EP1498197B1 - Casting process for reciprocating-piston combustion engine block - Google Patents

Casting process for reciprocating-piston combustion engine block Download PDF

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Publication number
EP1498197B1
EP1498197B1 EP03028389.9A EP03028389A EP1498197B1 EP 1498197 B1 EP1498197 B1 EP 1498197B1 EP 03028389 A EP03028389 A EP 03028389A EP 1498197 B1 EP1498197 B1 EP 1498197B1
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EP
European Patent Office
Prior art keywords
casting
crankcase
cylinder head
cast
mould
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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.)
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EP03028389.9A
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German (de)
French (fr)
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EP1498197A1 (en
Inventor
Ulf Schmidtgen
Roland Lutz
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MAN Truck and Bus SE
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MAN Truck and Bus SE
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082Sprues, pouring cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088Feeder heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • B22D18/04Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould

Definitions

  • the invention relates to a method for casting crankcases made of cast iron for reciprocating internal combustion engines with a power up to 1500 hp and a crankcase weight up to 500 kg.
  • crankcases of internal combustion engines of the generic order were previously either in normal standing position with cylinder head side (s) above - see 10 and 11 - or in a tilted horizontal position - see Fig. 9 - poured.
  • the crankcase of V-type internal combustion engines have been basically only upright - as out Fig. 11 apparent - poured.
  • casting-related weak points arose, in particular at the upper edge regions of the castings, with the consequence of a certain amount of rejects or consequential damage in later engine operation.
  • crankcases 1 for reciprocating internal combustion engines with a power up to 1500 hp and a crankcase weight up to 500 kg is in principle that the crankcase 1 is turned upside down, so with the cylinder head side 2 lying down, in a mold. 3 is poured with substantially vertical mold division by introducing the liquid casting material from below.
  • the vertical shape division of the mold 3 is in the FIGS. 6 and 7 indicated by the dash-dotted line 4.
  • the gate 5 for the introduction of the liquid casting material is provided at the lowest point of the casting mold 3, in order to avoid turbulence in the casting material during the mold filling.
  • the filling of the casting mold 3 with liquid casting material over the said lower gate 5 can either by low pressure from below into the mold 3 in pressed molding material - see Fig.
  • crankcase 1 Due to the casting position of the crankcase 1 according to the invention, it is also advantageously possible to cast the cylinder walls into the crankcase 1, which remain virtually free of porosities, gas bubbles or voids in the piston ring movement range, which casting defects can occur quite well in conventional upright casting position with cylinder head side 2 above , A particular advantage is that you can integrate the cylinder walls in such a way even with larger internal combustion engines easily, which allows a reduction in the crankcase length and thus a reduction in weight or alternatively, an increase in the cooling water space.
  • the sides of the water jacket on both sides of the cylinder walls to be enclosed are kept at a distance by means of metal support blocks, which are arranged comparatively far down in the casting mold 3 due to the cylinder head side 2 lying below and therefore can be melted cleanly in the casting material.
  • crankshaft or bearing block area 9 of the crankcase 1 results in this area particularly good mechanical properties. This is because, during the casting process, the casting material ascending in the casting mold 3 has cooled sufficiently on reaching the crankshaft or bearing block region 9 that it only has a temperature close to the eutectic lying and thus in this region compared to others Component sets higher cooling rate and a finer microstructure with very high mechanical strength sets. This is particularly advantageous because crankcases should have the highest strengths generally in the bearing block area or crankshaft bearing area 9.
  • the green sand method or core block method or Kokillenguss vide can be used as a casting method for producing the crankcase 1.
  • crankcase core In order to minimize the core sand volume, in particular in the crankshaft bearing area 9, it is possible to make this area hollow in the mold - see Fig. 6 , With 10 there is the crankcase core and designated 11 a receiving space for liquid casting material. Denoted at 13 are venting and / or casting material overflow channels.
  • crankcase area Due to this hollow design of the crankcase area this can fulfill several functions.
  • the cup-shaped crank chamber core 10 is subjected to very high thermal loads, which later leads to easy desanding.
  • the cavities are open at 12 upwards - into which, if not desired, no liquid casting material can enter.
  • the going through the crankcase core shell is largely thermally decomposed, so that there is no problem in sanding there.
  • Fig. 7 shows, the cavities in the mold 3 in the crankcase area with solid material, such. B. any shaped individual pieces or a contiguous piece of material 14 are filled, which forms a complaint weight or at least a part thereof. This can either rest only with gravity or optionally also be braced in addition to the frame or bottom of the mold 3.
  • the complaint weight 14 may also be integrated a holding or transport function, which can be used both in the core assembly and when removing the cast crankcase 1 from the mold 3. With 15 channels are designated, which serve the vent and / or as an overflow for liquid casting material or for attachment of feeders (if necessary).
  • the respective feeders 16 are preferably at the highest point of the crankcase to be cast 1, so the ⁇ lwannenstromflansch 17 and / or at a lower contrast Place as a support surface area 18 for the crankshaft bearing cap (not shown).
  • these feeders 16 can also be integrated into the crankcase core 10 or injected into it.
  • the sprue system 7 can either beside this - see for example Fig. 1 or by one or more of the cylinder bores bounded by the cylinder walls - see for example Fig. 2 - Be guided to the gate 5 out.
  • the sprue after cooling of the casting material can be used as a transport hook.
  • the sprue 8 can be integrated into this area, see the space 11 in FIG Fig. 6 ,
  • the inventive vertical casting position of the crankcase 1 with arranged below the cylinder head side 2 allows the realization of a graded structure within the crankcase 1, the use of z. B. two different cast materials can be realized. It will - like out Fig. 8 seen - in the area of the cylinder head surface zone and the adjoining upper cylinder wall areas a first material, for. B. GJL - see arrow 19 -, with better thermal properties poured off either via the sprue 8 and the Angusssystem 7 or a low pressure system 6 to the onsetting 5, whereas in the crankshaft or bearing block area 9 another Cast material, z.
  • crankcase which are lighter and dimensionally accurate than those which were prepared in conventional manner.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Gießen von Kurbelgehäusen aus Gusseisen für Hubkolbenbrennkraftmaschinen mit einer Leistung bis ca. 1500 PS und einem Kurbelgehäusegewicht bis ca. 500 kg.The invention relates to a method for casting crankcases made of cast iron for reciprocating internal combustion engines with a power up to 1500 hp and a crankcase weight up to 500 kg.

Die Kurbelgehäuse von Brennkraftmaschinen der gattungsgemäßen Größenordnung wurden bisher entweder in stehender Normallage mit Zylinderkopfseite(n) oben - siehe Fig. 10 und 11 - oder in gekippter Horizontallage - siehe Fig. 9 - gegossen. Die Kurbelgehäuse von V-Brennkraftmaschinen wurden bisher grundsätzlich nur stehend - wie aus Fig. 11 ersichtlich - gegossen. Dabei ergaben sich bedingt durch diese Gießlage in den Kurbelgehäusen gießtechnische Schwachstellen insbesondere an den oberen Randbereichen der Gussteile mit der Folge eines gewissen Ausschussanteils oder Folgeschäden im späteren Motorbetrieb.The crankcases of internal combustion engines of the generic order were previously either in normal standing position with cylinder head side (s) above - see 10 and 11 - or in a tilted horizontal position - see Fig. 9 - poured. The crankcase of V-type internal combustion engines have been basically only upright - as out Fig. 11 apparent - poured. As a result of this casting position in the crankcases, casting-related weak points arose, in particular at the upper edge regions of the castings, with the consequence of a certain amount of rejects or consequential damage in later engine operation.

Es war daher Aufgabe der Erfindung, ein Verfahren zum Gießen von Kurbelgehäusen aus Gusseisen für Brennkraftmaschinen mit der gattungsgemäßen Leistung und dem gattungsgemäßen Kurbelgehäusegewicht zu schaffen, mit dem die Qualität der gegossenen Kurbelgehäuse erheblich verbesserbar und auch die Ausschussquote signifikant reduzierbar ist.It was therefore an object of the invention to provide a method for casting crankcases made of cast iron for internal combustion engines with the generic power and the generic crankcase weight, with the quality of the cast crankcase significantly improved and the reject rate is significantly reduced.

Diese Aufgabe ist erfindungsgemäß durch ein Gießverfahren mit den im Anspruch 1 angegebenen Merkmalen gelöst.This object is achieved by a casting method with the features specified in claim 1.

Vorteilhafte Details dieses Verfahrens sind in den Unteransprüchen angegeben.Advantageous details of this method are given in the subclaims.

Die Vorteile des erfindungsgemäßen Verfahrens sind weiter hinten im Rahmen der weiteren Beschreibung desselben anhand der Zeichnung angegeben.The advantages of the method according to the invention are given later in the context of the further description of the same with reference to the drawing.

In der Zeichnung zeigen:

Fig. 1
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, hergestellt gemäß einer ersten Ausführungsform des erfindungsgemäßen Verfahrens durch Schwerkraftgießen,
Fig. 2
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, hergestellt gemäß einer zweiten Ausführungsart des erfindungsgemäßen Verfahrens durch Schwerkraftgießen,
Fig. 3
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, hergestellt gemäß einer dritten Ausführungsart des erfindungsgemäßen Verfahrens durch Niederdruckgießen,
Fig.4
ein Kurbelgehäuse einer V-Brennkraftmaschine in erfindungsgemäßer Gießlage, hergestellt gemäß dem erfindungsgemäßen Verfahrens durch Schwerkraftgießen oder Niederdruckgießen,
Fig. 5
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, mit angesetzten Speisern und Entlüftung/Überlauf,
Fig. 6
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, dargestellt in einer Gießform,
Fig. 7
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, dargestellt in einer gegenüber Fig. 6 abgewandelten Gießform, und
Fig. 8
ein Kurbelgehäuse einer Reihenbrennkraftmaschine in erfindungsgemäßer Gießlage, hergestellt im Rahmen des erfindungsgemäßen Verfahrens durch Gradientenguss aus zwei unterschiedlichen Gussmaterialien.
In the drawing show:
Fig. 1
a crankcase of a series internal combustion engine in a casting layer according to the invention, produced according to a first embodiment of the method according to the invention by gravity casting,
Fig. 2
a crankcase of a series internal combustion engine in casting according to the invention, produced according to a second embodiment of the method according to the invention by gravity casting,
Fig. 3
a crankcase of a series internal combustion engine in a casting layer according to the invention, produced according to a third embodiment of the method according to the invention by low-pressure casting,
Figure 4
a crankcase of a V-type internal combustion engine in a casting layer according to the invention, produced according to the method according to the invention by gravity casting or low-pressure casting,
Fig. 5
a crankcase of a series internal combustion engine in inventive casting position, with attached feeders and vent / overflow,
Fig. 6
a crankcase of a series internal combustion engine in casting according to the invention, shown in a mold,
Fig. 7
a crankcase of a series internal combustion engine in inventive casting position, shown in a opposite Fig. 6 modified casting mold, and
Fig. 8
a crankcase of a series internal combustion engine in casting according to the invention, produced in the context of the inventive method by gradient casting of two different casting materials.

Das erfindungsgemäße Verfahren zum Gießen von Kurbelgehäusen 1 für Hubkolbenbrennkraftmaschinen mit einer Leistung bis ca. 1500 PS und einem Kurbelgehäusegewicht bis ca. 500 kg besteht prinzipiell darin, dass das Kurbelgehäuse 1 auf den Kopf gestellt, also mit unten liegender Zylinderkopfseite 2, in einer Gießform 3 mit im Wesentlichen senkrechter Formteilung durch Einleitung des flüssigen Gussmaterials von unten her gegossen wird. Die vertikale Formteilung der Gießform 3 ist in den Figuren 6 und 7 durch die strich-punktierte Linie 4 angedeutet. Der Anschnitt 5 für die Einleitung des flüssigen Gussmaterials ist an der tiefsten Stelle der Gießform 3 gegeben, um Turbulenzen im Gussmaterial während der Formfüllung zu vermeiden. Das Füllen der Gießform 3 mit flüssigen Gussmaterial über den besagten unteren Anschnitt 5 kann entweder durch mit Niederdruck von unten her in die Gießform 3 hinein gedrücktes Gussmaterial - siehe Fig. 3 und 8, dort Pfeil 6 - oder über Schwerkraft von oben her über ein Angusssystem 7 mit Gussmaterialquelle (Einlauftrichter) 8 zugeführtes Gussmaterial erfolgen - siehe Figuren 1, 2 und 8. Im Fall des V-Kurbelgehäuses 1 von Fig. 4 kann die Gussmaterialzufuhr zu den beiden Anschnitten 5 ebenfalls entweder über Niederdruck- oder Schwerkraftheranführung erfolgen, insofern ist die gemeinsame Zuleitung mit 6 bzw. 7 bezeichnet. Der Einsatz von Gießfiltern im Anschnitt 5 bzw. Angusssysstem ist jederzeit möglich.The inventive method for casting of crankcases 1 for reciprocating internal combustion engines with a power up to 1500 hp and a crankcase weight up to 500 kg is in principle that the crankcase 1 is turned upside down, so with the cylinder head side 2 lying down, in a mold. 3 is poured with substantially vertical mold division by introducing the liquid casting material from below. The vertical shape division of the mold 3 is in the FIGS. 6 and 7 indicated by the dash-dotted line 4. The gate 5 for the introduction of the liquid casting material is provided at the lowest point of the casting mold 3, in order to avoid turbulence in the casting material during the mold filling. The filling of the casting mold 3 with liquid casting material over the said lower gate 5 can either by low pressure from below into the mold 3 in pressed molding material - see Fig. 3 and 8th , Arrow 6 there - or by gravity from above via a sprue system 7 with casting material source (inlet funnel) 8 supplied cast material - see FIGS. 1, 2 and 8th , In the case of the V-crankcase 1 of Fig. 4 the casting material supply to the two gates 5 can also be done either low pressure or gravity guidance, insofar is the common Supply line designated 6 and 7 respectively. The use of casting filters in the gate 5 or Angusssysstem is possible at any time.

Durch das Anschneiden am tiefsten Punkt des zu gießenden Kurbelgehäuses 1 ist es möglich, eine turbulenzarme und maximal beruhigte Füllung der Gießform 3 zu erreichen, wobei im Fall von Grauguss eine vergleichsweise niedrige, etwa zwischen 1350 und ca. 1380° C liegende Gießtemperatur gefahren werden kann. Aufgrund der turbulenzarmen Gießformfüllung werden insbesondere Metallspritzer oder Bereiche, in denen nur eine kurze Wandbenetzung erfolgt, erfolgreich vermieden und es ist daher ein Aufschmelzen dieser Bereiche zur Schaffung einer druckdichten Verbindung nicht erforderlich. Aufgrund dieser möglichen niedrigen Gießtemperatur ergeben sich innerhalb des gegossenen Kurbelgehäuses 1 ein geringes Temperaturgefälle und niedrige Eigenspannungen.By cutting at the lowest point of the crankcase 1 to be cast, it is possible to achieve a low-turbulence and maximum calmed filling of the mold 3, wherein in the case of gray cast iron, a comparatively low, lying approximately between 1350 and about 1380 ° C casting temperature can be driven , Due to the low-turbulence mold filling in particular metal splash or areas where only a short wall wetting occurs, successfully avoided and it is therefore not necessary to melt these areas to create a pressure-tight connection. Due to this possible low casting temperature arise within the cast crankcase 1, a low temperature gradient and low residual stresses.

Aufgrund der unten in der Gießform 3 gegebenen Zylinderkopfseite 2 ist es möglich, in deren Bereich die Materialzugabe für spätere spanabhebende Nachbearbeitung zu minimieren, weil während des Füllvorgangs die im Gussmaterial entstehenden Oxyde sich nicht im Bereich der Zylinderkopfflächenzone einlagern, sondern aufgrund ihres geringeren spezifischen Gewichts nach oben in weniger kritische Zonen des Kurbelgehäuses aufsteigen. Außerdem erstarrt in der Zylinderkopfflächenzone mit ihrer vergleichsweise geringen Wandstärke das eingeleitete Gussmaterial mit hoher Geschwindigkeit, wodurch sich dort ein Gefüge mit höheren Festigkeiten als bei anderen Verfahren an dieser Stelle üblich einstellt.Because of the cylinder head side 2 given at the bottom of the casting mold 3, it is possible to minimize the addition of material in the area for later machining, because during the filling process, the oxides arising in the casting material do not settle in the region of the cylinder head surface zone, but rather due to their lower specific weight ascend to the top in less critical zones of the crankcase. In addition, in the cylinder head surface zone with its comparatively small wall thickness, the introduced casting material solidifies at high speed, as a result of which a structure with higher strengths than is customary at this point is established there.

Aufgrund der erfindungsgemäßen Gießlage des Kurbelgehäuses 1 ist es in vorteilhafter Weise auch möglich, die Zylinderwände in das Kurbelgehäuse 1 miteinzugießen, wobei diese im Kolbenringbewegungsbereich praktisch frei von Porositäten, Gasblasen oder Lunkern bleiben, welche Gießfehler bei herkömmlicher aufrechtstehender Gießlage mit Zylinderkopfseite 2 oben durchaus auftreten können. Ein besonderer Vorteil ist, dass man die Zylinderwände solchermaßen auch bei größeren Brennkraftmaschinen problemlos integrieren kann, was eine Verringerung der Kurbelgehäuselänge und damit eine Gewichtsreduzierung oder alternativ auch eine Vergrößerung des Kühlwasserraumes ermöglicht.Due to the casting position of the crankcase 1 according to the invention, it is also advantageously possible to cast the cylinder walls into the crankcase 1, which remain virtually free of porosities, gas bubbles or voids in the piston ring movement range, which casting defects can occur quite well in conventional upright casting position with cylinder head side 2 above , A particular advantage is that you can integrate the cylinder walls in such a way even with larger internal combustion engines easily, which allows a reduction in the crankcase length and thus a reduction in weight or alternatively, an increase in the cooling water space.

Die Wassermantelseiten beiderseits der miteinzugießenden Zylinderwände werden mittels metallischer Stützböcke auf Abstand gehalten, welche aufgrund der unten liegenden Zylinderkopfseite 2 vergleichsweise weit unten in der Gießform 3 angeordnet sind und daher sauber im Gussmaterial miteinschmelzbar sind.The sides of the water jacket on both sides of the cylinder walls to be enclosed are kept at a distance by means of metal support blocks, which are arranged comparatively far down in the casting mold 3 due to the cylinder head side 2 lying below and therefore can be melted cleanly in the casting material.

Aufgrund der erfindungsgemäß vertikalen Gießlage mit der unten liegenden Zylinderkopfseite 2 wirkt beim Gießen des Kurbelgehäuses 1 der größte metallostatische und statische Druck in der Zylinderkopfflächenzone, weshalb ein Speisen der Zylinderkopfflächenzone auch bei Verwendung von zu Lunkerung neigenden Werkstoffen wie GJV und GJS nicht erforderlich ist.Due to the present invention vertical casting layer with the underlying cylinder head side 2 acts during casting of the crankcase 1, the largest metallostatic and static pressure in the cylinder head surface zone, which is not necessary feeding the cylinder head surface zone even when using prone to Lunkerung materials such as GJV and GJS.

Aufgrund des beim erfindungsgemäßen Verfahren in der Gießform oben gegebenen Kurbelwellen- bzw. Lagerstuhlbereiches 9 des Kurbelgehäuses 1 ergeben sich in diesem Bereich besonders gute mechanische Eigenschaften. Dies deshalb, weil sich während des Gießvorgangs das in der Gießform 3 aufsteigende Gussmaterial bei Erreichen des Kurbelwellen- bzw. Lagerstuhlbereiches 9 soweit abgekühlt hat, dass es nur noch eine nahe der eutektischen liegende Temperatur hat und sich somit in diesem Bereich eine im Vergleich zu anderen Bauteilbereichen höhere Abkühlungsgeschwindigkeit sowie ein feineres Gefüge mit sehr hoher mechanischer Festigkeit einstellt. Dies ist besonders vorteilhaft, weil Kurbelgehäuse die höchsten Festigkeiten generell im Lagerstuhlbereich bzw. Kurbelwellenlagerbereich 9 aufweisen sollten.Due to the given in the process according to the invention in the mold above crankshaft or bearing block area 9 of the crankcase 1 results in this area particularly good mechanical properties. This is because, during the casting process, the casting material ascending in the casting mold 3 has cooled sufficiently on reaching the crankshaft or bearing block region 9 that it only has a temperature close to the eutectic lying and thus in this region compared to others Component sets higher cooling rate and a finer microstructure with very high mechanical strength sets. This is particularly advantageous because crankcases should have the highest strengths generally in the bearing block area or crankshaft bearing area 9.

Als Gießverfahren zur Herstellung des Kurbelgehäuses 1 kann das Grünsandverfahren oder Kernblockverfahren oder Kokillengussverfahren zur Anwendung kommen.As a casting method for producing the crankcase 1, the green sand method or core block method or Kokillengussverfahren can be used.

Um das Kernsandvolumen insbesondere im Kurbelwellen- bzw. Lagerstuhlbereich 9 zu minimieren, ist es möglich, diesen Bereich in der Gießform hohl zu gestalten - siehe Fig. 6. Mit 10 ist dort der Kurbelraumkern und mit 11 ein Aufnahmeraum für flüssiges Gussmaterial bezeichnet. Mit 13 sind Entlüftungs- und/oder Gussmaterialüberlaufkanäle bezeichnet.In order to minimize the core sand volume, in particular in the crankshaft bearing area 9, it is possible to make this area hollow in the mold - see Fig. 6 , With 10 there is the crankcase core and designated 11 a receiving space for liquid casting material. Denoted at 13 are venting and / or casting material overflow channels.

Aufgrund dieser Hohlgestaltung des Kurbelraumbereiches kann dieser mehrere Funktionen erfüllen. Zum einen die Aufnahme des Überlaufmaterials, das über die Überläufe 13 in den Aufnahmeraum 11 zurückgelangen kann, was ein Durchgießen der Form (3) sicher gewährleistet. Außerdem wird der schalenförmige Kurbelraumkern 10 thermisch sehr hoch belastet, was später zu einem einfachen Entsanden führt. Zum anderen ist anzuführen, dass - da die Hohlräume bei 12 nach oben offen sind -, in diese, wenn nicht gewünscht, auch kein flüssiges Gussmaterial einlaufen kann. Die durch das Kurbelgehäuse gehende Kernschale wird weitestgehend thermisch zersetzt, so dass sich auch dort kein Problem beim Entsanden ergibt.Due to this hollow design of the crankcase area this can fulfill several functions. On the one hand, the inclusion of the overflow material that can get back over the overflows 13 in the receiving space 11, which ensures a continuous casting of the mold (3). In addition, the cup-shaped crank chamber core 10 is subjected to very high thermal loads, which later leads to easy desanding. On the other hand, it should be mentioned that - since the cavities are open at 12 upwards - into which, if not desired, no liquid casting material can enter. The going through the crankcase core shell is largely thermally decomposed, so that there is no problem in sanding there.

Wie Fig. 7 zeigt, können die Hohlräume in der Gießform 3 im Kurbelraumbereich auch mit festem Material, z. B. beliebig geformten Einzelstücken oder auch einem zusammenhängenden Materialstück 14 gefüllt werden, das ein Beschwergewicht oder zumindest ein Teil desselben bildet. Dieses kann entweder nur mit Schwerkraft aufliegen oder gegebenenfalls auch noch zusätzlich zum Rahmen oder Boden der Gießform 3 verspannt sein. In das Beschwergewicht 14 kann außerdem eine Halte- oder Transportfunktion integriert sein, die sowohl bei der Kernpaketmontage als auch beim Entnehmen des gegossenen Kurbelgehäuses 1 aus der Gießform 3 genutzt werden kann. Mit 15 sind Kanäle bezeichnet, die der Entlüftung und/oder als Überlauf für flüssiges Gussmaterial oder zum Ansetzen von Speisern (falls erforderlich) dienen.As Fig. 7 shows, the cavities in the mold 3 in the crankcase area with solid material, such. B. any shaped individual pieces or a contiguous piece of material 14 are filled, which forms a complaint weight or at least a part thereof. This can either rest only with gravity or optionally also be braced in addition to the frame or bottom of the mold 3. In the complaint weight 14 may also be integrated a holding or transport function, which can be used both in the core assembly and when removing the cast crankcase 1 from the mold 3. With 15 channels are designated, which serve the vent and / or as an overflow for liquid casting material or for attachment of feeders (if necessary).

Falls es aufgrund des verwendeten Gussmaterials und/oder der geforderten Qualität zur Vermeidung von Lunkern erforderlich sein sollte zu speisen, dann sind die betreffenden Speiser 16 vorzugsweise auf dem höchsten Punkt des zu gießenden Kurbelgehäuses 1, also dem Ölwannenanlageflansch 17 und/oder an einer demgegenüber tieferen Stelle wie einem Auflageflächenbereich 18 für die (nicht dargestellten) Kurbelwellenlagerdeckel anzusetzen. Alternativ können diese Speiser 16 aber auch in den Kurbelraumkern 10 integriert sein oder in diesen eingeschossen werden.If it should be necessary to feed due to the casting material used and / or the required quality to avoid voids, then the respective feeders 16 are preferably at the highest point of the crankcase to be cast 1, so the Ölwannenanlageflansch 17 and / or at a lower contrast Place as a support surface area 18 for the crankshaft bearing cap (not shown). Alternatively, however, these feeders 16 can also be integrated into the crankcase core 10 or injected into it.

Beim Schwerkraftgießen des Kurbelgehäuses 1 kann das Angusssystem 7 entweder neben diesem - siehe beispielsweise Fig. 1 - oder durch eine oder mehrere der durch die Zylinderwände begrenzten Zylinderbohrungen - siehe beispielsweise Fig. 2 - zur Angussstelle 5 hin geführt sein. Dabei kann der Anguss nach Erkaltung des Gussmaterials als Transporthaken verwendet werden. Aufgrund der oben liegenden Kurbelraumgasse kann der Angusstrichter 8 in diesen Bereich integriert werden, siehe den Raum 11 in Fig. 6.When gravity casting of the crankcase 1, the sprue system 7 can either beside this - see for example Fig. 1 or by one or more of the cylinder bores bounded by the cylinder walls - see for example Fig. 2 - Be guided to the gate 5 out. In this case, the sprue after cooling of the casting material can be used as a transport hook. Due to the overhead crankcase alley, the sprue 8 can be integrated into this area, see the space 11 in FIG Fig. 6 ,

Darüber hinaus ermöglicht die erfindungsgemäße vertikale Gießlage des Kurbelgehäuses 1 mit unten angeordneter Zylinderkopfseite 2 die Realisierung eines gradierten Gefüges innerhalb des Kurbelgehäuses 1, das durch die Verwendung z. B. zweier verschiedener Gusswerkstoffe realisierbar ist. Dabei wird - wie aus Fig. 8 ersichtlich - im Bereich der Zylinderkopfflächenzone und der sich daran anschließenden oberen Zylinderwandbereiche ein erster Werkstoff, z. B. GJL - siehe Pfeil 19 -, mit besseren Wärmeeigenschaften abgegossen und zwar entweder über den Angusstrichter 8 und das Angusssystem 7 oder ein Niederdrucksystem 6 zum Anstich 5, wohingegen im Kurbelwellen- bzw. Lagerstuhlbereich 9 ein anderer Gusswerkstoff, z. B. GJS oder GJV - siehe Pfeil 20 -, mit höheren Festigkeitseigenschaften abgegossen wird und zwar über einen Angusstrichter 21 und ein Angusssystem 22 zu einem Anstich 23 unterhalb des Lagerstuhlbereiches. Die Zone des Materialübergangs ist in Fig. 8 mit 24 gekennzeichnet. Eine alternative Eingussmöglichkeit für das zweite Gussmaterial ist von seitlich außen darstellbar. Im diesem Fall sind anstelle des Angusstrichters 21 und Angusssystems 22 ein seitlich oberhalb des zugießenden Kurbelgehäuses 1 angeordneter Angusstrichter 25 und ein äußeres Angusssystem 26 vorgesehen, das zu einem seitlichen Anstich 27 hinführt.In addition, the inventive vertical casting position of the crankcase 1 with arranged below the cylinder head side 2 allows the realization of a graded structure within the crankcase 1, the use of z. B. two different cast materials can be realized. It will - like out Fig. 8 seen - in the area of the cylinder head surface zone and the adjoining upper cylinder wall areas a first material, for. B. GJL - see arrow 19 -, with better thermal properties poured off either via the sprue 8 and the Angusssystem 7 or a low pressure system 6 to the onsetting 5, whereas in the crankshaft or bearing block area 9 another Cast material, z. As GJS or GJV - see arrow 20 - is discharged with higher strength properties through a sprue 21 and a Angusssystem 22 to a tap hole 23 below the bearing block area. The zone of material transfer is in Fig. 8 marked with 24. An alternative pouring possibility for the second casting material can be displayed from the side outside. In this case, instead of the sprue 21 and Angusssystems 22 a laterally above the zubringendes crankcase 1 arranged sprue 25 and an outer Angusssystem 26 is provided, which leads to a lateral puncture 27.

Mit dem erfindungsgemäßen Verfahren lassen sich mithin Kurbelgehäuse gießen, die leichter und maßgenauer sind als solche, die in herkömmlicher Verfahrensweise hergestellt wurden. With the method according to the invention can thus be cast crankcase, which are lighter and dimensionally accurate than those which were prepared in conventional manner.

Claims (11)

  1. A method for casting crankcases made of cast iron for reciprocating-piston combustion engines having a power of up to approximately 1500 hp and a crankcase weight of up to approximately 500 kg, wherein the crankcase (1), upside-down with the cylinder head side (2) facing downwards in a casting mould (3) with essentially vertical mould parting (4), is cast by introducing the liquid casting material from below (5), and the gate (5) for introduction of the liquid casting material is located at the lowest point in the casting mould (3) in order to avoid turbulence during filling of the mould, and in that filling of the casting mould (3) with liquid casting material via said bottom gate (5) is carried out either by low pressure (6) from below or by gravity (7, 8) from above, with a casting material source (8) positioned above the highest point of the crankcase that is to be cast, characterized in that the casting material is grey iron which is introduced into the casting mould (3) at just a relatively low casting temperature of approximately 1350 to approximately 1380°C, so as to produce a small temperature drop in the crankcase (1) that is to be cast and, after cooling, small internal stresses therein.
  2. The method according to Claim, characterized in that introduction of the casting material from below takes place directly with no additional redirection into the casting mould (3), and in that the cross section of the casting material supply line to the crankcase (1) that is to be cast is larger than the cross section of the runner, and thus filling of the casting mould (3) takes place with low turbulence and with minimum agitation.
  3. The method according to either of the preceding claims, characterized in that, owing to the cylinder head side (2) being at the bottom of the casting mould (3), it is possible to minimize, in that region, the casting-related addition of material which must subsequently undergo chip-removing post-machining, because during the filling procedure the oxides arising in the casting material do not become embedded in the cylinder head surface region but rather rise upwards to less-critical regions of the crankcase (1), and in that furthermore, in the cylinder head surface region with its relatively thin walls, the introduced casting material solidifies more rapidly and forms there a higher-strength structure than is usually formed at these points.
  4. The method according to one of the preceding claims, characterized in that the cylinder walls in the crankcase (1) are cast together with the same casting material and thus remain practically free from porosity, gas bubbles and voids in the piston ring movement region.
  5. The method according to Claim 4, characterized in that the water jacket sides on both sides of the cylinder walls that are to be cast together are held spaced apart from one another by means of metallic supporting blocks which, owing to the cylinder head side (2) being at the bottom, are arranged relatively low in the casting mould (3) and hence can melt cleanly into the casting material.
  6. The method according to one of Claims 1 to 3, characterized in that, owing to the vertical casting position of the crankcase (1) with the cylinder head side (2) being at the bottom when casting the crankcase (1), the greatest metallostatic and static pressure acts in the cylinder head surface region, and thus it is not necessary to feed the cylinder head surface region in question, even in the case of materials which tend to void formation, such as GJV or GJS.
  7. The method according to one of the preceding Claims 1 to 5, characterized in that material which rises in the casting mould (3) during the casting procedure cools such that, when it reaches the crankshaft region or thrust bearing region (9) of the crankcase (1) which is at the top of the casting mould (3), it is at a temperature close to the eutectic and thus this crankcase region (9) experiences a higher cooling rate than normal and establishes a finer structure with very high mechanical strength.
  8. The method according to Claim 1, characterized in that the crankcase (1) is produced using either the green sand method or the core block method or the shell mould casting method.
  9. The method according to one of the preceding claims, characterized in that if, owing to the casting material used or the required quality, it is necessary to feed in order to avoid voids, the feeders (16) are preferably positioned at the highest component point of the crankcase (1), that is to say the oil sump bearing flange (17), and/or at a somewhat lower point such as a bearing surface region (18) for the crankshaft bearing cover, or alternatively are already integrated into the crank space core (10).
  10. The method according to Claim 1, characterized in that, when gravity-casting the crankcase (1), the sprue system (7, 8) is either next to the crankcase (1) or is routed to the gate (5) via one or more cylindrical bores of the crankcase (1).
  11. The method according to Claim 1, characterized in that, owing to the vertical casting position of the crankcase (1), with the cylinder head side (2) arranged at the bottom of the crankcase (1), it is possible to achieve a graduated structure by using two different casting materials (19, 20), wherein a material (19), e.g. GJL, having better heat-conduction properties is cast in the region of the cylinder head surface region and the adjoining upper cylinder wall regions, and a material (20), e.g. GJS or GJV, having higher strength properties is cast in the region of the crankshaft bearings or thrust bearings (9), and wherein the gate (23) for the casting material (20) provided in the crankshaft or thrust bearing region (9) is arranged above the lower gate (5) for the other casting material (19).
EP03028389.9A 2003-07-18 2003-12-11 Casting process for reciprocating-piston combustion engine block Expired - Lifetime EP1498197B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10332721 2003-07-18
DE10332721 2003-07-18

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EP1498197B1 true EP1498197B1 (en) 2017-11-22

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EP03028389.9A Expired - Lifetime EP1498197B1 (en) 2003-07-18 2003-12-11 Casting process for reciprocating-piston combustion engine block

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Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009058730B8 (en) * 2009-12-17 2021-05-20 Bayerische Motoren Werke Aktiengesellschaft Method of manufacturing an engine block
DE102010051348B3 (en) * 2010-11-13 2011-11-03 Huppert Engineering Gmbh & Co. Kg Feeder cap for maintaining volume shrinkage of casting material occurring during solidification of casting through integrated transport device, comprises anchor arms plunging into feeder body, and coupling part
DE102011056985A1 (en) * 2011-12-23 2013-06-27 Martinrea Honsel Germany Gmbh Casting device for casting cylinder crankcases according to the low-pressure method
DE102012101887B4 (en) 2012-03-06 2018-04-19 Ks Huayu Alutech Gmbh Device for producing a cylinder crankcase in V-design
NO2756167T3 (en) * 2014-01-29 2018-06-16
DE102018128020B4 (en) * 2018-11-09 2024-05-23 Bayerische Motoren Werke Aktiengesellschaft Mould and method for producing a crankcase

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61147960A (en) * 1984-12-19 1986-07-05 Honda Motor Co Ltd Casting method of blank material for siamese type cylinder block
BR9107065A (en) * 1990-11-05 1993-09-28 Comalco Alu METAL OBJECTS FOUNDATION
US5163500A (en) * 1991-12-13 1992-11-17 Ford Motor Company Rollover method for metal casting
JPH06142834A (en) * 1992-11-13 1994-05-24 Toyota Motor Corp Casting machine for cylinder block
FR2775917B1 (en) * 1998-03-10 2000-06-02 Montupet Sa LARGE SERIES MOLDING PROCESS FOR ALUMINUM ALLOY PARTS AND ASSOCIATED EQUIPMENT

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EP1498197A1 (en) 2005-01-19

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