Molding and die casting apparatus and methods

Abstract

A mold, or die is easily and conveniently maintainable, includes releasably retained parts and permits access and removal of mold parts or elements that may need maintenance, repair or replacement without removal of the mold or die from a die casting machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a part of a mold including the invention for molding a six-cylinder engine block;

FIG. 2 is a partial perspective view of a portion of the mold part illustrated in FIG. 1 with the structure of the movable bank slide part surrounding the cylinder-forming die part broken away and shown in lightened outline only to display the cylinder-forming die part in darkened print;

FIGS. 3 and 4 are perspective views of the cylinder-forming die part and the means for removably retaining it in the mold part of FIG. 1; FIG. 3 illustrates a rear portion of the cylinder-forming die part and the means for removably retaining the cylinder-forming die part in the movable bank slide part of the mold, with the surrounding portions of the movable bank slide omitted; FIG. 4 illustrates a rear part of the cylinder-forming die part and the means for removably retaining the cylinder-forming mold element in the mold, with adjacent portions of the movable bank slide part shown in lightened outline;

FIG. 5 corresponds to FIG. 3 without a showing of the screw-retaining cover plate to show the various rods of the means for removably retaining the cylinder-forming die part in the movable bank slide part of the mold;

FIG. 6 is an illustration, from above, of a cross-section of a die, including the invention mounted on the stationary and movable platens of a die casting machine in the die open position, with its cylinder-forming die parts in there extended cylinder-forming positions;

FIG. 7 is an enlarged cross-sectional illustration of the portion of the die of FIG. 6 within the dashed-line box to better illustrate the cylinder-forming die part and the means for its removable retention in the die and FIG. 7A is an enlarged cross-sectional illustration of the portion of FIG. 7 within the circle; and

FIGS. 8-10 are three orthogonal views of tool for removal of cylinder-forming die parts from a mold, FIG. 8 being a view from above the tool, FIG. 9 being a view from the side of the tool, and FIG. 10 being a view from the end of the tool.

Claims

1. A mold comprising a mold element removably retained within a movable mold part, the mold element including a distal portion adapted to form a feature in work products formed in the mold and an enlarged proximal portion having a first surface facing the distal portion, the movable mold part including a first opening to receive the removably retained mold element and a second opening arranged generally transverse to the first opening to receive a locking element, the locking element being engagable with the first surface of the mold element and movable within the second opening between a retracted position permitting release of the mold element from the movable mold part and a locking position adapted to engage the first surface of the mold element proximal portion to retain the mold element within the movable mold part, and moving means for moving the locking element within the second opening between the retracted position and the locking position to permit replacement of the mold element while the mold is retained in a molding machine.

2. The mold of claim 1 wherein the locking element comprises a yoke adapted to straddle a portion of the mold element between the distal and proximal portions, the yoke including at least one threaded opening to receive said moving means.

3. The mold of claim 2 wherein the yoke includes at least one additional unthreaded opening for receiving another portion of said moving means.

4. The mold of claim 1 wherein the locking element includes a tapered face adapted to confront said first surface of the mold element proximal portion.

5. The mold of claim 1 further comprising a plate fixed to the movable mold part, the moving means being coupled to the plate for controlled movement of the locking element

6. A die for casting a V-block for an internal combustion engine in a die-casting machine having a stationary platen and a movable platen, comprising: a stationary die element for mounting on the stationary platen of the die casting machine, anda movable die element for mounting on the movable platen of the die-casting machine, said movable die element carrying a plurality of transversely movable, cavity-forming slides and at least a pair of cylinder-forming die parts removably retained in means for reciprocating the pair of cylinder-forming die parts at an acute angle with respect to the movement of the movable platen between extended positions within the die cavity and retracted positions within the movable die element, die core locking means for locking the cylinder-forming die parts in their extended positions, and locking elements for removably retaining said cylinder-forming die parts in said reciprocating means.

7. The die of claim 6, wherein said cylinder-forming die parts comprise cylinder-forming and water jacket-forming die pieces adapted to be removed together when the stationary platen and movable platen of the die-casting machine are separated.

8. The die of claim 7, wherein the cylinder-forming die pieces and the water jacket-forming die pieces are joined as a unit by interconnecting means.

9. The die of claim 8, wherein the cylinder-forming die pieces and water jacket-forming die pieces are interconnected by means comprising forwardly-facing surfaces of the cylinder-forming die pieces and rearwardly facing surfaces of the water jacket-forming die pieces.

10. The die of claim 6, wherein the cylinder-forming die parts are removably retained in the reciprocating means by locking elements accessible from outside of the movable die element.

11. The die of claim 10, wherein said locking elements comprise fastener pins.

12. The die of claim 11, wherein the pins include threaded portions for fastening the cylinder-forming die parts to their reciprocating means.

13. The die of claim 11, wherein the pins include threaded portions threadedly engaged with the means for reciprocating the pair of cylinder-forming die parts.

14. The die of claim 6, wherein the locking elements are movably carried within the reciprocating means between a locking engagement and an unlocking disengagement with the cylinder-forming die parts.

15. The die of claim 14, wherein the cylinder-forming die parts include portions extending rearwardly from their cylinder-forming portions with engagable portions adjacent their rears, and the locking elements are movably carried by the reciprocating means between locking positions in which they engage the engagable portions of the cylinder-forming die parts in the reciprocating means, and retracted positions in which they are disengaged from the engagable portions of the cylinder-forming die parts, permitting the cylinder-forming die parts to be removed from the die.

16. The die of claim 15, wherein the cylinder-forming die parts include rearwardly extending rods and the engagable portions of the cylinder-forming die parts comprise rod portions adjacent the rear of the rods that are larger than the rods and smaller than the cylinder-forming die parts, and the locking elements comprise yokes shaped and located to engage the rod portions in their locking positions.

17. The die of claim 6 wherein the die core locking means are movably carried within the movable die to a locking engagement with the cylinder-forming die parts in their extended positions.

18. The die of claim 17, wherein the die core locking means comprises a die core locking member reciprocatably carried within the movable die element along the axis of movement of the movable platen and operable in its forwardmost position to engage rear portions of the cylinder-forming die parts and lock the cylinder-forming die parts in their extended positions.

19. The die of claim 6, wherein the cylinder-forming die parts include means for reducing their temperatures.

20. The die of claim 19, wherein the temperature-reducing means of the cylinder-forming die parts comprise means for providing a coolant within the cylinder-forming die core parts.

21. The die of claim 20, wherein the temperature-reducing means of the cylinder-forming die parts comprise one or more coolant passageways within the cylinder-forming die parts connectable with an external source of coolant.

22. The die of claim 21, wherein the one or more coolant passageways are connected with one or more coolant conduits to form a closed circuit coolant path.

23. The die of claim 22, further comprising a source of coolant in the closed circuit coolant path.

24. The die of claim 22, wherein the one or more coolant conduits comprise one or more rigid tubular conduits connected to the cylinder-forming die parts in communication with the one or more coolant passageways of the cylinder-forming die parts.

25. The die of claim 24, wherein the one or more tubular conduits extend to adjacent the rear of the movable die element and provide at least one rearward surface that can be used to remove the cavity-forming die parts from the movable die element.

26. The die of claim 19, wherein the cylinder-forming die parts include water jacket-forming die pieces and means for reducing the temperature of the water jacket-forming die pieces.

27. The die of claim 26, wherein the cylinder-forming die parts include cylinder-forming die core pieces comprising means for conveying coolant adjacent portions of their outer surfaces, and the water jacket-forming die core pieces have interior surfaces that interface with said outer surface portions of the cylinder-forming die core pieces.

28. The die of claim 27, wherein the interior surfaces of the water jacket-forming die core pieces include openings to coolant passageways formed within the water jacket-forming portions.

29. A die for casting a V-block for an internal combustion engine in a die-casting machine having a stationary platen and a movable platen, comprising: a stationary die element for mounting on the stationary platen of the die casting machine, anda movable die element for mounting on the movable platen of the die-casting machine, said movable die element carrying a plurality of transversely movable, cavity-forming slides and at least a pair of cylinder-forming die parts, and means for reciprocating the at least pair of cylinder-forming die parts at an acute angle with respect to the movement of the movable platen between extended positions within the die cavity and retracted positions within the movable die element, said cylinder-forming die parts being removably held in said movable die element.

30. The die of claim 29, wherein at least one of said cylinder-forming parts comprises cylinder-forming and water jacket-forming die pieces adapted to be removed together when the stationary platen and movable platen at the die-casting machine are separated.

31. The die of claim 30, wherein the at least one cylinder-forming die piece and water jacket-forming die piece are interconnected.

32. The die of claim 30, wherein the at least one cylinder-forming die piece and water jacket-forming die piece are interconnected by a forwardly-facing surface of the cylinder-forming die piece and a rearwardly facing surface of the water jacket-forming die piece.

33. The die of claim 31, wherein the cylinder-forming die piece and the water jacket-forming die piece are joined by an interconnecting means.

34. The die of claim 33, wherein the interconnecting means comprises a flexible member adapted to engage adjacent surfaces of the cylinder-forming die piece and the water jacket-forming die piece.

35. The die of claim 34, wherein the interconnecting means comprises a partially open flexible ring adapted to be fitted over the cylinder-forming die piece and seated in a groove formed on the outer surface of the cylinder-forming die piece, said partially open flexible ring having a flexible outer surface adapted to be engaged with a groove formed on the inner surface of the water jacket-forming die piece.

36. The die of claim 29, wherein the cylinder-forming die parts are removably held in the movable die element by locking means accessible from outside of the movable die element.

37. The die of claim 36, wherein said locking means comprises pins.

38. The die of claim 37, wherein pins include threaded portions for fastening the cylinder-forming die parts to their reciprocating means.

39. The die of claim 37, wherein said pins include threaded portions threadably engaged with the means for reciprocating the at least pair of cylinder-forming die parts.

40. The die of claim 29, wherein the cylinder-forming die parts are removably held in said movable die element by locking elements movably carried within the movable die element between a locking engagement and an unlocking disengagement with the cylinder-forming die parts.

41. The die of claim 40, wherein the cylinder-forming die parts include portions extending rearwardly from their cylinder-forming portions with engagable portions adjacent their rears, and the locking elements are movably carried by the reciprocating means between locking positions in which they engage the engagable portions of the cylinder-forming die parts in the reciprocating means and retracted positions in which they are disengaged from the engagable portions of the cylinder-forming die parts, permitting the cylinder-forming die parts be removed from the die.

42. The die of claim 41, wherein the cylinder-forming die parts include rearwardly extending rods, and the engagable portions of the cylinder-forming die parts comprise rod portions adjacent the rear of the rods that are larger than the rods and smaller than the cylinder-forming die parts, and the locking elements comprise yokes shaped and located to engage the forward portions of the rod portions in their locking positions.

43. The die of claim 29, further comprising means for locking the cylinder-forming die parts in their extended positions movably carried within the movable die to a locking engagement with the cylinder-forming die parts in their extended positions.

44. The die of claim 43, wherein said locking means comprises a die core locking member reciprocatably carried within the movable die element for movement along the axis of movement of the movable platen and operable in its forwardmost position to engage portions of the means for reciprocating the at least pair of cylinder-forming die part and lock the cylinder-forming die parts in their extended positions.

45. The die of claim 44, wherein said die core locking member is carried by the movable die element for reciprocatable movement within a cavity formed by the movable die element, said cavity having an open front portion into which portions of the means for reciprocating the at least pair of cylinder-forming die parts move in their extended positions.

46. The die of claim 45, wherein the cavity formed by the movable die element further contains at least one lock element reciprocatably carried for movement transverse to the movement of the die core locking member between a first position between the die core locking member and a cavity rear surface, thereby further preventing movement of the cylinder-forming die parts within the die cavity, and a second position permitting the die core locking element to disengage from the cylinder-forming die parts and retraction of the cylinder-forming die parts.

47. The die of claim 44, wherein the movable platen carries at least one actuator, and the die core locking means is independently operable and includes a connection rod extending through the movable platen and connected with the at least one actuator for reciprocation by the actuator within the movable die element.

48. The die of claim 47, wherein the at least one actuator comprises two hydraulic cylinders connected at their one ends to the movable platen and at their other ends to a bar that drives a pair of connecting rods extending through the movable platen and movable die element for engagement with the die core locking member.

49. The die of claim 44, wherein at least one actuator for the die core locking member is carried by the die-casting machine and is connected with a connection rod engaged with the die core locking member.

50. The die of claim 43, wherein the cylinder-forming die part locking means is operated with at least one actuator carried by the die-casting machine.

51. The die of claim 50, wherein the at least one actuator is carried by the movable platen of the die-casting machine.

52. The die of claim 51, wherein the at least one actuator is carried at the back of the movable platen and is connected with the die core locking means by at least one connection rod passing through an opening in the movable platen.

53. The die of claim 50, wherein the die core locking means is independently driven, from a first position locking the at least pair of cylinder-forming die parts in their extended position to a second position permitting the cylinder-forming die parts to be retracted, by an actuator carried on the back of the movable platen of the die-casting machine.

54. The die of claim 29, wherein the cylinder-forming die parts include means for reducing their temperature.

55. The die of claim 54, wherein the temperature-reducing means of the cylinder-forming die parts comprises means for conveying a coolant within their bodies.

56. The die of claim 55, wherein the temperature-reducing means of the cylinder-forming die parts comprises one or more coolant passageways within the cylinder-forming die parts connectable with an external source of coolant.

57. The die of claim 56, wherein one or more rigid tubular conduits are connected to the cylinder-forming die parts in communication with the one or more coolant passageways of the cylinder-forming die parts.

58. The die of claim 57, wherein the one or more tubular conduits extend to adjacent the rear of the movable die element and provide a rearward surface that can be used to remove the cavity-forming die parts from the movable die element.

59. The die of claim 54, wherein the cylinder-forming die core parts also include means for reducing the temperature of attached water jacket-forming die core pieces.

60. The die of claim 59, wherein cylinder-forming die core pieces of the cylinder-forming die parts convey coolant adjacent portions of their outer surfaces, and the attached water jacket-forming die core pieces have interior surfaces that interface with said outer surface portions of the cylinder-forming die core pieces.

61. The die of claim 56, wherein the cylinder-forming die core parts include attached water jacket-forming die pieces, and the coolant passageways of the cylinder-forming die parts include one or more coolant passageways of the water jacket-forming die core pieces.

62. A method for maintenance of an internal combustion engine V-block casting die, including at least one cylinder-forming die part movably carried by the V-block casting die for reciprocation between first position extending into the cavity formed by the V-block casting die for formation of cylinders of the cast V-block and a second position retracted within the V-block casting die, and means for reciprocating the at least one cylinder-forming die part between its first and second positions, comprising; providing means for locking the cylinder-forming die part to the means for reciprocating the cylinder-forming die part between its first and second positions,providing access to the locking means from outside of the V-block casting die,disengaging the locking means, thereby permitting removal of the cylinder-forming die part from the V-block casting die, andremoving the cylinder-forming die part from the V-block casting machine by applying force urging the cylinder-forming die part in the direction of movement from its second position to its first position.

63. The method of claim 62, wherein the at least one cylinder-forming die part has been moved to its extended first position for removal of the cylinder-forming die part.

64. The method of claim 63, wherein force is applied to the rear of the at least one cylinder-forming die part to remove it from the V-block casting die.

65. The method of claim 63, wherein the extended part of the at least one cylinder-forming die part is grasped and the cylinder-forming die part is removed by pulling it from the V-block casting die.

66. The method of claim 65, wherein the cylinder-forming die part is grasped for removal by compressively engaging its outer surface.

67. The method of claim 63, wherein the at least one cylinder-forming die part is moved to its extended first position prior to disengaging the locking means.

68. The method of claim 63, wherein the locking means is disengaged from the at least one cylinder-forming die part before it has been moved to its extended first position.

69. The method of claim 62, wherein access is provided to the locking means by removing a portion of the V-block casting die.

70. The method of claim 62, wherein the locking means is contained within the V-block casting die and is disengaged from the at least one cylinder-forming die part by moving it within the V-block casting die from a first position locking the at least one cylinder-forming die part to the means for reciprocating the cylinder-forming die part between its first and second positions to a second position disengaged from at least one cylinder-forming die part.

71. The method of claim 70, wherein the means for reciprocating the cylinder-forming die part includes at least one actuator and an interconnecting element movably carried by the V-block casting die.

72. The method of claim 71, wherein the locking means is movably carried within the interconnecting element and is moved therein between its first and second positions.

73. The method of claim 69, wherein access to the locking means is provided by moving the cylinder-forming die part to its first position.

74. The method of claim 62, wherein the locking means is removed from the V-block casting die to permit removal of the cylinder-forming die part.

75. The method of claim 62, wherein the at least one cylinder-forming die part comprises at least one cylinder-forming die piece and at least one water jacket-forming die piece that are interconnected, and the cylinder-forming die piece and water jacket-forming die piece are removed together.

76. The method of claim 75, wherein the at least one cylinder-forming die piece and the at least one water jacket-forming die piece are separated after their removal.

77. The method of claim 75, wherein the at least one cylinder-forming die piece and at least one water jacket-forming die piece are interconnected by a forward facing outer surface on the cylinder-forming die piece and a connecting rearwardly-facing inner surface of the water jacket-forming die piece, and the at least one water jacket-forming die piece is replaced by moving it forwardly on the at least one cylinder-forming die piece.

78. The method of claim 75, wherein the at least one cylinder-forming die piece and the at least one water jacket-forming die piece are separably interconnected by a third removable interconnecting means.

79. A tool for removing a cylinder-forming die part from a V-block casting die, comprising first means for engaging a portion the cylinder-forming die part and second means permitting force to be applied to the first means for pulling the cylinder-forming die part from the die.

80. The tool of claim 79, wherein the first means includes a portion encircling the cylinder-forming die part and at least one threaded member threadedly carried by the encircling portion of the first means in position to compressively engage the cylinder-forming die part.

81. The tool of claim 80, wherein the cylinder-forming die part includes a water jacket-forming die piece, the first means includes a portion encircling the water jacket-forming die piece and the one or more threaded members compressively engage the water jacket-forming die piece.

82. The tool of claim 79, wherein the first means for engaging the cylinder-forming die piece provides at least one surface adapted to bite into the cylinder-forming die part.

83. The tool of claim 82, wherein the at least one surface adapted to bite into the cylinder-forming die part comprises at least one threaded member with a hardened part for biting into the surface of the cylinder-forming die part.

84. The tool of claim 79 further comprising an end portion adapted for attachment to a tethering means.

85. The tool of claim 84, wherein said end portion comprises a flange extending outwardly from said first means and including at least one opening for attachment of said tethering means.

86. The tool of claim 85, wherein said at least one opening comprises a plurality of spaced and threaded holes.

87. A cylinder-forming die part for a V-block casting die, comprising; a cylinder-forming die piece and a water jacket-forming die piece, said cylinder-forming die piece and water jacket-forming die piece being adapted to be moved together within a V-block casting die in the direction of their central axes and separated upon their removal from the V-block casting die.

88. The die part of claim 87, wherein the cylinder-forming die piece and water jacket-forming die piece are interconnected by a forwardly facing surface of the cylinder-forming die piece and a rearwardly facing surface of the water jacket-forming die piece.

89. The die part of claim 87, wherein the cylinder-forming die piece and water jacket-forming die piece are interconnected by a third interconnecting means.

90. The die part of claim 87, wherein the cylinder-forming die part is adapted at its rear to be connected with means for moving the cylinder-forming die piece and water jacket-forming die piece in the direction of their central axes.

91. The die part of claim 87, wherein the cylinder-forming die piece and water jacket-forming die piece are adapted at their rear to be removably locked with at least one interconnecting element engaged with means for moving the cylinder-forming die piece and water jacket-forming die piece in the direction of their central axes.

92. The die part of claim 91, wherein the water jacket-forming die piece includes a flange at its rear, said flange providing a rearwardly facing annular surface and a forwardly facing annular surface, and wherein the at least one interconnecting element comprises a first cylindrical element with a forward portion surrounding the water jacket-forming die piece and having a rearwardly facing annular surface engaged with the forwardly facing annular surface of the water jacket-forming die piece, and having a rearward portion adapted to be removably locked with means for moving the cylinder-forming die piece and water jacket-forming die piece in the direction of their central axes.

93. The die part of claim 92, wherein the at least one interconnecting element includes a second interconnecting element having a forward portion extending into the first cylindrical element and being adapted to be engaged with and removably locked to said first cylindrical element.

94. The die part of claim 93, wherein the second interconnecting element includes a forwardly facing surface engaged with the rearwardly facing annular surface of the water jacket-forming die piece.

95. The die part of claim 93, wherein the second interconnecting element includes a second forwardly facing surface engaged with the rear surface of the cylinder-forming die piece.

96. The die part of claim 92, wherein the second interconnecting element includes a third forwardly facing surface engaged with a second annular rearwardly facing surface of the first cylindrical element.

97. The die part of claim 87, wherein cylinder-forming die piece includes a rearwardly extending rod portion having an enlarged portion adjacent its rear with a forwardly facing surface adapted for connection with means for moving the cylinder-forming die piece and water jacket-forming die piece in the direction of their central axes.

98. The die part of claim 87, wherein the means for moving the cylinder-forming die piece and water jacket-forming die piece in the direction of their central axes includes at least one yoke portion adapted to slidably engage the rearwardly extending rod portion of the cylinder-forming die piece and adapted for movement in a direction transverse to the direction of the central axes of the cylinder-forming die piece and water jacket-forming die piece to engage the rod portion when moved toward the rod portion and to be disengaged from the cylinder-forming die piece when moved away from the rod portion, permitting movement of the cylinder-forming die piece in the direction of its central axis and releasably retaining the cylinder-forming die piece and water jacket-forming die piece in the V-block casting die.

99. The die part of claim 87, wherein the cylinder-forming die part includes means for reducing its temperature.

100. The die part of claim 99, wherein the temperature-reducing means of the cylinder-forming die part comprises means for conveying a coolant within its body.

101. The die part of claim 100, wherein the temperature-reducing means of the cylinder-forming die parts comprises one or more coolant passageways within the cylinder-forming die part connectable with an external source of coolant.

102. The die part of claim 101, wherein the temperature-reducing means comprises one or more rigid tubular conduits connected to the cylinder-forming die parts in communication with the one or more coolant passageways of the cylinder-forming die parts.

103. The die part of claim 102, wherein the one or more tubular conduits extend rearwardly and provide a rearward surface that can be used to remove the cavity-forming die parts from the V-block casting die.

104. The die part of claim 99, wherein cylinder-forming die core piece of the cylinder-forming die part comprises means for conveying coolant adjacent an outer surface portion, and the water jacket-forming die core piece has an interior surface that interfaces with said outer surface portion of the cylinder-forming die core piece.

105. The die part of claim 100, wherein the cylinder-forming die part comprises one or more coolant passageways extending outwardly within the cylinder-forming die piece to adjacent an outer surface portion of the cylinder-forming die piece.

106. The die part of claim 105, wherein means for reducing the temperature of the water jacket-forming die core piece comprises one or more coolant passageways of the cylinder-forming die piece that carry coolant into heat transfer relationship with an inner surface of the water jacket-forming die piece.

107. The die part of claim 106, wherein the one or more coolant passageways of the cylinder-forming die piece include an annular passageway formed around and adjacent the rear of the cylinder-forming die piece and closed at its outside by said inner surface of the water jacket-forming die piece.

108. The die part of claim 99, wherein the water jacket-forming die core piece includes one or more coolant passageways, and the cylinder-forming die core piece has one or more coolant passageways in communication with the one or more coolant passageways of the water jacket-forming die core piece.

109. A cylinder-forming die part for a V-block casting die comprising a cylinder-forming end, a rearwardly extending central rod portion leading to an enlarged rear portion having outside dimensions less than the diameter of the cylinder-forming end.