CN103658549A - Sand casted aluminum diesel piston equipped with as-cast, reentrant combustion bowl used for light or medium duty diesel engines - Google Patents
Sand casted aluminum diesel piston equipped with as-cast, reentrant combustion bowl used for light or medium duty diesel engines Download PDFInfo
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- CN103658549A CN103658549A CN201310411962.1A CN201310411962A CN103658549A CN 103658549 A CN103658549 A CN 103658549A CN 201310411962 A CN201310411962 A CN 201310411962A CN 103658549 A CN103658549 A CN 103658549A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
- B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
- B22D21/04—Casting aluminium or magnesium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group
Abstract
The present invention relates to a sand casted aluminum diesel piston equipped with an as-cast, reentrant combustion bowl and used for a light or medium duty diesel engines, and provides an aluminum-based diesel engine piston and a method of making the piston. The method involves casting the piston with complex geometries, including undercut or reentrant features. The casting uses an aggregate disposable mold that can be removed from the as-cast part. In one form, the complex geometry includes an undercut combustion bowl formed in the piston dome, while in another, it may include an internal cooling passage. The undercut bowl and internal passages may be produced using the aggregate disposable mold.
Description
The statement of correlation circumstance
The application is the U. S. application sequence number No.13/109 that is entitled as " SAND CASTING A DIESEL PISTON WITH AN AS-CAST; UNDERCUT COMBUSTION BOWL " that submit to and that abandon at present on May 17th, 2011,033 part continuation application, this application requires the provisional application sequence number No.61/405 that is entitled as " SAND CASTING A DIESEL PISTON WITH AN AS-CAST; UNDERCUT COMBUSTION BOWL " submitting on October 22nd, 2010,739 rights and interests.
Technical field
The present invention relates generally to for the equipment of cast engine parts and method, and relates more specifically to a kind of senior aluminium base diesel engine piston and casting method thereof with complex characteristic.
Background technology
The piston being used in explosive motor is formed by head (being also referred to as vault or bizet), skirt section, one or more ring-shaped groove and the ring platform between these grooves conventionally.Stricter discharge and efficiency require regulation, piston need to more approach stoichiometric condition, higher cylinder pressure and in pack mode, operate more closely in the future, and this will inevitably require higher component load and operational temperature conditions then.This is especially true for being used in the piston of diesel engine, and except the main engine type as for large commercial vehicle more, diesel engine is day by day for giving passenger vehicle energy supply.Equally, developing more complicated roof design to realize more thoroughly effectively combustion process, this has improved the temperature in combustion chamber more.These advanced roof designs with its three-dimensional (3D) profile need more complicated mold shape, thereby have improved the difficulty of cast pistons, or need to realize with extra machined desired vault geometry.
Higher operating temperature need to be used the material that can operate under those conditions.Equally, adopted cooling means as the means that improve the service life of piston and relevant high-temperature component.Realize cooling a kind of mode and be the engine oil gallery having existed by by being formed on the passage (being also referred to as path) in piston.This has significant benefit for cooling vault, because it is directly exposed to combustion process.But increase the difficulty that cast pistons has also been improved in cooling duct.
The casting mold of tradition recyclable (nonexpendable) form for example permanent mould casting mold is not suitable for formation complicated shape.Specifically, once limit casting mold with the permanent character of the mould of the recessed joint area for example existing in 3D dome shape as mentioned above in some shapes, have cured, make the ability of this parts retraction.Therefore, need to carry out further machined to produce complicated shape to casting mold.These extra machineds have caused complexity and the cost of permanent mould casting method high.Part quality also can be subject to the impact of permanent mould casting mold.The existence of rising head can affect the microstructure of piston and the grain refinement amount that can realize.For example, the relatively large thermal mass of large-scale rising head can slow down solidifying of foundry goods, and as the existence at less secondary dendritic arm interval (SDAS) verified faster cooling desirable often with mechanical property improvement that follow.By gate location and the comparison of rising head side, in mechanical properties, there is 20% difference.
In order to overcome the shape restriction of permanent mould, can adopt other scheme, comprise various forms of not recyclable casting molds, such as fusible pattern (or dewax) casting mold, sand mold etc.Invested mould is usually directed to use not recyclable mould and pattern (pattern), and adopts ceramic die material, and wherein parts solidify and make machined after the minimum casting of needs only in mould.The modification of sand mold scheme is known as salt core casting mold, adopts the technology that is similar to sand mold, except adopting soluble salt for inner mould geometry, rather than greensand or dry sand.Once manufacture component, available water is fallen salt stamping, and need not make parts be subject to extra heat load arbitrarily.Salt core casting mold has to be deposited and processing problem, and this has reduced its attraction.
The another kind of scheme that has been used for producing casting vault is semipermanent die casting.This scheme still needs burning bowl to carry out machined.The same with above-mentioned permanent die casting, also need to overflow significant quantity from vault.In addition, output higher (being high-performance) piston also can need a bowl edge remelting.These extra processes have obviously increased the cost of piston.This is particularly like this for remelting operation and bowl machined cost, even for example all the more so for high output diesel engine piston for being configured to the piston of working high temperature and high pressure condition (being equally also called as will be described in more detail below " heavy type " purposes) under.These pistons can operate at the cylinder pressure higher than 200 bar (even up to 230 bar) with at up to the temperature of 400 degrees Celsius, therefore need to adopt steel forgings, and this has brought more significant cost impact.
In the marked change aspect operating condition example temperature and pressure condition described above, make to need corresponding architectural difference between heavy (can comprise bus, trailer, high speed truck, Architectural Equipment etc.) diesel engine piston and those pistons of light-duty purposes (can comprise passenger vehicle, light truck etc.) or medium-sized purposes, wherein the vehicle of diesel engine energy supply (and load) has legal provisions in USA, Europe and various places.For example, at USA, in heavy type, between medium-sized and light duty engine, by hair vehicle weight quota (GVWR), distinguish, the vehicle that its medium-weight vehicle weight surpasses a certain amount of (for example stipulating about 33000 pounds according to federal and California), medium-sized (for example according to federal regulation between 19500 and 33000 pounds, and be defined between 14000 and 33000 pounds according to California) and light-duty (for example according to federal regulation between 8400 and 19500 pounds, and being defined between 8500 and 14000 pounds according to California) vehicle is corresponding to lower weight.Also can adopt other to measure, wherein for example medium-sized Diesel engine is that discharge capacity is about 4 to rise to the engine between about 7 liters, and its discharge capacity of heavy duty diesel engine is about 10 to rise between about 15 liters.In addition, in Diesel engine field, load cycle can require to limit by traction (this can stipulate cylinder pressure then).Specifically, heavy purposes relies on base steel piston, thereby they are applied to the severe rugged environment on them by bearing by said temperature and pressure.
Summary of the invention
One aspect of the invention is the method for manufacturing diesel engine piston.In one embodiment, the method comprises: be provided for the pattern of described piston, described pattern comprises vault and concave type bowl; Formation is round the Piston mould of described pattern, and described mould comprises aggregate material and bonding agent; From described Piston mould, remove described pattern; Described motlten metal is imported in described Piston mould; Make described Piston mould contact and remove described bonding agent and described aggregation with the solvent for described bonding agent; Cooling described motlten metal; And motlten metal is solidified to form and there is the piston of vault and concave type bowl, and only need the casting post processing of minimum degree.In current context, casting post processing includes, but is not limited to a bowl machined, some finishing operations or other method.Significance degrees of these casting post processings are such activities, and they relate to obvious extra cost or time to prepare the cast component for its final form.Different from machined after obvious casting etc., conventional or unexpectedly clean or similarly final preparation process do not form machined after obvious casting.Equally, the basic cast pistons going out constructed in accordance will not need these extra steps to limit for example basic concave type shape of the bowl in vault of complicated shape.In addition, aggregation and bonding agent have formed mould conventionally.Like this, according to sand casting of the present invention, need to before casting, duplication of production not go out foam or wax pattern formula or from ceramic die, remove these patterns.And, melting circulation timei under casting case of expection shorter (from mfg. moulding die to producing foundry goods institute's time spent) because take out foundry goods from mould before without making foundry goods completely curing.
For its iron-based counterpart, adopt method of the present invention particularly favourable for the cast aluminum base piston of Diesel engine purposes (especially for light-duty and medium duty engine, wherein cylinder pressure remains about 200 bar or lower) for casting.Aluminium is that as a reason of the metal of selecting its density is approximately 1/3rd (these cause the simplification of weight saving and the bearing of following and related support structure, and this is particularly favourable in the parts with high speed rotating or movement) of base steel component density.Another reason is, alumina-base material can finely be cast, and is included in the ability of lower part Li Wendu compacted under; This advantageously affects tool design, durability and cost conversely.In addition, because the twice that the thermal conductivity of aluminium is steel, so alumina-base part has reduced for being recycled during power operation by the cold oil of the path in piston, this can simplify oil pump for engine design conversely.This higher thermal conductivity (and the attached ability of distributing too much heat) has reduced such possibility, and the temperature around the coronal parts adjacent with burning with other will produce less desirable impact in discharge and efficiency.In addition, the technique that casting process for example adopted in the present invention allows the top annular groove and the above-mentioned interior oil path that comprise that these details are for example hardened, these inner portions as casting technique form, and steel forgings needs heat treatment, machined or assembly operation subsequently.
In addition, casting tool more can adapt to change or other design change that needs carry out due to validation test result.And, to compare with forging piston, casting diesel engine piston can be for as-cast condition quality optimization, even make to need in the situation of machine operations after significantly casting in casting.
As mentioned above, although integral cast (the especially casting of aluminium based metal) is favourable, for some types of casting operation, there are some restrictions.For example, semipermanent and permanent mould casting process is not suitable for and forms complicated shape and be for example used in the concave type burning bowl in the higher diesel engine piston of renewals, performance.The ablation method associated with the present invention eliminated and carried out a large amount of or obvious mach needs to having burning bowl or the other parts of the piston of concave type feature, still allows to comprise that many details are for example for core or the iron top annular groove Embedded Division of oily path simultaneously.Of the present invention, melt casting and for above-mentioned model casting, there are some obvious differences.For example, the pattern in melting casting is not reused unlike the mode of model casting pattern.Model casting has adopted the ceramic base mould based on slurry, and these moulds are smashed subsequently or be otherwise broken separated with foundry goods, but melt casting, have adopted silica sand, zircon sand, ferrochrome sand etc., and this does not need the sclerosis of repetitive coatings, stucco and mould; Obviously, the sand adopting in melting casting is reusable.Therefore, although the sand sill that is used to form aggregation of the present invention can present the attribute of some similar potteries (comprising relative fire resistance), but think that they are different from pottery, because they can not be changed (for example, by these coatings, stucco and sclerosis), become dissimilar structure.Equally, metal-cured in melting casting starts after filling in mould, and completes during the water of mould melts.Melt casting and still can need the rear machined of some castings.
The casting method that melts of the present invention also causes meticulous and casts uniformly micro-structural when being used to form aluminium base diesel engine piston.This is (at least partly) due to without large-scale rising head, and this can slow down hardening time and affect attainable grain refinement amount.By the present invention, the grainiess in the different piece of piston can be adjusted to the performance that will optimize.Therefore, can need stronger melting with cooling more thickness portion can adopt the speed different from thinner part cooling, to realize grain refinement or the pattern of special expectation.Other method for example antigravity implements expensive with relevant slow filling technique.By sand mold mould of the present invention the attainable faster mold filling time with by mould, melt the difficulty being cured in conjunction with can being advantageously used for avoiding adopting this filling technique at a slow speed to come cast aluminum base piston to encounter.
Modern complex component can not adopt dead size, monomer or relevant nearly clean shape method traditionally.Especially for piston, conventionally by independent casting discreet component, reduce to cast complexity.For example, can cast coronal and ring belt area, then be connected on the second component being formed by skirt section, piston pin etc. subsequently.Equally, the parts that have concave type feature (vault for example burns) easily further depart from net shape, monomer foundry goods.Foundry goods produced according to the invention does not need two part designs to realize dead size attribute for the cast aluminum base piston with undercutting concave type bowl and relevant complex characteristic.Therefore, they can adopt monomer structure form, and wherein each feature (for example vault, ring-shaped groove, oily path, skirt section and pin-and-hole) of many (or all) pistons forms single solid members.For example, the Hinged piston of the monomer structure motion irrelevant from wherein skirt section and pin or pin-and-hole is different.Monomer structure can monoblock cast, or they can be (for example, by welding) two separate parts together that are rigidly connected.Here disclosed piston can be taken as the design of casting monomer aluminium.In addition, these foundry goods can adopt cooling and parts fast to extract to guarantee excellent grainiess and high manufacture component output.In current context, the inventor has determined that employing aluminium piston and monolithic design are applicable to non-heavy duty diesel engine purposes, wherein has the operating pressure that is not more than 200 bar.In addition, this method realized undercutting bowl, oily path, interior casting ring-shaped groove insert and from mould the complexity of further feature out, and need operation after seldom (or do not need) casting.
According to another aspect of the present invention, disclosed and there is at least one concave type feature the inblock cast aluminum matrix piston of (being especially formed on the bowl in the vault of piston).Once this piston is constructed to be placed in Diesel engine and operation therein, this piston can bear up to the operating pressure of 200 bar cylinder pressures and the temperature up to about 400 degrees Celsius.These performances enable to operate on the normal service life of above-mentioned light-duty or medium-sized Diesel engine purposes.
The present invention also provides following scheme:
1. sand casting is for a method for the aluminum matrix piston of light-duty or medium-sized Diesel engine, and described method comprises:
Be provided for the pattern of described piston, described pattern comprises vault and concave type bowl;
Formation is round the Piston mould of described pattern, and described mould comprises aggregate material and bonding agent;
From described Piston mould, remove described pattern;
Molten aluminum matrix metal is incorporated in described Piston mould;
Make described Piston mould contact and remove described bonding agent and described aggregation with the solvent for described bonding agent; And
Cooling described molten aluminum matrix metal, makes when curing, and described piston substantially limits and can bear described vault and the female formula bowl that reaches the operating pressure of about 200 bar cylinder pressures and reach the temperature of about 400 degrees Celsius.
2. the method as described in scheme 1, is characterized in that, described aggregate material is sand base non-ceramic material.
3. the method as described in scheme 1, is characterized in that, also comprises cooling described motlten metal rapidly.
4. the method as described in scheme 3, is characterized in that, described rapidly coolingly carry out within about 5 minutes or time still less.
5. the method as described in scheme 1, is characterized in that, described piston comprises crown part and skirt portion, and they are cast in together as single parts to limit monomer foundry goods.
6. the method as described in scheme 5, is characterized in that, described piston also comprises piston pin part, and it casts to limit described monomer foundry goods with described crown part together with skirt portion.
7. the method as described in scheme 1, is characterized in that, described bonding agent is water miscible, and wherein said solvent is water.
8. the method as described in scheme 1, is characterized in that, cooling described motlten metal and curing described motlten metal are controlled separatedly, makes to form in the different piece of described piston the grainiess being conditioned.
9. the method as described in scheme 1, is characterized in that, cooling described motlten metal comprises the shell at described motlten metal curing metal around with described solvent contact.
10. the method as described in scheme 1, is characterized in that, also comprises:
Be provided for the mould of internal cooling channel, for the mould of described internal cooling channel, comprise the second aggregate material and the second bonding agent;
Before in described motlten metal is incorporated into described Piston mould, the described mould for described internal cooling channel is arranged on to described Piston mould; And
Use the solvent contact for described the second bonding agent be used for the mould of described internal cooling channel and remove described the second bonding agent and the second aggregation.
11. methods as described in scheme 10, is characterized in that, described the second aggregate material is identical with aggregate material and bonding agent for described Piston mould with the second bonding agent.
12. methods as described in scheme 1, is characterized in that, adopt solvent for described bonding agent to contact described Piston mould and comprise with Piston mould described in described ejection of solvent.
13. 1 kinds of manufactures are used for the aluminium base diesel engine piston of light-duty or medium duty engine purposes, and described method comprises:
Be provided for the pattern of described piston, described pattern comprises vault and concave type bowl;
Formation is round the Piston mould of described pattern, and described mould comprises aggregate material and water soluble adhesive;
From described Piston mould, remove described pattern;
Molten aluminum matrix metal is incorporated in described Piston mould;
Water contacts described Piston mould and removes described bonding agent and described aggregation;
Cooling described motlten metal; And
Solidify described motlten metal substantially to form the piston with vault and concave type bowl, and described piston is not cast to post processing, make when solidifying piston, described piston can bear the temperature that reaches the operating pressure of about 200 bar cylinder pressures and reach about 400 degrees Celsius.
14. methods as described in scheme 13, is characterized in that, cooling described motlten metal and solidify described motlten metal and controlled discretely.
15. methods as described in scheme 14, it is characterized in that, by applying water to a region of piston or control discretely the cooling of described motlten metal and solidifying described motlten metal by the water that the zones of different to described piston applies different amounts before other region.
16. methods as described in scheme 13, is characterized in that, also comprise:
Be provided for the mould of internal cooling channel, for the mould of described internal cooling channel, comprise the second aggregate material and the second bonding agent;
Before in described motlten metal is incorporated into described Piston mould, the mould for described internal cooling channel is arranged on to described Piston mould; And
Adopt the solvent contact for the second bonding agent to be used for the mould of described internal cooling channel, and remove described the second bonding agent and described the second aggregation.
17. methods as described in scheme 16, is characterized in that, described the second aggregate material is identical with aggregate material and bonding agent for described Piston mould with described the second bonding agent.
18. methods as described in scheme 13, is characterized in that, water contacts described Piston mould and comprises that water sprays described Piston mould.
19. 1 kinds of inblock cast pistons that comprise alumina-base material, it has the concave type bowl being formed in its vault, described piston forms while making to operate in being arranged to Diesel engine and in described Diesel engine, and it can bear up to the operating pressure of about 200 bar cylinder pressures and the temperature up to about 400 degrees Celsius.
20. pistons as described in scheme 19, is characterized in that, described piston is configured for light-duty or medium-sized Diesel engine purposes.
Accompanying drawing explanation
The detailed description of the following specific embodiments of understanding that can be best when accompanying drawing is read below combination, wherein represents same structure with identical Reference numeral, wherein:
The partial perspective that Fig. 1 is the diesel engine piston that can produce by sand casting of the present invention is cut off figure, highlights groove, concave type and relevant feature;
Fig. 2 is the cutaway view of diesel engine piston under casting condition; And
Once Fig. 3 is for having carried out the cutaway view of the diesel engine piston of final machined Fig. 2.
The specific embodiment
With reference to these accompanying drawings, these accompanying drawings demonstrate the relevant feature of aluminium base diesel engine piston that can cast according to the mode instructed here at first.Specifically, piston 1 comprises crown part (being also referred to as coronal) 10, skirt portion (being also referred to as skirt section) 20 and piston pin hole 30.Coronal 10 defines the upper surface 12 that is substantially plane, and this surface defines domeshape burning bowl 14 substantially therein.The wall 16 of bowl 14 is with profile and locate at an upper portion thereof to terminate in lip, thereby the suspension part forming thus limits concave type (reentrant) feature of bowl 14.The outer radial surface of coronal 10 comprises various longitudinally-spaced circumference extending flutes 18, and piston ring (not shown) can be inserted into wherein to help combustion seal and to scrape functional oil.Groove insert 19 can be arranged in one or more in groove 18.Skirt section 20 can comprise longitudinal sidewall to downward-extension, and rib, flange and relevant reinforcement structure (not shown) can be included in wherein.Skirt section 20 helps piston 1 during it moves back and forth in engine cylinder, to keep aiming at.Equally, piston pin hole 30 is integrated in side plate 40 and (in Fig. 1, specifically demonstrates), this part that has formed skirt section 20 is to limit the passage radially extending substantially, wherein be used for inserting pin so that piston 1 is supported on connecting rod rotationally, this connecting rod crosses cylinder in response to rotatablely moving of crank axle (do not demonstrate wherein any).On whole coronal 10, be formed with a plurality of openings, their form to form the oily passage of path, so that oil or relevant cooling agent are by import in cylinder.
Melting casting can be used for producing having and be combined with the vault of casting concave type bowl portion and the piston of optional internal cooling channel.Melt casting and adopted inorganic (water-soluble) core, and (preferably from many directions) be injected in water mould, this mould washes out (so term " melts ") lentamente, thus cooling casting mold promptly.The cooling material property that causes improves rapidly.In current context, rapidly cooling be for example, than tradition (model casting) cooling means obviously rapider.Investment casting method needs to carry out between half an hour to one hour fully cooling, but melts the aluminium base diesel engine piston that casting manufactures and can in 3 to 5 minutes, be cooled to room temperature according to current.In addition, applying water allows parts to solidify and is coolingly controlled independent of one another (for example, by applying water to the specific region of foundry goods or apply the water of different amounts by the region to different before other region).Therefore,, when expectation, melt casting and allow to produce all the time the complex component with trickle curing microstructure.By being provided as, realize whole higher mechanical performance (for example stretching under room temperature and high temperature and fatigue behaviour) conventionally required high curing rate and meticulous microstructure, melt casting and allow to form combination and have the parts of thin and thickness portion and those parts with complex internal core.Slightly for example, lower than the surperficial degree of depth (several mm), providing those parts of the bowl edge remelting manufacture of desired fine microstructures to compare with adopting just, overall performance is more excellent.
Be incorporated into as a reference in U.S. Patent No. 7121318 herein and described substantially and melted casting technique.With material, form pattern, and form mould round at least a portion of this pattern.This mould is made by aggregation (aggregate) material and bonding agent.From mould, remove pattern, then melted material is imported in mould.This mould contacts with solvent, and cooling molten metal, thereby it solidifies to form foundry goods at least partly.Cooling step comprises the curing metal shell that surrounds motlten metal is contacted with solvent.
Melt substantially casting and also be not used for casting diesel engine piston, and more particularly there is the diesel engine piston of concave type bowl portion, even more specifically for thering is the aluminium base diesel engine piston of concave type bowl portion or associated recesses feature.
U.S. Patent No. 7164963,7618823 and 7225049 has been described for losing the analytical method of foam casting (a kind of melt casting), and each piece of document is here cited as a reference.
The possibility that casting provides casting to have the piston of nearly end form vault is melted in employing, and without other techniques required obvious casting post processing and/or machined.Therefore, can cast out vault and burning bowl simultaneously.In concrete form, concave type bowl 14 and inner passage can be produced by aggregation disposable tool, and this can produce by have the common core technology of the instrument that can bounce back in molding die.In current content, the aggregate form of molded medium includes but not limited to silica sand, ferrochrome sand, ceramic microsphere etc.
One or more in including but not limited to below of beneficial effect of the present invention: machined cost reduces, the cast microstructure that becomes more meticulous of mechanical property improvement, utilized the advantage of sand mold (or relevant) casting technique to be adjusted in the concave type region in vault, alleviate casting weight, and eliminated the needs to inner salt core.Traditional salt core can use the aggregation core being formed by the material identical with Piston mould to replace.
In one form, can adopt sand casting to produce piston 1 of the present invention.This technique has reduced the thick and heavy rising head that permanent mould adopts conventionally substantially, thereby causes material output capacity to be improved.In addition, melting high cooling velocity inherent in casting makes it easier adjusting process and has the improved accurate microstructure of material property to realize.These improved material properties should provide firmer on the whole piston 1, and required piston cup 14 edge strengths (and not will this region remelting) are with consistently by strict cap gasket validation test.
In a concrete form, mould can be made by the sand that can melt casting, thereby can be easily and produce at an easy rate complicated dome shape, comprises those shapes with groove and internal cooling channel part.
By elimination, be typically used as the large-scale rising head of a part for permanent die casting operation, can realize better material output capacity.Specifically, by employing, melt casting method, inherent high cooling velocity can allow piston 1 to form to have uniform microstructure and relevant structural behaviour.
Except meticulousr microstructure and better piston performance, employing is melted technique meticulousr details can be casted in parts, comprises complicated cooling duct.This technique has reduced or eliminated mach demand after casting in vault or coronal 10 peripheral regions, especially at it, relates to concave type feature, piston pin hole 30 and the region, cooling duct of burning bowl 14.Because melting casting is the existing mode of production, so batch manufactures a large amount of pistons or associated components is relatively simple.Can adopt aggregation disposable tool to allow the burning bowl 14 of piston vault and the part that lubrication and cooling path (not shown) forms foundry goods.
For diesel engine piston adopt melt casting by reduce or eliminate for expensive assisted casting post processing for example the needs of machined or melting again contribute to realize obvious microstructure and become more meticulous.In the situation that the microstructure that expectation becomes more meticulous, for example the bowl edge of piston 1 or other complicated 3D region, can carry out Wolfram Inert Gas (TIG) or laser remolten (for example, in the concave type region of burning bowl 14) in part.Can reduce or eliminate equally the suitable shape that machined subsequently for example produces bowl edge.
The present invention has adopted the advantage that melts casting technique to eliminate the demand to large-scale rising head at piston vault or coronal 10 places.Ability rapider and cooling vault or coronal 10 equably should improve mechanical performance.Therefore,, once mold filling, the metal of casting starts skinning.Before having solidified, the water curtain that mould forms through the water jet (not shown) by one or more strands of injections, this is used for mould to dissolve, and in this process, foundry goods is carried out to effective water-cooled.Specifically, disposable aggregation mould should allow 14 castings of burning bowl to form.In addition, also can adopt aggregation mold materials to be formed on top annular groove 18 path 15 below, thereby eliminate the demand to salt core.This allows piston to carry out rapid prototyping manufacture extraly, and this can improve overall research and development test.Although not shown in the front cross sectional view at accompanying drawing, it being understood that can be by one or more passage monoblock cast in piston 1, oil inflow and outflow pathway 15 thereby these passages can extend upward from the lower surface of path 15.The passage that further feature-be for example convenient to oil droplet is fallen on bar or pin can be formed in the lower surface of piston 1 equally.
Different from steel pistons, the entrance and the associated openings general size that wherein pass in and out path are large a bit to guarantee sufficient core removal, water-based solvent is used in melting casting method and can keep less on aluminum matrix piston of the present invention, because can pass the less opening of these sizes.As mentioned above, because piston moves forward and backward fast, these are simplified for example access tube linear dimension and reduce to have multiple auxiliary benefit for bearing and support structure designs arbitrarily, because designer can reduce weight, complexity or the relevant steady heavily fortified point of this structure.In a non-limiting embodiment of plunger designs constructed in accordance, for the oil-in of path 15 and its diameter of the hole of oil-out, be approximately 8mm, and more particularly in being approximately the scope of 4mm and 7mm.Equally, can form on a 50-50 basis lubrication oil dropping hole.
It is to be noted, term for example " preferably ", " generally " and " conventionally " is not here for limiting scope of invention required for protection or implying that some feature is crucial, vital or even important for structure or the function of invention required for protection.Yet these terms are only used for emphasizing the optional or other feature that can adopt in specific embodiment of the invention scheme or can not adopt.
In order to describe and limit the present invention, it is to be noted, term " device " is used for representing the combination of parts and all parts here, and no matter these parts whether with other component combination.For example, " device " according to the present invention can comprise electro-chemical conversion assembly or fuel cell, is combined with according to vehicle of electro-chemical conversion assembly of the present invention etc.
In order to describe and limit the present invention, it is to be noted, term " substantially " is used for representing inherent uncertainty degree here, this can be for any quantization comparison, numerical value, measure or other expression.Term " substantially " is here also used for representing the degree that quantization means is different from the reference value of defined, and can not causes the basic function of discussed object to change.
Although demonstrated some representative embodiment and details in order to exemplify explanation the present invention, but it will be obvious to those skilled in the art that and do not departing from the situation that the scope of the present invention limiting in appended claims can be made various variations.
Claims (10)
1. sand casting is for a method for the aluminum matrix piston of light-duty or medium-sized Diesel engine, and described method comprises:
Be provided for the pattern of described piston, described pattern comprises vault and concave type bowl;
Formation is round the Piston mould of described pattern, and described mould comprises aggregate material and bonding agent;
From described Piston mould, remove described pattern;
Molten aluminum matrix metal is incorporated in described Piston mould;
Make described Piston mould contact and remove described bonding agent and described aggregation with the solvent for described bonding agent; And
Cooling described molten aluminum matrix metal, makes when curing, and described piston substantially limits and can bear described vault and the female formula bowl that reaches the operating pressure of about 200 bar cylinder pressures and reach the temperature of about 400 degrees Celsius.
2. the method for claim 1, is characterized in that, described aggregate material is sand base non-ceramic material.
3. the method for claim 1, is characterized in that, also comprises cooling described motlten metal rapidly.
4. method as claimed in claim 3, is characterized in that, described rapidly coolingly carry out within about 5 minutes or time still less.
5. the method for claim 1, is characterized in that, described piston comprises crown part and skirt portion, and they are cast in together as single parts to limit monomer foundry goods.
6. method as claimed in claim 5, is characterized in that, described piston also comprises piston pin part, and it casts to limit described monomer foundry goods with described crown part together with skirt portion.
7. the method for claim 1, is characterized in that, described bonding agent is water miscible, and wherein said solvent is water.
8. the method for claim 1, is characterized in that, cooling described motlten metal and curing described motlten metal are controlled separatedly, makes to form in the different piece of described piston the grainiess being conditioned.
9. the method for claim 1, is characterized in that, cooling described motlten metal comprises the shell at described motlten metal curing metal around with described solvent contact.
10. manufacture is for an aluminium base diesel engine piston for light-duty or medium duty engine purposes, and described method comprises:
Be provided for the pattern of described piston, described pattern comprises vault and concave type bowl;
Formation is round the Piston mould of described pattern, and described mould comprises aggregate material and water soluble adhesive;
From described Piston mould, remove described pattern;
Molten aluminum matrix metal is incorporated in described Piston mould;
Water contacts described Piston mould and removes described bonding agent and described aggregation;
Cooling described motlten metal; And
Solidify described motlten metal substantially to form the piston with vault and concave type bowl, and described piston is not cast to post processing, make when solidifying piston, described piston can bear the temperature that reaches the operating pressure of about 200 bar cylinder pressures and reach about 400 degrees Celsius.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/609821 | 2012-09-11 | ||
| US13/609,821 US20130000482A1 (en) | 2010-10-22 | 2012-09-11 | Sand Casting An Aluminum Diesel Piston With An As-Cast, Reentrant Combustion Bowl For Light Or Medium Duty Diesel Engines |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN103658549A true CN103658549A (en) | 2014-03-26 |
Family
ID=50153509
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201310411962.1A Pending CN103658549A (en) | 2012-09-11 | 2013-09-11 | Sand casted aluminum diesel piston equipped with as-cast, reentrant combustion bowl used for light or medium duty diesel engines |
Country Status (4)
| Country | Link |
|---|---|
| KR (1) | KR20140034068A (en) |
| CN (1) | CN103658549A (en) |
| DE (1) | DE102013217251A1 (en) |
| MX (1) | MX2013009848A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107282881A (en) * | 2017-06-30 | 2017-10-24 | 南昌航空大学 | A kind of water-soluble sand mould casting method of rapid solidification |
| CN108367340A (en) * | 2015-11-19 | 2018-08-03 | Ks科尔本施密特有限公司 | What is cast in cast-steel piston and cast-iron piston enters opening and outlet opening |
| CN110666138A (en) * | 2019-10-28 | 2020-01-10 | 吉林大学 | High-wear-resistance piston preparation device and method |
| CN115090857A (en) * | 2022-06-29 | 2022-09-23 | 山西中兵铸造有限公司 | Tile hole embedded casting structure and process for aluminum alloy box body |
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| EP0209090A2 (en) * | 1985-07-12 | 1987-01-21 | Toyota Jidosha Kabushiki Kaisha | Production of pistons having a cavity |
| US5595145A (en) * | 1995-05-31 | 1997-01-21 | Kabushiki Kaisha Komatsu Seisakusho | Cooling structure of diesel engine piston |
| US20060037471A1 (en) * | 2004-07-21 | 2006-02-23 | Xiluo Zhu | One piece cast steel monobloc piston |
| CN101073827A (en) * | 2007-06-15 | 2007-11-21 | 镇江中船设备有限公司 | Method for casting piston |
| US20080034961A1 (en) * | 2004-10-25 | 2008-02-14 | Industrial Parts Depot Inc. | One piece cast ferrous crown piston for internal combustion engine |
| US20120097354A1 (en) * | 2010-10-22 | 2012-04-26 | GM Global Technology Operations LLC | Sand casting a diesel piston with an as-cast, reentrant combustion bowl |
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| US7121318B2 (en) | 2002-09-20 | 2006-10-17 | Alotech Ltd. Llc | Lost pattern mold removal casting method and apparatus |
| US7618823B2 (en) | 2004-06-30 | 2009-11-17 | Gm Global Technology Operations, Inc. | System, method and apparatus for lost foam casting analysis |
| US7225049B2 (en) | 2004-06-30 | 2007-05-29 | Gm Global Technology Operations, Inc. | Lost foam casting analysis method |
| US7164963B2 (en) | 2004-06-30 | 2007-01-16 | Gm Global Technology Operations, Inc. | System, method and apparatus for lost foam casting analysis |
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2013
- 2013-08-27 MX MX2013009848A patent/MX2013009848A/en not_active Application Discontinuation
- 2013-08-29 DE DE201310217251 patent/DE102013217251A1/en not_active Withdrawn
- 2013-09-05 KR KR1020130106520A patent/KR20140034068A/en not_active Application Discontinuation
- 2013-09-11 CN CN201310411962.1A patent/CN103658549A/en active Pending
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| EP0209090A2 (en) * | 1985-07-12 | 1987-01-21 | Toyota Jidosha Kabushiki Kaisha | Production of pistons having a cavity |
| EP0209090B1 (en) * | 1985-07-12 | 1991-08-21 | Toyota Jidosha Kabushiki Kaisha | Production of pistons having a cavity |
| US5595145A (en) * | 1995-05-31 | 1997-01-21 | Kabushiki Kaisha Komatsu Seisakusho | Cooling structure of diesel engine piston |
| US20060037471A1 (en) * | 2004-07-21 | 2006-02-23 | Xiluo Zhu | One piece cast steel monobloc piston |
| US20080034961A1 (en) * | 2004-10-25 | 2008-02-14 | Industrial Parts Depot Inc. | One piece cast ferrous crown piston for internal combustion engine |
| CN101073827A (en) * | 2007-06-15 | 2007-11-21 | 镇江中船设备有限公司 | Method for casting piston |
| US20120097354A1 (en) * | 2010-10-22 | 2012-04-26 | GM Global Technology Operations LLC | Sand casting a diesel piston with an as-cast, reentrant combustion bowl |
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108367340A (en) * | 2015-11-19 | 2018-08-03 | Ks科尔本施密特有限公司 | What is cast in cast-steel piston and cast-iron piston enters opening and outlet opening |
| CN108367340B (en) * | 2015-11-19 | 2020-04-14 | Ks科尔本施密特有限公司 | Inlet and outlet openings cast in cast steel pistons and cast iron pistons |
| CN107282881A (en) * | 2017-06-30 | 2017-10-24 | 南昌航空大学 | A kind of water-soluble sand mould casting method of rapid solidification |
| CN107282881B (en) * | 2017-06-30 | 2019-07-12 | 南昌航空大学 | It is a kind of quickly to solidify water-soluble sand mould casting method |
| CN110666138A (en) * | 2019-10-28 | 2020-01-10 | 吉林大学 | High-wear-resistance piston preparation device and method |
| CN110666138B (en) * | 2019-10-28 | 2023-10-20 | 吉林大学 | High-wear-resistance piston preparation device and method |
| CN115090857A (en) * | 2022-06-29 | 2022-09-23 | 山西中兵铸造有限公司 | Tile hole embedded casting structure and process for aluminum alloy box body |
| CN115090857B (en) * | 2022-06-29 | 2024-01-09 | 山西中兵铸造有限公司 | Aluminum alloy box tile hole embedded casting structure and process |
Also Published As
| Publication number | Publication date |
|---|---|
| DE102013217251A1 (en) | 2014-03-13 |
| MX2013009848A (en) | 2014-03-25 |
| KR20140034068A (en) | 2014-03-19 |
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Application publication date: 20140326 |
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