CA1136376A - Method of producing ingot mold stools - Google Patents
Method of producing ingot mold stoolsInfo
- Publication number
- CA1136376A CA1136376A CA000322664A CA322664A CA1136376A CA 1136376 A CA1136376 A CA 1136376A CA 000322664 A CA000322664 A CA 000322664A CA 322664 A CA322664 A CA 322664A CA 1136376 A CA1136376 A CA 1136376A
- Authority
- CA
- Canada
- Prior art keywords
- mold
- insulative
- flat
- stools
- insulative board
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 238000000034 method Methods 0.000 title claims abstract description 13
- 238000005266 casting Methods 0.000 claims abstract description 11
- 229910001018 Cast iron Inorganic materials 0.000 claims abstract description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 13
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 239000004576 sand Substances 0.000 claims description 7
- 230000002093 peripheral effect Effects 0.000 claims description 2
- 239000003110 molding sand Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 2
- 241001080526 Vertica Species 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/062—Stools for ingot moulds
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Devices For Molds (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
METHOD OF PRODUCING INGOT MOLD STOOLS
Cast iron ingot mold stools having exceptionally smooth flat surfaces and a longer average life are pro-duced by casting such stools in a mold, the inside of which is formed by rigid, thermally insulative boards.
METHOD OF PRODUCING INGOT MOLD STOOLS
Cast iron ingot mold stools having exceptionally smooth flat surfaces and a longer average life are pro-duced by casting such stools in a mold, the inside of which is formed by rigid, thermally insulative boards.
Description
~3~
METHOD OF PRODUCING INGOT MOLD STOOLS
The present invention relates to a method of producing ingot mold stools.
Ingot molds used in the production of steel ingots usually consist of upright cast iron, box-like shells open at both ends. To close the bottom for casting steel therein, the mold is placed upright on a thick cast iron m~l~~s~boI~` Hence, an ingot mold cavity is formed by the mold stool on the bottom and the interiOr side-walls of the ingot mold thereover. A reasonabl~ close fit between the mold and stool should be assured to prevent leakaye of molten steel therebetween.
Ingot molds and mold stools-are usually manufac-tured in accordance with established sand-mold foundry 1~ techniques. While molding techniques for the manufacture of ingot molds has undergone some refinements, such as chill casting procedures, mold stools are still usually produced by conventional age-old foundry practices. Speci~ically, a rectangular molding flask is placed over and clamped to a rigid mQlding plate to form an open-topped box-like structure. Molding sand is then spread over the inside - . ~ , . ;
63~ .
bottom to a depth of several inches (cms.), and then com-pacted to form a flat sand surface. A rectangular pattern, usually made of wood, is then placed on the flat sand sur-face such that there is several i.nches tcms.) o~ clearance between the sides of the pattern and the flask walls.
Molding sand is then compacted into that space. The pattern is then carefully removed to leave a rectangular cavity in the molding sand. A pouring gate must also be provided in the molding sand adjacent to the cavity to funnel molten cast iron to the bottom of the cavity. After the mold stool has been cast in the cavity and solidified, the cast metal is removed from the sand mold, the gate broken-of~ and the surfaces cleaned. Surface cleaning is usually performed by hand, using a pneumatic chipper to scrape-off the molding sand adhering to the as-cast surface.
According to the present invention, there is proviaed a method of producing ingot mold stools having smooth flat surfacas, comprising the steps of placing a first flat, thermally insulative board onto a flat, hori-~ontal heat resistant surface, placing a rigid moldingflask over said first insulative board such that the molding flask holds said first insulative board in place and pro-vides a peripheral seal at the interface, lining the inside surfaces of said molding flask with vertically disposed thermally insulative boards, casting molten iron into the cavity defined by the first horizontal insulative board and the vertica:L insulative boards thereover, allowing said
METHOD OF PRODUCING INGOT MOLD STOOLS
The present invention relates to a method of producing ingot mold stools.
Ingot molds used in the production of steel ingots usually consist of upright cast iron, box-like shells open at both ends. To close the bottom for casting steel therein, the mold is placed upright on a thick cast iron m~l~~s~boI~` Hence, an ingot mold cavity is formed by the mold stool on the bottom and the interiOr side-walls of the ingot mold thereover. A reasonabl~ close fit between the mold and stool should be assured to prevent leakaye of molten steel therebetween.
Ingot molds and mold stools-are usually manufac-tured in accordance with established sand-mold foundry 1~ techniques. While molding techniques for the manufacture of ingot molds has undergone some refinements, such as chill casting procedures, mold stools are still usually produced by conventional age-old foundry practices. Speci~ically, a rectangular molding flask is placed over and clamped to a rigid mQlding plate to form an open-topped box-like structure. Molding sand is then spread over the inside - . ~ , . ;
63~ .
bottom to a depth of several inches (cms.), and then com-pacted to form a flat sand surface. A rectangular pattern, usually made of wood, is then placed on the flat sand sur-face such that there is several i.nches tcms.) o~ clearance between the sides of the pattern and the flask walls.
Molding sand is then compacted into that space. The pattern is then carefully removed to leave a rectangular cavity in the molding sand. A pouring gate must also be provided in the molding sand adjacent to the cavity to funnel molten cast iron to the bottom of the cavity. After the mold stool has been cast in the cavity and solidified, the cast metal is removed from the sand mold, the gate broken-of~ and the surfaces cleaned. Surface cleaning is usually performed by hand, using a pneumatic chipper to scrape-off the molding sand adhering to the as-cast surface.
According to the present invention, there is proviaed a method of producing ingot mold stools having smooth flat surfacas, comprising the steps of placing a first flat, thermally insulative board onto a flat, hori-~ontal heat resistant surface, placing a rigid moldingflask over said first insulative board such that the molding flask holds said first insulative board in place and pro-vides a peripheral seal at the interface, lining the inside surfaces of said molding flask with vertically disposed thermally insulative boards, casting molten iron into the cavity defined by the first horizontal insulative board and the vertica:L insulative boards thereover, allowing said
2 -;: ' ' ' , , ' , :
.-.
~363~6 cast iron to solidify and removing the iron casting fromthe insulative board mold.
The invention is further described, by way of example, with reference to the accompanying drawings, in which:-Figure 1 is a cross-secitional side view of a mold used to cast an ingot mold stool according to this invention, Figure 2 is a cross-sectional side view of a gate shown in Figure 1, and Figure 3 is a partial top view of the mold.
With reference to Figure 1, an ingot stool mold is formed by first providing a smooth flat surface 10 upon which the rest of the mold is constructed. For example, a metallic plate 1~ may be laid flat on the foundry floor. Thereafter, a rectangular thermaily insulative board 14 is placed on top of surface 10. A rectangular molding flask 16 is then placed on top of insulative board 14. Insulative board 14 should be suitably sized so that it extends at least to the outer perimeter of molding flask 16 so that the weight of flask 16 will readily hold insulative board 14 in place and provide as much of a seal therebetween as possible. Foux thermally insulative boards 18 (only two are shown) are then secured to the inside surfaces of molding flask 16. Although any suitable means may be used to secure insulative boards 18 to the inside face of flask 16, it is preferred to use a commercially .
~,~3~6, available nailing system wherein a nail is driven through the molding board 18 and into the molding flask 16 to hold the insulative boards 18 in place.
Although it is possible to cast the molten iron directly into the open-topped mold as shown in Figure 1, it is preferred to provide a gate, as shown in Fi~ure 2, so that the smooth flat surface of insulative board 14 is not disturbed. The gate is formed by providing a small rectangular extension 20 on one wall of flask 16 (Figure 3) sufficient to receive a preshaped and baked sand gate 22 having a pouring gate 24 therethrough.
When the mold is completed as shown in the - drawings, molten iron is cast into gate 28 filling the mold cavity defined by insulative boards 14 and 18, and the molten metal therein is allowed to solidify. When - solidified, the casting is removed and the gate metal broken-off. The resulting casting~ i.e. those surfaces formed against insulative boards 14 and 18 are exceptio~ally smooth and flat. Since no sand was used to form any of the stool surfaces, no chipping or surface conditioning is necessary. All that may be necessary is that portions o~
the insulative boards may have to be scraped-off.
The procedure as described above not only elimi-nated the use of molding sand ~except for the gate) but it also significantly reduces the manpower necessary to produce the mold and to condition the casting, and it also produces a cast stool of greatly improved quality. The . . .
- ~ ,;. .
:,, . :::
: ', ';; ' " ' ,',' :.
.
~3~3~ ~
quality improvements are not only physical in that the surfaces are smoother and flatter as compared to stools produced in sand molds, but also such stools have been shown to have a longer average life. For example, the first mold stool produced accord:ing to the above-described embodiment was used in excess of 100 pours, whereas prior art stools are scrapped after about 50 pours on an average.
After the above-described practice was established as the standard practice for producing mold stools in one foundry, the stool condemnation rate dropped over a period of eight months from 18 lbs/ton to 14 lbs/ton (9 kg/tonne to 7 kg/tonne). The condemnation rate is the weight of stool scrapped per unit weight of steel poured thereon. The improved rate of 14 lbs/ton (7 kg/tonne) noted above`does not fully re~lect the advantages of this invention as it is the rate of all stools on hand including those produced pursuant to prior art practices. Hence, the improved rate of from 18 lbs/ton to 14 lbs/ton (9 kg/tonne to 7 kg/tonne) reflects a gradual improvement in condemnation rate as the stools produced by this inventive method gradually increase in number and in proportion to the prior art stools.
. ~ . ~ ' :
.-.
~363~6 cast iron to solidify and removing the iron casting fromthe insulative board mold.
The invention is further described, by way of example, with reference to the accompanying drawings, in which:-Figure 1 is a cross-secitional side view of a mold used to cast an ingot mold stool according to this invention, Figure 2 is a cross-sectional side view of a gate shown in Figure 1, and Figure 3 is a partial top view of the mold.
With reference to Figure 1, an ingot stool mold is formed by first providing a smooth flat surface 10 upon which the rest of the mold is constructed. For example, a metallic plate 1~ may be laid flat on the foundry floor. Thereafter, a rectangular thermaily insulative board 14 is placed on top of surface 10. A rectangular molding flask 16 is then placed on top of insulative board 14. Insulative board 14 should be suitably sized so that it extends at least to the outer perimeter of molding flask 16 so that the weight of flask 16 will readily hold insulative board 14 in place and provide as much of a seal therebetween as possible. Foux thermally insulative boards 18 (only two are shown) are then secured to the inside surfaces of molding flask 16. Although any suitable means may be used to secure insulative boards 18 to the inside face of flask 16, it is preferred to use a commercially .
~,~3~6, available nailing system wherein a nail is driven through the molding board 18 and into the molding flask 16 to hold the insulative boards 18 in place.
Although it is possible to cast the molten iron directly into the open-topped mold as shown in Figure 1, it is preferred to provide a gate, as shown in Fi~ure 2, so that the smooth flat surface of insulative board 14 is not disturbed. The gate is formed by providing a small rectangular extension 20 on one wall of flask 16 (Figure 3) sufficient to receive a preshaped and baked sand gate 22 having a pouring gate 24 therethrough.
When the mold is completed as shown in the - drawings, molten iron is cast into gate 28 filling the mold cavity defined by insulative boards 14 and 18, and the molten metal therein is allowed to solidify. When - solidified, the casting is removed and the gate metal broken-off. The resulting casting~ i.e. those surfaces formed against insulative boards 14 and 18 are exceptio~ally smooth and flat. Since no sand was used to form any of the stool surfaces, no chipping or surface conditioning is necessary. All that may be necessary is that portions o~
the insulative boards may have to be scraped-off.
The procedure as described above not only elimi-nated the use of molding sand ~except for the gate) but it also significantly reduces the manpower necessary to produce the mold and to condition the casting, and it also produces a cast stool of greatly improved quality. The . . .
- ~ ,;. .
:,, . :::
: ', ';; ' " ' ,',' :.
.
~3~3~ ~
quality improvements are not only physical in that the surfaces are smoother and flatter as compared to stools produced in sand molds, but also such stools have been shown to have a longer average life. For example, the first mold stool produced accord:ing to the above-described embodiment was used in excess of 100 pours, whereas prior art stools are scrapped after about 50 pours on an average.
After the above-described practice was established as the standard practice for producing mold stools in one foundry, the stool condemnation rate dropped over a period of eight months from 18 lbs/ton to 14 lbs/ton (9 kg/tonne to 7 kg/tonne). The condemnation rate is the weight of stool scrapped per unit weight of steel poured thereon. The improved rate of 14 lbs/ton (7 kg/tonne) noted above`does not fully re~lect the advantages of this invention as it is the rate of all stools on hand including those produced pursuant to prior art practices. Hence, the improved rate of from 18 lbs/ton to 14 lbs/ton (9 kg/tonne to 7 kg/tonne) reflects a gradual improvement in condemnation rate as the stools produced by this inventive method gradually increase in number and in proportion to the prior art stools.
. ~ . ~ ' :
Claims (3)
IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE AS FOLLOWS:-
1. A method of producing ingot mold stools having smooth flat surfaces, comprising the steps of placing a first flat, thermally insulative board onto a flat, horizon-tal heat resistant surface, placing a rigid molding flask over said first insulative board such that the molding flask holds said first insulative board in place and pro-vides a peripheral seal at the interface, lining the inside surfaces of said molding flask with vertically disposed thermally insulative boards, casting molten iron into the cavity defined by the first horizontal insulative board and the vertical insulative boards thereover, allowing said cast iron to solidify and removing the iron casting from the insulative board mold.
2. A method as claimed in claim 1, including providing said molding flask with a preformed sand gate received in an extended wall portion of the flask, and casting said molten iron through said gate.
3. A method as claimed in claim 1 or claim 2, in which said flat, horizontal heat resistant surface is provided by a heavy metallic plate.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US88302878A | 1978-03-03 | 1978-03-03 | |
| US883,028 | 1978-03-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1136376A true CA1136376A (en) | 1982-11-30 |
Family
ID=25381838
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000322664A Expired CA1136376A (en) | 1978-03-03 | 1979-03-02 | Method of producing ingot mold stools |
Country Status (6)
| Country | Link |
|---|---|
| BE (1) | BE874585A (en) |
| CA (1) | CA1136376A (en) |
| DE (1) | DE2908240A1 (en) |
| FR (1) | FR2418686A1 (en) |
| GB (1) | GB2015395B (en) |
| LU (1) | LU80986A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB8423000D0 (en) * | 1984-09-12 | 1984-10-17 | Chappell J J | Ingot mould bottom plate protection |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3438424A (en) * | 1967-07-18 | 1969-04-15 | John W North | Method of direct casting of steel slabs and billets |
| FR2081182A1 (en) * | 1970-03-16 | 1971-12-03 | Purmetall Werner Funk | Baseplates for ingot moulds for slab and - ingot casting |
| US3783933A (en) * | 1971-08-20 | 1974-01-08 | United States Steel Corp | Method of making an ingot mold stool |
-
1979
- 1979-02-09 GB GB7904743A patent/GB2015395B/en not_active Expired
- 1979-02-28 FR FR7905246A patent/FR2418686A1/en active Granted
- 1979-03-02 CA CA000322664A patent/CA1136376A/en not_active Expired
- 1979-03-02 LU LU80986A patent/LU80986A1/en unknown
- 1979-03-02 BE BE0/193811A patent/BE874585A/en not_active IP Right Cessation
- 1979-03-02 DE DE19792908240 patent/DE2908240A1/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| DE2908240A1 (en) | 1979-09-06 |
| FR2418686B1 (en) | 1984-05-11 |
| GB2015395B (en) | 1982-04-15 |
| FR2418686A1 (en) | 1979-09-28 |
| BE874585A (en) | 1979-09-03 |
| LU80986A1 (en) | 1980-04-21 |
| GB2015395A (en) | 1979-09-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |