Automated variable dimension mold and bottom block system

Abstract

A molten metal mold and bottom block system, including apparatus and method embodiments, which may include a mold cavity framework with a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity, and wherein one or more of the sides are movably mounted relative to the second side, and are controllably moved during the casting. This system may also include embodiments wherein the castpart produced has a tapered form at one or both of the castpart ends. Aspects of this invention may be considered to be a castpart shrinkage management system or a castpart form or profile control system due to the advantage of increased controls of castpart form during the casting process.

1 . A molten metal mold comprising:
 a mold cavity framework including a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity;   wherein the first side is movably mounted relative to the second side.   
   
   
       2 . A molten metal mold as recited in  claim 1 , and further wherein the second side is movably mounted relative to the first side. 
   
   
       3 . A molten metal mold as recited in  claim 1 , and further wherein the first side moves linearly relative to the second side. 
   
   
       4 . A molten metal mold as recited in  claim 1 , and further wherein the first side is pivotally mounted. 
   
   
       5 . A molten metal mold as recited in  claim 1 , and further wherein pivotal movement of the first side relative to the mold cavity framework alters the defined mold cavity. 
   
   
       6 . A molten metal mold as recited in  claim 2 , and further wherein the movement of the first side and the second side is asynchronous. 
   
   
       7 . A vertical molten metal mold casting system comprising:
 a mold cavity framework including a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and wherein the inner surfaces define a mold cavity;   wherein the first side and second side are movably mounted relative to one another; and   a bottom block configured to fit within the mold cavity at startup of the mold casting system.   
   
   
       8 . A vertical molten metal mold casting system as recited in  claim 7 , and further wherein the first side and second side move linearly relative to one another. 
   
   
       9 . A vertical molten metal mold casting system as recited in  claim 7 , and further wherein the first side and second side are pivotally mounted for movement relative to one another. 
   
   
       10 . A vertical molten metal mold casting system as recited in  claim 7 , and wherein the bottom block includes two sidewalls and further wherein the third side and the fourth side of the mold cavity framework combined with the two sidewalls of the bottom block to define the mold cavity on startup. 
   
   
       11 . A vertical molten metal mold casting system as recited in  claim 7 , and further wherein the bottom block includes an internal cooling apparatus. 
   
   
       12 . A vertical molten metal mold casting system as recited in  claim 7 , and further wherein the bottom block is configured for vertical movement within the mold cavity during startup to control a spout to bottom block distance during startup casting. 
   
   
       13 . A method for vertical direct chill molten metal casting comprising:
 providing a mold cavity framework with a first side and a second side opposite the first side, a third side and a fourth side opposite the third side, with inner surfaces of the first side, second side, third side and fourth side defining a mold cavity disposed to receive molten metal;   providing a vertically movable bottom block configured relative to the mold cavity to contain molten metal entering the mold cavity upon startup;   providing molten metal to the mold cavity;   moving the bottom block downward at a predetermined rate; and   moving the first side and the second side of the mold cavity framework relative to one another during casting and thereby varying dimensions of a resulting castpart during casting.   
   
   
       14 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the first side and second side are moved linearly relative to one another. 
   
   
       15 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the first side and second side are moved asymmetrically relative to one another. 
   
   
       16 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the first side and the second side are pivotally mounted relative to the mold cavity framework such that pivotal movement of the first side and the second side alter the defined mold cavity. 
   
   
       17 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the moving of the first side and the second side are at the same approximate rate. 
   
   
       18 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and wherein moving the first side and the second side of the mold cavity framework relative to one another during casting further comprises:
 moving the first side and the second side away from each other at an early portion of the casting after startup, to provide an increasing cross-section of the castpart from its bottom portion.   
   
   
       19 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and wherein moving the first side and the second side of the mold cavity framework relative to one another during casting further comprises:
 moving the first side and the second side toward one another at an end portion of the casting to provide a decreasing cross-section of the castpart at its top portion.   
   
   
       20 . A method for vertical direct chill molten metal casting as recited in  claim 18 , and wherein moving the first side and the second side of the mold cavity framework relative to one another during casting further comprises:
 moving the first side and the second side toward one another at an end portion of the casting to provide a decreasing cross-section of the castpart at its top portion.   
   
   
       21 . A method for vertical direct chill molten metal casting as recited in  claim 18 , and further wherein the increasing cross-section of the castpart from its bottom portion provides a taper on the bottom portion of the castpart at an angle in the range of 22 degrees to 29 degrees. 
   
   
       22 . A method for vertical direct chill molten metal casting as recited in  claim 19 , and further wherein the increasing cross-section of the castpart from its top portion provides a taper on the top portion of the castpart at an angle in the range of 22 degrees to 29 degrees. 
   
   
       23 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the moving of the first side and the second side of the mold cavity framework relative to one another during casting produces a castpart with a larger cross-section in a middle portion than the bottom block. 
   
   
       24 . A method for vertical direct chill molten metal casting as recited in  claim 13 , and further wherein the moving of the first side and the second side of the mold cavity framework relative to one another during casting produces a castpart with a larger cross-section in its middle portion than at its bottom portion and top portion. 
   
   
       25 . A molten metal mold comprising:
 a mold cavity framework including a first side, a second side opposite the first side and spaced apart from the first side by a variable distance, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity; and   wherein the mold cavity framework is alternatively configurable to cast a first castpart with a first thickness and to cast a second castpart with a second thickness.   
   
   
       26 . A method for vertical direct chill molten metal casting comprising:
 providing a mold cavity framework with a first side and a second side opposite the first side and spaced apart from the first side by a variable distance, a third side and a fourth side opposite the third side, with inner surfaces of the first side, second side, third side and fourth side defining a mold cavity disposed to receive molten metal;   providing a vertically movable bottom block configured relative to the mold cavity to contain molten metal entering the mold cavity upon startup;   providing molten metal to the mold cavity;   casting a first castpart of a first thickness; and   moving the first side and the second side of the mold cavity framework relative to one another; and   casting a second castpart of a second thickness different than the first thickness.   
   
   
       27 . A molten metal mold comprising:
 a mold framework;   a mold operative connected to the mold framework, the mold being comprised of:
 a first side movably mounted relative to the mold framework; 
 a second side opposite the first side and movably mounted to the mold framework; 
 a third side; 
 a fourth side opposite the third side; 
   wherein each side includes an inner surface and the inner surfaces define a mold cavity;   a first motor operatively connected to the first side and configured to move the first side relative to the mold framework;   a second motor operatively connected to the second side and configured to move the second side relative to the mold framework; and   a programmable logic controller operatively connected to and controlling the first motor and the second motor to control predetermined movement of the first side and the second side of the mold.   
   
   
       28 . A molten metal mold as recited in  claim 27  and further wherein the the first motor and the second motor are servo motors. 
   
   
       29 . A molten metal mold as recited in  claim 27  and further comprising a human user interface operatively attached to the programmable logic controller. 
   
   
       30 . A method to optimize the rolling surfaces of a castpart produced during continuous molten metal casting, comprising:
 providing a mold cavity framework with a first side and a second side opposite the first side, a third side and a fourth side opposite the third side, with inner surfaces of the first side, second side, third side and fourth side defining a mold cavity disposed to receive molten metal;
 providing a vertically movable bottom block configured relative to the mold cavity to contain molten metal entering the mold cavity upon startup; 
 providing molten metal to the mold cavity; 
 moving the bottom block downward at a predetermined cast speed; and 
 moving the first side and the second side of the mold cavity framework in a predetermined way relative to one another during casting to optimize the castpart configuration for later operations. 
   
   
   
       31 . A method to optimize the rolling surfaces of a castpart produced during continuous molten metal casting as recited in  claim 30 , and further wherein moving the first side and the second side of the mold cavity is to at least substantially offset predicted shrinkage during casting at the predetermined cast speed.