FORM 2
THE PATENT ACT 1970
(39 OF 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1 TITLE OF THE INVENTION:
A PERMANENT MOULDING PROCESS FOR NON-FERROUS SLIDE BLOCK CASTINGS.

2 APPLICANT (S)
Name : Nationality :
Address:

STEEL AUTHORITY OF INDIA LIMITED.
A Govt, of India Enterprise;
Bhilai Steel Plant, Bhilai, State of Chattisgarh,India.

3 PREAMBLE TO THE DESCRIPTION
COMPLETE

The following specification particularly describes the invention and the manner in which it is to be performed.


FIELD OF THE INVENTION
The present invention relates to chill moulds for a moulding process for non-ferrous castings. The invention, is particularly directed to permanent chill moulding for non-ferrous castings, and especially the non-ferrous side block castings. The casting of non-ferrous slide block is carried out by adopting the chill moulding process that enable producing/preparing the top and bottom chill mould assembly in horizontal position and pouring of liquid metal in vertical position of finished mould. The bottom and top chill moulds are prepared from cast iron in bottom and top halves that are clamped to provide the mould system, following a moulding process using a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill. The chill mould system generate the desired cavity for non-ferrous slider block castings. The present invention thus providing a permanent chill mould for quick preparation of mould with less manpower, avoiding risk of moisture content in mould or occurrence of sand falling and also ensuring good quality of non-ferrous slider block casting providing sound castings with fine grain size and better dimensional accuracy due to metal mould, directed to improve productivity in moulding/casting shop of foundry.
BACKGROUND ART
The conventional method of non-ferrous slide block castings involved sand moulding by horizontal ramming of the top and bottom mould. The pouring is done in vertical position, with sprue opening at top. In this existing process of moulding for casting non-ferrous slide block, the mould is made by keeping the pattern in a horizontal position into the mould box, the mould being made in top and bottom halves. The two parts are usually assembled in horizontal position by clamping/bolting and then erected by means of trunion or the like means to hold the assembled mould in vertical position so that the liquid metal is carried out from top within the mould cavity through the sprue and gate arrangements provided in said sand moulds. The conventional sand moulding for casting of non-ferrous slide block castings suffered from the disadvantages like (a) moisture content in the mould leading to blow holes in solidified castings, and (b) falling of sand from top mould box and thereby damaging the casting cavity or shape of casting and or sand inclusion during pouring in vertical position. Thus the existing method of producing non-ferrous slide block
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castings suffered from the disadvantages and the limitations as described above and thereby, causing poor quality of casting with defects like blow holes etc due to moisture in mould and also dimensional inaccuracy/surface roughness due to sand moulding and also due to falling sand from the top mould during pouring in vertical position of the assembled mould.
There has been therefore a continuous need for developing a method for the casting of non-ferrous castings and in particular non-ferrous slide block castings by a method that would overcome the limitations of the conventional sand casting process and would favor obtaining sound casting free of defect and having improved surface finish and accuracy of dimension on one hand and on the other hand the time taken for mould making for re-use after one casting shall be minimized and facilitate repeated use of the same mould a number of times after cooling, cleaning and finish painting, thereby improving productivity of the foundry shop.
OBJECTS OF THE INVENTION
It is thus the basic object of the present invention to provide an improved method of permanent chill moulding for non ferrous slide block casting in a simple, reliable and cost effective manner ensuring higher productivity and also improved quality of finished non-ferrous casting.
A further,object of the present invention directed to a method of permanent cast iron chill moulding for non-ferrous slide block casting which is capable of avoiding moisture content in the mould and sand falling from top mould during pouring and thus eliminating resultant defects of the casting, producing sound casting having fine grain size of resulting cast structure, by way of favored rate of cooling through said metal mould.
A still further object of the present invention directed to a method of permanent chill moulding for non ferrous slide block casting in a simple manner that need less manpower having less skill, making the process cost effective. .
A still further object of the present invention directed to a method of permanent chill moulding for non ferrous slide block casting, wherein the mould cavity is maintained in the bottom mould and the top mould is a block of CI with flat surface binding the pouring
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cavity at the parting line between the two halves/cope and drag, needing less time and cost of manufacturing/assembly.
A still further object of the present invention directed to a method of permanent chill moulding for non ferrous slide block casting, wherein the pouring of liquit cast iron is carried out keeping the assembled and clamped top and bottom CI chill moulds in vertical position and provision of an integrated riser in the mould cavity ensure proper metal flow and producing sound non ferrous slide block castings.
A still further object of the present invention directed to a method of permanent chill moulding for non ferrous slide block casting, wherein the preparing of the chill moulds for reuse takes minimum time in between successive casting in batches, needing only cooling cleaning and painting for surfacing of mould after each pouring and solidification of the non-ferrous slid block casting.
SUMMARY OF THE INVENTION
Thus according to the basic aspect of the present invention there is provided a permanent moulding process for non-ferrous slide block castings comprising:
selectively carrying out horizontal preparation and vertical pouring involving chill mould process.
According to a preferred aspect of the invention there is provided a permanent moulding process for non-ferrous slide block castings comprising:
providing the chill mould by providing a replica core of the casting;
providing rectangular sand mould for outside profile;
placing the replica core inside the sand mould;
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providing gating arrangement for chill mould followed by clamping arrangement;
pouring by cast iron and finishing the casting.
Advantageously, in the above process of permanent moulding the same involves providing trunion arrangement for said chill mould/replica core. Also , there is clamping provision for top and bottom clamping.
Importantly, the mould is preferably painted and dried before pouring by casting.
More importantly, the casting following the above method comprises casting involving fine grain size without any moisture content in the mould and no sand falling.
In accordance with another aspect of the invention, the bottom and top chill moulds are prepared from cast iron in bottom and top halves that are clamped to provide the mould system, following said moulding process using a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill.
According to yet further aspect of the invention there is provided a chill mould system adapted to generate the desired cavity for non-ferrous slider block castings comprising bottom and top chill moulds obtained from cast iron in bottom and top halves adapted to be clamped to provide the mould system, a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill.
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The details of the invention, its objects and advantages are explained hereunder in greater detail in relation to non-limiting exemplary illustrations as per the following accompanying figures:
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURE
Figure 1(a): is the illustration of the assembled position of the chill moulds prepared for casting the non-ferrous slide blocks, showing the provision of cavity in the bottom half of the mould.
Figure 1(b): is the illustration of the prepared/assembled and clamped top and bottom chill moulds erected vertically to favour pouring of liquid metal through the sprue at top connected to the runner/gates and provision of an integrated runner, for the desired non-ferrous slide block casting.
Figure 2: is the flow diagram representing the process steps for producing the chill mould for application in non-ferrous slide block casting.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES
The invention, is particularly directed to permanent chill moulding for non-ferrous castings, and especially the non-ferrous side block castings. The non-ferrous slide block casting is carried out by adopting the chill moulding process that enable producing/preparing the top and bottom chill mould assembly in horizontal position and pouring of liquid metal in vertical position of finished mould. The bottom and top chill moulds are prepared from cast iron in bottom and top halves that are clamped to provide the mould system, following a moulding process using a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill. The assembly of the chill mould system when clamped generated the desired cavity for non-ferrous slider block castings. The present invention thus providing a permanent chill mould for quick preparation of mould with less manpower, avoiding risk of moisture content in mould or occurrence of sand falling and
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also ensuring good quality of non-ferrous slider block casting providing sound castings with fine grain size.
The making of the bottom chill mould involves preparing a replica core of the casting and a rectangular sand mould made surrounding the core to generate outside profile of chill mould. The gate arrangement, clamping arrangement and provision of trunions is made. Molten Cast iron is poured in the bottom chill mould cavity thus prepared, through the sprue to obtain the bottom CI chill mould for generating non-ferrous slide block casting. The top chill mould is prepared and cast in the same way as of the bottom chill except that the replica core is not required or used in this case, and the top chill having flat surface at the parting line. These two metal chills are prepared and assemble to obtain desired mould for casting the nono-ferrous slide blocks.
Reference is now invited to the accompanying Figure 1(a) that illustrates the top and bottom chill in assembled condition in horizontal position, with the provisioning of mould cavity in the bottom chill as described in the preceding paragraph. The top and bottom chill moulds are assembled and clamped after painting the inside surface of cavity. Trunions are provided on the mould box favor handling the complete assembled mould in two halves for desired vertical positioning before pouring.
Reference is next invited to accompanying Figure 1(b) wherein the assembled top and bottom chill moulds are seen to be in vertical position for pouring molten non-ferrous metal from top for producing slider casting. Necessary sprue, runner and gates are provided inside the mould for entry of metal in mould cavity from one side. An integrated riser provided in the mould facilitating gravity feed and ensuring sound casting without blowholes or similar other defects. The permanent metal chill moulds are adapted to generate superior quality slide block castings having fine grained structure and with higher productivity and less cost.
The accompanying flow diagram in Figure 2 illustrates the steps involved in sequence for manufacturing of the cast iron chill mould adapted to be used for non-ferrous casting of slider block. It is clearly apparent that the chill mould making involve the following steps:
a. Making of replica core similar in shape and size as of the chill mould for slider casting;
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b. Making rectangular sand mould for obtaining outside profile of chill, particularly of
bottom chill embodying the slider block shape;
c. Placing replica core inside the sand mould;
d. Providing gating arrangement for chill mould for pouring;
e. Provide trunion and clamping arrangements for the chill mould;
f. Painting and drying of mould;
g. Top and bottom moulds are clamped in horizontal position;
h. Molten cast iron is poured in mould to get the bottom chill on solidification; i. The top chill is made by following the same steps except that replica core is not used as the surface at parting line is flat.
it is thus possible by way of this invention to obtain permanent chill moulds for non-ferrous slider block casting wherein the chill moulding process and casting of slider blocks favor obtaining sound castings with fine grains at less cost, free of any blow holes or similar defects and with improved productivity in foundry shop.
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WE CLAIM:
1. A permanent moulding process for non-ferrous slide block castings comprising:
selectively carrying out horizontal preparation and vertical pouring involving chill mould process.
2. A permanent moulding process for non-ferrous slide block castings comprising:
providing the chill mould by providing a replica core of the casting;
providing rectangular sand mould for outside profile;
placing the replica core inside the sand mould;
providing gating arrangement for chill mould followed by clamping arrangement;
pouring by cast iron and finishing the casting.
3. A permanent moulding process as claimed in claim 1 comprising providing trunion arrangement for said chill mould/replica core.
4. A permanent moulding process as claimed in anyone of claims 1 to 3 wherein said clamping arrangement is provided for top and bottom clamping.
5. A permanent moulding process as claimed in anyone of claims 1 to 4 comprising painting and drying the mould before pouring by casting.
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Dated this the 31st day of May, 2008. Anjan Sen
Of Anjan Sen & Associates (Applicants Agent)
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6. A permanent moulding process as claimed in anyone of claims 1 to 5 comprising casting involving fine graion size without any moisture content in the mould and no sand falling.
7. A permanent moulding process as claimed in anyone of claims 1 to 6 wherein the bottom and top chill moulds are prepared from cast iron in bottom and top halves that are clamped to provide the mould system, following said moulding process using a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill.
8. A chill mould system generate the desired cavity for non-ferrous slider block castings comprising bottom and top chill moulds obtained from cast iron in bottom and top halves adapted to be clamped to provide the mould system, a replica core in rectangular mould for the bottom chill for the desired shape/dimension of slide block casting and a simple machined CI block without the use of core to be used as top chill.
9. A permanent moulding process for non-ferrous slide block castings and a chill mould system for use in such casting substantially as hereindescribed and illustrated with reference to the accompanying illustrations and figures.