CA1197972A - Method of die casting a reducible core - Google Patents

Method of die casting a reducible core

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Publication number
CA1197972A
CA1197972A CA000383137A CA383137A CA1197972A CA 1197972 A CA1197972 A CA 1197972A CA 000383137 A CA000383137 A CA 000383137A CA 383137 A CA383137 A CA 383137A CA 1197972 A CA1197972 A CA 1197972A
Authority
CA
Canada
Prior art keywords
die
core
liner
cavity
reducible
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000383137A
Other languages
French (fr)
Inventor
Richard R. Booy
Robert C. Shebuski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Outboard Marine Corp
Original Assignee
Outboard Marine Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Outboard Marine Corp filed Critical Outboard Marine Corp
Application granted granted Critical
Publication of CA1197972A publication Critical patent/CA1197972A/en
Expired legal-status Critical Current

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  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Abstract

METHOD OF DIE CASTING
A REDUCIBLE CORE UNIT
ABSTRACT OF THE DISCLOSURE

A die-cast core is formed by fabricating a die defining a cavity in which the core is formed, and injecting under pressure a reducible material in a molten state into the cavity of the die, thereby die casting the core. A preformed liner may be placed in the cavity of the die prior to the injection of the molten reducible material, so that after the injection, the liner is provided with a reducible die-cast core. The die-cast core can be used in fabricating various machine parts, such as a cylinder block for an internal combustion engine.

Description

~ 97~72 METHOD OF DIE CAST~NG A
REDUCIBLE CORE

FIELD OF THE INVENTION

The invention generally relates to the manufacture of reducible cores used in the manufacture of machine parts. The invention also generally relates to the manufacture of cylinder blocks using reducible cores to form the intecior cylinder bores and passages associated therewith.

DESCRIPTION OF THE PRIOR ART
-Cores are used to form interior passages or cavities in cast machine parts. Such cores can be formed of a reducible material, such as sand or salt, which is molded into a configuration conforming to the desired shape of the interior cavity or passage.
The core maintains this configuration while the part is being cast around it, and is thereafter reduced or removed to open the passage or cavity in the part.

z Attention is directed to Canadian Patent 1,167,716, issued May 22, 1984 and entitled "CYLINDER BLOCK HAVING A
CAST IN CORE UNIT AND PROCESS OF .~ANUFACTURING
SAME".

Attention is also directed to the following United Staces Patents:

Leach 2,858,587 Nov. 4, 1958 Hrabovsky 2,978,764 April 11, 1961 Seyffer et al 3,149,383 Sept. 22, 1964 Chramm et al 4,003,422 Jan. 18, 1977 Hayashi et al 4,077,458 Mar. 7, 1978 Edwards 4,102~733 Aug. 1, 1978 SUMMARY OF THE INYENTION

The invention provides a method of die casting a core comprising the steps of fabricating a die defining a cavity in which the core is formed, and injec~ing under pressure a reducible material in a molten state into the cavity of the die, thereby die casting the core.

In one embodiment, the method includes the additional steps of fabricating a preformed liner having a bore and placing the liner in the cavity of the die. In this embodiment~ the step of injecting the molten reducible material comprises : ,..

~ 2 injecting under pressure the molten reducible material into the bore of the liner, thereby providing the liner with a reducible die-cast core.

In one embodiment, the step of fabricating the die comprises fabricating a die defining a main cavity in which a main body portion of the core is formed and an auxiliary cavity which communicates with the main cavity and in which an auxiliary body portion of t`he core is formed. In this embodiment, che step of injecting the molten reducible material comprises injecting under pressure a reducible material in a molten state into the main and auxiliary cavities of the die, thereby die-casting the core having a main body portion and an auxiliary body portion communicating with the main body portion.

In one embodiment, the preformed cylinder liner is placed in the main cavity of the die. In this embodiment, the step of injecting the molten material comprises injecting under pressure the molten reducible material into the bore of the liner and the auxiliary cavity of the die, thereby providing the liner with a reducible die cast core having an auxiliary body portion extending outwardly o~ the liner.

The invention also provides a method of fabricating a cylinder block comprising the steps of die casting a core following the method as above described and then placing the die-cast core into a cylinder block mold. ~olten metal is caused to enter the cylinder block mold, thereby forming a cylinder block surrounding the die-cast core. The reducible material is then removed to provide a cavity in the cylinder block conforming to the shape of the die-cast core. In the preferred embodiment, the cavity defines the cylinder bore and exhaust and transfer passages communicating with the bore.

One of the principal features of the invention is the provision of a die-cast core which is uniformly dense and dimensionally stable and which is capable of being formed into intricate configurations.

Other features and advantages of the embodiments of the invention will become apparent upon reviewing the fo]lowing general description, the drawings, and the appended claims.

DESCRIPTION OF THE D~AWINGS

Fig. l is a sectional diagrammatic view oE
a cylinder block cast around a die-cast core which embodies various of the features of the invention;

Fig. 2 is a perspective view, partially broken away, of a die in which the die-cast core used to cast the cylinder block in Fig. 1 can be formed;

~ ~ ~ 7 ~ 7 ~
Fig. 3 is an exploded perspective view of the die shown in Fig. 2 and showing one embodiment of the core which can be formed therein;

Fig. 4 is the die-cast core shown Fig. 3 in position in a cylinder block mold;

Fig. 5 is a perspective view9 partially broken away, of the die similar to Fig. 2, except that a preformed cylinder liner is located in the cavity of the die;

Fig. 6 is a preformed cylinder liner and die-cast core unit which is formed in the die shown in Fig. 5; and Fig. 7 is the preformed cylinder liner and die-cast core unit shown in Fig. 6 in position in a cylinder block mold.

Before explaining the embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construct:ion and the arrangements of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways.
Also, it is to be understood that the phraseology and terminology employed herein is for purpose of description and should not be recorded as limiting.

~g7~72 GENERAL DESCRIPTION
-Machine parts are typically manufactured by casting in permanent molds or in high pressure die casting machines. By design, such machine parts often include integrally cast open interior areas or cavities. To form these open interior areas during casting, a preEormed core of a reducible material, such as salt or sand, can be utilized.

In the illustrated embodiment, in order to manufacture a reducible core which is uniformly dense, dimensionally stable, and capable of main-taining intricate configurations during casting, a core 10 is fabricated by die casting.

While a die-cast core is applicable for use whenever it is desired to fabricate cored machine parts, for the purpose of description, the core 10 of the illustrated embodiment is fabricated for particular use in the production of cylinder bores for internal combustion engines.

In this environment (see Fig. 1), a cylinder block 12 ir,cludes integrally cast open interior areas and passages. As illustrated, such areas take the form of a cylinder bore 14 as well as a transfer passage 16 and an exhaust passage 18 communicating with the bore 14. Typically more than a single transfer passage 16 is provided, however only one such transfer passage 16 is illustrated in the drawings. A cylinder liner 36 is located in the bore 14. The liner 36 has ~ 97~
openings 38 or ports which provide the desired communication between the bore 14 and the transfer and exhaust passages 16 and 18.

In order to manufacture the core 10 used in the production oE the above described cylinder block 12 (see Figs. 2 and 3), a die 22 is fabricated.
As is shown in Fig. 3, the die 22 includes two separable members 22a and 22b. When the members are assembled (see Fig. 2), the die 22 defines a cavity 24 in which the core 10 can be formed. In the illustrated construction, the cavity 24 includes a main portion 26 and two auxiliary portions 28a and 28b which communicate with the main portion 26.

Molten reducible material is placed in the die 22 through a top opening in the die 22 and is then injected under pressure, such as by the use of a ram 23, into the main and auxiliary cavity portions 26, 28a and 28b of the die 22, thereby forming the die-cast core 10. The die members are then separated taS shown in Fig. 3) to remove the die cast core 10.

~ s shown in Fig. 3, the resulting die-cast core 10 includes a main body portion 30 which was formed in the main cavity portion 26 of the die 22 and3 which forms the core for the cylinder bore 14 shown in Fig. 1. The core 10 also includes au~iliary body portions 32a and 32b which were formed, respectively, in the auxiliary cavity portions 28a and 28b of the die 22 and which form, respectively, 7~72 the cores for the transfer and exhaust passages 16 and 18 which communicate with the bore 14.

To use the core 10 to manufacture the cylinder block 12 shown in Fig. 1, the core 10 is placed into a cylinder block mold 34 (shown in Fig.
4), and molten metal is caused to enter the cylinder block mold 34. Alternatively, the core 10 could be placed in a high pressure die casting machine in which the block 12 is cast. In either case, the block 12 is formed surrounding the reducible core 10 .

The reducible material of the core 10 is then removed by breaking or crushing and/or by flushing the material out by water to open the cylinder bore 14 and associated transEer and exhaust passages 16 and 18.

The liner 36 can then be pressed into the open cylinder bore 14, with the liner openings 38 properly aligned with the transfer and exhaust passages 16 and 18. The desired communication between the bore 14 and these passages 16 and 18 i5 thus provided.

An alternate construction of the core 10 is shown in Figs. 5 and 6. Structural components in this embodiment which are shared with the previously discussed embodiment are given common reference numerals.

~ 9 7 ~ ~ Z
In this construction, and like the construc-tion shown in Figs. 2 and 3, the separable two-piece die 22 includes the main cavity portion 26 and auxiliary cavity portions 28a and 28b whicn commu-nicate with the main cavity portion 26.

However, in this embodiment and unlike theemodiment shown in Figs. 2 and 3, the liner 36 is itself placed in the main cavity portion 26 of the die 22 (see Fig. 5) be~ore the die-cast core 10 is formed. The liner 36 is positioned in the main cavity portion 26 so that its openings 38 are properly aligned with the auxiliary cavity portions 28a and 28b of the die 22.

Molten reducible material is then injected under pressure by the ram 23 into the main cavity portion 26 and the auxiliary cavity portions 28a and 28b of the die 22. The preformed liner 36 is thus provided with the integral reducible die-cast core 10 (as is shown in Fig. 6) which includes the main bod~ portion 30 forming the core for the liner bore and auxiliary body portions 32a and 32b extending outwardly from the liner 36 and forming the cores of the transfer and exhaust passages 16 and 18 which communicate with the liner bore.

To use the core 10 as shown in Fig. 6 to manufacture the cylinder block 12 as shown in Fig.
1, the preformed liner 36 and its die-cast core 10 is placed in the cylinder block mold 3~ or in the high-pressure die casting machine (see Fig. 7).
Molten metal is then caused to enter the cylinder ~ '72 block mold 34 to form a cylinder block 12 surround-ing the liner 36 and its die-cast core 10. The reducible material is removed as above described and a cylinder block 12 having a cast-in cylinder liner 20 and integrally cast transfer and exhaust passages 16 and 18 is thereby formed.

In the preferred embodiment, the reducible material is salt, such as sodium chloride or potassium chloride. Alternatively, a salt mixture of two or more salts can be utilized. The salt is heated to a temperature sufficiently above its melting point to permit liquid flow. Typical melting temperatures are 1200 F or less for salt mixtures, and 1~74 F for sodium chloride. The mol-ten salt is injected into the die at a pressure consistent with the minimum required to prevent excessive porosity and shrink of the core, and within ~he maximum allowable by the die cmd injection machine.
Typical pre,ssures used might be 3000 to 10,000 pounds per square inch, Various of the ~eatures of the invention are set ~orth in the following claims.

Claims (10)

1. A method of die casting a core compris-ing the steps of fabricating a die defining a cavity in which the core is formed and injecting under pressure a reducible material in a molten state into the cavity of the die, thereby die casting the core.
2. A method according to Claim 1 and further including the steps of fabricating a preformed liner having a bore and placing the liner in the cavity of the die, and wherein said step of injecting the molten reducible material comprises injecting under pressure the molten reducible material into the bore of the liner, thereby providing the liner with a reducible die-cast core.
3. A method according to Claim 1 wherein said step of fabricating a die comprises fabricating a die defining a main cavity in which the main body of the core is formed and an auxiliary cavity communicating with the main cavity and in which an auxiliary body portion of the core is formed, and wherein said step of injecting the molten reducible material comprises injecting under pressure a reducible material in a molten state into the main and auxiliary cavities of the die, thereby die casting the core having a main body portion and an auxiliary body portion communicating with the main body portion.
4. A method according to Claim 3 and further including the steps of fabricating a preformed liner having a bore and placing the liner in the main cavity of the die, and wherein said step of injecting the molten material comprises injecting under pressure the molten reducible material into the bore of the liner and the auxiliary cavity of the die, thereby providing the liner with a reducible die cast core having an auxiliary body portion extending outwardly of the liner.
5. A method of fabricating a cylinder block comprising the steps of fabricating a die defining a cavity, injecting under pressure a reducible material in a molten state into the cavity of the die to thereby provide a die-cast core, placing the die cast core into a cylinder block mold, causing molten metal to enter the cylinder block mold, thereby forming a cylinder block surrounding the die-cast core, and removing the reducible material of the die-cast core from the block to provide a cavity in the cylinder block.
6. A method according to Claim 5 and further including after said step of removing the reducible material the step of pressing a cylinder liner into the cylinder block cavity.

12.
7. A method according to Claim 5 and further including the steps of fabricating a preformed cylinder liner having a bore and placing the cylinder liner in the cavity of the die, wherein said step of injecting the molten reducible material comprises injecting under pressure the molten reducible material into the bore of the cylinder liner, thereby providing the cylinder liner with a reducible die-cast core, and wherein said step of placing the core into the cylinder block mold comprises placing the cylinder liner and die-cast liner core into the cylinder block mold.
8. A method according to Claim 5 wherein said step of fabricating a die comprises fabricating a die defining a main cavity in which the main body of the core is formed and an auxiliary cavity communicating with the main cavity and in which an auxiliary body portion of the core is formed, and wherein said step of injecting the molten reducible material comprises injecting under pressure a reducible material in a molten state into the main and auxiliary cavities of the die, thereby die casting the core having a main body portion and an auxiliary body portion communicating with the main body portion.

13.
9. A method according to Claim 8 and further including the steps of fabricating a preformed cylinder liner having a bore and placing the cylinder liner in the main cavity of the die, wherein said step of injecting the molten reducible material comprises injecting under pressure the molten reducible material into the bore of the cylinder liner and auxiliary cavity of the die, thereby providing the cylinder liner with a reducible die cast core having an auxiliary body portion defining the core of a passage extending outwardly of the liner, and wherein the step of placing the core into the cylinder block mold comprises placing the cylinder liner and die-cast core into the cylinder block mold.
10. A method according to Claim 1 or 5 and wherein the reducible material is salt.
CA000383137A 1980-10-29 1981-08-04 Method of die casting a reducible core Expired CA1197972A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US20198180A 1980-10-29 1980-10-29
US201,981 1980-10-29

Publications (1)

Publication Number Publication Date
CA1197972A true CA1197972A (en) 1985-12-17

Family

ID=22748080

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000383137A Expired CA1197972A (en) 1980-10-29 1981-08-04 Method of die casting a reducible core

Country Status (2)

Country Link
JP (1) JPS57103756A (en)
CA (1) CA1197972A (en)

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5263818A (en) * 1975-11-21 1977-05-26 Nippon Musical Instruments Mfg Method of making core of water soluble salt for casting cylinder

Also Published As

Publication number Publication date
JPS57103756A (en) 1982-06-28

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