Description:FIELD
The present disclosure relates to methods used for casting automotive components.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicate otherwise.
Insert – The term “insert” refers to steel or non-ferrous materials placed in the die and molten metal is passed into the die over the insert to form the casting embedded with the insert.
Thermal insulation wax - The term “thermal insulation wax” refers to a wax that is resilient to thermal loads, thus providing thermal insulation to the component on which the wax is applied.
Die coat – The term ‘die coat’ refers to a coat applied on inserts that prevent premature solidification of the molten metals injected during casting process and also prevent adhesion of the molten metal to the die.
Lumen – The term ‘lumen’ refers to the inner surface of a hollow insert that can transport a fluid therethrough.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, cast components such as a crank case of an automobile is configured with a fluid flow path for circulating oil there through. This fluid flow path manufactured by the casting process involves positioning an insert hollow tubular insert on casting dies and then pouring molten metal in the casting dies. However, due to high temperature, high injection pressure and high velocity of molten metal, the hollow tubular insert on the casting dies gets deformed. As a result, the fluid flow path formed in the cast component gets obstructed and obstructs the flow of or circulation of lubricating oil through the cast component. Thus, the conventional casting process fails to deliver a desired level of accuracy in manufacturing the fluid flow path in the cast component.
There is, therefore, felt a need of a method of insert casting where the casting includes a hollow tubular insert, that alleviates the above-mentioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide of a method of insert casting where the casting includes a hollow tubular insert that eliminates inaccuracies in manufacturing process the cast components.
Another object of the present disclosure is to of a method of insert casting where the casting includes a hollow tubular insert that is economical.
Still another object of the present disclosure is to provide of a method of insert casting where the casting includes a hollow tubular insert that avoids excessive thermal strain and mechanical strain during the casting process.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure discloses a method of insert casting where the casting includes a hollow tubular insert, the method comprising the following steps:
* providing a hollow tubular insert, the hollow tubular insert defining a lumen therethrough;
* applying a layer of coat on the inner lumen of the hollow tubular insert while ensuring that the operative outer surface of the hollow tubular insert is free of the coat, to form a casting die-coated hollow tubular insert having a predetermined coating thickness of the coat;
* providing a casting die;
* positioning and locating the coated hollow tubular insert 10 on the casting die;
* passing molten metal at a predetermined temperature, pressure and velocity into the casting die; and
* cooling of the molten metal to cast a component embedded with the hollow tubular insert.
In an embodiment, wherein the step of applying the layer of coat includes the substeps of :
* dipping the hollow tubular insert in container filled with the coat for a predetermined amount of time;
* ensuring that the lumen of the hollow insert tube is completely filled with the coat;
* draining the coat filled in the lumen of the tubular hollow insert; and
* wiping the operative outside surface of the hollow insert tube.
In a preferred embodiment, the predetermined amount of time is in the range of 3 minutes to 7 minutes.
In a preferred embodiment, the predetermined thickness of the layer of the coat is in the range of 10 microns to 15 microns.
In a preferred embodiment, positioning of the coated hollow tubular insert insde the casting die is performed within a time period in the range of 8 minutes to 12 minutes after applying the coat.
In a preferred embodiment, the predetermined temperature of the molten metal to be passed into the casting die is in the range between 650 degrees Celsius and 670 degrees Celsisus.
In a preferred embodiment, the predetermined pressure of the molten metal to be passed into the casting die is in the range between 270 bar and 290 bar.
In a preferred embodiment, the predetermined velocity of the molten metal to be passed into the casting die is in the range between 3.2 m/s and 3.6 m/s.
In an embodiment, the hollow tubular insert has a non-linear geometry profile.
In a preferred embodiment, the coat is a die coat to prevent adhesion on molten metal to the casting die.
In a preferred embodiment, the tubular insert has an outside diameter of 8 mm, an inner diameter of 5mm and a length of 345 mm.
In a preferred embodiment, the step of applying the coat on the inner lumen of the hollow insert tube includes introducing a thin tube filled with the coat into the lumen of the hollow insert tube and releasing the coat from the thin tube.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
10 – hollow tubular insert
12 – section of hollow tubular insert
20 – coat
30 – casting die
32 – inlets
34 – runner
50 – component
100 – apparatus
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A method of insert casting where the casting includes a hollow tubular insert, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a side view of location of the fluid flow path to be made in the cast component, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a radiography image of the cast component with the hollow tubular insert in a deformed condition due to thermal loads, of the prior art;
Figure 3 illustrates an internal view of the hollow tubular insert of the Figure 2;
Figure 4 illustrates the hollow tubular insert being dipped in the coat, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates the hollow tubular insert having the coat positioned on a casting die, for casting the fluid flow path; and
Figure 6 illustrates a radiography image of the cast component with the hollow tubular insert in an undeformed condition, of the the present disclosure;
DETAILED DESCRIPTION OF THE PRESENT DISCLOSURE
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
When an element is referred to as being "mounted on", “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Referring to the figures 1-3, a conventional method of insert casting of a hollow tubular insert 10 in a component 50 will now be described. Figure 1 shows a view of the cast component 50. In an embodiment, the cast component 50 is a crank case of a two-wheeled vehicle. In figure 2 is shown a casting die 100 for casting the cast component 50. The hollow tubular insert 10 facilitates casting the fluid flow path in the cast component 50. The hollow tubular insert 10 has a section 12 that undergoes deformation under high temperature, high pressure and high velocity. A molten metal such as Aluminium is made to flow through a runner 34 of the casting die 100 and the molten metal enters the space of the casting die 30 through inlets 32. The section 12 of the hollow tubular insert 10 is observed for deformation during the casting process of the component 50, in the conventional method of the prior art. The deformation of the section 12 is observed by obtaining radiographic images of the cast component 50. As shown in the figures 2 and 3, the section 12 of the hollow tubular insert 10 is observed to be deformed due to high temperature, high pressure and high velocity of the molten metal. In an embodiment, the injection pressure of the molten metal is approximately between 270 and 290 bar, the temperature of the molten metal is between 650 and 670 degree Celsius and the injection velocity of the molten metal is between 3.2 m/s and 3.6 m/s, to ensure flowability of the molten metal into the space of the casting die 50 and accuracy of the shape of cast component 50. Figure 3 shows the deformation of the inner lumen of the hollow tubular insert 10. This deformation is required to be prevented to allow passage of lubricating oil there through. In the deformed condition, it can be understood that the fluid flow path through the inner lumen of the hollow tubular insert 10 is obstructed.
Referring to the figures 4-6, a method of insert casting where the casting includes a hollow tubular insert 10 in the component 50, of the present disclosure will now be described. The fluid flow path is configured in the cast component 50 to facilitate passage of a fluid such as lubricating oil. The method comprises the following:
* providing a hollow tubular insert (10), the hollow tubular insert (10) defining a lumen therethrough;
* applying a layer of coat (20) on the inner lumen of the hollow tubular insert (10) while ensuring that the operative outer surface of the hollow tubular insert (10) is free of the coat (20), to form a casting die-coated hollow tubular insert (10) having a predetermined coating thickness of the coat (20);
* providing a casting die (30);
* positioning and locating the coated hollow tubular insert (10) on the casting die (30);
* passing molten metal at a predetermined temperature, pressure and velocity into the casting die (30); and
* cooling of the molten metal to cast a component (50) embedded with the hollow tubular insert (10).
In a preferred embodiment, the predetermined amount of time is in the range of 3 minutes to 7 minutes.
In a preferred embodiment, the step of applying the coat (20) includes the substeps of:
* dipping the hollow tubular insert (10) in container filled with the coat (20) for a predetermined amount of time;
* ensuring that the lumen of the hollow insert tube (10) is completely filled with the coat (20);
* draining the coat (20) filled in the lumen of the tubular hollow insert (10); and
* wiping the operative outside surface of the hollow insert tube (10) with a cloth.
The coat 20 from the operative outer surface of the hollow tubular insert 10 is wiped out, so as to avoid probability of casting defects arising due to formed porosities.
In another embodiment, the operative inner lumen of the hollow tubular insert 10 is coated with the coat 20 by inserting a flexible tube containing the coat 20 inside the hollow tubular insert 10 and releasing the coat 20 contained in the flexible tube.
In a preferred embodiment, the predetermined thickness of the layer of coat 20 is in the range of 10 microns to 15 microns.
In a preferred embodiment, positioning of the coated hollow tubular insert 10 on the casting die 30 is performed within a time period in the range of 8 minutes to 12 minutes after applying the coat 20.
In a preferred embodiment, the predetermined temperature of the molten metal to be passed into the casting die 30 is in the range between 650 degrees Celsius and 670 degrees Celsius.
In a preferred embodiment, the predetermined pressure of the molten metal to be passed into the casting die 30 is in the range between 270 bar and 290 bar.
In a preferred embodiment, the predetermined velocity of the molten metal to be passed into the casting die 30 is in the range between 3.2 m/s and 3.6 m/s.
In a preferred embodiment, the coat 20 is a thermal insulation wax.
In an embodiment, the hollow tubular insert 10 has a non-linear geometry profile.
In an embodiment, the coat 20 is a die coat to prevent adhesion on molten metal to the casting die 30.
The step of applying the coat (20) on the inner lumen of the hollow insert tube (10) includes introducing a thin tube filled with the coat (20) into the lumen of the hollow insert tube (10) and releasing the coat (20) from the thin tube.
As can be seen from the figure 9, the section 12 of the hollow tubular insert 10 is free from deformation due to the layer of the coat 20 applied on the hollow tubular insert 10. The coat 20 layer prevents deformation of the hollow tubular insert 10 under high temperature, high pressure and high velocity of molten metal.
Example
A comparative study was conducted between the hollow tubular insert 10 of the prior art without the coat 20, and the hollow tubular insert 10 of the present disclosure with the coat 20. In this example, the casting was a crank case of a two-wheeled vehicle made of Aluminium Casting die Cast 12 (ADC 12) and the hollow tubular insert 10 is made of carbon steel grade Electric Resistance Welded 2 (ERW2). The sample size was 1000 from for each case. In both the cases, the length of the hollow tubular insert 10 was 345 mm having an inner diameter of 5 mm and an outer diameter of 8 mm. The hollow tubular insert 10 of the prior art without the coat 20, and the hollow tubular insert 10 of the present disclosure with the coat 20 applied were observed during the casting process. The coat 20 was applied on the hollow tubular insert 10 of the present disclosure by dipping the hollow tubular insert 10 inside a container filled with the coat 20 for a time period of 5 minutes. The product name for the coat 20 is CAST ALL 2060. The layer thickness of the coat 20 applied on the inner lumen of the hollow tubular insert 10 of the present disclosure was 12 microns. During the casting process, the temperature of the molten metal was 660 degrees Celsius, the injection pressure of the molten metal was 280 bar and the injection velocity was 3.4 m/s. It was observed that the 1000 samples of the hollow tubular insert 10 without the coat 20 of the prior art deformed siginificantly, while the 1000 samples of the hollow tubular insert 10 with the coat 20 of the present disclosure did not undergo any deformation. A radiography analysis facilitated the above observations based on which it was concluded that the presence of the coat 20 of the hollow tubular insert 10 offered resistance against the described parameters of the casting process. Thus the coat 20 offered thermal insulation characteristics against the described parameters. The amount of the coat 20 applied on the inner lumen of the hollow tubular insert 10 of the present disclosure was 10 ml. so as to get an estimate and establish a correlation between the length of hollow tubular insert 10 and the amount of the coat 20 needed.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENT
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a method of insert casting where the casting includes a hollow tubular insert, that:
• offers increased accuracy of manufacturing;
• requires less cost of manufacturing; and
• avoids damage to the construction of component due to thermal loads.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or step, or group of elements, or steps, but not the exclusion of any other element, or step, or group of elements, or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingrecasting dients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A method of insert casting where the casting includes a hollow tubular insert, said method comprising the following steps:
* providing a hollow tubular insert (10), said hollow tubular insert (10) defining a lumen therethrough;
* applying a layer of coat (20) on the inner lumen of said hollow tubular insert (10) while ensuring that the operative outer surface of said hollow tubular insert (10) is free of said coat (20), to form a casting die-coated hollow tubular insert (10) having a predetermined coating thickness of said coat (20);
* providing a casting die (30);
* positioning and locating said coated hollow tubular insert (10) on said casting die (30);
* passing molten metal at a predetermined temperature, pressure and velocity into said casting die (30); and
* cooling of the molten metal to cast a component (50) embedded with said hollow tubular insert (10).
2. The method as claimed in claim 1, wherein the step of applying said layer of coat (20) includes the substeps of :
* dipping said hollow tubular insert (10) in container filled with said coat (20) for a predetermined amount of time;
* ensuring that the lumen of the hollow insert tube (10) is completely filled with said coat (20);
* draining said coat (20) filled in the lumen of said tubular hollow insert (10); and
* wiping the operative outside surface of the hollow insert tube (10).
3. The method as claimed in claim 2, wherein said predetermined amount of time is in the range of 3 minutes to 7 minutes.
4. The method as claimed in claim 1, wherein said predetermined coating thickness of said layer of coat (20) is in the range of 10 microns to 15 microns.
5. The method as claimed in claim 1, wherein positioning of said casting die-coated hollow tubular insert (10) on said casting die (30) is performed within a time period in the range of 8 minutes to 12 minutes after applying said coat (20) on said hollow tubular insert (10).
6. The method as claimed in claim 1, wherein the predetermined temperature of the molten metal to be passed into said casting die (30) is in the range between 650 degrees Celsius and 670 degrees Celsius.
7. The method as claimed in claim 1, wherein the predetermined pressure of the molten metal to be passed into said casting die (30) is in the range between 270 bar and 290 bar.
8. The method as claimed in claim 1, wherein the predetermined velocity of the molten metal to be passed into said casting die (30) is in the range between 3.2 m/s and 3.6 m/s.
9. The method as claimed in claim 1, wherein said coat (20) is a thermal insulation wax with viscosity in the range of 2 cP to 3 cP, at 250 degrees Celsius.
10. The method as claimed in claim 1, wherein the molten metal is passed into said casting die (30) at a pressure of 280 bar, a temperature of 660 degrees Celsius and velocity of 3.4 metre per second.
11. The method as claimed in claim 1, wherein said hollow tubular insert (10) has a non-linear geometry profile.
12. The method as claimed in claim 1, wherein said coat (20) is a die coat to prevent adhesion on molten metal to the casting die (30).
13. The method as claimed in claim 1, wherein the tubular insert (10) has an outside diameter of 8 mm, an inner diameter of 5mm and a length of 345 mm.
14. The method as claimed in claim 1, wherein the step of applying said coat (20) on the inner lumen of said hollow insert tube (10) includes introducing a thin tube filled with said coat (20) into the lumen of said hollow insert tube (10) and releasing said coat (20) from the thin tube.
Dated this 10th day of December, 2022

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant