Self-aligning sand mold insert assembly
AssigneeFord Global Technologies, LLC
InventorRobert G. Gurdebeke
Life of this patent
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Abstract
A retractable metal insert assembly for a core sand mold having at least one sand core element provided with walls to define an opening communicating with a molding cavity, the walls presenting a stepped neck which is dimensionally accurate within .+-.0.002 inches, the mold further including a metal support associated with the core element. The insert assembly comprises: (a) a metal guide detachably secured to the metal support; (b) a metal chill element extendible through the opening to present a metal molding surface which insert has walls mateable with the stepped neck for accurate alignment; and (c) biasing means acting between the guide and insert to urge the mating walls together for self positioning of the insert. The insert assembly can be repeatedly reused in a method of making castings.
Claims16
A casting mold comprising a retractable metal insert assembly, the mold having at least one sand core element provided with walls to define an opening communicating with a molding cavity, said walls presenting a stepped neck which is dimensionally accurate within .+-.0.002 inches, said mold including a metal support associated therewith, the assembly comprising;
- (a) a metal guide detachably secured to said metal support;
- (b) a metal chill element extendible through said opening to present a metal molding surface in said cavity, said chill having walls mateable with said metal guide for alignment and said metal chill element walls mateable with the stepped neck for accurate alignment;
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- (c) biasing means acting between said guide and said metal chill element to urge said metal chill element walls into engagement with said stepped neck of said core walls for self positioning of the chill element relative to the mold.
A method of making a light metal casting, using retractable and reusable metal chill elements, comprising:
- (a) forming a core sand mold with a cavity, the mold having at least core element provided with walls to define an opening communicating with the mold cavity, the walls presenting a stepped neck which is dimensionally accurate within .+-.0.002 inches, and has a metal support associated with the core sand mold;
- (b) forming and installing a retractable metal insert assembly in said mold, said assembly comprising a metal guide detachably secured to the metal support and a metal chill element extendible through the opening of said core element to present a metal molding surface within said cavity, said chill element having walls mateable with said metal guide for alignment and said metal chill element walls mateable with the stepped neck of the mold for accurate alignment, said insert assembly further having a biasing means acting between the guide and said metal chill element to urge the metal chill element walls into engagement with said stepped neck of said core walls for self positioning and having a stop means to prevent total separation of the chill element from the guide;
- (c) pouring molten light metal into the cavity while the insert assembly accelerates the cooling of said metal in contact with the insert metal surface to thereby decrease the dendritic arm spacing of the solidified metal adjacent to said insert;
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- (d) after allowing for said poured metal to solidify within said cavity to form a casting, retracting said insert assemblies by releasing said guide from said support and withdrawing said insert assembly, said stop means retaining said insert assembly as a unified assembly free of said mold.
Dependencies are inferred from the claim text.