Abstract: The invention relates to a method for producing heat-resistant casting molds from molding sand containing binder, particularly for producing an inner contour of casting molds for prototypes, large volumes and deep grooves often being produced especially in the machining of molds for rapid production of prototypes from casting materials. To increase efficiency, in a first step blocks of molding material are produced whose dimensions correspond to a mold cavity depth typically of 300 mm to 400 mm. The inner contour of the mold is then produced oversized with spacing close to the contour of the inner wall of the mold cavity by means of a roughing tool (4) that has an effective cutting diameter of 12 mm to 35 mm. The mold cavity is then machined by fast milling away of the oversize material following the contour, with a finishing cutter (3) that has a diameter-to-length ratio between 1:10 and 1:30.

Abstract: A shank-end tool is described that is simple and economical to manufacture, with permanently attached wing-like inserts for the milling-type machining of chipless materials that remains functional with unavoidable frictional wear and with increasing erosion. The shank-end tool is characterized by a shank (1) rotatable around its longitudinal axis (2) that can be connected detachably to a drive device and is provided at its free end section (6) with at least one groove-shaped recess (7) extending in the axial direction and one flat cutter blade (8), which is provided with a non-cutting blade edge (12) on its leading face viewed in the direction of advance (9). The shank-end tool is used for the manufacture of molds, especially heat-resistant casting molds for the production of metal castings.

Abstract: A method is described for uphill casting in sand molds with high-resin casting cores or especially casting cores containing binders, and with directed solidification of metallic castings that have at least one cavity. In particular, these are prototypes of engine blocks or cylinder heads, for example for internal combustion engines that are provided with a cavity through which coolant water flows. To provide for low-turbulence flow of the liquid molten metal during the deaeration of the casting mold, the casting mold is provided with at least one feeder head that is connected through a casting system to an infeed funnel, and the molten metal it contains is displaced by gravity through the casting system into the casting mold, with the cavity in the molten metal being subjected after the filling to reduced pressure that is greater than the pressure of the core gases formed in the core. This eliminates the hindrance to filling the mold from air pockets in the mold.

Abstract: The invention is directed to a method for directly producing a lost mold by machining a sand mold made with curable binders. The invention is intended in particular to decrease tool wear and to increase dimensional accuracy and exactness in the reproduction of the mold, in that a mold blank (1) to be machined is constructed by means of a pattern set (4) with the use of a variable or fixed molding box (2) and includes in its volume the desired contours of the casting mold and a machining allowance for the milling of the mold material. After filling of the molding box (2) with curable foundry mold materials, curing, and removal from the mold, the mold blank (1) is transformed into the casting mold by removal of the machining allowance by high-speed machining, milling or 3-D machining of freeform surfaces. The invention concerns lost molds for metal castings and the fabrication of casting prototypes and odd parts in the range of small-and medium-sized articles and production runs.