Quick change tool for die casting metal

Abstract

A quick change tool for use in die casting. The tool includes a pair of frame plates permanently bolted into a die casting machine. A first frame plate bolted to an upper platen of the machine and a second frame plate bolted to the lower platen. Each frame or plate can include a plurality of slotted rails that form a slotted rectangular periphery groove adapted to accept a standard size periphery ear attached to an existing die. This allows a die casting operation to retrofit old dies to fit the system while also making new dies to fit. The system allows for dies to be quickly slid out of a casting machine substantially reducing set up time in a die casting operation while still allowing for a precise relocation of the dies at each change over.

Description

CROSS REFERENCES TO RELATED APPLICATIONS

U.S. Provisional Application for Patent No. 61/066,049, filed Feb. 15, 2008, with title “Quick Change Tool and Method for Die Casting Metal” which is hereby incorporated by reference. Applicant claim priority pursuant to 35 U.S.C. Par. 119(e)(i).

Statement as to Rights to inventions made under Federally sponsored research and development: Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This present invention relates to a method and system for casting metals. Aluminum, zinc and alloys for example are commonly die cast. Molten metal under high pressure is poured into a tool steel mold and when an aluminum part has cooled it is ejected from the tool steel mold.

2. Background Information

Parts can be cast from molten metal by sand casting or by die casting. Die casting has the advantage that many parts can be formed using a single tool. A disadvantage to die casting is the time it takes to set up a die for use. Typically a die is held in a casting machine that delivers molten metal under pressure to the die and provides the power to open the die and antomatically eject parts. A significant per piece cost of die casting products comes from the cost to build the die and then the set up required each time the die is used. Typically a die is bolted and pinned to the platen of a casting machine, the process of exactly positioning the heavy die on the platen is time consuming. The dies are heavy and can be damaged during the change over operation.

Accordingly, there is a need for an improved tool and method for die casting.

SUMMARY OF THE INVENTION

According to the present invention, a novel method and tool is provided for die casting. A quick change die casting tool set includes;

a first plate frame bolted to an upper platen of a die casting machine;

and a second plate frame bolted to a lower platen of a die casting machine.

The first and second plate frames each can include a plurality of slotted die rails forming a rectangular plate frame having a slotted interior perimeter or groove.

A first ear plate bolted to the top die shoe of a die set and a second ear plate is bolted to the bottom die shoe of a die set, wherein the first ear plate is sized to slidingly fit in the slotted interior perimeter and the second ear plate is sized to slidingly fit in the second slotted perimeter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of an embodiment of the present invention, a quick change tool for die casting metal.

FIG. 2 shows details of the embodiment of FIG. 1.

FIG. 3 shows a cross sectional view through the upper frame.

FIG. 4 shows a second embodiment of the system open.

FIG. 5 shows a partial view of the second embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In accordance with the present invention, a quick change tool for casting metal is disclosed. The tool and method consists of components configured and correlated with respect to each other so as to attain the desired objective. FIG. 1 shows a quick change die assembly 100 mounted in a mold machine 200. The die assembly 100 mounts to the upper platen 200A and the lower platen 200B of a conventional die casting mold machine 200. Clamps 102 hold bolts 104 used to mount the die assembly 100 to the upper 200A and lower 200B platens. The clamps 102A hold an upper die shoe 110 to the upper platen 200A. The upper die shoe 110 includes a slot 112 to accommodate each clamp 102A. The lower die shoe 120 also includes a slot 122 around its perimeter to accommodate clamps 102B. The upper die shoe 110 has upper die rails 130, 132, 134 and 136 bolted to it to form a plate like frame. The lower die shoe 120 has lower die rails 140, 142, 144 and 146 bolted to it to form a lower plate like frame. The die assembly 100 can include at least one manifold 150 for air, die lubricant and/or die coolant as required.

FIG. 2 shows a partially disassembled view with the die rails 132 and 142 removed for disclosure. The die assembly 100 is shown open in the part ejection position. As can be seen, a conventional die set 300 is shown ready for use in the die assembly 100. The conventional die set 300 includes a lower die shoe 310, an upper die shoe 320, and guides 330. The upper die shoe 320 is bolted to an upper ear plate 340 and the lower die shoe 310 is bolted to a lower die ear plate 350. The upper ear plate 340 is designed to slide into slots 131 and 134 in the upper die rails as shown as well as slots in two (2) other upper die rails 132 and 136. Thus when installed, the peripheral edge of the rectangular upper ear plate 340 is held within the slots 131, 134 and the slots in the other two die rails 132 and 136.

Similarly, the lower die ear plate 350 periphery is held within lower die rail slots. Because molten metal is delivered under pressure, the upper die ear plate must be ground for a tight fit to the upper die shoe 110 and the upper die shoe 320. Molten metal under pressure passes through the casting machine upper platen 200A, through an opening in the upper die shoe 110, through an opening in the upper ear plate 340 and into the die set 300.

The arrangement shows that a conventional die set 300 can be attached to upper and lower die ear plates 340 and 350 and the die ear plates are held in slots. Thus a conventional die set can be retrofit to fit into the upper frame 400 (See FIG. 3) which includes the upper die shoe 110 and four (4) upper die rails 130, 132, 134 and 136 and a lower frame plate which includes the lower die shoe 120 and lower die rails 140, 142, 144 and 146. A plurality of different die sets can be attached to ear plates 340, 350 such that dies can be quickly changed in and out of the system 100. The upper and lower frames stay bolted in the casting machine platens 200A and 200B. The die ear plates 340 and 350 and slots 131, 134 and 141, 145 are precisely ground such that when a die 300 is slid into the upper and lower frames plates it will be quickly and precisely located which saves substantial time.

FIG. 3 shoes a cross-sectional view of the upper frame 400. The upper die shoe 110 includes an opening 410 that allows access to the die set 300 such that molten metal can be delivered to the interior space of the die set 300. The upper ear plate 340 and upper die shoe 320 will also have openings aligned with the opening 410.

In use when it is time to perform a die change over, bolts holding rails 132 and 142 are removed so that the die rails 132 and 142 can be removed. Once the die rails 132 and 142 are removed, one of several eye bolts can be installed in holes such as 322 such that the die 300 can be slid out of the upper and lower frames and another die can then be installed.

FIG. 4 shows a second embodiment of the die assembly 500. The die assembly 500 is shown removed from the mold machine 200 and opened with an upper frame and die shoe of the die 502 on the left and a lower frame and die shoe 504 on the right. The upper frame and die shoe 502 includes four (4) guides 510 that cooperate with holes 512 in the lower frame and die shoe 504 to guide the die assembly as it opens and closes. The upper frame and die shoe 502 includes a parameter groove 505 that allows it to be attached to the upper platen of a die casting machine 200 (See FIG. 1). The upper frame and die shoe 502 includes an upper die tool insert 520 that is held in place by bolt clamps 522 and parameter ear 531 that can be on three (3) sides of upper shoe 520. The bolt clamps 522 bolt into the main upper die shoe frame plate 530. The parameter ear 531 can be formed by a separate plate as in the first embodiment or it can be part of the upper die tool insert. The upper die shoe frame plate 530 includes an opening, shot hole similar to shot hole 410 (See FIG. 3) that allows for molten metal to be injected into a shape to be molded inside the tool insert 520. The insert of tool insert 520 is not shown and it will be understood that the tool insert will have a conventional mold shape in it. The tool insert 520 includes a threaded hole 532 that allows an eye bolt to be attached when it is time to remove the tool insert 520 from the upper die frame plate 530. The upper die shoe 502 includes an upper portion 602 of spring loaded part ejector 600. As can be seen, the slide unit part ejector 600 includes a rod 606 that cooperates in hole 608 in the lower portion 604 of the spring loaded part ejector 600. The tilt of rod 606 creates motion as the machine 200 opens, the motion can be used to eject a part that has been cast.

The lower die shoe 504 includes a lower tool insert 540 and a lower ejection insert 542 both held in place by bolt clamps 522. The lower tool insert 540 and lower ejection insert 543 each include at least one threaded hole 532 to facilitate removal with an eye bolt. The lower tool insert 540 and lower ejection insert 542 are held in a slot in lower two (2) piece die shoe frame plate 536. The parameter ear 533 holds the lower tool insert 540 and the parameter ear 534 holds the lower ejection tool 542. The lower die shoe frame plate 536 includes a parameter groove 507 that allows it to be attached to a lower platen of a die casting machine.

FIG. 5 shows the upper die body 530 and the lower die body 536 with the upper and lower tool inserts 520, 540, the lower ejection insert 542 and the spring loaded part ejector 600 removed. As can be seen, what is left is a system of slotted openings that allow the die assembly 500 to be put together. The upper die frame plate 530 includes a slotted groove 550 that holds the upper tool insert 520 in place. Slots 522 and 554 hold the upper portions 602 of part ejector 600. The upper die frame plate 530 includes a shot hole 560.

The lower die frame plate 536 includes an interior slotted groove 570 for the lower tool insert 540 and an interior slotted groove 572 for the lower ejection insert 542. The lower die frame plate 536 also includes slots 580 and 582 that hold the lower portions 604 of spring loaded part ejector 600. These slots 552, 554, 580 and 582 and slotted grooves 550, 570 and 572 provide exact placement of the tool inserts 520, 540 and 542 as well as location of the spring loaded ejector 600. This allows for tool inserts 520, 540 and 542 to be inserted and removed from the die assembly 500 to create an inner changeable tool system. Tool change over simply requires the removal of both clamps 522 and the tool inserts 520, 540, 542 can be slid out.

While the best mode for carrying out the invention has been described, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention. Thus, the above-described preferred embodiment is intended to be illustrative of the invention which may be modified within the scope of the appended claims.

Claims

1. A quick change die casting tool set comprising:

a first frame attached to an upper platen of a die casting machine,

a second frame bolted to a lower platen of said die casting machine,

wherein said first frame includes a plurality of slotted die rails forming a first rectangular frame having a first slotted interior perimeter,

wherein said second frame includes a plurality of slotted die rails forming a second rectangular frame having a second slotted interior perimeter,

a first perimeter ear on a top die shoe of a die set and a second perimeter on a bottom die shoe of a die set, wherein said first perimeter ear is sized to slidingly fit within said first slotted perimeter and said second perimeter ear is sized to slidingly fit within said second slotted perimeter.

2. The quick change die casting tool as recited in claim 1, wherein said top and bottom die shoes can be removed by removing a first and second slotted die rails and sliding said die set out of said first and second slotted interior perimeter.

3. The quick change die casting tool as recited in claim 2, wherein said die set includes a spring loaded part ejector and an upper portion of said part ejector is held on said upper first body by a slot and groove.

4. A quick change die casting tool set comprising:

a first plate attachable to an upper platen of a die casting machine,

a second plate attachable to a lower platen of said die casting machine,

wherein said first plate has an interior slotted groove,

wherein said second plate has an interior slotted groove,

a first ear on a top tool insert of a die set and a second ear on a bottom tool insert of a die set, wherein said first ear is sized to slidingly fit within said first slotted groove and said second ear is sized to slidingly fit within said second slotted groove.

5. The quick change die casting tool as recited in claim 4, wherein said die set includes a spring loaded part ejector and an upper portion of said part ejector is held on said upper first body by a slot and groove.

6. The quick change die casting tool set as recited in claim 4, wherein said first plate includes a plurality of individual rails attached together to form said plate and wherein each rail includes a portion of said first slotted groove.

7. The quick change die casting tool as recited in claim 4, wherein the second plate includes a plurality of individual rails attached together to form said plate and wherein each rail includes a portion of said second slotted groove.

8. The quick change die casting tool as recited in claim 4, wherein said first plate is formed from a single piece and said first slotted groove is machined into an interior perimeter of the piece.

9. A quick change die casting tool assembly comprising:

a first plate attachable to an upper platen of a die casting machine,

a second plate attachable to a lower platen of said die casting machine,

wherein said first plate has an interior slotted groove formed on an interior perimeter,

wherein said second plate has an interior slotted groove formed on an interior perimeter,

a first ear on a top portion of a die set and a second ear on a bottom portion of a die set,

wherein said first ear is sized to slidingly fit within said first slotted groove and said second ear is sized to slidingly fit within said second slotted groove, and wherein a threaded fastener holds said top portion of said die set in said first slotted groove and a second threaded fastener holds said bottom portion of said die set in said second slotted groove.

10. The quick change die casting tool assembly as recited in claim 9, wherein said die set includes a spring loaded part ejector held on said upper first body adjacent said upper portion of said die set.

11. The quick change die casting tool assembly as recited in claim 9, wherein said first plate includes a plurality of individual rails attached together to form said plate and wherein each of said individual rail includes a portion of said first slotted groove and wherein the second plate includes a plurality of individual rails attached together to form said plate and wherein each of said individual rail includes a portion of said second slotted groove.

12. The quick change die casting tool assembly as recited in claim 9, wherein said first plate is formed from a single piece and said first slotted groove is machined into an interior perimeter of the piece.

13. The quick change die casting tool assembly as recited in claim 9, wherein said die set can be removed by removing said first and second fasteners and sliding said die set out of said first and second slotted grooves.