Method and apparatus for machining molding elements for foundry casting operations

Abstract

A method for machining a molding core from an aggregate material block, comprising: positioning the aggregate material block on a rotative base member; and rotating the base member and simultaneously machining the aggregate material block into the molding core. There is also provided a method for forming a casting mold including a molding core and a foundry casting core comprising: a core body having at least one convex shaped core print. The method comprises: providing at least one molding element having a mold cavity with at least one core-print pocket defined in a top side of the molding element; forming the molding core having at least one convex shaped core print; and inserting the molding core in the mold cavity with the at least one convex shaped core print engaged in a respective one of the at least one core-print pocket.

1 . A method for machining a molding core from an aggregate material block, comprising:
 positioning the aggregate material block on a rotative base member; and   rotating the base member and simultaneously machining the aggregate material block into the molding core.   
     
     
         2 . A method as claimed in  claim 1 , wherein said rotating comprises rotating continuously the base member. 
     
     
         3 . A method as claimed in  claim 1 , wherein the machining is performed by at least one stationary robot carrying at least one machining tool on a manipulated arm. 
     
     
         4 . A method as claimed in  claim 1 , wherein the base member performs at least one 360 degree rotation. 
     
     
         5 . A method as claimed in  claim 1 , wherein the base member performs more than one 360 degree rotation. 
     
     
         6 . A method for forming a casting mold including a molding core, comprising:
 providing at least one molding element having a mold cavity with at least one core-print pocket defined in a top side of the molding element;   forming the molding core having at least one convex shaped core print; and   inserting the molding core in the mold cavity with the at least one convex shaped core print engaged in a respective one of the at least one core-print pocket.   
     
     
         7 . A method as claimed in  claim 6 , wherein the at least one convex shaped core print comprises two inclined surfaces meeting at a contact edge and wherein the contact edge of the at least one convex shaped core print is substantially aligned with a top side of the at least one molding element in which the molding core is inserted. 
     
     
         8 . A method as claimed in  claim 7 , comprising providing two molding elements with complementary mold cavities and juxtaposing the two molding elements with the molding core inserted therebetween with the contact edge of the at least one convex shaped core print substantially aligned with the top sides of the two molding elements. 
     
     
         9 . A method as claimed in  claim 6 , wherein the molding core comprises at least two convex shaped core prints. 
     
     
         10 . A method as claimed in  claim 6 , wherein said forming comprises:
 providing a core base member having a concave surface;   forming the aggregate material block on the core base member with a surface of the aggregate material block resting on the concave surface of the core base member; and   machining the molding core in the aggregate material block, the core having a first convex shaped surface complementary to the concave surface of the core base member, the first convex shaped surface corresponding to one of the at least one convex shaped core print.   
     
     
         11 . A method as claimed in  claim 10 , wherein the core base member comprises two inwardly inclined surfaces defining the concave surface. 
     
     
         12 . A method as claimed in  claim 10 , wherein said machining comprises machining a second convex surface in the aggregate material block and wherein the second convex surface is part of a core print. 
     
     
         13 . A method as claimed in  claim 10 , wherein said machining comprises rotating the aggregate material block during said machining. 
     
     
         14 . A method as claimed in  claim 13 , wherein said rotating comprises rotating continuously the aggregate material block during said machining. 
     
     
         15 . A foundry casting core comprising: a core body having at least one convex shaped core print. 
     
     
         16 . A foundry casting core as claimed in  claim 15 , wherein the aggregate material body comprises at least two convex shaped core prints. 
     
     
         17 . A foundry casting core as claimed in  claim 15 , wherein the at least one convex shaped core print comprises two inclined surfaces meeting at a contact edge. 
     
     
         18 . A foundry casting core as claimed in  claim 15 , wherein the core body comprises bonded sand.