Casting Mould, Process, and Device For Casting Metal Melts

Abstract

A casting mould for manufacturing a cast part from a metal melt includes a mould cavity for reproducing a cast part and comprising an inlet for pouring metal melt into the mould cavity and also to a device and a process for casting metal melts of this type. The casting mould provides further optimized casting results even under hard practical operating conditions. In addition, the use or application of the device according to the invention and the process minimizes the risk of jamming during casting. This is achieved in that the casting mould has at least one compensation chamber which is linked to the mould cavity via a channel and comprises at least one portion which is arranged above the maximum filling level (F max ) of the casting mould during solidification of the metal melt.

1 . A casting mould for manufacturing a cast part from a metal melt, the casting mould comprising a mould cavity for reproducing a cast part and comprising an inlet for pouring metal melt into the mould cavity, wherein the mould cavity includes at least one compensation chamber which is linked to the mould cavity via a channel, the at least one compensation chamber including at least one portion which is arranged above the maximum filling level of the casting mould during solidification of the metal melt. 
   
   
       2 . The casting mould of  claim 1 , wherein the cross section of the channel is delimited in such a way as to be sealed immediately with metal melt that solidifies after completion of the mould filling process. 
   
   
       3 . The casting mould of  claim 1  wherein the casting mould is made of a molding sand and a molding material comprising a binder. 
   
   
       4 . The casting mould of  claim 1  wherein the at least one compensation cavity is linked to a portion of the mould cavity that is located on top while the metal melt is being poured in. 
   
   
       5 . The casting mould of  claim 1  wherein the casting mould has an inspection opening to the mould cavity for inspecting the filling level of the metal melt in the mould cavity. 
   
   
       6 . The casting mould of  claim 5 , wherein the inspection opening to the mould cavity and the at least one compensation cavity intersect a common horizontal plane. 
   
   
       7 . The casting mould of  claim 1  wherein the casting mould includes a plurality of molded parts. 
   
   
       8 . The casting mould of  claim 7 , wherein the at least one compensation cavity is incorporated into a lid molded part. 
   
   
       9 . (canceled) 
   
   
       10 . A device for casting metal melt to form a cast part, comprising:
 a casting mould defining a mould cavity for reproducing the cast part and comprising an inlet for pouring the metal melt into the mould cavity, wherein the mould cavity includes at least one compensation chamber which is linked to the mould cavity via a channel, the at least one compensation chamber including at least one portion which is arranged above the maximum filling level of the casting mould during solidification of the metal melt;   a melt container, comprising an outlet for the metal melt;   a supply channel connected to the outlet;   a means for docking the casting mould to the melt container in such a way that the inlet in the casting mould is connected to the supply channel when docked;   a measuring means for detecting the amount of melt introduced into the casting mould;   a regulating means for regulating the flow of melt from the melt container into the casting mould; and   a control means which evaluates the amount of melt detected by the measuring means and issues a control signal for sealing the outlet in the melt container once a specific filling level in the casting mould has been reached, wherein the control means issues the control signal once the amount of melt poured into the casting mould has reached a limit value at which the amount of metal melt which is then still present in the supply channel is sufficient to fill the mould cavity completely and at most a portion of the at least one compensation cavity.   
   
   
       11 . The device of  claim 10 , wherein the measuring means monitors the filling level in the casting mould and the control means issues the control signal once the metal melt in the mould cavity has reached the limit value. 
   
   
       12 . The device of  claim 11 , wherein the casting mould includes an inspection opening to the mould cavity for inspecting the filling level of the metal melt in the mould cavity, the measuring means comprising a laser that directs a laser beam through the inspection opening onto the surface of the melt introduced into the casting mould, and (ii) a sensor that detects the laser beam reflected by the surface of the melt. 
   
   
       13 . The device of  claim 10  wherein the regulating means comprises a stopper for sealing the outlet in the melt container and an adjustment means for raising the stopper out of and lowering it into its sealed position. 
   
   
       14 . The device of  claim 13 , wherein the regulating means regulates the adjustment movement of the stopper. 
   
   
       15 . A process for casting metal melt to form a cast part, comprising:
 providing a casting mould comprising a mould cavity and at least one compensation cavity;   guiding in a regulated manner the metal melt from a melt container into the casting mould via a supply channel; and   interrupting the inflow of the metal melt into the supply channel once the metal melt in the mould cavity has reached a filling level at which the amount of metal melt which is still present in the supply channel is sufficient to fill the mould cavity completely and at most a portion of the at least one compensation cavity.   
   
   
       16 . The process of  claim 15 , wherein the filling level in the casting mould is monitored and the inflow of metal melt into the supply channel is interrupted once the filling level has reached a height at which the volume of metal melt which is then still present in the supply channel is sufficient to fill the mould cavity completely and at most a portion of the compensation cavity ( 8 ,  9 ). 
   
   
       17 . The device of  claim 10  wherein the casting mould includes an inspection opening to the mould cavity for inspecting the filling level of the metal melt in the mould cavity, the measuring means comprising (i) a laser that directs a laser beam through the inspection opening onto the surface of the melt introduced into the casting mould, and (ii) a sensor that detects the laser beam reflected by the surface of the melt. 
   
   
       18 . The process of  claim 15  wherein the casting mould defines a mould cavity for reproducing the cast part and comprises an inlet for pouring the metal melt into the mould cavity, wherein the mould cavity includes at least one compensation chamber which is linked to the mould cavity via a channel, the at least one compensation chamber including at least one portion which is arranged above the maximum filling level of the casting mould during solidification of the metal melt.