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Патент USA US2501663

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March 28, 1950
Filed Dec. 29, 1945
2 Sheets-Sheet l
Frank (‘O/“04.05
March 28, 1950
Filed Dec. 29, 1945
2 Sheets-Sheet 2
Frank Cora’es
Patented Mar. 28, 1,950
Frank Cordes, Pittsburgh, Pa.
_Application December 29, 1945, Serial No. 637,845
2 Claims. (Cl. 22-127)
This invention relates to the manufacture of
shown at Ila in dot-and-dash lines, providing a
substantially uniform thickness of surface mate
rial to be removed in the ?nishing operation.
As shown- in the drawings, the roll Ila to be cast
in the cavity l I includes, in addition to the usual
necks l2, spaced cylindrical body portions of vari-.
cast rolls, e. g., steel or iron rolls such as those
used in rolling mills and, in particular, to rolls
having a body including a plurality of cylindrical
portions of various diameters.
The casting of high-quality mill rolls involves
the exercise of a good deal of skill and experience
in order to produce rolls which are tough and
sound and have surfaces highly resistant to wear
ous diameters,-i. e., collar portions I3, I 4 and lb
of one diameter and intermediate body portions
or grooves l6 and ll of a smaller diameter.
The ?ask I0 comprises a plurality of super
during use.
The demands of the rolling-mill art-are such
posed wall portions or sections of different diame
ters. A cylinder l8 resting on a base l9 has upper
that the roll maker is oftentimes called upon to
produce a cast rollwhose body is of different
and lower ?anges. The inside diameter of the
diameters at di?erent ‘points along its length, as
distinguished from the plain cylindrical roll body
cylinder 18 exceeds that of the portion of the
cavity ll forming the lower neck 12 by a prede
termined amount. A second cylinder 20 having
or “barrel” of uniform diameter from end to end.
upper and lower ?anges rests on the upper ?ange
In making a roll with a body of varying diameter,
it should be cast to a form approximating the
of the cylinder I8 and is disposed coaxially there
desired con?guration, that is to say, the roll as
with. The inside diameter of the cylinder it
cast should ideally be of such con?guration that 20 exceeds the diameter of the body portion l5 by
the ?nishing of the cast roll in the roll lathe
the same predetermined amount aforementioned.
A ?anged cylinder 2! resting on the cylinder 26
involves the removal of substantially the same
thickness of metal from all of the surfaces, in the
also has an inside diameter exceeding that of
body portion, at least, of the casting.
the roll portion ll by said predetermined amount.
The casting of such a roll body by present 25 The cylinder 2| is also disposed coaxially with the
methods is not wholly satisfactory. The result
ing roll may not be uniform in its physical char
cylinders 20 and I8.
stantially unchanged.
shown at 2 I.
Similarly, cylinders 22, 23 and 24, when super
acteristics, or may be otherwise of less than top
posed coaxially on those already mentioned, to
quality metallurgically. Difficulties in molding
gether with a second cylinder l8 for the upper
and casting are also encountered. Despite the 30 neck, complete the ?ask. The cylinder 23, as
existence of these shortcomings over a long span
shown, is actually a solid ring of appropriate
thickness but may be a ?anged cylinder like that
of years, the molding process has remained sub
My invention eliminates these di?lculties and
The ?ask sections may be secured together in ,
results in a cast roll of superior physical proper 35 any convenient way, as, for example, by clamps
ties. My invention is also advantageous in that
25 and wedges 26. In certain cases the sections
may be divided longitudinally, as indicated by the
the manufacture of the rolls is simpli?ed in many
respects and the percentage of sound and satis—
unsectioned surface Me of the section 2|. It
factory castings is increased.
is thus possible to remove the ?ask portions when
A complete understanding or the invention may‘ 40 desired, either after complete cooling or when
be obtained from the following detailed descrip
the casting has solidi?ed but has not completely
tion, referring to the accompanying drawings
cooled, if metallurgical considerations demand
such treatment. In the' case of a deeply entrant
?ask for use in casting rolls in accordance with
section, such as the cylinder 23, it will be nec45 essary to make the same in parts or else to destroy
my invention. In the drawings,
Figure l is a central vertical section through
it, in order to remove it from the casting.
The mold cavity may be ‘formed by sweeping
one form of mold for practicing the invention;
in the customary manner. on the other hand, all
the cylinders may be divided along an axial
Figure 2 is a similar view of a modi?cation.
which illustrate somewhat diagrammatically ' a
Referring in detail to the drawings, I provide
a ?ask ID for a sand mold having a cavity II
corresponding in shape to the roll which it is
desired to cast. It will be understood that the
cavity is somewhat larger in all dimensions than
the desired ?nished roll, the outline of which is 56
plane and the cavity formed by the use of a
The mold may be bottom-poured in well known _
manner through an aperture 21 and is provided
with the usual riser 28 at the top.
The cylinders 20, 2!, 22, etc., constitute wall
portions of the ?ask corresponding to the roll por
tionsli, l1 and M, respectively; the inside di
ameter of each wall portion exceeding the di
ameter of the corresponding roll portion by sub
stantially the same amount. The axial length of
the wall portion 20, furthermore, exceeds the
axial length of the roll portion l5 by about twice
tively low limits. At the same time, the cost of a
?ask according to the invention is comparable to
that of a ?ask heretofore employed and presents
no additional di?lculties in use. It will be under
stood that cylindrical ?ask wall portions having
dimensions appropriate to those of the roll por
tions generally cast may be made available and
said amount. The axial length of the wall por
tion 2|, however, is less than the axial length of
combined in various ways as may be necessary
molding material within the ?ask de?ning the
cavity II is substantially the same both radially
- a. preferred embodiment of the invention, it will
to produce a roll having body portions of the
the roll portion H by about ‘twice said amount; 10 desired diameters.
Although I have illustrated and described but
Consequently, the thickness of the layer of
and longitudinally at all points. This means
that, during cooling of the molten metal, the
loss of heat from all points on the surface of the
casting to adjacent points on the ?ask will occur
at substantially the same rate, thereby effecting
a substantially uniform cooling throughout‘ the
he recognized that changes in the details of the
construction may be made without departing from
the spirit of the invention or the scope of the
appended claims.
I claim:
1. A mold for casting a ferrous rolling mill roll
having a grooved body, comprising in combina
surface area of the roll. While the cylinders l8 20 tion, a metal ?ask, said ?ask having a plurality
of cylindrical wall sections connected together
forming the bottom and top of the ?ask as il
coaxially, said wall sections being of different
lustrated have the proper inside diameter to give
internal diameters and forming a substantially
the uniform thickness of molding sand adjacent
the roll necks, this is not so important as the ' continuous metal internal surface the axial and
uniform cooling of all portions of the roll body. 25 radial con?guration of which is generally similar
to that of said grooved body, said internal sur
Figure 2 illustrates a mo'di?ed ?ask 30 which is
face being in direct metallic contact with the
split longitudinally and comprises a body 3| and
exteriors of said respective wall sections so that
ends 32 secured to the body. Instead of being
the ambient air contacting the said exteriors
composed of rings of various inside diameters
‘according to the diameters of the roll portions 30 removes the heat conveyed by the metallic con
tact from said internal surface, and a layer of
l3 through I‘! as in the ?ask ill, the body 3| of
molding material such as sand covering said in
?ask 30 is composed of a cylindrical wall having
ternal surface of said wall sections to substan
rings 33 projecting inwardly therefrom adjacent
tially the same thickness, whereby substantially
the roll portions of smaller diameter. The rings
33 and the portions of the ?ask body therebetween 35 uniform cooling throughout the surface area of
83.1% grooved body is obtained when said roll is
constitute mold wall portions of different diam:
eters corresponding to those afforded by the rings
2. A mold for casting a ferrous rolling mill
roll having a grooved body, comprising in com
The body and ends of ?ask 30 may be cast or
a hollow cylindrical metal ?ask, a hollow
fabricated. In either case, they may be provided 40 bination,
annular ring axially spaced along the interior
with water jackets 34 and 35, in order to hasten
wall of said ?ask in each position corresponding
the cooling of the roll cast therein. Pipe con—
to a circumferential groove in said roll and form
nections 36 supply water to the jackets and it
20, II, 22, etc. of Figure 1.
drains therefrom through outlet pipes 31. The
jackets may be provided with longitudinal sep
arator webs 38 to insure proper distribution of
the cooling water around the ?ask body and ends.
If the rings 33 are made hollow, holes 39 in the
wall of the ?ask body permit entry of cooling
water thereinto. If the ?ask is made by casting, -
the rings 33 may be integral with the wall of the
'ing- with the remainder of said interior wall a con
; tinuous metal surface in direct metallic contact
with a cooling ?uid adapted to be circulated
through said hollow ?ask and ring or rings, said
metal surface substantially conforming in con
?guration to the con?guration of the roll to be
cast and uniformly larger than said con?guration
of said roll, and a layer of molding material such
as sand covering each portion of said metal sur
face to a substantially even depth corresponding
It will be apparent'that a mold formed in ?ask
to the distance between said con?gurations,
30 will have a wall of substantially uniform thick
substantially uniform cooling throughout
ness at all points, despite variations in the di
the surface area of said roll is obtained when said
ameter of the roll in different portions thereof.
roll is cast.
The advantage of the invention has already
been indicated, viz., the fact that the cooling of
the roll as cast takes place at substantially the
same rate at all points on the surface thereof.
The following references are of record in the
This makes it possible to control the metallurgical
?le of this patent:
structure more precisely than heretofore and to
avoid under-cooling at some points and over
body portion.
cooling at others. '
In‘ addition, the ?ask of my invention simpli 65 Number
?es the problem of supporting the sand forming
the mold, ,each ?ask section of smaller diameter
carrying a portion of the vertical height of the
sand layer. The ?ask also permits the mold
‘ recesses to be shaped to an accuracy within rela 70 2,377,731
- Name
Totten __________ __ Sept. 26,
Johns ____________ __ Feb. 12,
Crook ____________ __ Apr. 25,
Mueller et a1 _______ __ Jan. 11,
Walcher __________ __ June 5,
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