Mold for casting forged material, and method for casting forged material

Abstract

The invention is directed to a method for casting a forged material and a mold usable therefor. A finished metal product which is free from the internal defects is manufactured by solidifying a forged material in a specified direction, with concentrating the defects in the riser portion of the mold for casting a forged material. The finished metal product having a lightweight is produced with a less cost, resultantly, carbon dioxide discharged from the automobiles is reduced, thereby the present invention can contribute to environmental protection measures such as preventing global warming.

What is claimed is:  
     
         1 . A mold for casting a molten forged material, which comprises a first divided mold part and a second divided mold part, an open gate located on one end of the mold, a cavity for a riser connecting through said gate, a cavity connecting through said cavity for riser and formed between said first and second divided mold parts; and 
 a shaft for inclining the mold so as to solidify a molten metal in the cavity in a specified direction from one end opposite to said gate to another end located on said gate side.    
     
     
         2 . A mold for casting a forged material according to  claim 1 , wherein at least one of said first divided mold part and said second divided mold part has a plural number of hollow paths for passing a coolant therethrough and 
 a mechanism for passing a coolant through the hollow paths so as to cool a molten metal with some time difference from the one end opposite to said gate to the other end located on said gate side.    
     
     
         3 . A mold for casting a forged material according to  claim 1 , wherein said coolant is cooling water or cooling gas of a temperature of 40° C. or below.  
     
     
         4 . A mold for casting a forged material according to  claim 1 , wherein said first divided mold part and said second divided mold part is made of metal having high thermal conductivity of 100 to 400 W/m·K.  
     
     
         5 . The mold for casting a forged material according to  claim 4 , wherein said metal having high thermal conductivity is an aluminum alloy or a copper alloy.  
     
     
         6 . A mold for casting a forged material according to  claim 1 , wherein said mold has a shape such that a forging ratio of a preform made of forged material obtained by casting the molten forged material with said mold for casting a forged material to a metal product obtained by forging said preform made of forged material is approximately 10:1 to 2:1.  
     
     
         7 . The mold for casting a forged material according to  claim 5 , wherein said shape is a shape capable of forming a preform made of forged material of a substantially cylindrical shape.  
     
     
         8 . A method for casting a forged material, which comprises: 
 a step of melting a forged material, and    a step of charging a molten forged material into a cavity of a mold to cast a cast-forged material,    wherein the mold used is one which comprises a first divided mold part and a second divided mold part, an open gate located on one end of the mold, a cavity for a riser connecting through said gate, a cavity connecting through said cavity for riser and formed between said first and second divided mold parts; and a mechanism capable of cooling a molten metal in the cavity; said mechanism being formed in at least one of said first divided mold part and said second divided mold part, and,    a step of cooling stepwise the molten forged material from one end one end at any one end of the mold to another end located on opposite to said one end at any one end of the mold with some time difference, thereby the molten forged material charged into the mold is solidified in a specified direction.    
     
     
         9 . A method for casting a forged material according to  claim 8 , wherein said mechanism is a mechanism comprising a plural number of hollow paths formed in at least one of said first divided mold part and said second divided mold part, and a device capable of passing a coolant through said plural number of hollow paths one by one from one end at any one end of the mold to another end located on opposite to said one end one end at any one end of the mold with some time difference.  
     
     
         10 . A method for casting a forged material according to  claim 8 , wherein said one end at any one end of the mold is located at the end of the mold opposite to the gate.  
     
     
         11 . The method for casting a forged material according to  claim 9 , wherein said coolant is cooling water or cooling gas of temperature of 40° C. or below.  
     
     
         12 . The method for casting a forged material according to  claim 8 , wherein forged material is aluminum alloy.  
     
     
         13 . The method for casting a forged material according to  claim 8 , wherein said mold is made of metal having high thermal conductivity of 100 to 400 W/m·K.  
     
     
         14 . The method for casting a forged material according to  claim 8 , wherein an inner surface of said mold is coated with a mold wash.  
     
     
         15 . The method for casting a forged material according to  claim 8 , wherein the cast-forged material has an approximately cylindrical shape.  
     
     
         16 . A method for casting a forged material, which comprises: 
 a step of melting a forged material, and    a step of charging a molten forged material into a cavity of a mold to cast a cast-forged material for a gate of the mold,    wherein the mold used is one which comprises a first divided mold part and a second divided mold part, an open gate located on one end of the mold, a cavity for a riser connecting through said gate, a cavity connecting through said cavity for riser and formed between said first and second divided mold parts; and a mechanism capable of inclining the mold, and,    a step of rotating the mold by operating said mechanism capable of inclining the mold within a predetermined time in such manner that the charging of the molten forged material is initiated when the mold is kept in a horizontal state, and the charging is completed when the mold is turned in vertical state with the gate upward, thereby the molten forged material charged into the mold is solidified in a specified direction.    
     
     
         17 . A method for casting a forged material according to  claim 16 , wherein forged material is aluminum alloy.  
     
     
         18 . The method for casting a forged material according to  claim 16 , wherein said mold is made of metal having high thermal conductivity of 100 to 400 W/m·K.  
     
     
         19 . The method for casting forged material according to  claim 16 , wherein an inner surface of said mold is coated with a mold wash.  
     
     
         20 . The method for casting forged material according to  claim 16 , wherein the cast-forged material has an approximately cylindrical shape.