers 6 and 6A. The turn table 7 is rotatably supported by the main shaft in a horizontal plane to alternately transfer the pattern carriers 6 and 6A to and from above a central portion of the molding base board 3. The turn table 7 is rotated by an actuator (not illustrated). The actuator is a hydraulic cylinder or the like, for example. The plurality of support units is mounted in a mounting portion of each of the pattern carriers 6 and 6A in the turn table 7.
The pattern carrier 6 includes a frame 9, a plurality of guide pins 10, a body frame 11, and an urging unit (not illustrated). The frame 9 slides up and down while surrounding an outer periphery of the pattern plate 8. The plurality of guide pins 10 is coupled to a lower portion of the frame 9. The guide pins 10 are vertically slidably inserted into the body frame 11, and the pattern plate 8 is mounted on an upper surface of the body frame 11. The urging unit has opposite ends each hooked to the frame 9 and the body frame 11, and applies urging force in a direction lowering the frame 9. The urging unit is a plurality of tension coil springs, for example. The pattern carrier 6A has the same structure as that of the pattern carrier 6.
On the central portion of the molding base board 3, a hydraulic cylinder (oil-absorbing cylinder) 14 is provided. The hydraulic cylinder 14 includes a piston rod provided at its upper end with an engaging head 13. The engaging head 13 is fitted into an engaging groove 12 provided in a central portion at lower end of each of the pattern carriers 6 and 6A. In addition, a plurality of lifting cylinders 15 is provided on the molding base board 3, below the corresponding plurality of guide pins 10. Each of the lifting cylinders 15 moves up and down the frame 9 with the guide pin 10. The lifting cylinder 15 includes a piston rod including an upper end to which a rod head 16 is coupled.
When the lifting cylinder 15 extends to its extension end, the frame 9 projects such that its upper surface is slightly (e.g., 30 mm) above a parting surface of the pattern plate 8 (refer to
A lifting support frame 17 is provided between upper ends of piston rods 4A of the respective flask setting cylinders 4 and 4. To the lifting support frame 17, a plurality of sand injection hopper lifting cylinders 18 is attached. Each of the sand injection hopper lifting cylinders 18 includes a piston rod including a leading end coupled to a sand injection hopper 19.
The sand injection hopper 19 is provided at its upper end with a sand supply port 21 that is opened and closed by a slide gate 20. The sand injection hopper 19 has an upper portion with which an air supply pipe 23 communicates, the air supply pipe 23 allowing low-pressure air (e.g., 0.05 to 0.18 MPa) to be guided through an on-off valve 22. The sand injection hopper 19 has a lower portion formed of forked chutes 24. Each of the chutes 24 has an inner surface provided with a plurality of air injection chambers 25 and 25 communicating with a compressed air source (not illustrated) through an on-off valve (not illustrated).
The plurality of air injection chambers 25 and 25 is configured to form aeration for floating and fluidizing molding sand S by injecting low-pressure air (e.g., 0.05 to 0.18 MPa) into the sand injection hopper 19. Each of the chutes 24 in the sand injection hopper 19 has a lowermost portion provided with a sand injection port 26.
Each of the chutes 24 has a lower portion inside which a filling frame 27 is provided while being fixed. The filling frame 27 includes a lower opening 27c connectable to an upper opening 33a of a molding flask 33. The filling frame 27 has a lower portion (side portion) provided with a sand injection nozzle 28. The sand injection nozzle 28 has one end communicating with the sand injection port 26, and the other end communicating with a molding space described below. The filling frame 27 is provided in its inside with a squeeze head mechanism 29. The squeeze head mechanism 29 includes a squeeze board 30 being able to be moved into and out from the filling frame 27, and a plurality of squeeze feet 31. The plurality of squeeze feet 31 is formed by a segment method, and is attached by passing through the squeeze board 30 to enable control of moving up and down of the squeeze board 30. The squeeze board 30 has an upper end fixed to a lower end of the lifting support frame 17. The filling frame 27 described above surrounds an outer periphery of the squeeze head mechanism 29 in a vertically movable manner. The squeeze head mechanism 29 is surrounded by the sand injection hopper 19. The squeeze head mechanism 29 is surrounded by the sand injection hopper 19 from at least two directions.
The lifting support frame 17 includes a transfer frame 32 extending to a position below the squeeze head mechanism 29, and a transfer conveyor 34 of the molding flask 33, being hung from the transfer frame 32. The transfer conveyor 34 transfers the molding flask 33.
As described above, the squeeze head mechanism 29 is configured to be supported by the two flask setting cylinders 4 and 4 so that the squeeze head mechanism 29 descends to perform a flask setting step and a squeezing step.
Then, operation of the molding machine 100 configured as described above will be described. The state of
In the state illustrated in
In a molding machine in which a flask is set upward from the bottom, the pattern carrier 6 is lifted by a table when a flask setting step is started. When a deceleration step is provided in a lifting step to prevent an impact from occurring, a cycle time may increase. Meanwhile, in the molding machine 100 of the present embodiment, the pattern carrier 6 is pressed on the fixed stopper 2 by the hydraulic cylinder 14 when a flask setting step is started, and at the same time, flask setting operation from above can be overlapped. This enables a cycle time to be reduced by time required for the deceleration step, as compared with a conventional molding machine in which a frame is set upward from the bottom, because there is not a deceleration step when the flask setting step is started.
After the sand supply port 21 is closed by operating the slide gate 20, the flask setting cylinders 4 and 4 is operated to contract. This causes the molding flask 33 to be mounted on the upper surface of the frame 9 projecting upward around the outer periphery of the pattern plate 8. Then, each of the sand injection hopper lifting cylinders 18 is operated to extend. This causes the sand injection hopper 19 and the filling frame 27 to descend, so that the filling frame 27 is pressed on and brought into close contact with an upper surface of the molding flask 33. In addition, each of the squeeze feet 31 is operated. Then, projections and depressions are formed respectively corresponding to projections and depressions of the pattern plate 8 below the molding flask 33, so that the state illustrated in
Subsequently, a sand injection is performed by using aeration.
Subsequently, the flask setting cylinders 4 and 4 are operated to further contract. This causes the sand injection hopper lifting cylinders 18 to contract. The flask setting cylinders 4 and 4 cause the lifting support frame 17 and components supported thereby (e.g., the squeeze head mechanism 29, the transfer frame 32, the transfer conveyor 34, and the like) to descend. As described above, a first squeeze of the molding sand S is performed until all of lower surfaces of the squeeze feet 31 become flat, so that the state illustrated in
Subsequently, the lifting cylinders 15 each are switched to a state where operation fluid is relieved. Then, the flask setting cylinders 4 and 4 each are operated to contract by a pressure higher than that in the first squeeze. This causes the molding flask 33, the filling frame 27, the sand injection hopper 19, and the squeeze head mechanism 29 to integrally descend to apply a second squeeze to the entire molding sand S.
Subsequently, when the squeeze pressure reaches the set pressure of the second squeeze, a squeeze stability timer is operated to maintain squeeze for a predetermined time. At the time, to respond to when the frame 9 does not reach the descending end, the sand injection hopper lifting cylinders 18 are operated to extend to cause the filling frame 27 to descend so that the molding flask 33 is pressed down until the frame 9 reaches the descending end. This enables the lower surface of the molding flask 33 and a lower surface of a mold to be almost flush with each other every time.
Subsequently, while the lifting cylinders 15 are operated to extend to cause the molding flask 33 to be pressed on the filling frame 27 with the guide pins 10 and the frame 9, the flask setting cylinders 4 and 4 are reversely operated to remove a mold. In the meantime, the molding flask 33, the filling frame 27, the sand injection hopper 19, and the squeeze head mechanism 29 integrally rise. After that, the molding flask 33 including formed a mold is removed and supported with the guide pins 10 and the frame 9 by operation of the lifting cylinders 15. Then, each of the filling frame 27, the sand injection hopper 19, and the squeeze head mechanism 29 rises. In midway through rising, the molding flask 33 including formed a mold is picked up by the transfer conveyor 34 to be completely separated from the pattern plate 8. In the meantime, the filling frame 27 and the sand injection hopper 19 rise by using contract operation of the sand injection hopper lifting cylinders 18. After the slide gate 20 is reversely operated to open the sand supply port 21, molding sand S is supplied into the sand injection hopper 19 to achieve the state of
Subsequently, the lifting cylinders 15 are operated to contract to cause the guide pins 10 and the frame 9 to descend. In the meantime, the plurality of tension coil springs (not illustrated) applies urging force in a direction in which the frame 9 descends, so that the frame 9 can reliably descend to its descending end. Subsequently, the hydraulic cylinder 14 is operated to extend to raise the engaging head 13, so that the compression spring (not illustrated) in the support unit (not illustrated) lifts the pattern carrier 6 by about 5 mm from the molding base board 3 to release pressing of the molding base board 3 to the fixed stopper 2.
Subsequently, the molding flask 33 including formed a mold is transferred out with the transfer conveyor 34 and the molding flask 33 being empty is transferred in therewith. In addition, the pattern changer 5 is operated by the actuator (not illustrated), so that the pattern plate 8 and the pattern plate 8A are switched.
The above-described molding machine 100 includes the sand injection nozzle 28 communicating with the molding space, being formed in the filling frame 27, and allows molding sand to be injected from a lateral side of the molding space. This enables the molding machine 100 to use a layout of the squeeze feet 31 determined from a viewpoint of uniform compression as a whole without considering a placement of the sand injection nozzle 28. For example, the squeeze feet 31 can be disposed in the periphery of the molding flask 33 to enable more uniform mold strength throughout the squeeze board to be acquired. As a result, the molding machine 100 can form an excellent mold.
Subsequently, details of the sand injection nozzle 28 and the sand injection port 26 will be described.
The sand injection nozzle 28 is formed in the filling frame 27. The sand injection nozzle 28 is inclined to become lower from its inlet formed in an outer surface 27a of the filling frame 27 toward its outlet formed in an inner surface 27b thereof. This structure allows molding sand S to be injected from obliquely above with respect to the pattern plate 8. Thus, there is an advantage in that the molding sand S injected is less likely to collide with the squeeze feet 31 in which projections and depressions are respectively formed corresponding to projections and depressions of the pattern plate 8, thereby improving filling ability of molding sand S. To the inner surface of the filling frame 27, an exchangeable filling frame liner can be attached. As a material of the exchangeable filling frame liner, a material with high wear resistance, such as urethane (for example, VULKOLLAN® made by Maeda Shell Service Co., Ltd.), is available along with a material all of which is steel such as stainless steel. This enables wear prevention of the filling frame.
In addition, the sand injection nozzle 28 has a ceiling surface 28a with an inclination angle (30 degrees in the present embodiment) that is larger than an inclination angle (15 degrees in the present embodiment) of its bottom surface 28b. This structure provides an advantage in that crosswise squeezing force is less likely to be applied to molding sand S in the sand injection nozzle 28, so that the molding sand S in the sand injection nozzle 28 is further less likely to be compressed. There is also an advantage in that the molding sand S in the sand injection nozzle 28 is further less likely to fall.
The sand injection port 26 has an inclined bottom surface 26a. This structure provides an advantage in that molding sand S passing through the sand injection port 26 is liable to be guided into the sand injection nozzle 28. The bottom surface 26a has an inclination angle that is larger than an inclination angle of the bottom surface 28b of the sand injection nozzle 28, and that is defined as 30 degrees in the present embodiment.
In addition, a material of the bottom surface 26a of the sand injection port 26 is ultra-high molecular weight polyethylene (e.g., “Saxin New Right” made by Saxin Corp.). This structure provides an advantage in that adhesion of molding sand S to the bottom surface 26a is inhibited to enable the molding sand S to be prevented from being deposited. In the embodiment, a block component 35 formed by processing ultra-high molecular weight polyethylene material is provided in a lowermost portion of the chute 24 such that the bottom surface 26a is made of ultra-high molecular weight polyethylene. In the embodiment, the sand injection nozzle 28 is attached to a side surface of the filling frame, and is exchangeable. As a material of the sand injection nozzle 28, a resin all of which is high molecule polyethylene with high wear resistance, or the like, may be used, other than a material all of which is steel. In addition, a part of steel may be thermally sprayed with a wear-resistant material. These structures enable maintenance of molding and wear prevention of a nozzle.
In the molding machine 100 according to the embodiment, the filling frame 27 is fixed to the inside of the forked chutes 24. This structure causes the filling frame 27 to be lifted together with the sand injection hopper 19 by the sand injection hopper lifting cylinders 18, so that an actuator for directly lifting the filling frame 27 itself is unnecessary. This provides an advantage of reducing the number of actuators.
While the molding machine 100 according to the embodiment is configured to allow the pattern carrier 6 to include the frame 9 that slides up and down while surrounding the outer periphery of the pattern plate 8, the molding machine 100 is not limited to this. For example, the frame 9 may be omitted. As described in the above embodiment, when the pattern carrier 6 includes the frame 9 to define a molding space by the pattern plate 8 mounted on the pattern carrier 6, the frame 9, the molding flask 33, the filling frame 27, and the squeeze head mechanism 29, the above-described second squeeze (squeeze from a model surface side) becomes possible.
The frame 9 is not limited to that described in the above embodiment. Next, another embodiment of the frame will be described.
As illustrated in
The urethane rubber 39 may have a heat-resistant temperature of 70 to 90° C., for example. In the present embodiment, the urethane rubber 39 has a heat-resistant temperature of 80° C. When it is expected that the molding flask 33 has a temperature higher than a normal temperature, the urethane rubber 39 may have a heat-resistant temperature of 110 to 130° C. For example, the urethane rubber 39 has a heat-resistant temperature of 120° C. VULKOLLAN® made by Maeda Shell Service Co., Ltd. can be used as an example of the urethane rubber 39.
While the molding machine 100 according to the embodiment is configured to provide the block component 35 formed by processing ultra-high molecular weight polyethylene material in the lowermost portion of the chute 24, the molding machine 100 is not limited to this. For example, the air injection chambers 25 may be provided in place of the block component 35 so that the above-described low-pressure air is injected from the bottom surface 26a of the sand injection port 26.
In the molding machine 100 according to the embodiment, sand is injected by using low-pressure air to enable uniform sand filling. Sand filling by low-pressure air has a feature in which sand is injected at a low flow rate under pressure (e.g., 0.05 to 0.18 MPa) lower than that in sand filling (e.g., 0.2 to 0.5 MPa) by a blow method, thereby reducing wear of a model.
Sand filling by a blow method has a high filling rate of sand, so that a blocking phenomenon occurs particularly in a pocket portion, thereby deteriorating filling ability of sand. In contrast, the molding machine 100 according to the present embodiment also enables setting in which a filling rate of sand is reduced in an initial stage of low-pressure air by an electric pneumatic high-regulating valve to improve filling ability, and pressure is increased from midway to reduce a filling time. A filling rate decreases when pressure is kept low, so that a filling time of sand may increase to increase cycle time. To acquire mold forming at high speed while reducing wear, it is preferable that a filling rate of low-pressure air is initially reduced and is increased from midway.
In the molding machine 100 according to the above embodiment, the sand injection nozzle 28 is provided in the filling frame 27. However, in another embodiment, the sand injection nozzle 28 may be provided in an injection frame BF that is provided separately from the filling frame 27, and that is able to be separately operated, as illustrated in
While there is described an example in which the sand injection nozzle 28 is directly formed in the filling frame 27 in the above embodiment, the sand injection nozzle 28 may not be directly formed in the filling frame 27. For example, an opening may be formed in a side portion of the filling frame 27, and the sand injection nozzle 28 may be formed in a component attached to the opening.
When the sand injection nozzles 28A and 28B wear, the components 50A and 50B may be exchanged, and thus the entire filling frame does not need to be exchanged. Thus, the molding machine is excellent in maintenance and availability.
The components 50A and 50B can be made of material (such as resin) with high wear resistance, such as urethane, other than steel such as stainless steel. As described above, the components 50A and 50B can be made of material in consideration of wear resistance, and the filling frame 27A can be made of material suitable for molding. In addition, the filling frame 27A can be provided with an exhaust port 27f for low-pressure air. This enables low-pressure air to be discharged through the exhaust port 27f. As a result, there is an effect in which more excellent filling is achieved.
6, 6A . . . pattern carrier, 8, 8A . . . pattern plate, 9, 36 . . . frame, 19 . . . sand injection hopper, 24 . . . chute, 26 . . . sand injection port, 26a . . . bottom surface, 27 . . . filling frame, 27a . . . outer surface, 27b . . . inner surface, 28, 28A, 28B . . . sand injection nozzle, 28a . . . ceiling surface, 28b . . . bottom surface, 29 . . . squeeze head mechanism, 33 . . . molding flask, 37 . . . liner, 39 . . . urethane rubber, 50A, 50B . . . component, 100 . . . molding machine, BF . . . injection frame.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-023787 | Feb 2016 | JP | national |
| 2016-086360 | Apr 2016 | JP | national |
This application is a continuation of International Application No. PCT/JP2016/069051, filed Jun. 27, 2016. Note that this application claims the benefit of priority from Japanese Patent Application No. 2016-023787 and Japanese Patent Application No. 2016-086360, and the entire contents of the basic applications are incorporated herein.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2016/069051 | Jun 2016 | US |
| Child | 16059505 | US |
