DESC:FIELD OF THE INVENTION
The present invention relates to a system for casting mold buffing and a method thereof. More particularly, the present invention provides an adjustable vertical system and method to perform buffing on at least one side of the mold at a time, which improves the cooling rate of casted ingot, improves quality of ingot and eventually increase the life of the casting mold.
BACKGROUND OF THE INVENTION
Generally, in casting industry, molding process, refers to molding material melted by heating in a furnace and laid under gravity into a cavity of a mold, closed at a high temperature and is cooled to obtain a finished or semi-finished mold product. The common method to performing the cooling operation involves passing the molten material packed mold through water channel. However, the high temperatures involved in the process induce the formation of a layer or scaling on the mold surface due to presence of calcium and magnesium salts present in water reacting with atmospheric oxygen and water. This formation of a layer or scaling is particularly prominent on the side of the mold exposed directly to the water or water channel.
This formation of a layer or scaling significantly increases the thermal resistance and creates a thermal interlocking of the mold which further decreases the rate of heat transfer causing uneven cooling and heating of casted pattern that leads to defects because of shrinking or wrapping and eventually affecting the quality of product. Further, in terms of productivity from this point of view the slow rate of heating undermines the efficiency of manufacturing operations. Also, in some of the extreme cases this formation of a layer or scaling results in shortened lifespans of mold and ultimately increases the operation costs.
Amid the competitive business world where every single industry is down in a race to achieve maximum productivity with quality, it is required to develop a system and method that will buff the formation of layer or scales from the casting mold in order to improve the cooling rate of the casting mold and reduce the adverse effects of uneven cooling on the productivity.
The state-of-the-art systems that provide buffing are too complex and cumbersome, that are complex and expensive. Further, there is no flexibility when it comes to accommodating size of the casting mold.
CN213793060U, The utility model discloses a cleaning device for processing metal castings, which comprises a cleaning box body, wherein the top of the cleaning box body is provided with a cleaning water tank, the bottom and the right side of the cleaning water tank are both connected with water outlet pipes, the outer side wall of each water outlet pipe is provided with a valve switch, one end of each two groups of water outlet pipes is connected with a water distribution plate, one side of each water distribution plate facing the inner cavity of the cleaning box body is provided with a plurality of groups of spray heads, the left side of the inner cavity of the cleaning box body is provided with a cleaning device, the left side wall and the right side wall of the inner cavity of the cleaning box body are directly provided with a filter screen plate, the inner cavity of the filter screen plate is rotatably connected with a rotating shaft, the outer side wall of the rotating shaft is provided with a positioning device, a rotating roller is rotatably connected between the bottoms of the left side wall and the right side wall of the inner cavity of the cleaning box body, the outer side wall of the inner motor is provided with a waterproof cover, the left side wall of the cleaning box body is respectively provided with a de-slagging port and a water outlet, the utility model provides an efficient, effectual metal casting belt cleaning device, and
CN111941190A, The invention discloses a rough machining device for producing a metal steel casting, which comprises a workbench, wherein the top of the workbench is connected with a supporting rod, the supporting rod is connected with a longitudinal adjusting assembly, a transverse adjusting assembly is arranged above the longitudinal adjusting assembly, the transverse adjusting assembly is connected with a connecting plate through a first electric telescopic rod, the bottom of the connecting plate is fixedly connected with a first motor, the first motor is connected with a polishing disc through a rotating shaft, the top of the workbench is provided with a clamping assembly, the top of the workbench is provided with a plurality of groups of through holes, the bottom of the workbench is fixedly connected with a placing frame, the top of the placing frame is provided with a water tank, and the rear side of the; can adjust the longitudinal position of making the mill through vertical adjusting part, can adjust the lateral position of making the mill through horizontal adjusting part, fix the casting through the center gripping subassembly simultaneously, detach the cuttings that produce when polishing through the dust absorption subassembly, prevent to cause the injury to staff's health, wash the workstation through the shower nozzle.
Therefore, there is a technological gap wherein a system for casting mold buffing and method thereof is required, to improve the quality of cast parts, the efficiency of manufacturing and a simple system with adjustable system that is cost effective.
OBJECT OF THE INVENTION
Accordingly, to overcome the drawbacks of the prior art, the main object of the present invention is to provide an adjustable vertical buffing system for casting mold buffing and method thereof to improve the quality of cast parts and the efficiency of manufacturing.
Yet another object of the present invention is to provide an adjustable vertical buffing system for buffing casting mold, that requires less area to install and operate than the horizontal systems.
Yet another object of the present invention is to provide a vertical standing system for buffing casting mold, that requires less area to install and operate and is adjustable to accommodate different size casting molds.
Yet another object of the present invention is to provide a system for casting mold buffing and method thereof that improves heat distribution within molds, ensuring uniform cooling and solidification of cast material without defects due to shrinkage or warping.
Yet another object of the present invention is to provide a vertical standing system for buffing casting mold that can accommodate the width of any conveyor system.
SUMMARY OF THE INVENTION
In carrying out the above objects of the present invention, the present invention provides a vertical standing system for buffing casting mold and method thereof, the buffing operation is executed in at least one side of the mold which improves the cooling rate of casted ingot and eventually increasing the life of the casting mold.
The present invention provides a vertical standing system for buffing casting mold comprising plurality of adjustable base channels provided with plurality of bearing blocks defining a supporting structure for a buffing wheel mounted on a shaft for removing layers or scales from the sides of the casting mold, and a motor coupled to the buffing wheel to transmit power required to rotate the buffing wheel.
In preferred embodiment of the system for casting mold buffing is sequentially assembled over a conveyor and the buffing wheel is rotating along the opposite direction of the conveying direction of the conveyor.
In preferred embodiment of the system for casting mold buffing improves the cooling rate by 9 to 16 degrees Celsius.
In an embodiment of the present invention, the present invention provides a system for casting mold buffing comprises of plurality of adjustable base channels provided with plurality of adjustable bearing blocks, a buffing wheel mounted via the adjustable bearing blocks rotated by a motor coupled to the shaft to transmit power required to rotate the buffing wheel for removing layers or scales from the sides of the casting mold, wherein the angle of buffing wheel is adjusted by moving the bearing blocks, vertically up or down, either alone or together; the height of the buffing wheel is adjusted by adjusting the adjustable frame and by moving it vertically up or down along with the motor, and the bearing blocks, vertically up or down, either alone or together, and the width of the system for casting mold buffing is adjustable via the adjustable base channels.
In an embodiment of the present invention, the present invention the method of casting mold buffing comprising steps of passing plurality of casting mold on a conveyor, and allowing a buffing wheel mounted on an adjustable shaft for accommodating and removing layers or scales from the sides of the casting mold, and a motor installed on an adjustable frame, and the motor is further coupled to the shaft to transmit power required to rotate the buffing wheel, wherein the angle of buffing wheel is adjusted by moving the bearing blocks, vertically up or down, either alone or together; the height of the buffing wheel is adjusted by adjusting the adjustable frame and by moving it vertically up or down along with the motor, and the bearing blocks, vertically up or down, either alone or together, and the width of the system for casting mold buffing is adjustable via the adjustable base channels.
In another embodiment of the present invention, the present invention provides specific advantage of accommodating casting molds of different sizes and shapes as it provides an adjustable frame for moving the motor, vertically up or down, thereby adjusting the height of the shaft. This feature specifically allows adjusting the position of the buffing wheel with reference to the molds which allows proper alignment and positing of the buffing wheel to configure the right distance for proper buffing.
In another embodiment of the present invention, the present invention provides another specific advantage wherein the angle of the shaft can be easily manipulated by moving the bearing blocks. This allows the shaft to places either at an incline or a decline, which specifically allows sides to be buffed specifically.
In another embodiment of the present invention, the present invention provides another specific advantage wherein the width of the system for casting mold buffing is adjustable via the adjustable base channels, which allows the system to accommodate large and small conveyor system.
In another embodiment of the present invention, the present invention provides another specific advantage wherein a vertical standing system is simple, cost effective and requires considerably less space to be installed and operated.
These and other features, aspects, and advantages of the present subject matter will become better understood with reference to the following description and appended claims. This summary is provided to introduce a selection of concepts in a simplified form. This summary is neither intended to identify key features or elements of the claimed subject matter nor is it intended to be used to limit the scope for the claimed, subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
The object of the invention may be understood in more details and more particularly description of the invention briefly summarized above by reference to certain embodiments thereof which are illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective equivalent embodiments.
Figure 1 illustrates a perspective view of an exemplary buffing machine; and
Figure 2 elucidates a prospective view of the vertical standing system for mold buffing.
DETAILED DESCRIPTION OF THE INVENTION
Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder. The illustrative embodiments described in the detailed description are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.
In an embodiment of the present invention, the present invention provides a system for casting mold buffing and method thereof to perform buffing operation on at least one side of the mold which will improve the cooling rate of casted ingot and will eventually increase the life of the casting mold.
The purpose of present invention is to provide the system for buffing layers and scale from the side of a mold exposed to water to leverage the diverse benefits by enhancing mold performance and also elevates part quality and increases overall productivity.
Further, the present invention optimizes heat transfer within molds, thereby ensuring uniform cooling and solidification of cast materials. Consequently, this mitigates defects such as shrinkage or warping in the final cast parts caused because of uneven cooling of casting mold. Moreover, the buffing significantly extends the lifespan of molds by reducing wear and tear, a critical aspect especially for molds subjected to frequent use or abrasive casting.
The aforesaid and other advantages of the present subject matter would be described in greater detail in the following description.
Referring to Figure 1, a system for casting mold buffing (100) comprises of plurality of adjustable base channels (102) provided with plurality of bearing blocks (104) defining a supporting structure for a buffing wheel (106) mounted on an adjustable shaft (108) for removing layers or scales from the sides of the casting mold, and a motor (110) coupled to the adjustable shaft (108) to transmit power required to rotate the buffing wheel (106).
In preferred embodiment, the buffing wheel (106) is a brush type buffing wheel that is made of mild steel. However, in another embodiment, the buffing wheel (106) may be made of different material in accordance with the material strength required in the system for casting mold buffing (100).
In preferred embodiment, the shaft (108) is supported by the bearing blocks (104) which supports the weight as well as the rotation provided to the shaft (108) through the motor (110).
In preferred embodiment, system for casting mold buffing (100) is crafted for the buffing of the casting mold (200), more particularly the side that is exposed to the cooling water, to keep the mold (200) free from scaling and reduce the adverse effects on the productivity and the quality of the ingots.
In preferred embodiment of the system for casting mold buffing (100) is sequentially assembled over a conveyor and the buffing wheel (106) is rotating along the opposite direction of the conveying direction of the conveyor.
In Figure 2, elucidates a prospective view of the vertical standing system for mold buffing. The system for casting mold buffing (100) provides an adjustable frame (112) for moving the motor, vertically up or down, thereby adjusting the height of the shaft. This feature specifically allows adjusting the position of the buffing wheel (106) with reference to the molds which allows proper alignment and positing of the buffing wheel to configure the right distance for proper buffing. The system for casting mold buffing (100) further provides adjustments to the angle of the shaft by moving the bearing blocks. This allows the shaft to be adjusted either at an incline or a decline, which specifically allows sides to be buffed. Furthermore, the height of the system for casting mold buffing (100) is adjustable via the adjustable base channels (102), which allows the system to accommodate large and small casting mold and buff them with equal efficiency and proficiency.
In an embodiment of the present invention provides adjustable base channels which has a massive base to counterbalance the extended support member. The adjustable frame (112) and the adjustable base channel (102) include mechanisms utilize state of the art technologies that are incorporated in the invention. The adjustable frame (112) preferably uses radial clamping systems, whereas a tapered collet is drawn down into a taper by a threaded nut, that allow the frame (112) to be adjusted vertically up or down. The adjustable base channel (102) frame allows the frame to be extended via the massive base include systems which allow an adjustable frame that includes a fixed lower portion and a moveable upper portion coupled to, and moveable relative to, the upper portion; and a guide tube that includes a handle detachably coupled to the upper portion of the frame.
In another embodiment of the present invention, the invention provides a significant advantage when a temperature analysis was performed. The results of the final temperature of the ingot and the temperature of metal poured into the mold for casting in the casting mold with buffing and casting mold without buffing is shown in below table.

It is noted that there is 9 to16 degree (verified by data) Celsius temperature difference in the final ingot temperature, which impacts significantly on the final quality of the ingot.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention.
,CLAIMS:We Claim,

1. A system for casting mold buffing (100) comprises of plurality of adjustable base channels (102) provided with plurality of adjustable bearing blocks (104), a buffing wheel (106) mounted via the adjustable bearing blocks (104) rotated by a motor (110) coupled to the shaft (108) to transmit power required to rotate the buffing wheel (106) for removing layers or scales from the sides of the casting mold.

2. The system for casting mold buffing (100) as claimed in claim 1, wherein the angle of buffing wheel (106) is adjusted by moving the bearing blocks (104), vertically up or down, either alone or together.

3. The system for casting mold buffing (100) as claimed in claim 1, wherein the height of the buffing wheel (106) is adjusted by adjusting the adjustable frame (112) and by moving it vertically up or down along with the motor (110), and the bearing blocks (104), vertically up or down, either alone or together.

4. The system for casting mold buffing (100) as claimed in claim 1, wherein the width of the system for casting mold buffing (100) is adjustable via the adjustable base channels (102).

5. The system for casting mold buffing (100) as claimed in claim 1, wherein the width of the system is adjusted by adjusting the base channels (102).

6. The system for casting mold buffing (100) as claimed in claim 1, wherein the buffing wheel (106) is a brush type buffing wheel that is made of mild steel.

7. The system for casting mold buffing (100) as claimed in claim 1, wherein the shaft (108) is supported between the bearing blocks (104) which will support the weight as well as the rotation provided to the shaft (108) through the motor (110).

8. The system for casting mold buffing (100) as claimed in claim 1, wherein the casting mold buffing (100) is sequentially assembled over a conveyor and the buffing wheel (106) is rotating along the opposite direction of the conveying direction of the conveyor.

9. A method of casting mold buffing (100) comprising steps of passing plurality of casting mold on a conveyor, and
allowing a buffing wheel (106) mounted on an adjustable shaft (108) for accommodating and removing layers or scales from the sides of the casting mold, and a motor (110) installed on an adjustable frame (112), and the motor (110) is further coupled to the shaft (108) to transmit power required to rotate the buffing wheel (106),
wherein
the angle of buffing wheel (106) is adjusted by moving the bearing blocks (104), vertically up or down, either alone or together; the height of the buffing wheel (106) is adjusted by adjusting the adjustable frame (112) and by moving it vertically up or down along with the motor (110), and the bearing blocks (104), vertically up or down, either alone or together, and the width of the system for casting mold buffing (100) is adjustable via the adjustable base channels (102).