EP1525384B8 - Diecast cylinder crankcase - Google Patents

Diecast cylinder crankcase

Info

Publication number
EP1525384B8
EP1525384B8 EP03764931A EP03764931A EP1525384B8 EP 1525384 B8 EP1525384 B8 EP 1525384B8 EP 03764931 A EP03764931 A EP 03764931A EP 03764931 A EP03764931 A EP 03764931A EP 1525384 B8 EP1525384 B8 EP 1525384B8
Authority
EP
European Patent Office
Prior art keywords
cylinder
cast
die
row
liners
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP03764931A
Other languages
German (de)
French (fr)
Other versions
EP1525384B1 (en
EP1525384A1 (en
Inventor
Norbert Grunenberg
Guido Söll
Heinrich Wodarski
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.)
Mercedes Benz Group AG
Original Assignee
Daimler AG
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
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Application filed by Daimler AG filed Critical Daimler AG
Publication of EP1525384A1 publication Critical patent/EP1525384A1/en
Publication of EP1525384B1 publication Critical patent/EP1525384B1/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00—Casings, e.g. crankcases
    • F02F7/0002—Cylinder arrangements
    • F02F7/0007—Crankcases of engines with cylinders in line
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • F02F1/108—Siamese-type cylinders, i.e. cylinders cast together
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • F02F2001/106—Cylinders; Cylinder heads  having cooling means for liquid cooling using a closed deck, i.e. the water jacket is not open at the block top face
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00—Casings, e.g. crankcases
    • F02F7/0085—Materials for constructing engines or their parts
    • F02F2007/009—Hypereutectic aluminum, e.g. aluminum alloys with high SI content
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/02—Light metals
    • F05C2201/021—Aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0433—Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0436—Iron
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2203/00—Non-metallic inorganic materials
    • F05C2203/06—Silicon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/4927—Cylinder, cylinder head or engine valve sleeve making

Definitions

  • the invention relates to a die-cast cylinder crankcase according to the preamble of claim 1 and a method for producing a die-cast cylinder crankcase according to claim 5.
  • the cylinder crankcases of large series engines are preferably manufactured in die-cast aluminum.
  • cylinder liners are usually inserted into the tool and overmolded. The distances between the cylinder liners partially decrease to less than 3 mm. Narrower webs reduce the rigidity of the cylinder crankcase.
  • the object of the invention is to provide a die-cast cylinder crankcase and a method for its production which, compared to the prior art, has improved rigidity and more effective cooling with a small web width between the cylinder liners.
  • the object is achieved in a die-cast cylinder crankcase according to claim 1, and in a method for producing a die-cast cylinder crankcase according to claim 5.
  • the die-cast cylinder crankcase according to claim 1 is characterized in that it has a number of cylinder liners cast together. Such a series of cylinder liners is referred to in technical jargon as a liner, which is why this term is also used in the following.
  • the liner is cast into the cylinder crankcase.
  • Die-casting is understood here to mean both die-casting and squeeze-casting, the cylinder crankcase basically being able to consist of all alloys suitable for this, in particular aluminum alloys, but also magnesium alloys.
  • the liner is cast in sand or gravity die casting and therefore has the advantage that cavities or undercuts can be represented comparatively easily. Therefore, the liner has an at least partially closed water jacket with different cooling channels. INS in particular, the water jacket is at least partially closed in the direction of a cylinder head side of the cylinder crankcase. This leads to a larger sealing surface on a mounting surface of the cylinder head and to a better seal between the cylinder head and the cylinder crankcase.
  • Another advantage of the cylinder crankcase according to the invention is that the webs between the cylinder liners can be provided with cooling channels.
  • the distances between them are only between 3 mm and 4 mm. Milling or drilling cooling channels in the land areas between cylinder liners is complex and expensive. Cooling channels in the web areas can already be integrated when using the liners according to the invention.
  • the liner can be made of any castable material that meets the tribological and thermal requirements for cylinder liners.
  • the liners are preferably made of a gray cast iron material.
  • a liner is usually made of an over-eutectic aluminum-silicon alloy or ordinary aluminum casting alloys (standard alloys) ) used.
  • the liner is represented by a standard casting alloy based on aluminum instead of a hypereutectic AlSi alloy.
  • mold or sand-cast components have a lower porosity.
  • the lower porosity makes it easier to apply a tribologically stable layer, preferably a thermal spray layer, and improves its adhesion.
  • the spray layer serves as a wear protection layer and cylinder running surface.
  • Another advantage of this variant is the more favorable casting properties of standard aluminum alloys.
  • Another component of the invention is a method for producing a cylinder crankcase according to claim 5, which comprises the following method steps:
  • a liner is manufactured using a casting process known per se (sand or permanent mold casting). The casting takes place using a lost core, which is used to form cooling channels. The liner has an at least partially closed water jacket.
  • the liner is then inserted into a die casting tool.
  • the bores of the individual cylinder liners of the liner are placed on quills in the die casting tool and thus fixed.
  • the die casting tool is then also poured out using a known die casting method.
  • the liner is poured into the cylinder crankcase, with the two metal alloys (liner and cylinder crankcase) being at least partially connected.
  • FIG. 1 is a plan view of a cylinder crankcase with a liner
  • Fig. 2 shows a cross section through a cylinder crankcase with a liner in the region of a cylinder bore
  • Fig. 3 is a longitudinal section through a cylinder crankcase with a liner.
  • FIG. 1 starting from a cylinder head side 18 (see FIG. 2), a top view of a cylinder crankcase 2 with a liner 4 cast in accordance with the invention is shown.
  • the Liner 4 comprises a plurality of cylinder liners 5, which are each separated from one another by web regions 12 and are delimited by the cylinder liners 15.
  • the cylinder liners 5 of the liner 4 are cast together in one casting process.
  • a water jacket 6 is cast in the outer region 9 of the liner 4.
  • the water jacket 6 comprises a plurality of cooling ducts 8, 10, which are usually connected to one another.
  • the water jacket 6 of the liner 4 is through transfer openings
  • the course of cooling channels 10 in the web area 12 is also shown in dashed lines. Screw holes 16 are used to fasten the cylinder head.
  • FIG. 2 The cross section shown in FIG. 2 through the cylinder crankcase 2 and the liner 4 illustrates the course of the largely closed outer cooling channels 8, and the water jacket 14 in the cylinder crankcase is also shown.
  • FIG. 3 shows a longitudinal section through a cylinder crankcase 2 with a liner 4.
  • the cooling channels 10 are highlighted in the web area 12. These are also largely closed and, as shown in broken lines in FIG. 1, are connected to the cooling channels 8.
  • a mold with an integrated sand core is provided.
  • the mold has the contour of the liner 4, the sand core forms the later water jacket 6.
  • the core can have a minimum width of 1.5 mm.
  • an over-eutectic aluminum-silicon alloy for example AlSil5, A1SÜ7 or AlSi9
  • AlSil5 an over-eutectic aluminum-silicon alloy
  • the liner 4 is removed from the mold, the sand core is removed and the liner 4 is deburred and / or machined if necessary.
  • a surface treatment of the liner 4 can optionally be carried out, which can improve the connection to the cylinder crankcase 2. This can include mechanical roughening, such as sandblasting, chemical treatments, or coatings.
  • the liner 4 is placed in a die-casting tool on quills.
  • a suitable aluminum alloy e.g. B. poured an AlSi9Cu3.
  • the liner 4 can be designed closed toward an oil pan side 20. This can be done through a base (not shown) that is already cast on during the manufacture of the liner 4. This measure prevents penetration (injection) of the aluminum melt between the cylinder surfaces 15 and the sleeve during die casting. The postprocessing effort is significantly reduced. Only the bottom, which closes the cylinder liner 5, has to be machined.
  • Another advantage of the cylinder crankcase 2 according to the invention is that the individual Cylinder liners increased surface area of the liner 4 leads to a better connection between the cylinder crankcase 2 and the cast part (liner 4). This in turn improves the heat transfer between the thermally highly loaded cylinder running surfaces 15 and the cylinder crankcase 2.
  • the integrated design of the liner 4 prevents the cylinder liners from occasionally dropping slightly during engine operation (setting). It also prevents cooling water from getting into the oil circuit, which can occur if there is a gap between the bushing and the encapsulation (cylinder crankcase) for individual bushings.
  • the liner is cast in the mold casting by an AISi7Mg alloy. After machining, a layer is applied to the inner surfaces of the cylinder liners by plasma spraying. This layer of a hypereutectic AlSi alloy serves as a cylinder running surface after finishing (fine turning, honing).
  • the layer can be applied by all common coating methods.
  • Thermal spray coatings such as plasma spraying, arc wire spraying or flame spraying, have proven their worth.
  • any wear-resistant material that is tribologically coordinated with the friction partner, a piston ring (and piston shirt) can also be used as the layer material.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Abstract

The invention relates to a diecast cylinder crankcase into which a liner (4) consisting of a plurality of cylinder sleeves is cast. Said liner (4) is produced by sandcasting and is placed in the diecasting mould. The liner (4) comprises an at least partially closed water jacket (6) which can optionally comprise cooling channels (10) in the connecting section (12).

Description

Druckguss-Zylinderkurbelgehäuse Die-cast cylinder crankcase
Die Erfindung betrifft ein Druckguss-Zylinderkurbelgehäuse nach dem Oberbegriff des Anspruchs 1, sowie ein Verfahren zur Herstellung eines Druckguss-Zylinderkurbelgehäuse nach Anspruch 5.The invention relates to a die-cast cylinder crankcase according to the preamble of claim 1 and a method for producing a die-cast cylinder crankcase according to claim 5.
Moderne Motoren müssen zunehmend mit weniger Bauraum auskommen, gleichzeitig steigen die thermischen und mechanischen Belastungen der Motoren stetig an. Dies erfordert eine aufwändige Kühlung, wobei auf Grund des ebenfalls angestrebten möglichst geringen Gewichts auch die Wandstärken immer geringer werden und somit weniger tragendes Material zur Verfügung steht .Modern engines increasingly have to make do with less installation space, and at the same time the thermal and mechanical loads on the motors increase steadily. This requires complex cooling, and due to the low weight that is also sought, the wall thicknesses are also becoming ever smaller and less load-bearing material is thus available.
Bevorzugt werden die Zylinderkurbelgehäuse von Großserienmotoren aus Gründen der Wirtschaftlichkeit im Aluminiumdruck- guss hergestellt. Hierzu werden in der Regel Zylinderlauf- buchsen in des Werkzeug eingelegt und umgössen. Die Abstände zwischen den Zylinderlaufbuchsen verringern sich teilweise auf unter 3 mm. Durch schmalere Stege verringert sich die Steifigkeit des Zylinderkurbelgehäuses.For reasons of economy, the cylinder crankcases of large series engines are preferably manufactured in die-cast aluminum. For this purpose, cylinder liners are usually inserted into the tool and overmolded. The distances between the cylinder liners partially decrease to less than 3 mm. Narrower webs reduce the rigidity of the cylinder crankcase.
Durch die räumliche Enge im Bereich der Zylinderlaufbuchsen wird zudem die Gestaltung des Wassermantels erschwert, da im Druckguss nur eine begrenzte Gestaltungsfreiheit bezüglich Hinterschneidungen und Hohlräumen gegeben ist. Die US 4,446,906 beschreibt ein Verfahren, zur Herstellung eines Zylinderkurbelgehäuses unter Verwendung von Salzkernen. Hiermit können komplexe Kühlkanäle ausgestaltet werden, die Prozesssicherheit hat sich jedoch bei einem so großen Bauteil wie dem Zylinderkurbelgehäuse als nicht großserientauglich erwiesen.The spatial constriction in the area of the cylinder liners also makes the design of the water jacket more difficult, since in die casting there is only a limited freedom of design with regard to undercuts and cavities. US 4,446,906 describes a method for producing a cylinder crankcase using salt cores. This allows complex cooling channels to be designed, but the process reliability has not proven to be suitable for large-scale production such as the cylinder crankcase.
Die Aufgabe der Erfindung besteht darin, ein Druckguss- Zylinderkurbelgehäuse und ein Verfahren zu dessen Herstellung bereitzustellen, das gegenüber dem Stand der Technik bei geringer Stegbreite zwischen den Zylinderlaufbuchsen eine verbesserte Steifigkeit und eine effektivere Kühlung aufweist .The object of the invention is to provide a die-cast cylinder crankcase and a method for its production which, compared to the prior art, has improved rigidity and more effective cooling with a small web width between the cylinder liners.
Die Lösung der Aufgabe besteht in einem Druckguss- Zylinderkurbelgehäuse nach Anspruch 1, sowie in einem Verfahren zur Herstellung eines Druckguss-Zylinderkurbelgehäuse nach Anspruch 5.The object is achieved in a die-cast cylinder crankcase according to claim 1, and in a method for producing a die-cast cylinder crankcase according to claim 5.
Das erfindungsgemäße Druckguss-Zylinderkurbelgehäuse nach Anspruch 1 zeichnet sich dadurch aus, dass es eine Reihe von aneinandergegossenen Zylinderlaufbuchsen aufweist. Eine derartige Reihe von Zylinderlaufbuchsen wird in der Fachsprache als Liner bezeichnet, weshalb dieser Begriff auch im Weiteren so gebraucht wird. Der Liner ist in das Zylinderkurbelgehäuse eingegossen.The die-cast cylinder crankcase according to claim 1 is characterized in that it has a number of cylinder liners cast together. Such a series of cylinder liners is referred to in technical jargon as a liner, which is why this term is also used in the following. The liner is cast into the cylinder crankcase.
Unter Druckguss wird hierbei sowohl Druckguss als auch Squee- ze-Casting verstanden, wobei das Zylinderkurbelgehäuse grundsätzlich aus allen hierfür geeigneten Legierungen, insbesondere Aluminium-Legierungen jedoch auch Magnesium-Legierungen bestehen kann.Die-casting is understood here to mean both die-casting and squeeze-casting, the cylinder crankcase basically being able to consist of all alloys suitable for this, in particular aluminum alloys, but also magnesium alloys.
Der Liner wird im Sandguss oder im Kokillenguss gegossen und besitzt deshalb den Vorteil, dass Hohlräume oder Hinter- schneidungen vergleichsweise einfach dargestellt werden können. Deshalb weist der Liner einen zumindest teilweise geschlossenen Wassermantel mit verschieden Kühlkanäle auf. Ins- besondere ist der Wassermantel in Richtung einer Zylinderkopfseite des Zylinderkurbelgehäuses zumindest teilweise geschlossen. Dies führt an einer Montagefläche des Zylinderkopfes zu einer größeren Dichtfläche und zu einer besseren Dichtung zwischen Zylinderkopf und Zylinderkurbelgehause.The liner is cast in sand or gravity die casting and therefore has the advantage that cavities or undercuts can be represented comparatively easily. Therefore, the liner has an at least partially closed water jacket with different cooling channels. INS in particular, the water jacket is at least partially closed in the direction of a cylinder head side of the cylinder crankcase. This leads to a larger sealing surface on a mounting surface of the cylinder head and to a better seal between the cylinder head and the cylinder crankcase.
Ein weiterer Vorteil des erfindungsgemäßen Zylinderkurbelgehäuses besteht darin, dass die Stege zwischen den Zylinderlaufbuchsen mit Kühlkanälen versehen werden können. Bei der Verwendung von einzelnen Zylinderlaufbuchsen betragen die Abstände zwischen diesen lediglich zwischen 3 mm und 4 mm. Das Einfräsen oder Bohren von Kühlkanälen in die Stegbereiche zwischen Zylinderlaufbuchsen ist aufwändig und teuer. Kühlkanäle in den Stegbereichen können bei der Verwendung der erfindungsgemäßen Linern bereits integriert sein.Another advantage of the cylinder crankcase according to the invention is that the webs between the cylinder liners can be provided with cooling channels. When using individual cylinder liners, the distances between them are only between 3 mm and 4 mm. Milling or drilling cooling channels in the land areas between cylinder liners is complex and expensive. Cooling channels in the web areas can already be integrated when using the liners according to the invention.
Grundsätzlich kann der Liner aus jedem gießbaren Material bestehen, das den tribologischen und thermischen Anforderungen für Zylinderlaufflächen entspricht. Bei Motoren mit besonders hohen Drücken, etwa bei Dieselmotoren, bestehen die Liner bevorzugt aus einem Graugussmaterial, bei Benzinmotoren wird aus Gewichtsgründen in der Regel ein Liner aus einer übereu- tektischen Aluminium-Silizium-Legierung oder gewöhnlichen A- luminium-Gießlegierungen (Standard-Legierungen) verwendet.Basically, the liner can be made of any castable material that meets the tribological and thermal requirements for cylinder liners. In engines with particularly high pressures, for example in diesel engines, the liners are preferably made of a gray cast iron material. For gasoline engines, for reasons of weight, a liner is usually made of an over-eutectic aluminum-silicon alloy or ordinary aluminum casting alloys (standard alloys) ) used.
In einer weiteren Ausgestaltungsform wird der Liner an Stelle einer übereutektischen AlSi-Legierung durch eine Standard- Gießlegierung auf Aluminiumbasis dargestellt. Im Gegensatz zu Druckguss-Bauteilen weisen Kokillen- oder Sandguss-Bauteile eine geringere Porosität auf. Die geringere Porosität erleichtert das Aufbringen einer tribologisch beständigen Schicht, bevorzugt eine thermische Spritzschicht und verbessert deren Haftung. Die Spritzschicht dient als Verschleißschutzschicht und Zylinderlauffläche. Ein Vorteil dieser Variante besteht in günstigeren Gießeigenschaften von Aluminium-Standard-Legierungen. Ein weiterer Bestandteil der Erfindung ist ein Verfahren zur Herstellung eines Zylinderkurbelgehäuses nach Anspruch 5, das folgende Verfahrensschritte umfasst:In a further embodiment, the liner is represented by a standard casting alloy based on aluminum instead of a hypereutectic AlSi alloy. In contrast to die-cast components, mold or sand-cast components have a lower porosity. The lower porosity makes it easier to apply a tribologically stable layer, preferably a thermal spray layer, and improves its adhesion. The spray layer serves as a wear protection layer and cylinder running surface. One advantage of this variant is the more favorable casting properties of standard aluminum alloys. Another component of the invention is a method for producing a cylinder crankcase according to claim 5, which comprises the following method steps:
Ein Liner wird nach einem an sich bekannten Gießverfahren (Sand- oder Kokillenguss) hergestellt. Das Gießen erfolgt unter Verwendung eines verlorenen Kerns, der zur Ausbildung von Kühlkanälen dient. Der Liner weist einen zumindest teilweise geschlossenen Wassermantel auf.A liner is manufactured using a casting process known per se (sand or permanent mold casting). The casting takes place using a lost core, which is used to form cooling channels. The liner has an at least partially closed water jacket.
Der Liner wird anschließend in ein Druckgusswerkzeug eingesetzt. Hierbei werden die Bohrungen der einzelnen Zylinderlaufbuchsen des Liners auf Pinolen im Druckgusswerkzeug aufgesetzt und somit fixiert. Anschließend wird das Druckgusswerkzeug ebenfalls nach einem bekannten Druckgießverfahren ausgegossen. Während des Druckgießens erfolgt das Eingießen des Liners in das Zylinderkurbelgehäuse, wobei es zumindest teilweise zu einer Verbindung der beiden Metalllegierungen (Liner und Zylinderkurbelgehäuse) kommt.The liner is then inserted into a die casting tool. The bores of the individual cylinder liners of the liner are placed on quills in the die casting tool and thus fixed. The die casting tool is then also poured out using a known die casting method. During the die casting, the liner is poured into the cylinder crankcase, with the two metal alloys (liner and cylinder crankcase) being at least partially connected.
Vorteilhafte Ausgestaltungsformen werden im Folgenden an Hand der Figuren und dem Verfahrensbeispiel beschrieben.Advantageous embodiments are described below with reference to the figures and the process example.
Es zeigen:Show it:
Fig. 1 eine Draufsicht auf ein Zylinderkurbelgehäuse mit einem Liner,1 is a plan view of a cylinder crankcase with a liner,
Fig. 2 einen Querschnitt durch eine Zylinderkurbelgehäuse mit Liner im Bereich einer Zylinderbohrung undFig. 2 shows a cross section through a cylinder crankcase with a liner in the region of a cylinder bore and
Fig. 3 eine Längsschnitt durch ein Zylinderkurbelgehäuse mit Liner.Fig. 3 is a longitudinal section through a cylinder crankcase with a liner.
In Fig. 1 ist ausgehend von einer Zylinderkopfseite 18 (s. Fig. 2) eine Draufsicht auf ein Zylinderkurbelgeh use 2 mit einem erfindungsgemäß eingegossenen Liner 4 dargestellt. Der Liner 4 umfasst mehrere Zylinderlaufbuchsen 5, die jeweils durch Stegbereiche 12 voneinander getrennt sind und von den Zylinderlaufflächen 15 begrenzt werden. Die Zylinderlaufbuchsen 5 des Liners 4 sind in einem Gießvorgang aneinandergegos- sen. Im Außenbereich 9 des Liners 4 ist ein Wassermantel 6 eingegossen. Der Wassermantel 6 umfasst mehrere, meistens miteinander verbundene Kühlkanäle 8, 10. Hierbei unterscheidet man zwischen äußeren Kühlkanälen 8, die im Außenbereich 9 des Liners 4 verlaufen und Kühlkanäle 10, die im StegbereichIn FIG. 1, starting from a cylinder head side 18 (see FIG. 2), a top view of a cylinder crankcase 2 with a liner 4 cast in accordance with the invention is shown. The Liner 4 comprises a plurality of cylinder liners 5, which are each separated from one another by web regions 12 and are delimited by the cylinder liners 15. The cylinder liners 5 of the liner 4 are cast together in one casting process. A water jacket 6 is cast in the outer region 9 of the liner 4. The water jacket 6 comprises a plurality of cooling ducts 8, 10, which are usually connected to one another. A distinction is made between outer cooling ducts 8, which run in the outer region 9 of the liner 4, and cooling ducts 10, which run in the web region
12 verlaufen.12 run.
Der Wassermantel 6 des Liners 4 ist durch ÜbertrittsöffnungenThe water jacket 6 of the liner 4 is through transfer openings
13 mit einem Wassermantel 14 (Fig. 2) des Zylinderkurbelgehäuses 2 und mit einem Wassermantel eines nicht dargestellten Zylinderkopfes verbunden. Die äußeren Kühlkanäle 8 verlaufen, wie in Fig. 1 gestrichelt dargestellt ist, zumindest teilweise geschlossen im Liner 4. Ebenfalls gestrichelt ist der Verlauf von Kühlkanälen 10 im Stegbereich 12 dargestellt. Ver- schraubungsbohrungen 16 dienen zur Befestigung des Zylinderkopfes .13 with a water jacket 14 (FIG. 2) of the cylinder crankcase 2 and with a water jacket of a cylinder head, not shown. The outer cooling channels 8, as shown in dashed lines in FIG. 1, run at least partially closed in the liner 4. The course of cooling channels 10 in the web area 12 is also shown in dashed lines. Screw holes 16 are used to fasten the cylinder head.
Der in Fig. 2 dargestellte Querschnitt durch das Zylinderkurbelgehäuse 2 und den Liner 4 veranschaulicht den Verlauf der weitgehend geschlossenen äußeren Kühlkanäle 8, zudem ist der Wassermantel 14 im Zylinderkurbelgehäuse dargestellt.The cross section shown in FIG. 2 through the cylinder crankcase 2 and the liner 4 illustrates the course of the largely closed outer cooling channels 8, and the water jacket 14 in the cylinder crankcase is also shown.
In Fig. 3 wird ein Längsschnitt durch ein Zylinderkurbelgehäuse 2 mit Liner 4 dargestellt. In dieser Ansicht sind im Stegbereich 12 die Kühlkanäle 10 hervorgehoben. Diese verlaufen ebenfalls weitgehend geschlossen und sind, wie in Fig. 1 gestrichelt dargestellt, mit den Kühlkanälen 8 verbunden.3 shows a longitudinal section through a cylinder crankcase 2 with a liner 4. In this view, the cooling channels 10 are highlighted in the web area 12. These are also largely closed and, as shown in broken lines in FIG. 1, are connected to the cooling channels 8.
Im folgenden Beispiel wird das Verfahren zur Herstellung des erfindungsgemäßen Zylinderkurbelgehäuse 2 näher erläutert. Es wird eine Kokille mit einem integrierten Sandkern bereitgestellt. Die Kokille weist die Kontur des Liners 4 auf, der Sandkern bildet den späteren Wassermantel 6 aus. Im Bereich der Stegkühlkanäle 10 kann der Kern eine minimale Breite von 1,5 mm aufweisen.In the following example, the method for producing the cylinder crankcase 2 according to the invention is explained in more detail. A mold with an integrated sand core is provided. The mold has the contour of the liner 4, the sand core forms the later water jacket 6. In the area of the web cooling channels 10, the core can have a minimum width of 1.5 mm.
Im Schwerkraftguss oder im Niederdruckguss wird eine übereu- tektische Aluminium-Siliziumlegierung beispielsweise AlSil5, A1SÜ7 oder AlSi9 in die Kokille eingegossen. Nach dem Abkühlen wird der Liner 4 aus der Kokille entnommen, der Sandkern entfernt und der Liner 4 gegebenenfalls entgratet und/oder spanend bearbeitet. Zudem kann fakultativ eine Oberflächenbehandlung des Liners 4 erfolgen, die die Anbindung zum Zylinderkurbelgehäuse 2 verbessern kann. Hierzu können mechanisches Aufrauen, wie Sandstrahlen, chemische Behandlungen, o- der Beschichtungen gehören.In gravity or low-pressure casting, an over-eutectic aluminum-silicon alloy, for example AlSil5, A1SÜ7 or AlSi9, is poured into the mold. After cooling, the liner 4 is removed from the mold, the sand core is removed and the liner 4 is deburred and / or machined if necessary. In addition, a surface treatment of the liner 4 can optionally be carried out, which can improve the connection to the cylinder crankcase 2. This can include mechanical roughening, such as sandblasting, chemical treatments, or coatings.
Anschließend wird der Liner 4 in ein Druckgusswerkzeug auf Pinolen aufgesetzt. Durch die Verbindung der einzelnen Zylinderlaufbuchsen 5 im Liner 4 ist eine sehr genaue Zentrierung der Buchsen 5 möglich, was zu einem genaueren Bohrungsabstand im Zylinderkurbelgehäuse 2 führt. Das Zylinderkurbelgehäuse 2 wird nun im Druckgussverfahren mit einer geeigneten Aluminiumlegierung, z. B. eine AlSi9Cu3 ausgegossen. Beim Druckgießen kommt es zumindest bereichsweise zu einer chemischen Verbindung zwischen der Legierung des Liners und des Zylinderkurbelgehäuse an deren Grenzflächen.Then the liner 4 is placed in a die-casting tool on quills. By connecting the individual cylinder liners 5 in the liner 4, very precise centering of the liners 5 is possible, which leads to a more precise hole spacing in the cylinder crankcase 2. The cylinder crankcase 2 is now die-cast with a suitable aluminum alloy, e.g. B. poured an AlSi9Cu3. In die casting, there is a chemical connection, at least in some areas, between the alloy of the liner and the cylinder crankcase at their interfaces.
Gegebenenfalls kann der Liner 4 zu einer Ölwannenseite 20 hin geschlossen ausgestaltet sein. Dies kann durch einen (nicht dargestellten) Boden geschehen, der bereits bei der Herstellung des Liners 4 angegossen wird. Durch diese Maßnahme wird ein Eindringen (Einspritzen) der Aluminiumschmelze zwischen Zylinderlaufflächen 15 und Pinole beim Druckgießen verhindert. Der Nachbearbeitungsaufwand wird so deutlich reduziert. Es muss lediglich der Boden, der die Zylinderlaufbuchse 5 abschließt, spanend abgearbeitet werden.If necessary, the liner 4 can be designed closed toward an oil pan side 20. This can be done through a base (not shown) that is already cast on during the manufacture of the liner 4. This measure prevents penetration (injection) of the aluminum melt between the cylinder surfaces 15 and the sleeve during die casting. The postprocessing effort is significantly reduced. Only the bottom, which closes the cylinder liner 5, has to be machined.
Ein weiterer Vorteil des erfindungsgemäßen Zylinderkurbelgehäuse 2 besteht darin, dass durch die gegenüber von einzelnen Zylinderlaufbuchsen vergrößerte Oberfläche des Liners 4 zu einer bessern Anbindung zwischen dem Zylinderkurbelgehäuse 2 und dem Eingussteil (Liner 4) führt. Hierdurch wird wiederum der Wärmeübergang zwischen den thermisch hochbelasteten Zylinderlaufflächen 15 und dem Zylinderkurbelgeh use 2 verbessert .Another advantage of the cylinder crankcase 2 according to the invention is that the individual Cylinder liners increased surface area of the liner 4 leads to a better connection between the cylinder crankcase 2 and the cast part (liner 4). This in turn improves the heat transfer between the thermally highly loaded cylinder running surfaces 15 and the cylinder crankcase 2.
Weiterhin wird durch die integrierte Bauweise des Liners 4 ein gelegentlich auftretendes, geringfügiges Absinken der Zylinderlaufbuchsen im Motorbetrieb (Setzen) verhindert. Ebenfalls wird verhindert, dass Kühlwasser in den Ölkreislauf gelangen kann, was unter Umständen vorkommt, wenn bei einzelnen Buchsen eine Spalt zwischen der Buchse und dem Umguss (Zylinderkurbelgehäuse) auftritt.Furthermore, the integrated design of the liner 4 prevents the cylinder liners from occasionally dropping slightly during engine operation (setting). It also prevents cooling water from getting into the oil circuit, which can occur if there is a gap between the bushing and the encapsulation (cylinder crankcase) for individual bushings.
In einer weiteren Aüsgestaltungsform der Erfindung wird der Liner im Kokillenguss durch eine AISi7Mg-Legierung gegossen. Nach einer Bearbeitung wird auf Innenflächen der Zylinderlaufbuchsen des Liners durch Plasmaspritzen eine Schicht aufgebracht. Diese Schicht aus einer übereutektische AlSi- Legierung dient nach einer Endbearbeitung (Feindrehen, Honen) als Zylinderlauffläche.In a further embodiment of the invention, the liner is cast in the mold casting by an AISi7Mg alloy. After machining, a layer is applied to the inner surfaces of the cylinder liners by plasma spraying. This layer of a hypereutectic AlSi alloy serves as a cylinder running surface after finishing (fine turning, honing).
Grundsätzlich kann die Schicht durch alle gebräuchlichen Be- schichtungsverfahren aufgebracht werden. Thermische Spritzschichten, wie Plasmaspritzen, Lichtbogendrahtspritzen oder Flammspritzen haben sich bewährt. Als Schichtmaterial kann e- benfalls grundsätzlich jedes verschleißbeständige Material verwendet werden, das mit dem Reibpartner, einem Kolbenring (und Kolbenhemd) tribologisch abgestimmt ist . Basically, the layer can be applied by all common coating methods. Thermal spray coatings, such as plasma spraying, arc wire spraying or flame spraying, have proven their worth. In principle, any wear-resistant material that is tribologically coordinated with the friction partner, a piston ring (and piston shirt) can also be used as the layer material.

Claims

Pat ent ansprüche Pat claims
1. Druckguss-Zylinderkurbelgehäuses, d a d u r c h g e k e n n z e i c h n e t ,1. Die-cast cylinder crankcase, d a d u r c h g e k e n n z e i c h n e t,
• dass in das Zylinderkurbelgehäuse (2) mindestens eine zusammenhängende Reihe (4) aus mindestens zwei Zylinderlaufbuchsen (5) eingegossen ist,• that at least one continuous row (4) of at least two cylinder liners (5) is cast into the cylinder crankcase (2),
• die Reihe Zylinderlaufbuchsen (4) aus einem Sand- oder Kokillengussstück besteht,The row of cylinder liners (4) consists of a sand or permanent mold casting,
• die Reihe Zylinderlaufbuchsen (4) mindestens einen Wassermantel (6) aufweist,• the row of cylinder liners (4) has at least one water jacket (6),
• wobei der Wassermantel bezüglich einer einem Zylinderkopf zugewandten Seite (18) des Zylinderkurbelgehäuses• wherein the water jacket with respect to a side facing a cylinder head (18) of the cylinder crankcase
(2) mindestens teilweise geschlossenen ist.(2) is at least partially closed.
2. Druckguss-Zylinderkurbelgehäuses, d a d u r c h g e k e n n z e i c h n e t ,2. Die-cast cylinder crankcase, d a d u r c h g e k e n n z e i c h n e t,
• dass in das Zylinderkurbelgehäuse (2) mindestens eine zusammenhängende Reihe (4) aus mindestens zwei Zylinderlaufbuchsen (5) eingegossen ist,• that at least one continuous row (4) of at least two cylinder liners (5) is cast into the cylinder crankcase (2),
• die Reihe Zylinderlaufbuchsen (4) aus einem Sand- oder Kokillengussstück besteht,The row of cylinder liners (4) consists of a sand or permanent mold casting,
• die Reihe Zylinderlaufbuchsen (4) mindestens einen Wassermantel (β) aufweist,• the row of cylinder liners (4) has at least one water jacket (β),
• das mindestens ein Kühlkanal (10) des Wassermantels (6) durch den Stegbereich (12) zwischen den Zylinderlaufbuchsen (5) verläuft.• The at least one cooling channel (10) of the water jacket (6) runs through the web area (12) between the cylinder liners (5).
3. Druckguss-Zylinderkurbelgehäuses nach Anspruch 1 oder 2, d a d u r c h g e k e n n z e i c h n e t , dass die Reihe Zylinderlaufbuchsen (4) aus einem Gussmaterial auf Eisenbasis besteht .3. Die-cast cylinder crankcase according to claim 1 or 2, characterized in that the row of cylinder liners (4) is made of a cast iron-based material.
4. Druckguss-Zylinderkurbelgehäuses nach einem der. Ansprüche 1 bis 3, d a d u r c h g e k e n n z e i c h n e t , dass die Reihe Zylinderlaufbuchsen (4) aus einer übereu- tektischen Aluminium-Silizium-Legierung besteht.4. Die-cast cylinder crankcase according to one of the. Claims 1 to 3, so that the row of cylinder liners (4) consists of a hypereutectic aluminum-silicon alloy.
5. Druckguss-Zylinderkurbelgehäuses nach einem der Ansprüche 1 bis 4, d a d u r c h g e k e n n z e i c hn e t , dass die Reihe Zylinderlaufbuchsen (4) aus einer Standard-Aluminium-Gießlegierung besteht und eine Zylinderlauffläche mit einer tribologisch beständigen Schicht beschichtet ist.5. Die-cast cylinder crankcase according to one of claims 1 to 4, d a d u r c h g e k e n n z e i c hn e t that the row of cylinder liners (4) consists of a standard aluminum casting alloy and a cylinder liner is coated with a tribologically resistant layer.
6. Druckguss-Zylinderkurbelgehäuses nach Anspruch 5, d a d u r c h g e k e n n z e i c h e t , dass die Schicht eine thermische Spritzschicht ist .6. Die-cast cylinder crankcase according to claim 5, d a d u r c h g e k e n n z e i c h e t that the layer is a thermal spray layer.
7. Verfahren zur Herstellung eines Druckguss- Zylinderkurbelgehäuses nach Anspruch 1 oder 2, umfassend folgende Schritte:7. A method for producing a die-cast cylinder crankcase according to claim 1 or 2, comprising the following steps:
• Gießen einer Reihe von Zylinderlaufbuchsen (4) unter Verwendung eins verlorenen Kerns zur Ausbildung eines zumindest teilweise geschlossenen Wassermantels (6) ,Casting a row of cylinder liners (4) using a lost core to form an at least partially closed water jacket (6),
• Einlegen der Reihe von Zylinderlaufbuchsen (4) in ein Druckgießwerkzeug eines Zylinderkurbelgehäuses (2) und• Insert the row of cylinder liners (4) into a die casting tool of a cylinder crankcase (2) and
• Druckgießen des Zylinderkurbelgehäuses (2) und gleichzeitiges Eingießen der Reihe Zylinderlaufbuchsen (4) . • Die-casting the cylinder crankcase (2) and simultaneously casting the row of cylinder liners (4).
EP03764931A 2002-07-23 2003-07-01 Diecast cylinder crankcase Expired - Lifetime EP1525384B8 (en)

Applications Claiming Priority (3)

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DE10233359 2002-07-23
DE10233359A DE10233359A1 (en) 2002-07-23 2002-07-23 Die-cast cylinder crankcase
PCT/EP2003/006984 WO2004009986A1 (en) 2002-07-23 2003-07-01 Diecast cylinder crankcase

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EP1525384A1 EP1525384A1 (en) 2005-04-27
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EP1525384B1 (en) 2007-11-14
CA2492896A1 (en) 2004-01-29
DE50308609D1 (en) 2007-12-27
WO2004009986A1 (en) 2004-01-29
MXPA05000689A (en) 2005-04-08
US20060124082A1 (en) 2006-06-15
EP1525384A1 (en) 2005-04-27

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