EP0092690A1 - Noyau de moulage pour la coulée d'un bloc-cylindres de moteur - Google Patents

Noyau de moulage pour la coulée d'un bloc-cylindres de moteur Download PDF

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Publication number
EP0092690A1
EP0092690A1 EP83103190A EP83103190A EP0092690A1 EP 0092690 A1 EP0092690 A1 EP 0092690A1 EP 83103190 A EP83103190 A EP 83103190A EP 83103190 A EP83103190 A EP 83103190A EP 0092690 A1 EP0092690 A1 EP 0092690A1
Authority
EP
European Patent Office
Prior art keywords
core
evaporative pattern
cylinder block
cavity
cylinder
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.)
Withdrawn
Application number
EP83103190A
Other languages
German (de)
English (en)
Inventor
Kimio c/o Yokohama Plant Ueta
Tetsuo c/o Yokohama Plant Sakamoto
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.)
Nissan Motor Co Ltd
Original Assignee
Nissan Motor Co Ltd
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 Nissan Motor Co Ltd filed Critical Nissan Motor Co Ltd
Publication of EP0092690A1 publication Critical patent/EP0092690A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores

Definitions

  • the present invention relates to a molding core to be used for casting an internal combustion engine cylinder block, and a method for making such a core.
  • cores When casting a cylinder block, cores are used to form internal openings such as cylinder bores, a crank chamber, water jackets and lubricating oil passages in a cylinder block casting. Cores are made from a core material such as a mixture of silica sand, a binder and other ingredients by using a core box.
  • a cylinder block casting must be provided with one or more main bearing portions for supporting a crankshaft.
  • Such a main bearing portion has an intricate shape because it includes a housing of a main bearing, ribs and lubricating oil passages. Therefore, if such an intricate main bearing portion is included in a single piece core for forming a crankcase, it is very difficult or impossible to remove such a single piece core from its core box, especially in the case that the single piece core includes an intermediate main bearing portion lying in between outer walls of the crankcase. If, on the other hand, a core piece for forming a main bearing portion is prepared separately from a main core for forming a crankcase, it is difficult and time-consuming to accurately and reliably attach the core piece to the main core.
  • a core to be used, in cooperation with a mold, for casting an internal combustion engine cylinder block which has at least one cylinder bore, a crankcase wall for forming a crank chamber and at least one bearing portion for supporting a crankshaft of the engine comprises a main body and at least one evaporative pattern.
  • the main body of the core has at least one cylinder portion for forming the cylinder bore of the cylinder block and a crankcase portion for forming the crank chamber.
  • the evaporative pattern has the same shape as the bearing portion or one of the bearing portions of the cylinder block.
  • the evaporative pattern is made integral with the main body of the core and is made of a material which is capable of dissipating and leaving a cavity having the shape of the evaporative pattern.
  • the evaporative pattern is embedded in the main body of the core by the process comprising the steps of fixing the evaporative pattern in a predetermined position within a core box for shaping the core, packing a core material from which the core is made, in a cavity formed by the core box and the evaporative pattern, and hardening the core material.
  • the evaporative pattern may have the same shape as the bearing portion which lies in an intermediate position between two ends of the cylinder block spaced along the axial direction of the crankshaft, and the evaporative pattern may be embedded in a corresponding intermediate position in the main body of the core.
  • Fig. 1 shows a casting mold for casting a cylinder block of an internal combustion engine.
  • the mold consists of an upper part or cope 1 and a bottom part or drag 2. Between the upper part 1 and the bottom part 2, there are fixed a core 5 for a cylinder block and a core 7 for a water jacket.
  • the cylinder block core 5 has a cylinder portion 3 for forming an engine cylinder and a crankcase portion 4 for forming a crankcase.
  • a molten metal is poured from a sprue 6 into a cavity 8 formed between the mold and the cores.
  • a cylinder block casting having the same shape as the cavity 8 is made.
  • the cylinder block core 5 is made of aggregate such as silica sand, a binder, an accelerator of hardening and other ingredients.
  • a core binder phenolic resin, linseed oil or other appropriate substances are used.
  • the cylinder block core 5 is shaped by using a core box made of metal or other materials.
  • Fig. 2 shows a conventional design of the cylinder block core 5.
  • the cylinder block core 5 has one or more intermediate bearing portions 9.
  • a cylinder block casting is formed with an intermediate bearing portion of the crankcase for supporting a crankshaft.
  • the intermediate bearing portion of the cylinder block core 5 has uneven surfaces for making a main bearing housing portion, ribs and lubricating oil passages. Therefore, if the core is made in a single piece including the crankcase portion and the intermediate bearing 'portion, the cylinder block core 5 can not be removed from its core box in which the core is shaped, after the core is hardened.
  • the cylinder block core is divided into a main body 5a and core pieces 11, as shown in Fig. 2.
  • the main body 5a of the cylinder block core 5 has the cylinder portions 3 and the crankcase portion 4.
  • the main body 5a is formed with flat walls 10.
  • the core pieces 11 have a shape for making the intermediate bearing portion of the cylinder block casting.
  • the core pieces 11 are made by a core box or boxes different from the core box for the main body 5a.
  • the core pieces 11 are attached to the flat walls 10 of the main body by adhesive.
  • the complete cylinder block core 5 as shown in Fig. 2a is produced.
  • the main body 5a having the shape shown in Fig.
  • Fig. 3 shows a cylinder block core 15 embodying the present invention.
  • the cylinder block core 15 has one or more cylinder portion 13 corresponding to the cylinder bore and a crankcase portion 14 corresponding to the crankcase of the cylinder block.
  • the cylinder block core 15 further has a evaporative pattern 18 which is disposed in the middle of the crankcase portion 14.
  • the evaporative pattern 18 has the same shape as the intermediate bearing portion of the casting to be produced.
  • the main body 16 is made of a mixture of aggregate such as silica sand, a binder, an accelerator and other ingredients, as in the ordinary core molding.
  • the evaporative pattern 18 is made of polystyrene foam or the like which is capable of dissipating or evaporating when heat is applied.
  • the evaporative pattern 18 has the same shape as the intermediate bearing portion having a bearing housing, ribs and lubricating oil passages.
  • the evaporative pattern 18 is incorporated in the main body 16 of the cylinder block core.
  • the evaporative pattern 18 has projecting portions 19 for holding the evaporative pattern 18 in place in the core box for molding the core.
  • Fig. 4 show a core box 20 for molding the complete cylinder block core 15 shown in Fig. 3a.
  • the core box 20 comprises right/left metallic pattern 21, 22, front/rear metallic pattern 23, 24 and an upper metallic pattern (not shown).
  • the core box 20 made up of the metallic pattern 21 to 24 has a cavity 25 having a shape corresponding to the shape of the cylinder block core 15 including one or more cylinder portions 13, the crankcase portion 14 integral with the cylinder portions and the evaporative pattern 18.
  • Each of the right/left metallic pattern 21 and 22 is formed with a recess portion 26 to be engaged with the projecting portion 19 of the evaporative pattern 18.
  • the unshown upper metallic pattern is provided with an opening through which aggregate such as silica sand, a binder and other ingredients are blown into the cavity 25.
  • the core box 20 is assembled by first putting the right/left metallic pattern 21, 22 together and then attaching the front/rear metallic pattern 23, 24 to the right/left metallic pattern 21, 22.
  • the cavity 25 having the shape corresponding to the cylinder block core 15 including the one or more cylinder portion 13, the crankcase portion 14 integral with the cylinder portions 13 and the evaporative pattern 18.
  • the evaporative pattern 18, which is made by forming a foam material such as polystyrene foam into the required shape, is disposed in a predetermined position.
  • the evaporative pattern 18 is accurately positioned by engaging the projections 19 of the evaporative pattern 18 with the recesses 26 of the core box 20 and by compressing the projections 19 with the unshown upper metallic pattern. It is optional to use the movable fixing devices 27 for fixing the evaporative pattern 18 to the mettalic pattern 21, 22. In this case, the movable fixing devices 27 are inserted into the evaporative pattern 18 in the sequence of Figs. 5a, 5b and 5c, before or after the upper metallic pattern is attached.
  • the core materials for making the main body 16 of the core are blown by air through the opening formed in the upper metallic pattern, into the cavity 25 formed by the core box 20 and the evaporative pattern 18.
  • the core materials are then hardened and become integral with the evaporative pattern 18.
  • the core box 20 is disassembled and the hardened cylinder block core 15 is removed.
  • the core materials may be rammed into the cavity 25 by hand rather than by the air blowing method.
  • the projecting portion 19 may be made in the form of a belt-like long narrow strip extending over the full circumferential length, and at the same time, the recess portion of the core box may be made in the form of a long groove having the corresponding size and shape.
  • the evaporative pattern can be positioned more accurately, and can be firmly held in position without being shifted during charging of the core materials.
  • the thus fabricated core 15 is removed by detaching the metallic pattern 21-24 and the unshown upper pattern, and is set in a predetermined position between the upper part 1 and the lower part 2 of the master mold shown in Fig. 1. Then, a molten metal is poured from the sprue 6. The poured molten metal fills the cavity 8 and dissolves the evaporative pattern 18. Thus, the evaporative pattern 18 disappears and the space of the evaporative pattern 18 is also filled with the molten metal, so that the produced casting has the intermediate bearing portion having the same shape as the evaporative pattern. A finer surface of the cylinder block casting can be obtained by applying a wash to the evaporative pattern 18.
  • the core can be made by hardening oil sand by applying heat.
  • the carbon dioxide process or the cold box process is preferable because they make it possible to harden the core at nonelevated temperatures.
  • the cold box process utilizes polyisocyanate resin and phenolic resin as a binder and amine gas such as triethylamine or dimethylamine as a curing catalyst.
  • the evaporative pattern 18 may be dissipated by the heat of a molten metal during pouring, or by heating or burning before a molten metal is poured.
  • the present invention is available not only for a two cylinder engine but also for a one cylinder engine, a four cylinder engine and so on.
  • the present invention provides a single piece core including main body for forming a cylinder bore and a crankcase, and the evaporative pattern for forming a main bearing portion. Accordingly, the present invention can prevent production of flashes which would be produced when an assembled core is used.
  • the present invention can improve the accuracy of a produced casting, especially in the main bearing portion.
  • the present invention can reduce the finishing or machining allowance of a cylinder block casting, and serve to reduce the weight of an internal combustion engine.
  • the present invention there is no need of production step to attach a separate piece to a main core body by adhesive, as required in the conventional method, so that the present invention can reduce remarkably the man-hour required for making a cylinder block core.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
EP83103190A 1982-04-22 1983-03-30 Noyau de moulage pour la coulée d'un bloc-cylindres de moteur Withdrawn EP0092690A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP6638582A JPS58184040A (ja) 1982-04-22 1982-04-22 内燃機関のシリンダブロツク用中子及びその造型方法
JP66385/82 1982-04-22

Publications (1)

Publication Number Publication Date
EP0092690A1 true EP0092690A1 (fr) 1983-11-02

Family

ID=13314300

Family Applications (1)

Application Number Title Priority Date Filing Date
EP83103190A Withdrawn EP0092690A1 (fr) 1982-04-22 1983-03-30 Noyau de moulage pour la coulée d'un bloc-cylindres de moteur

Country Status (3)

Country Link
EP (1) EP0092690A1 (fr)
JP (1) JPS58184040A (fr)
AU (1) AU1362983A (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0227308A2 (fr) * 1985-12-06 1987-07-01 Ford Motor Company Limited Procédé pour joindre des parties de modèles en mousse afin de former un assemblage pour utilisation dans un procédé évaporatif
EP0280675A2 (fr) * 1987-02-25 1988-08-31 AVL Gesellschaft für Verbrennungskraftmaschinen und Messtechnik mbH.Prof.Dr.Dr.h.c. Hans List Moule pour une boîte de moteur
FR2672003A1 (fr) * 1991-01-30 1992-07-31 Snecma Procede de realisation de noyaux complexes en ceramique pour fonderie.
US5253615A (en) * 1992-12-24 1993-10-19 Ford Motor Company Cylinder block cylinder bore isolator
EP0924008A1 (fr) * 1997-12-22 1999-06-23 Ford Global Technologies, Inc. Production rapide d' articles de forme complexe par moulage de précision à la cire perdue
FR2819206A1 (fr) * 2001-01-10 2002-07-12 Peugeot Citroen Automobiles Sa Procede de moulage a element de moule utilisant un modele tridimensionnel, element de moule mis en oeuvre lors de ce procede, et piece obtenue par ce procede
WO2004035245A1 (fr) * 2002-10-04 2004-04-29 Meccanica Bassi S.P.A. Procede de coulage, en particulier pour culasse de moteur
US7093341B2 (en) * 2001-11-28 2006-08-22 Caterpillar Inc. Method of making an axial piston pump barrel with a cast high pressure collection cavity

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60121038A (ja) * 1983-12-02 1985-06-28 Mazda Motor Corp 鋳型の組立方法
JPS61144237A (ja) * 1984-12-17 1986-07-01 Mitsubishi Motors Corp 消失性原型を使用する鋳造法
US4657063A (en) * 1985-05-17 1987-04-14 Outboard Marin Corporation Foam pattern for casting an air cooled cylinder head
US4757857A (en) * 1985-12-18 1988-07-19 Fritz Winter Eisengiesserei O.H.G. Mold for casting cylinder blocks of combustion engines
JPH01122633A (ja) * 1987-11-06 1989-05-15 Daikin Ind Ltd シリンダブロックの製造方法
JP4557659B2 (ja) * 2004-09-30 2010-10-06 株式会社新エィシーイー 可変スワール吸気装置付きシリンダヘッド鋳造用中子
US8555950B2 (en) * 2011-10-25 2013-10-15 Ford Global Technologies, Llc Organic-like casting process for water jackets
CN105081212B (zh) * 2015-09-22 2017-06-23 南车戚墅堰机车有限公司 一种制作车钩钩体中间芯的模具系统

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT262524B (de) * 1965-02-13 1968-06-10 Gruenzweig & Hartmann Verfahren zur Herstellung von Gußstücken und verlorenes Modell zu dessen Durchführung
DE2746233A1 (de) * 1976-10-19 1978-04-20 Deere & Co Aus mehreren teilen bestehender verlorener kern fuer metallgiessformen und verfahren zu seiner herstellung
DE3018782A1 (de) * 1979-06-04 1980-12-18 Deere & Co Verfahren zum herstellen eines verlorenen, aus mehreren teilen bestehenden kernes fuer metallgiessformen

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT262524B (de) * 1965-02-13 1968-06-10 Gruenzweig & Hartmann Verfahren zur Herstellung von Gußstücken und verlorenes Modell zu dessen Durchführung
DE2746233A1 (de) * 1976-10-19 1978-04-20 Deere & Co Aus mehreren teilen bestehender verlorener kern fuer metallgiessformen und verfahren zu seiner herstellung
DE3018782A1 (de) * 1979-06-04 1980-12-18 Deere & Co Verfahren zum herstellen eines verlorenen, aus mehreren teilen bestehenden kernes fuer metallgiessformen

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0227308A2 (fr) * 1985-12-06 1987-07-01 Ford Motor Company Limited Procédé pour joindre des parties de modèles en mousse afin de former un assemblage pour utilisation dans un procédé évaporatif
EP0227308A3 (en) * 1985-12-06 1987-10-07 Ford Motor Company Limited Method of joining foam pattern members to form an assembly for use in an evaporative casting process
EP0280675A2 (fr) * 1987-02-25 1988-08-31 AVL Gesellschaft für Verbrennungskraftmaschinen und Messtechnik mbH.Prof.Dr.Dr.h.c. Hans List Moule pour une boîte de moteur
EP0280675A3 (en) * 1987-02-25 1989-02-22 Avl Gesellschaft Fur Verbrennungskraftmaschinen Und Messtechnik Mbh.Prof.Dr.Dr.H.C. Hans List Mould for a crankcase
FR2672003A1 (fr) * 1991-01-30 1992-07-31 Snecma Procede de realisation de noyaux complexes en ceramique pour fonderie.
EP0497682A1 (fr) * 1991-01-30 1992-08-05 Societe Nationale D'etude Et De Construction De Moteurs D'aviation "Snecma" Procédé de réalisation de noyaux complexes en céramique pour fonderie
US5253615A (en) * 1992-12-24 1993-10-19 Ford Motor Company Cylinder block cylinder bore isolator
EP0924008A1 (fr) * 1997-12-22 1999-06-23 Ford Global Technologies, Inc. Production rapide d' articles de forme complexe par moulage de précision à la cire perdue
FR2819206A1 (fr) * 2001-01-10 2002-07-12 Peugeot Citroen Automobiles Sa Procede de moulage a element de moule utilisant un modele tridimensionnel, element de moule mis en oeuvre lors de ce procede, et piece obtenue par ce procede
US7093341B2 (en) * 2001-11-28 2006-08-22 Caterpillar Inc. Method of making an axial piston pump barrel with a cast high pressure collection cavity
WO2004035245A1 (fr) * 2002-10-04 2004-04-29 Meccanica Bassi S.P.A. Procede de coulage, en particulier pour culasse de moteur

Also Published As

Publication number Publication date
AU1362983A (en) 1983-11-17
JPS58184040A (ja) 1983-10-27

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Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 19830330

AK Designated contracting states

Designated state(s): DE FR GB IT

RAP1 Party data changed (applicant data changed or rights of an application transferred)

Owner name: NISSAN MOTOR CO., LTD.

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 19851112

RIN1 Information on inventor provided before grant (corrected)

Inventor name: UETA, KIMIOC/O YOKOHAMA PLANT

Inventor name: SAKAMOTO, TETSUOC/O YOKOHAMA PLANT