Herein disclosed is a centrifugally cast pole having a substantially uniform wall thickness along the long axis of the pole. During centrifugal casting, molten metal is poured inside a rotating, tapered mold. As chilled liquid is poured over the outside of the rotating mold, the metal forms, or pain
Herein disclosed is a centrifugally cast pole having a substantially uniform wall thickness along the long axis of the pole. During centrifugal casting, molten metal is poured inside a rotating, tapered mold. As chilled liquid is poured over the outside of the rotating mold, the metal forms, or paints, to the contour of the mold interior creating a metal pole. By precisely controlling casting gyrations such as the spin, travel, pitch, and yaw of the rotating mold and the calibration and physical mechanisms of the casting machine, hollow, tapered, tubular metal poles are produced with previously unknown uniformity of wall thickness. The controlling principles, designs, and mechanisms of this centrifugal casting method enable wall uniformity to extremely high tolerances. By extension, the ability to precisely control the metal volume painted inside the mold allows, as a design choice, wall thickness variation in any embodiment if so desired.
대표청구항▼
1. A method of forming a hollow, tapered, cylindrical structural member having an outer diameter that varies along a length of the member, comprising: providing a rotatable cylindrical mold having an interior diameter that varies along a length of the mold, wherein the mold is mounted on a carriage
1. A method of forming a hollow, tapered, cylindrical structural member having an outer diameter that varies along a length of the member, comprising: providing a rotatable cylindrical mold having an interior diameter that varies along a length of the mold, wherein the mold is mounted on a carriage that is movable in a longitudinal direction of the mold;positioning the carriage such that a runner configured to deliver a molten metal material to an interior of the mold extends from a first end of the mold into the interior of the mold and such that a discharge end of the runner is located adjacent a second end of the mold;causing the mold to rotate;causing a molten metal material to be delivered from the discharge end of the runner to an interior of the mold; andcausing the carriage to move in the longitudinal direction of the mold such that the molten metal material being delivered from the discharge end of the runner forms a tapered cylindrical wall of the structural member on the interior surface of the mold, wherein at least one of a pour rate of the molten metal material and/or a movement rate of the carriage is selectively varied as the molten metal material is being delivered into the mold to thereby control a thickness of the tapered cylindrical wall of the structural member such that the thickness of the wall is substantially constant along a majority of the length of the structural member. 2. The method of claim 1, wherein providing the mold comprises providing a tapered cylindrical mold having a tapered interior diameter that narrows along the length of the mold. 3. The method of claim 1, wherein the pour rate of the molten metal material is selectively varied as the carriage is moved such that a thickness of the tapered cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 4. The method of claim 1, wherein the movement rate of the carriage is selectively varied as the molten metal material is delivered into the mold such that a thickness of the tapered cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 5. The method of claim 1, wherein the movement rate of the carriage and the pour rate of the molten metal material are both selectively varied as the carriage moves and as the molten metal material is delivered into the mold such that a thickness of the tapered cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 6. The method of claim 1, wherein the pour rate of the molten metal material is selectively varied as the carriage is moved such that a thickness of the tapered cylindrical wall of the structural member is selectively varied at a larger diameter end of the structural member. 7. The method of claim 1, wherein the movement rate of the carriage is selectively varied as the molten metal material is delivered into the mold such that a thickness of the tapered cylindrical wall of the structural member is selectively varied at a large diameter end of the structural member. 8. The method of claim 1, wherein the movement rate of the carriage and the pour rate of the molten metal material are both selectively varied as the carriage moves and as the molten metal material is delivered into the mold such that a thickness of the tapered cylindrical wall of the structural member is selectively varied at a large diameter end of the structural member. 9. The method of claim 1, further comprising inserting a core mold into the second end of the mold before the molten metal material is delivered into the mold, wherein the core mold is positioned such that a central longitudinal axis of the core mold and a central longitudinal axis of the rotatable mold are substantially concentric, and such that an annular gap is formed between an exterior surface of the core mold and an interior surface of the rotatable mold. 10. The method of claim 1, wherein a rotational speed of the mold is selectively varied as the molten metal material is delivered into the mold. 11. The method of claim 1, wherein causing the carriage to move results in molten metal material being delivered into the mold from the second end of the mold to the first end of the mold. 12. The method of claim 11, wherein the second end of the mold has a larger diameter than the first end of the mold. 13. The method of claim 1, wherein causing the carriage to move comprises causing the carriage to move substantially horizontally. 14. The method of claim 1, wherein providing a mold comprises providing a mold having a randomly textured interior surface that results in an exterior of a structural member made in the mold having a randomly textured exterior surface. 15. A method of forming a hollow structural member having a tapered outer diameter, comprising: providing a mold assembly that includes a tapered, cylindrical mold having a tapered interior diameter that is rotatably mounted on a movable carriage;positioning the mold assembly relative to a molten metal material delivery unit that includes a horizontally extending runner such that the runner extends through an opening at a first end of the mold into an interior of the mold and such that a discharge end of the runner is located adjacent a second end of the mold;causing the mold to rotate;causing a molten metal material to be delivered from the discharge end of the runner to an interior of the mold while the mold is rotating; andcausing the mold assembly to move in a longitudinal direction of the mold as the molten metal material is delivered from the discharge end of the runner into the interior of the mold such that the molten metal material cools and hardens on the interior surface of the mold to form a tapered, cylindrical wall of the structural member, wherein at least one of a pour rate of the molten metal material and/or a movement rate of the mold assembly is selectively varied as the molten metal material is being delivered into the mold to thereby control a thickness of the tapered cylindrical wall of the structural member such that the thickness of the wall is substantially constant along a majority of the length of the structural member. 16. The method of claim 15, wherein the pour rate of the molten metal material is selectively varied as the mold assembly is moved such that a thickness of the tapered, cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 17. The method of claim 15, wherein the movement rate of the mold assembly is selectively varied as the molten metal material is delivered into the mold such that a thickness of the tapered, cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 18. The method of claim 15, wherein the movement rate of the mold assembly and the pour rate of the molten metal material are both selectively varied as the mold assembly moves and as the molten metal material is delivered into the mold such that a thickness of the tapered, cylindrical wall of the structural member is substantially constant along a majority of the length of the structural member. 19. The method of claim 15, wherein at least one of the pour rate of the molten metal material and/or the movement rate of the mold assembly are selectively varied as the molten metal material is delivered into the mold such that a thickness of the tapered, cylindrical wall of the structural member is selectively varied at a larger diameter end of the structural member. 20. The method of claim 15, further comprising inserting a core mold into the second end of the mold before the molten metal material is delivered into the mold, wherein the core mold is positioned such that a central longitudinal axis of the core mold and a central longitudinal axis of the rotatable mold are substantially concentric, and such that an annular gap is formed between an exterior surface of the core mold and an interior surface of the rotatable mold. 21. The method of claim 1, wherein at least one of a pour rate of the molten metal material and/or a movement rate of the carriage is selectively varied as the molten metal material is being delivered into the mold such that the wall of the structural member has a first substantially uniform thickness along a first portion of the length of the structural member, and a second substantially uniform thickness along a second portion of the structural member that is located at a larger diameter end of the structural member. 22. The method of claim 15, wherein at least one of a pour rate of the molten metal material and/or a movement rate of the carriage is selectively varied as the molten metal material is being delivered into the mold such that the wall of the structural member has a first substantially uniform thickness along a first portion of the length of the structural member, and a second substantially uniform thickness along a second portion of the length of the structural member that is located at a larger diameter end of the structural member.
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