Abstract: An injection molding assembly comprising a collapsible core assembly, an injection mold press comprising an internal cavity configured to receive the collapsible core assembly, and an actuator configured to insert the collapsible core assembly into the internal cavity of the mold press and method of using the same. The collapsible core assembly may comprise a static core member, a moveable core member coaxial to the static core member and moveable relative to the static core member, and a stripper plate moveable within the collapsible core assembly relative to the static core and configured to eject the molded part. The moveable core member may comprise an external engagement feature disposed at an end of the moveable core member. The external engagement feature may define a geometry operable to matingly engage an internal feature of a molded part supported on the moveable core member upon formation of the molded part.

Abstract: A sand knock-out head clamping assembly of a casting vibratory apparatus for engaging a casting to be vibrated is provided. The assembly includes a holder configured to be releasably mounted to a vibratory mechanism of the vibratory apparatus. The holder includes a holder body having a first face in contact with the vibratory mechanism and a second face opposite the first face. The holder body includes an engagement member extending outwardly from the second face. An insert is removably mounted only to the holder. The insert is configured to at least partially receive the engagement member.

Abstract: An apparatus for casting material has a die for receiving a compressive force, the die having a shaped-opening for receiving a die insert. The die insert has an exterior shape that is adapted to cooperate with and be received in the opening such that compressive forces impinging upon the die are focused upon the die insert such that tensile forces within the die and impinging upon the die insert are minimized.

Abstract: A decoring method and system is provided. The method includes the steps of providing the casting having a core material disposed in the internal passage; providing the decoring apparatus configured to selectively oscillate the casting and selectively rotate the casting; securing the casting in the decoring apparatus; introducing a quantity of shot into the internal passage of the casting; oscillating the casting; and rotating the casting. A decoring apparatus configured to selectively oscillate the casting along a first axis, rotate the casting about a second axis, and rotate the casting about a third axis, is also provided.

Abstract: An apparatus for core gas removal in a low-pressure cylinder head die casting operation includes an upper die, a lower die, an ejector plate disposed above the upper die to eject a part that has been cast, a plurality of tight plugs fastened into cavities formed in the upper die, and a plurality of clean pins attached to the ejector plate, each clean pin corresponding to a location of one of the tight plugs. The clean pins and the tight plugs have matching geometries. The ejector plate lowers to eject a casted cylinder head from the upper die such that a portion of the clean pins extend axially into the tight plugs to clean core gas residue formed on inner walls of the tight plugs during the casting cycle.

Abstract: A decoring method and system is provided. The method includes the steps of providing the casting having a core material disposed in the internal passage; providing the decoring apparatus configured to selectively oscillate the casting and selectively rotate the casting; securing the casting in the decoring apparatus; introducing a quantity of shot into the internal passage of the casting; oscillating the casting; and rotating the casting. A decoring apparatus configured to selectively oscillate the casting along a first axis, rotate the casting about a second axis, and rotate the casting about a third axis, is also provided.

Abstract: A method for core pulling and insertion in synchronization with the opening and closing of the mold in a cavity including a fixing half and a moving half, or a fixing half, a moving half and several cavity plates installed between fixing half and moving half as well as the core moving reciprocally inside the cavity, wherein a downward movement of a transmission gear is coupled with an opening of the mold, synchronous with a pulling of the core out of the cavity, and an upward movement of the transmission gear is coupled with a closing of the mold, synchronous with an insertion of the core into the cavity.

Abstract: To destructively remove a casting core from a cast part, the part is exposed to a combination of nitric acid and sulfuric acid. The combination may have, by volume, a nitric acid concentration of 4-20 times the sulfuric acid concentration. The combination may be an aqueous solution including, by volume, 40-60% nitric acid and 3-10% sulfuric acid. The method may remove a ceramic casting core and a refractory metal-based casting core. A first leaching step may remove a major portion of the ceramic casting core and may comprise alkaline leaching. A second leaching step may remove a major portion of the refractory metal-based casting core and may comprise acid leaching. The acid leaching may comprise the combination of nitric acid and sulfuric acid.

Abstract: A method for controlling the retention time of a casting retained in a mold comprises providing a vibratory shakeout conveyor having a conveying surface, placing the mold on the conveyor; and imparting a vibratory force to the conveyor at a predetermined angle to the conveying surface whereby the predetermined angle determines the retention time of said casting in said mold. A plurality of sensors for detecting mold position and media breakdown may also be employed to detect appropriate mold retention time.

Abstract: A wall cooling arrangement comprising on one side of a wall a multiplicity of cooling fluid inlet apertures and on the opposite of the wall a multiplicity of cooling fluid exit apertures, and in the body of the wall linking said inlet and exit apertures a network of multiply branched cooling passages. Flow of cooling fluid through a network is controlled by a throat positioned either at or close to the inlet to the passage network or at a location part way through the network, in which case there may be a plurality of inlet apertures feeding through a single throat to a plurality of outlet apertures.

Abstract: In a cylinder device of the present invention, based on a screwing relationship between a screw rod 30 and a ball screw mechanism 35 and through oil supply port control, the piston and sleeve 15 is made to advance or retract while being rotated. A rear end side of a rod 12 is fitted into a sleeve portion 34 of the piston and sleeve 15. Then, a fitting and coupling mechanism that uses an engagement key 41 and a key groove 42 causes only a rotation torque of the piston and sleeve 15 to act on the rod 12. The rod 12 with a screw core 22 coupled thereto operates at a pitch defined by a screwing relationship between the rod 12 and a rod cover 13. The pitch defined by the screwing relationship is the same as a pitch of the screw core 22.

Abstract: To destructively remove a refractory metal casting core from a cast part the part is exposed to a combination of nitric acid and sulfuric acid.

Abstract: A thermal-oxidative process is used to remove a casting core from a cast part.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply fluid to the castings for heat treating the castings and degrading the sand cores for removal from the castings.

Abstract: A die-casting system includes a core withdrawing device (50). The core withdrawing device is configured independently of a die (D1, D2) and is operable to withdraw a core (d) from the die.

Abstract: The removal of ceramic material from the interior of cast metallic components is accomplished in a closed system. A vessel within the system is filled with a chemical leaching fluid that immerses the cast component having the ceramic material and/or ceramic cores therein. The leaching fluid is superheated and boiling is controlled by varying the pressure within the closed system without changing the molecules in the vessel.

Abstract: A plurality of profile portion divided metal molds 12 surround a profile portion 11a of a supercharger rotor 11 to allow division. A pair of end metal molds 14 and 15 surround both ends of the rotor. A helical core 16 is attached to one end metal mold 14 so as to be helically passed through the profile portion of the rotor. A rotor-shaped cavity 13 is formed inside by the profile portion divided metal molds, and the end metal molds. Hot metal is pressurized, and injected and solidified in the cavity. Then, the end metal mold 14 having the helical core is pulled out by being rotated along a helical line.

Abstract: The removal of ceramic material from the interior of cast metallic components is accomplished in a closed system. A vessel within the system is filled with a chemical leaching fluid that immerses the cast component having the ceramic material and/or ceramic cores therein. The leaching fluid is superheated and boiling is controlled by varying the pressure within the closed system without changing the molecules in the vessel.

Abstract: A system and method for heat treating castings and removing sand cores therefrom. The castings are initially located in indexed positions with their x, y, and z coordinates known. The castings are passed through a heat treatment station typically having a series of nozzles mounted in preset positions corresponding to the known indexed positions of the castings passing through the heat treatment station. The nozzles apply heat to the castings for heat treating the castings and dislodging the sand cores for removal from the castings.

Abstract: A casting 31 is fixed to a support member 23, and the casting 31 is hit by a hammer 43 while vibrating the support member, so that vibrations of different properties are applied to the casting to shake out the sand.

Abstract: The invention relates to a casting method for producing a box piston which comprises recesses between the hub support and the ring band. The invention aims to further reduce the weight of the piston. The casting cores which produce the recesses can therefore be pivoted during stripping.

Abstract: The removal of bonded sand, either core sand or mold sand, from a metal casting comprises placing the metal casting in a furnace chamber and subjecting the metal casting to the action of a high velocity heated gas stream (preferably above 3000 ft/minute) from hot air generators positioned on opposite sides of the chamber at the approximate level of the metal casting and directed to the metal casting. The heated gas stream is at a temperature and oxygen content sufficient to oxidize the binder in the bonded sand and a velocity sufficient to remove the debonded sand. The sand is removed by gravity from the furnace chamber.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: An apparatus and method for extracting a cast iron pipe from a centrifugal casting machine and for also breaking the continuity of an annular sand core used to form the bell end of the pipe. The apparatus has a carrier member on which are mounted extractor carrier jaw assemblies and core continuity breaking members. The extractor jaw assemblies are movable between extended and retracted positions. One end of the carrier member is inserted into the bell end of the pipe while the pipe is in the casting machine. The extractor jaw assemblies are retracted as the carrier member enters the pipe. As the carrier member enters the pipe, the core continuity breaking members plow through parts of the sand core to break the continuity of the sand core. The extractor jaw assemblies are then extended to contact the interior surface of the pipe wall and the apparatus is retracted, pulling the pipe out of the mold in the casting machine.

Abstract: A metal mold arrangement for producing a closed deck type cylinder block in which a plurality of bridge portions partly cover an open end of a water jacket at a top deck side of the cylinder block. A water jacket die provides a configuration of a water jacket. A plurality of recesses are formed in the water jacket die, and each separate core having a shape complementary to the recess is insetted in each recess. Each separate core has a top deck side end face and a crank case side end face opposite thereto. The two faces are slanted in a direction opposite to each other for serving as drafts. A bottom of each recess is also slanted coincident with the slant of the top deck side end face, and each bridge portion is formed adjacent the bottom of the recess. Upon solidification of a molten metal, the water jacket die is removed from the casted product while each separate core remains in a resultant water jacket.

Abstract: A system for removing waste material from the bell end of a cast iron pipe is disclosed. The system has both a cleaning assembly and an exhaust system. The cleaning assembly has a plurality of wire brushes mounted on a shaft. The shaft is mounted on a cart that also supports a movable part of the exhaust system. The cart moves the wire brushes and part of the movable part of the exhaust system into and out of the bell end of the pipe. A motor on the cart rotates the shaft and brushes, and a tilt mechanism tilts the brushes down to contact the pipe. The pipe is rotated about its central longitudinal axis as the brushes contact and clean the pipe. The rotating brushes clean the sand core from the end of the pipe, and the waste sand is drawn by the exhaust system to the bag house where it is filtered. The exhaust system also includes a stationary duct. The stationary duct has a door and a chute. Larger chunks of waste sand can be removed from the exhaust system through the door and chute.

Abstract: A melt tank is disclosed having a plurality of cartridges wherein each cartridge is adapted to hold at least one molded part. An annular tank is provided having an open top while a substantially circular plate is coaxially rotatably mounted to the top of the annular tank. The circular plate includes a plurality of circumferentially spaced openings formed around its outer periphery wherein each opening is adapted to slidably receive and support one cartridge. The annular tank is filled with a heated liquid while a motor rotatably drives the plate with the molded parts immersed in the heated liquid. A robotic gantry selectively lifts the cartridges from the circular plate to enable the removal of finished melted out parts as well as the insertion of new molded over parts into the cartridges.

Abstract: Apparatus for removing a ceramic core from a casting in a relatively rapid manner wherein the casting and a fluid spray nozzle are disposed in a manner to expose a region of the core to a core dissolving fluid discharge of the nozzle and a core dissolving fluid is discharged from the nozzle toward the core region to contact the core region and dissolve core material therefrom and progressively from further regions of the core within the casting as they become exposed as core material is progressively removed. The discharge of fluid from the nozzle can be interrupted periodically to allow dissolved core material and fluid to drain from inside the casting or, alternately, the casting and nozzle can be relatively moved so that the casting can drain and/or forced air can be directed at the casting to this same end at a location spaced apart form the nozzle.

Abstract: The device comprises a rigid frame (12) having a vertical axis of symmetry X) forming a virtual axis of oscillation of the frame defined by the intersection of the longitudinal and transverse vertical median planes of the frame. This frame is connected to a fixed support (14) by elastically deformable connecting elements (16). The decoring device further comprises two devices (24) for clamping castings to be decored carried by two opposite ends of the frame (12) and aligned in the longitudinal median plane, and two out of balance motors (26) fixed to two opposite sides of the frame (12), these motors having axes of rotation parallel to the axis of symmetry (X) of the frame (12) and being aligned with this axis of symmetry in the transverse median plane. The motors (26) are adapted, in operation, to cause the frame (12) to oscillate about its virtual axis X so that the centre of gravity of each casting to be decored describes a substantially horizontal and ellipsoidal path.

Abstract: The apparatus includes a wheel mold that has a top segment having a plurality of openings formed therethrough. Movable cores are carried in the top segment openings. A mechanism is mounted on the top segment to alternately extend the cores into the mold cavity and retract the cores into the openings. To form a wheel, the movable cores are extended and molten metal is introduced into the mold cavity. The movable cores form recesses in the resulting wheel casting. After casting has cooled sufficiently, the movable cores are retracted from the recesses allowing the top segment to be withdrawn from the wheel casting. The casting is then removed from the mold.

Abstract: The special angular fixture or jig for mounting a casting, such as a die cast engine block, resiliently holds the casting both inside and outside of a cabinet, in which cabinet the casting is high-frequency-vibrated for removing an expendable and disintegrated core, such as of sand, from the casting. The fixture is so located with respect to the door to the cabinet so that when the door is closed, the casting on the fixture is resiliently held between the closed door and a vibrating plate of a high-frequency vibrator. Specifically, the fixture disclosure is L-shaped and mounted on cushioned legs to a downwardly open door to a cabinet, which legs permit the casting to be urged against a vibrating plate mounted in the cabinet when the door of the cabinet is closed. The cabinet collects the particles of the disintegrated core which are vibrated from the casting.

Abstract: A die casting apparatus for casting an article with an internally screw-threaded bore. The die casting apparatus includes a support, a die assembly coupled to the support, a core pin with external threads which are movable into and out of the die assembly, a lead screw for moving the core pin, a fixed bushing threadedly receiving the lead screw therein, a drive assembly, and a control assembly. The drive assembly has a hydraulic motor with an ouptut shaft that is axially arranged relative to the core pin for smoothly driving the core pin and lead screw. The external threads of the core pin and the external thread of the lead screw are identical for driving the core pin and the lead screw at the same rate to avoid damaging the newly formed internal threads of the cast article.

Abstract: A vibratory stress relief apparatus is provided and has a resiliently supported base and an adjustable rate vibratory member on the base. A housing having a support plate and spaced side walls is resiliently supported on the base. A casting rests in the housing with a closure secured to the support plate in spaced relation to the casting. Shims are provided for positioning the closure a predetermined distance from the casting whereby the vibratory member will vibrate the housing and the casting and will hammer and rattle the casting between the closure and the support plate to relieve stresses in the casting and to clean sand and other impurities from the internal and external surfaces of the casting.

Abstract: An apparatus usable for cleaning foreign material from the internal and external surfaces of a part, including a container of particulate media, a vibration generator for the container which creates an amplitude and frequency which will fluidize the media, and means for suspending the part in the fluidized media. The suspending means is vibrated at an amplitude and frequency different from the amplitude and frequency of the container whereby the fluidized media will clean the foreign material from the internal and external surfaces of the part.

Abstract: A casting decoring device to decore metal castings by vibration within an enclosure. The enclosure provides a dust and sound isolation of the casting from the environment with the casting held in an isolation fixture within. A time control circuit is provided to cycle the device according to the size and number of castings within to be treated.

Abstract: A moulding machine comprising a framework and at least one core extraction jack mounted on a bearing element movable on the framework. It is characterized in that the bearing element (6) is carried by at least two supports (5) secured against motion to the guide devices (4) each comprising a securing member (8) clamping the corresponding guide device and at least one arm (9) integral with the securing member, the bearing element being fixed to an arm of each of the supports.

Abstract: The specification discloses a die casting machine of the type adapted to form an article with an internal threaded portion. The threaded portion is formed by means of a threading device which is retractable. The threading device is rotatably and retractably operated by a pinion which in turn is rotated by a cog wheel. The die casting machine may contain a plurality of molding cavities, each being provided with the threading device. The cog wheels may be driven by a common rack which is hydraulically operated. Since the threading device of this invention is retractable, it is feasible to repeat a casting cycle without replacing the mold. Thus, it is much faster to fabricate such articles with the present machine than conventional die casting threading apparatus. Because no part is replaced or removed from the die casting machine in the present invention, it is possible to minimize possible dimensional variation among the articles fabricated.

Abstract: An acoustically enclosed apparatus for shaking out sand-cores from metal castings. A plurality of percussive shakeout stations are spaced around the circumference of a turntable. The stations are separated one from the other and from their surroundings by an acoustical enclosure which rotates with the turntable and within a stationary enclosure. The castings are loaded and unloaded through outwardly facing access openings in the rotatable enclosure as they become registered with an access port in the stationary enclosure. Shaking out is effected while the access openings are out of registry with the access port. The sand collector beneath the stations attenuates the sound emitted from beneath the station.

Abstract: A sound-sealing sand trap for rotary acoustic sand-core shakeouts including bottom-opening, sand-funneling chutes beneath each decoring station and an open-centered tray beneath the sand-funneling chutes. The tray includes a sand-supporting shelf bound on its outer periphery by a sand-level-retaining rim, and on its inner periphery, and edge defining the central opening. Debris entering the tray from the chutes is readily removable through the central opening either manually by the operator or automatically by the plowing action of the chutes through the sand bed.

Abstract: A mold, for screw-threaded articles, has screw-thread forming spindles rotatable by obliquely toothed gearing so as to apply axial thrust to the spindles and thus compensate for friction and adhesion in unloading of the mold.

Abstract: An expandable core for forming an internal recess in a molded part, composed of a stationary core pin having a generally conical outer surface and a segmented sleeve composed of two groups of lateral slides disposed around the pin with the slides of one group alternating with the slides of the other group. The conicity of the pin outer surface and the slide guidance along the pin are identical for all slides of the same group but are different from one group to the other.

Abstract: An apparatus for and method of removing a flexible tubular conduit from around an associated elongated rigid supporting mandrel which is at least several feet in length is provided wherein the mandrel and its conduit is supported on a support structure whereupon the conduit and mandrel are relatively moved axially to remove the mandrel from within the conduit.

Abstract: Seamless tubular products made of metal, particularly steel, by the apparatus and method are manufactured by casting molten metal into a round, downwardly converging mold cavity having a coaxial removable cooled core of substantially uniform diameter throughout and which is less than the cavity's minimum diameter, the metal solidifying initially where it contacts the cavity wall and the core with solidification proceeding upwardly with incidental possible formation of pipe in the upper portion of the casting. Prior to the resulting casting cooling below a forging temperature, the core is removed and replaced by a mandrel having a flaring portion and which is pressed into the casting under pressure forging the casting radially outwardly and upwardly against the mold cavity wall with consequent closing and welding of any pipe.

Abstract: Fusion-cast articles of refractory material are formed with cavities or hollow portions by means of apparatus and method employing a core formed of material more refractory than the fusion-cast refractory material, which core is disengaged from the refractory material solidifying therearound when such solidified portion has the capability of maintaining its integrity and shape absent support of the core, but before cooling shrinkage of the solidified portion onto the core has caused cracking of such portion. A stored energy device is connected to the core through an aperture in the mold which is sealably engaged by the core, and upon release of the stored energy, the disengagement of the core is effected, e.g. by at least partial removal from the mold through the aperture.