EP1919644B1 - Method for producing a cast component with a cast-in pipe - Google Patents

Method for producing a cast component with a cast-in pipe Download PDF

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Publication number
EP1919644B1
EP1919644B1 EP07785637A EP07785637A EP1919644B1 EP 1919644 B1 EP1919644 B1 EP 1919644B1 EP 07785637 A EP07785637 A EP 07785637A EP 07785637 A EP07785637 A EP 07785637A EP 1919644 B1 EP1919644 B1 EP 1919644B1
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EP
European Patent Office
Prior art keywords
cast
pipe
component
casting
mould
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.)
Not-in-force
Application number
EP07785637A
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German (de)
French (fr)
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EP1919644A1 (en
Inventor
Horst Henkel
Michael KLÄS
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.)
WINTER FRITZ EISENGIESSEREI
Fritz Winter Eisengiesserei GmbH and Co KG
Original Assignee
WINTER FRITZ EISENGIESSEREI
Fritz Winter Eisengiesserei GmbH and Co KG
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Application filed by WINTER FRITZ EISENGIESSEREI, Fritz Winter Eisengiesserei GmbH and Co KG filed Critical WINTER FRITZ EISENGIESSEREI
Publication of EP1919644A1 publication Critical patent/EP1919644A1/en
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Publication of EP1919644B1 publication Critical patent/EP1919644B1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C21/00—Flasks; Accessories therefor
    • B22C21/12—Accessories
    • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • 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 
    • F02F1/24—Cylinder heads
    • F02F1/243—Cylinder heads and inlet or exhaust manifolds integrally cast together
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals

Definitions

  • the invention relates to a method for producing a cast component of an internal combustion engine with a cast-in tube in a casting mold with lost molds and permanent model or in a casting process with permanent molds, in which a solid core mold is stored in a split outer mold, and a cast component of an internal combustion engine with a cast-in pipe and a corresponding casting mold.
  • Internal combustion engines in the form of internal combustion engines, are an integral part of vehicles (for example cars and commercial vehicles, ships, etc.) and are also used as stationary engines.
  • internal combustion engines include numerous molded components having at least one supply line (also called a guide channel) which relays a fluid medium (e.g., oil, water, gas, or other liquid or gaseous media) to a demand site in the engine or adjacent areas.
  • a fluid medium e.g., oil, water, gas, or other liquid or gaseous media
  • Some guide channels can also be used to cool a component itself. Where needed are the locations where the particular medium is needed, e.g. bearings to be lubricated, areas to be cooled, fuel pumps, fuel injectors, etc.
  • a supply line or a plurality of supply lines comes or come in particular in a cylinder head, cylinder crankcase or adjacent thereto add-on parts.
  • Inner contours of a cylinder head are for example: lower and upper water jacket, inlet channel (possibly with manifold), exhaust duct, Stoesel- and wheel core, oil return, nozzle assembly, etc.
  • Supply lines eg fuel lines and lubricating oil lines - in each case supply lines and return lines (leakage oil lines)
  • supply lines and return lines are introduced in a known manner by mechanical processing on machine tools or transfer lines, ie drilled.
  • machine tools or transfer lines ie drilled.
  • Subsequently, numerous, unnecessary accesses must be closed permanently and safely.
  • Very long, rectilinear supply lines, such as those of the main oil passage in a cylinder crankcase are nowadays also occasionally cast by casting over a pipe or by clearing through a corresponding core.
  • a disadvantage of subsequently mechanically introduced into a component or freed by encapsulation of cores supply lines is that the cast component has casting porosities.
  • supply lines are drilled to connect, for example, a fuel injection nozzle, it is difficult to establish liquid-tight transitions in the transition regions.
  • the DE 103 04 971 B4 discloses in a cast crankcase as pipes cast-in lubricant channels for supplying bearings (camshaft bearing or crankshaft bearing) with lubricant. By the subsequent introduction of a main oil hole in the crankcase, the cast-in pipes are opened and thus connected the supply lines to the bearings to the main oil well.
  • Cast components with cast as pipes supply lines, which are opened by mechanical processing at exactly predetermined locations, are in practice so far not or not satisfactorily produced.
  • the difficulties in producing a cast component with a cast-in pipe are due to the fact that the tube introduced into an outer mold and / or a core mold due to the strong heating during the casting process (in cast iron, the heating of the pipe is about 800 - 900 ° C) learns by the buoyancy forces of the liquid casting material as well as by the own thermal expansion loads that change it in its mounted original position. This has the consequence that the tube in the cast component is no longer in the predetermined position. This leads in particular to problems if the cast-in pipe is to be opened locally at precisely predetermined points in the course of a mechanical post-processing of the casting.
  • the above-mentioned core mold forms the inner contour of the casting and comprises one or more individual cores or an assembled core package, said components of the core mold being manufactured in a known manner using different and conventional manufacturing methods, e.g. be made of a mineral, refractory, granular base material and a binder in core tools.
  • the invention has for its object to provide a method for producing a cast component of an internal combustion engine with one or more cast-in tube (s), with the problem of the change in position of the tube during the casting is dissolved. It is another object of the invention to provide a cast component with at least one cast-in tube and a corresponding mold.
  • the tube holder used in the method according to the invention is a separate element which is integrated into the outer mold or into the core mold (into a single core or into a core package) before casting.
  • the exact number of pipe supports that is required for the accurate pouring of the tube depends on the type of component to be cast. With several pipe supports, these can be integrated exclusively in the outer form or exclusively in the core form. It is also possible to integrate at least one pipe holder into the outer mold and at least one pipe holder into the core mold. The pipe holder is firmly anchored in the outer mold or in the core mold. If several pipe supports are used, these are present as separate elements, ie, they are individual elements that have no rigid connection with each other.
  • the tube holder used in the context of the method according to the invention has an anchoring section for anchoring in the outer mold or core mold and a holding section for receiving and supporting the pipe to be infiltrated.
  • the pipe holder can also be referred to as a "centering element”.
  • the tube is inserted into the holding portion of the pipe holder.
  • the holding portion has been formed such that it locally surrounds the outer circumference of the tube at least partially, the tube is secured during the casting process against caused by the buoyancy forces of the liquid casting material radial deviation from the central position.
  • the tube is stored in close tolerance.
  • the holding portion may preferably have a loop-like or bow-like shape. Of course, other configurations are possible with adapted to the pipe contours. Characterized in that between the inner contour of the holding portion and the outer circumference of the tube is a small distance (ie, a small clearance), the pipe can expand or move during casting in its axial direction, so that it undergoes no deformation.
  • the tube is thus stored floating during the pouring.
  • the distance between the inner contour of the holding section and the outer circumference of the tube depends on the respective tolerance range from.
  • the height of the respective tolerance range is determined by the size of each component to be cast.
  • the distance can be 0.2 mm circumferentially (based on cast components for internal combustion engines from the passenger car and commercial vehicle sector). Subsequently, the component is cast with the respective method.
  • the component can be manufactured using different casting methods.
  • the component is cast in a casting method with lost shape and permanent model, e.g. in a pure core molding process, a core molding i.V.m. Green mold method, core mold i.V.m. Cold-resin molding method, etc.
  • the component is cast in a continuous casting method, e.g. Mold casting, die casting, injection molding, etc.
  • the pipe support is made of a material which is related to the cast material of the cast component, ie the physical properties (in particular the melting points) should match one another. If the respective materials are matched to one another, this advantageously achieves the result that the pipe holder melts marginally during the casting of the component, thereby forming a firm connection with the casting.
  • the holder should therefore also advantageously consist of cast iron, a cast iron alloy or preferably of steel.
  • a light metal holder In the case of a component made of light metal, a light metal holder should be used; in the case of a component made of non-ferrous metal or a non-ferrous metal alloy, a holder made of non-ferrous metal or a non-ferrous metal alloy should be used, etc.
  • the material of the einzug manenden tube is advantageously matched to the respective casting material that the tube melts during casting at the periphery. As a result, a particularly strong connection is made and achieved a high load capacity of the casting.
  • a plate-like element is integrated into the outer mold or into the core mold as a pipe holder.
  • “Plate-like” means that it is a flat element, which is bounded on two opposite sides by one each in relation to the thickness extended substantially flat surface.
  • Such a pipe support can be manufactured in an inexpensive manner in large numbers from a metal sheet, e.g. cut out.
  • Further advantages of a plate-like pipe holder are that it can be easily picked up by the core tool and can be well integrated in the core production or mold production.
  • the single tube holder could also be designed differently, e.g. a single body made of a welded or cast construction, each of which is integrated into the outer mold or core mold at a single location (i.e., where the pipe is to be held in position).
  • the anchoring portion of the pipe holder is introduced directly into the outer mold or core mold (eg injected) directly in the production of the outer mold or the core mold, as a solid, backlash-free anchoring is generated. Subsequent insertion of the pipe holder in the outer mold or core shape is also possible, but more complex.
  • the tube holder is advantageously aligned in three dimensions positioned.
  • the pipe support has at least one installation (eg a peripheral installation), preferably several installations, installations, contact surface or the like.
  • At least one recess has been advantageously formed on the pipe support.
  • the core form strength or core strength thus remains despite inserted pipe holder.
  • non-cast-in parts of the pipe holder are removed after the casting of the component.
  • a pipe holder is cast, which has at least one predetermined breaking point in at least one predetermined area or at least one defined location. This may be, for example, a locally impressed notch.
  • the pipe supports are different in their design and adapted to the respective needs. If, for example, according to an advantageous variant, several tubes are to be cast and stored in a positionally accurate position during casting, it is advantageous to use a tube holder with a plurality of corresponding holding sections.
  • the cast-in tube is opened in the course of the mechanical processing of the cast component at a predetermined location, i. severed or - which is advantageous feasible - marginal cut.
  • the manufacturing method according to the invention is particularly well suited.
  • the use according to the invention of a pipe holder according to the invention or of a plurality of pipe holders according to the invention makes it possible, for the first time with an uncomplicated measure, to accurately pour positionally precise pipes into a cast component. Despite the forces acting on the tube during pouring, the cast-in tube in the cast component is precisely in the position in which it is needed for subsequent mechanical processing.
  • the first time to selectively cut the cast-in tube only marginally in the course of a mechanical processing.
  • mechanical machining may be, for example, the introduction of a main oil bore, the introduction of a bore for injection nozzles or plug-in pumps, etc.
  • the very high position accuracy required in the cutting region of the mechanical processing to the cast-in tube is achieved by the method according to the invention.
  • the pipe support based on the mold design, positioned in the center of the planned mechanical processing, since the cast-in pipe is encountered there with the highest accuracy.
  • a cylinder head, a crankcase or an attachment of the crankcase in particular a transmission housing, a gear housing, an oil pan or the like, wherein at least one tube is poured as a fuel line, lubricant line or as a supply line for another fluid medium.
  • the components mentioned, in which the inner contours are formed by core shapes, can have a multiplicity of different supply lines. Precisely cast-in pipes, which are partially mechanically opened (cut or cut) at predetermined points, thus offer many advantages.
  • tube holders with in each case one or more holding sections are integrated as required in core molds or in individual cores, each of which frees a recess (for example in pump cores, nozzle cores, channel cores, water jacket cores, crankcase cores, bore cores, etc.).
  • a recess for example in pump cores, nozzle cores, channel cores, water jacket cores, crankcase cores, bore cores, etc.
  • One or more tubes are inserted into the holding portions, and after casting of the component, non-poured portions of the tube holders are removed.
  • the pipes are opened, if necessary, in the areas of the recessed openings or at other locations, in particular by mechanical machining.
  • the molded component of an internal combustion engine formed according to the invention is characterized in that it has a cast-in holding portion of a pipe holder or a part thereof, which is arranged locally on the outer circumference of the cast-in tube.
  • the tube holder integrated into the outer mold or into the core mold had served during the casting of the component, the pipe in such a way to store that it could extend in the axial direction, but was secured in radial directions against displacements caused by the buoyancy forces of the liquid casting material.
  • the cast component according to the invention thus has a positionally cast-in pipe, which is a prerequisite, for example, if the pipe is to be selectively opened in the course of a mechanical processing at a precisely predetermined location or just not to be hit by a hole introduced at a predetermined location.
  • the cast-in tube is a fuel line.
  • a cast as a pipe lubricant line or a conduit for another fluid medium is advantageously feasible.
  • the cast component may advantageously be a cylinder head. Due to the tight space conditions in such a component described above, the solution according to the invention offers here.
  • the cast component can advantageously be a crankcase or an attachment of the crankcase, in particular a transmission housing, a wheel housing, an oil sump or the like.
  • Fig. 1 is a schematic representation and shows different stages in the inventive production of a cast component 1 of an internal combustion engine according to the invention with a cast-in pipe 3 as a supply line.
  • the illustrated, already mechanically machined component is exemplarily a cylinder head 2, which was produced in a casting process with lost molds and permanent model or a casting process with permanent molds, in each of which a solid core mold 4 is stored in a divided outer mold.
  • the illustrated supply line in this example is a fuel line.
  • the tube 3 was by means of a pipe holder according to the invention 5, which in Fig. 2 is shown separately, accurately cast in the cylinder head 2. This was done before pouring in a core mold 4 (here in a single core, which frees a recess for an injection nozzle), the pipe holder 5 is integrated.
  • a pipe holder 5 has been integrated into a plurality of core molds 4, each of which has an injection nozzle recess.
  • the einzug manende tube 3 was in holding sections 6 of the pipe supports 5, the training and function will be described below, used in the course of core assembly.
  • the cylinder head 2 After assembly of the core molds 4 to the complete inner mold, which forms the inner contour of the component 1, and the assembly of the inner mold in the respective single or multiple divided outer mold, which forms the outer contour of the component, the cylinder head 2 was cast with the respective method.
  • the core or cores for the injection nozzle recess (s) could alternatively also be mounted in a hood core or in an outer mold half.
  • the in the Fig. 1 and 2 illustrated pipe holder 5 is formed in this perennialsbeisiel as a plate-like element 5a and was made for example of a steel sheet. It has an anchoring portion 7, which in the in Fig. 1 to recognize core shape 4 is anchored backlash-free, and a holding section 6 for receiving the einzugelloenden tube 3.
  • the holding portion 6 is formed such that it - as in Fig. 2 can be seen - locally surrounds the outer circumference 8 of the tube 3 at least partially and with little play (here circumferentially preferably 0.2 mm). It is thereby achieved that the tube 3 can expand during casting in the axial direction, but is secured against caused by the buoyancy forces of the liquid casting material displacements in the radial directions.
  • the holding section 6 is here advantageous bow-like formed and includes to secure the pipe inside a pipe abutment point. 9
  • the anchoring section 7 has a system 10, advantageously at least two systems 10 (contact points, contact surfaces, etc.), on.
  • the holding portion 6 of the pipe holder 5 advantageously forms a centering point 11, for example, by a mandrel engages in the holding portion 6 in the core tool.
  • the pipe holder 5 has at least one cutout 12. In the illustrated embodiment, three such recesses 12 are formed in the anchoring portion 7.
  • the Rohguss Swisses After casting the component 1 and Entsanden the Rohguss Publishedes (ie the removal of core or molding material) are in the context of cleaning measures not poured areas of Pipe holder 5, in particular the integrated into the core mold 4 anchoring sections 7, removed. Thus, only the areas of the tube holder 5 cast into the casting remain (in particular, parts of the holding sections 6) in the cast component 1.
  • Fig. 1 It can be seen that the tube 3 (the fuel line), which has been cast into position accurately in the cylinder head 2, is opened at a predetermined point in the course of the mechanical machining of the cast component 1. Namely, the pipe is cut marginal in the introduction of the stepped injection nozzle bore 13. - Further, in the component 1 further formed by cores cavities 14 and subsequently introduced holes 15, some of which are exemplarily provided with reference numerals to recognize.
  • the diameter of the injection nozzle bore 13 in the region of the cast-in tube 3 is in Fig. 2 indicated by D.
  • D The diameter of the injection nozzle bore 13 in the region of the cast-in tube 3 is in Fig. 2 indicated by D.
  • the tube 3 is opened tangentially for the supply of an injection nozzle used later in the injection nozzle bore 13.
  • the Fig. 3 shows a second embodiment of a pipe support according to the invention 5.
  • the same features are denoted by the same reference numerals as in Fig. 2 designated.
  • the tube holder 5 has a plurality of holding sections 6 (shown by way of example here are 3 holding sections, of course, other numbers are possible), so that a plurality of tubes 3 are mounted with exact positioning during the casting of the component 1 with such a tube holder 5 introduced into a core mold 3 or an outer mold can be.
  • the pipe holder 5 has several systems 10.
  • a holding section 6 is a centering point 11 of the holder 5 during insertion into the core mold 4.
  • the pipe holder 5 in Fig. 3 has predetermined breaking points 16. By this measure, it is possible to remove the non-cast part of the pipe holder 5 from the recess produced by the core mold 4 in an unobtrusive manner after the casting and sanding of the component 1.
  • the principle of a predetermined breaking point is in Fig. 3a illustrated, and it is, for example, a locally impressed in the pipe holder 5 in a predetermined region notch 16a. By bending the pipe bracket 5 can be stopped at these points. Of course, other types of breaking point are possible.
  • a second exemplary embodiment of a component 1 according to the invention cast by the method according to the invention for an internal combustion engine with a plurality of precisely cast-in tubes 3 as supply lines is shown. This is a section of a cast crankcase 17th
  • the pipe holder 5 was integrated before casting into a core mold 4 (here in a single core, which frees a recess for a fuel pump).
  • a tube holder 5 was integrated into a plurality of core molds 4, each of which has a fuel pump recess.
  • the einzug manenden tubes 3 were in the holding sections 6 of the pipe supports 5, the training and function will be described below, used in the course of core assembly.
  • the core molds 4 After installation of the core molds 4 in the outer mold, the core molds 4 here form part of the outer contour of the component 1, and the assembly of the inner mold into the respective single or multiple divided outer mold, which forms the outer contour of the component, the crankcase 17 with the cast in each case.
  • the in the 4 and 5 illustrated pipe holder 5 is formed in this mecanicsbeisiel as a plate-like element 5a and was made for example of a steel sheet. It has here web-like anchoring sections 7, which in the in Fig. 4 to be recognized core shape 4 anchored backlash, and four holding section 6 for receiving the pipes 3 zuzugelloenden.
  • the holding portions 6 are formed such that they - as in Fig. 5 can be seen - locally the outer circumference 8 of the respective tube 3 here completely and with little play (here circumferentially preferably 0.2 mm) surrounded. It is thereby achieved that the tubes 3 can expand during casting in the axial direction, but are secured against movements caused by the buoyancy forces of the liquid casting material in the radial directions.
  • the holding portions 6 are advantageously formed like a ring here. Of course Other numbers, configurations and Anornditch of holding sections on the pipe support are possible, for example, areas in which the holding portion does not completely surround a pipe.
  • the pipe holder 5 has been positioned accurately in the core mold 4.
  • the pipe 3a surrounded by the core mold 4 is a fuel pipe.
  • the non-cast-in areas of the tube holder 5 are removed after the casting and sanding of the cast component 1.
  • the cast-in tube 3b forms e.g. a fuel return line.
  • the cast-in pipe 3c may be a lubricant line.
  • the lower tube 3d which has been cut laterally here by a mechanically introduced bore 18, can guide lubricant and form a connection point for the lubricant supply to an attachment of the crankcase 17.
  • FIGS. 4 and 5 has been described above by way of example the positionally accurate pouring of supply lines as pipes in a crankcase.
  • the illustrated or a correspondingly modified pipe holder can of course also other occupied with a fluid medium supply lines in a crankcase or in another cast component of an internal combustion engine (eg, gear housing, gear housing, cylinder head, etc.) pour.
  • core shape type or at which points of the outer shape the respective pipe holder is introduced depends on the component to be cast and the structural conditions.
  • the method according to the invention can also be applied to cast components, in particular those with core-formed inner contours, which are not part of an internal combustion engine, for example cast components that are used in installation technology.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Pens And Brushes (AREA)
  • Discharging, Photosensitive Material Shape In Electrophotography (AREA)

Abstract

A method produces a cast component of an internal combustion engine with a cast-in pipe. Expendable molds and a permanent pattern, or permanent molds are used in the method. A solid core mold is mounted in a split outer mold. To solve the problem of the pipe changing its position during the casting of the component, a separate pipe holder is integrated into the outer mold or the core mold. The pipe is inserted into a retaining section of the pipe holder that is configured in such a manner that it locally surrounds the outer circumference of the pipe at least in part and with little play so that the pipe can expand in the axial direction during casting but is secured against displacements in radial directions caused by buoyancy forces of the liquid casting material. Subsequently the component is cast.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen eines gegossenen Bauteiles einer Brennkraftmaschine mit einem eingegossenen Rohr in einem Gießverfahren mit verlorenen Formen und Dauermodell oder in einem Gießverfahren mit Dauerformen, bei welchem eine feste Kernform in einer geteilten Außenform gelagert wird, sowie ein gegossenes Bauteil einer Brennkraftmaschine mit einem eingegossenen Rohr und eine entsprechende Gießform.The invention relates to a method for producing a cast component of an internal combustion engine with a cast-in tube in a casting mold with lost molds and permanent model or in a casting process with permanent molds, in which a solid core mold is stored in a split outer mold, and a cast component of an internal combustion engine with a cast-in pipe and a corresponding casting mold.

Brennkraftmaschinen sind in Form von Verbrennungsmotoren wesentlicher Bestandteil von Fahrzeugen (z.B. PKW und Nutzfahrzeuge, Schiffe etc.) und kommen auch als stationäre Motore zum Einsatz. Dabei enthalten Brennkraftmaschinen zahlreiche gegossene Bauteile, die mindestens eine Versorgungsleitung (auch Führungskanal genannt) aufweisen, die ein fluides Medium (z.B. Öl, Wasser, Gas oder andere flüssige bzw. gasförmige Medien) zu einer Bedarfstelle im Motor bzw. in angrenzenden Bereichen weiterleitet. Manche Führungskanäle können auch selbst der Kühlung eines Bauteils dienen. Bedarfstellen sind die Orte, an denen das jeweilige Medium benötigt wird, z.B. zu schmierende Lager, zu kühlende Bereiche, Kraftstoffpumpen, Kraftstoffeinspritzdüsen usw.Internal combustion engines, in the form of internal combustion engines, are an integral part of vehicles (for example cars and commercial vehicles, ships, etc.) and are also used as stationary engines. In this regard, internal combustion engines include numerous molded components having at least one supply line (also called a guide channel) which relays a fluid medium (e.g., oil, water, gas, or other liquid or gaseous media) to a demand site in the engine or adjacent areas. Some guide channels can also be used to cool a component itself. Where needed are the locations where the particular medium is needed, e.g. bearings to be lubricated, areas to be cooled, fuel pumps, fuel injectors, etc.

Eine Versorungsleitung bzw. mehrere Versorgungsleitungen kommt bzw. kommen insbesondere in einem Zylinderkopf, Zylinderkurbelgehäuse bzw. dazu benachbarten Anbauteilen vor. Dabei handelt es sich um gegossene konturenreiche Bauteile mit kerngebildeten Innenkonturen. Innenkonturen bei einem Zylinderkopf sind beispielsweise: unterer und oberer Wassermantel, Einlasskanal (evtl. mit Sammelrohr), Auslasskanal, Stösel- und Räderkern, Ölrücklauf, Düsenstock etc.A supply line or a plurality of supply lines comes or come in particular in a cylinder head, cylinder crankcase or adjacent thereto add-on parts. These are molded contour rich components with nucleated inner contours. Inner contours of a cylinder head are for example: lower and upper water jacket, inlet channel (possibly with manifold), exhaust duct, Stoesel- and wheel core, oil return, nozzle assembly, etc.

Aufgrund der Vielzahl der in solchen gegossenen Bauteilen unterzubringenden Komponenten (in einem Zylinderkopf z.B. Durchbrüche oder Freisparungen für Zündkerzen, Einspritzdüsen, Ventile, Befestigungsmittel - z.B. Zylinderkopfschrauben -, Versorgungsleitungen, Kühlkanäle, Kühlwasserkammern, Nockenwellenlagerstellen usw.) sind die Platzverhältnisse sehr beengt, weswegen zum Gießen relativ komplexe Gießformen erforderlich sind. Der Verlauf der Versorgungsleitungen richtet sich nach den jeweiligen konstuktiven Gegebenheiten und kann nicht frei gewählt werden.Due to the large number of housed in such cast components (in a cylinder head, for example, breakthroughs or recesses for spark plugs, injectors, valves, fasteners - eg cylinder head bolts -, supply lines, cooling channels, cooling water chambers, camshaft bearings, etc.), the space is very cramped, therefore, for casting relatively complex molds are required. The course of the supply lines depends on the respective constructive conditions and can not be chosen freely.

Versorungsleitungen (z.B. Kraftstoffleitungen und Schmierölleitungen - jweils Zulaufleitungen und Rücklaufleitungen (Leckölleitungen) -) werden in bekannter Weise durch mechanische Bearbeitung auf Werkzeugmaschinen bzw. Transferstraßen eingebracht, d.h. gebohrt. Dazu werden in mehreren aufwändigen, hochpräzise auszuführenden Arbeitsschritten lange (z.T. parallele) Bohrungen und mehrere kürzere Bohrungen, die Abzweigungen zu den einzelnen Bedarfstellen bilden, in das Bauteil gebohrt, was einen erheblichen Arbeits- und damit Kosten- sowie Investitionsaufwand darstellt. Anschließend müssen zahlreiche, nicht benötigte Zugänge dauerhaft und sicher verschlossen werden. Sehr lange, geradlinige Versorungsleitungen, wie die des Hauptölkanales bei einem Zylinderkurbelgehäuse werden heute auch schon vereinzelt gegossen durch Umgießen eines Rohres oder durch Freisparen durch einen entsprechenden Kern.Supply lines (eg fuel lines and lubricating oil lines - in each case supply lines and return lines (leakage oil lines)) are introduced in a known manner by mechanical processing on machine tools or transfer lines, ie drilled. For this purpose, in several complex, highly precise steps to be carried out long (partly parallel) holes and several shorter holes that form branches to the individual needs, drilled into the component, which represents a considerable work and thus cost and investment. Subsequently, numerous, unnecessary accesses must be closed permanently and safely. Very long, rectilinear supply lines, such as those of the main oil passage in a cylinder crankcase, are nowadays also occasionally cast by casting over a pipe or by clearing through a corresponding core.

Ein Nachteil bei nachträglich mechanisch in ein Bauteil eingebrachten oder durch Umgießen von Kernen freigesparten Versorgungsleitungen besteht darin, dass das gegossene Bauteil Gießporositäten aufweist. Wenn derartige Versorgungsleitungen angebohrt werden, um beispielsweise eine Kraftstoffeinspritzdüse anzuschließen, ist es schwierig, flüssigkeitsdichte Übergänge in den Übergangsbereichen herzustellen.A disadvantage of subsequently mechanically introduced into a component or freed by encapsulation of cores supply lines is that the cast component has casting porosities. When such supply lines are drilled to connect, for example, a fuel injection nozzle, it is difficult to establish liquid-tight transitions in the transition regions.

Aus der DE 199 61 092 A1 ist bekannt, in einem gegossenen Zylinderblock bzw. Zylinderkopf eines Verbrennungsmotors während der Fertigung als Rohre vorgeformte Kühlkanäle mit kleinem Durchmesser einzugießen. Diese führen um Bauelemente wie Zündkerzen oder Kraftstoffeinspritzdüsen herum und bilden ein Kühlsystem für die Flüssigkeitskühlung des Verbrennungsmotors. Die DE 33 00 924 C2 lehrt, zur Wasserkühlung von Stegen zwischen eng und direkt zusammengegossenen Zylindern eines Zylinderblockes einer wassergekühlten Brennkraftmaschine in das die Stege bildende Gußmaterial Rohre einzugießen, die eine Verbindung zwischen den seitlichen Kühlwassermänteln des Zylinderblockes herstellen. Dadurch ergibt sich eine intensive Kühlung der hoch beanspruchten Stegbereiche.From the DE 199 61 092 A1 It is known to pour in a cast cylinder block or cylinder head of an internal combustion engine during manufacture as pipes preformed cooling channels with a small diameter. These lead around components such as spark plugs or fuel injection nozzles and form a cooling system for the liquid cooling of the internal combustion engine. The DE 33 00 924 C2 teaches for water cooling of webs between closely and directly cast cylinders of a cylinder block of a water-cooled internal combustion engine in the web forming casting material pour tubes, which establish a connection between the lateral cooling water jackets of the cylinder block. This results in intensive cooling of the highly stressed web areas.

Die DE 103 04 971 B4 offenbart in ein gegossenes Kurbelgehäuse als Rohre eingegossene Schmiermittelkanäle zur Versorgung von Lagerstellen (Nockenwellenlager bzw. Kurbelwellenlager) mit Schmiermittel. Durch das nachträgliche Einbringen einer Hauptölbohrung in das Kurbelgehäuse werden die eingegossenen Rohre geöffnet und somit die Versorgungsleitungen zu den Lagerstellen an die Hauptölbohrung angeschlossen.The DE 103 04 971 B4 discloses in a cast crankcase as pipes cast-in lubricant channels for supplying bearings (camshaft bearing or crankshaft bearing) with lubricant. By the subsequent introduction of a main oil hole in the crankcase, the cast-in pipes are opened and thus connected the supply lines to the bearings to the main oil well.

In der DE 102 60 837 A1 ist eine als Rohr in einen Zylinderkopf eingegossene Kraftstoffleitung beschrieben. Im Zuge der mechanischen Bearbeitung des Zylinderkopfes wird das Rohr durchbohrt und ein Kraftstoffeinspritzventil in diese Bohrung mittels Dichtelementen eingesetzt.In the DE 102 60 837 A1 is described as a pipe poured into a cylinder head fuel line. In the course of mechanical machining of the cylinder head, the pipe pierced and a fuel injection valve inserted into this bore by means of sealing elements.

Gegossene Bauteile mit als Rohren eingegossenen Versorgungsleitungen, die durch mechanische Bearbeitungsmaßnahmen an genau vorgegebenen Stellen geöffnet werden, sind in der Praxis bisher nicht bzw. nicht zufriedenstellend herstellbar. Die Schwierigkeiten, ein gegossenes Bauteil mit einem eingegossenen Rohr herzustellen, gehen darauf zurück, dass das in eine Außenform und/oder in eine Kernform eingebrachte Rohr aufgrund der starken Aufheizung während des Gießprozesses (bei Gusseisen beträgt die Aufheizung des Rohres ca. 800 - 900°C) durch die Auftriebskräfte des flüssigen Gussmaterials sowie durch die eigene Wärmeausdehnung Belastungen erfährt, die es in seiner montierten Ursprungslage verändern. Das hat zur Folge, dass sich das Rohr in dem gegossenen Bauteil nicht mehr in der vorgegebenen Lage befindet. Dies führt insbesondere dann zu Problemen, wenn das eingegossene Rohr im Zuge einer mechanischen Nachbearbeitung des Gussteiles an exakt vorbestimmten Stellen lokal geöffnet werden soll.Cast components with cast as pipes supply lines, which are opened by mechanical processing at exactly predetermined locations, are in practice so far not or not satisfactorily produced. The difficulties in producing a cast component with a cast-in pipe are due to the fact that the tube introduced into an outer mold and / or a core mold due to the strong heating during the casting process (in cast iron, the heating of the pipe is about 800 - 900 ° C) learns by the buoyancy forces of the liquid casting material as well as by the own thermal expansion loads that change it in its mounted original position. This has the consequence that the tube in the cast component is no longer in the predetermined position. This leads in particular to problems if the cast-in pipe is to be opened locally at precisely predetermined points in the course of a mechanical post-processing of the casting.

Die oben genannte Kernform bildet die Innenkontur des Gussstückes und umfasst einen oder mehrere Einzelkerne oder ein zusammengebautes Kernpaket, wobei die genannten Komponenten der Kernform in bekannter Weise mit unterschiedlichen und üblichen Fertigungsverfahren z.B. aus einem mineralischen, feuerfesten, körnigen Grundstoff und einem Bindemittel in Kernwerkzeugen hergestellt werden.The above-mentioned core mold forms the inner contour of the casting and comprises one or more individual cores or an assembled core package, said components of the core mold being manufactured in a known manner using different and conventional manufacturing methods, e.g. be made of a mineral, refractory, granular base material and a binder in core tools.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zum Herstellen eines gegossenen Bauteiles einer Brennkraftmaschine mit einem oder mehreren eingegossenen Rohr(en) bereitzustellen, mit dem das Problem der Lageveränderung des Rohres während des Gießens gelöst wird. Ferner ist es Aufgabe der Erfindung ein gegossenes Bauteil mit mindestens einem eingegossenen Rohr und eine entsprechende Gießform zu schaffen.The invention has for its object to provide a method for producing a cast component of an internal combustion engine with one or more cast-in tube (s), with the problem of the change in position of the tube during the casting is dissolved. It is another object of the invention to provide a cast component with at least one cast-in tube and a corresponding mold.

Diese Aufgabe wird bei einem Verfahren der oben geannten Art erfindungsgemäß gelöst durch die Merkmale des Anspruches 1.This object is achieved according to the invention in a method of the type mentioned above by the features of claim 1.

Durch das Vorsehen mindestens einer gesonderten, in die einfach oder mehrfach geteilte Außenform bzw. in die Kernform integrierten Rohrhalterung mit den erfindungsgemäßen Merkmalen gelingt es, in ein Bauteil ein Rohr mit hoher Positionsgenauigkeit einzugießen. Das bedeutet, dass das Rohr trotz der beim Gießen auf das Rohr einwirkenden Kräfte genau die vorgegebene Lage beibehält bzw. sich die Lage nur in vorgegebenen Grenzen ändern kann. Vorteilhafterweise werden mehrere Versorgungsleitungen als Rohre eingegossen.By providing at least one separate, in the singly or multiply divided outer mold or in the core mold integrated pipe holder with the features of the invention, it is possible to pour a pipe into a component with high position accuracy. This means that despite the forces acting on the tube during casting, the tube retains exactly the predetermined position or the position can only change within predetermined limits. Advantageously, several supply lines are cast as tubes.

Die in dem erfindungsgemäßen Verfahren eingesetzte Rohrhalterung ist ein gesondertes Element, das vor dem Gießen in die Außenform bzw. in die Kernform (in einen Einzelkern oder in ein Kernpaket) integriert wird. Die genaue Anzahl an Rohrhalterungen, die für das lagegenaue Eingießen des Rohres erforderlich ist, hängt von der Art des zu gießenden Bauteiles ab. Bei mehreren Rohrhalterungen können diese ausschließlich in der Außenform oder ausschließlich in der Kernform integriert sein. Auch ist es möglich, mindestens eine Rohrhalterung in die Außenform und mindestens eine Rohrhalterung in die Kernform zu integrierten. Die Rohrhalterung wird dabei fest in der Außenform bzw. in der Kernform verankert. Wenn mehrere Rohrhalterungen eingesetzt werden, liegen diese als gesonderte Elemente vor, d.h. es handelt sich um Einzelelemente, die untereinander keine starre Verbindung haben. Sie können jeweils an den Stellen innerhalb des gesamten Formaufbaus zum Einsatz kommen, an denen sie benötigt werden, um dem eingegossenen Rohr seine vorbestimmte Position zu sichern. Dadurch, dass die einzelnen Rohrhalterungen untereinander nicht verbunden sind, unterliegen sie nicht den gießtechnisch bedingten Deformationskräften, wie sie eingegossene Rohre ohne Halterung oder eingegossene Rohre zusammen mit einer starren Positioniervorrichtung (vgl. DE 42 26 207 C1 ) erfahren.The tube holder used in the method according to the invention is a separate element which is integrated into the outer mold or into the core mold (into a single core or into a core package) before casting. The exact number of pipe supports that is required for the accurate pouring of the tube depends on the type of component to be cast. With several pipe supports, these can be integrated exclusively in the outer form or exclusively in the core form. It is also possible to integrate at least one pipe holder into the outer mold and at least one pipe holder into the core mold. The pipe holder is firmly anchored in the outer mold or in the core mold. If several pipe supports are used, these are present as separate elements, ie, they are individual elements that have no rigid connection with each other. They can each be used at the points within the entire mold design come where they are needed to secure the cast-in tube its predetermined position. Because the individual pipe supports are not connected to one another, they are not subject to the casting-related deformation forces, such as cast-in pipes without support or cast-in pipes together with a rigid positioning device (cf. DE 42 26 207 C1 ) Experienced.

Die im Rahmen des erfindungsgemäßen Verfahrens eingesetzte Rohrhalterung weist einen Verankerungsabschnitt zur Verankerung in der Außenform bzw. Kernform und einen Halteabschnitt zur Aufnahme und Lagerung des einzugießenden Rohres auf. Die Rohrhalterung kann auch als "Zentrierelement" bezeichnet werden.The tube holder used in the context of the method according to the invention has an anchoring section for anchoring in the outer mold or core mold and a holding section for receiving and supporting the pipe to be infiltrated. The pipe holder can also be referred to as a "centering element".

Im Zuge der Kernmontage (d.h. dem Zusammenbau der Gießform) wird das Rohr in den Halteabschnitt der Rohrhalterung eingesetzt. Dadurch dass der Halteabschnitt derart ausgebildet wurde, dass er örtlich den Außenumfang des Rohres mindestens teilweise umgibt, ist das Rohr während des Gießprozesses gegen durch die Auftriebskräfte des flüssigen Gussmaterials bedingte radiale Abweichung von der zentrischen Lage gesichert. Das Rohr wird in enger Toleranz gelagert. Der Halteabschnitt kann vorzugsweise eine ösenartige oder bügelartige Form haben. Selbstverständlich sind andere Ausbildungen mit an das Rohr angepassten Konturen möglich. Dadurch, dass zwischen der Innenkontur des Halteabschnittes und dem Außenumfang des Rohres ein geringer Abstand (d.h. ein geringes Spiel) besteht, kann sich das Rohr beim Gießen in seiner Achsrichtung ausdehnen bzw. bewegen, so dass es keine Deformationen erfährt. Das Rohr wird somit während des Eingießens schwimmend gelagert. Der Abstand zwischen der Innenkontur des Halteabschnittes und dem Außenumfang des Rohres hängt von dem jeweiligen Toleranzbereich ab. Die Höhe des jeweiligen Toleranzbereiches wird durch die Größe des jeweils zu gießenden Bauteiles bestimmt. Vorzugsweise kann der Abstand 0,2 mm umlaufend betragen (bezogen auf gegossene Bauteile für Brennkraftmaschinen aus dem PKW- und Nutzfahrzeug-Bereich). Anschließend wird das Bauteil mit dem jeweiligen Verfahren gegossen.As part of the core assembly (ie, the assembly of the mold), the tube is inserted into the holding portion of the pipe holder. Characterized in that the holding portion has been formed such that it locally surrounds the outer circumference of the tube at least partially, the tube is secured during the casting process against caused by the buoyancy forces of the liquid casting material radial deviation from the central position. The tube is stored in close tolerance. The holding portion may preferably have a loop-like or bow-like shape. Of course, other configurations are possible with adapted to the pipe contours. Characterized in that between the inner contour of the holding portion and the outer circumference of the tube is a small distance (ie, a small clearance), the pipe can expand or move during casting in its axial direction, so that it undergoes no deformation. The tube is thus stored floating during the pouring. The distance between the inner contour of the holding section and the outer circumference of the tube depends on the respective tolerance range from. The height of the respective tolerance range is determined by the size of each component to be cast. Preferably, the distance can be 0.2 mm circumferentially (based on cast components for internal combustion engines from the passenger car and commercial vehicle sector). Subsequently, the component is cast with the respective method.

Das Bauteil kann dabei mit unterschiedlichen Gießverfahren gefertigt werden. Gemäß einer ersten vorteilhaften Verfahrensvariante wird das Bauteil in einem Gießverfahren mit verlorener Form und Dauermodell gegossen, z.B. in einem reinen Kernform-Verfahren, einem Kernform- i.V.m. Grünform-Verfahren, Kernform- i.V.m. Kaltharzform-Verfahren usw. Nach einer zweiten vorteilhaften Verfahrensvariante wird das Bauteil in einem Gießverfahren mit Dauerform gegossen, z.B. Kokillen-Guß, Druckguß, Spritzguß usw.The component can be manufactured using different casting methods. According to a first advantageous variant of the method, the component is cast in a casting method with lost shape and permanent model, e.g. in a pure core molding process, a core molding i.V.m. Green mold method, core mold i.V.m. Cold-resin molding method, etc. According to a second advantageous variant of the method, the component is cast in a continuous casting method, e.g. Mold casting, die casting, injection molding, etc.

Es ist vorteilhaft, wenn die Rohrhalterung aus einem Material besteht, das mit dem Gussmaterial des gegossenen Bauteiles verwandt ist, d.h die physikalischen Eigenschaften (insbesondere die Schmelzpunkte) sollten zueinander passen. Wenn die jeweiligen Materialien aufeinander abgestimmt sind, wird dadurch vorteilhaft erreicht, dass die Rohrhalterung beim Gießen des Bauteiles randlich anschmilzt und dadurch eine feste Verbindung mit dem Gussteil entsteht. Bei einem zu gießenden Bauteil aus Gusseisen oder einer Gusseisen-Legierung sollte die Halterung somit ebenfalls vorteilhaft aus Gusseisen, einer Gusseisen-Legierung oder bevorzugt aus Stahl bestehen. Bei einem Bauteil aus Leichtmetall sollte eine Leichtmetall-Halterung, bei einem Bauteil aus Buntmetall bzw. einer Buntmetall-Legierung sollte eine Halterung aus Buntmetall- bzw. einer Buntmetall-Legierung zum Einsatz kommen usw.It is advantageous if the pipe support is made of a material which is related to the cast material of the cast component, ie the physical properties (in particular the melting points) should match one another. If the respective materials are matched to one another, this advantageously achieves the result that the pipe holder melts marginally during the casting of the component, thereby forming a firm connection with the casting. In the case of a component made of cast iron or a cast iron alloy to be cast, the holder should therefore also advantageously consist of cast iron, a cast iron alloy or preferably of steel. In the case of a component made of light metal, a light metal holder should be used; in the case of a component made of non-ferrous metal or a non-ferrous metal alloy, a holder made of non-ferrous metal or a non-ferrous metal alloy should be used, etc.

Auch das Material des einzugießenden Rohres wird vorteilhafterweise so auf das jeweilige Gussmaterial abgestimmt, dass das Rohr während des Gießens am Umfang anschmilzt. Dadurch wird eine besonders feste Verbindung hergestellt und eine hohe Belastbarkeit des Gussteiles erreicht.The material of the einzugießenden tube is advantageously matched to the respective casting material that the tube melts during casting at the periphery. As a result, a particularly strong connection is made and achieved a high load capacity of the casting.

Nach einer vorteilhaften Weiterbildung des erfindungsgemäßen Verfahrens wird als Rohrhalterung ein plattenartiges Element in die Außenform bzw. in die Kernform integriert. "Plattenartig" bedeutet dabei, dass es sich um ein flaches Element handelt, das auf zwei gegenüberliegenden Seiten von je einer im Verhältnis zur Dicke ausgedehnten im wesentlichen ebenen Fläche begrenzt ist. Eine derartige Rohrhalterung lässt sich auf unaufwändige Weise in großer Stückzahl aus einem Metallblech fertigen, z.B. herausschneiden. Weitere Vorteile einer plattenartigen Rohrhalterung sind, dass sie vom Kernwerkzeug gut aufgenommen und bei der Kernfertigung bzw. Formfertigung gut integriert werden kann. Selbstverständlich könnte die einzelne Rohrhalterung auch anders ausgebildet sein, z.B. ein in Schweißkonstruktion oder Gusskonstruktion gefertigter einzelner Körper, der jeweils an einer einzigen Positionsstelle (d.h. Stelle, an der das Rohr positionsgenau gehalten werden soll) in die Außenform bzw. in die Kernform integriert wird.According to an advantageous development of the method according to the invention, a plate-like element is integrated into the outer mold or into the core mold as a pipe holder. "Plate-like" means that it is a flat element, which is bounded on two opposite sides by one each in relation to the thickness extended substantially flat surface. Such a pipe support can be manufactured in an inexpensive manner in large numbers from a metal sheet, e.g. cut out. Further advantages of a plate-like pipe holder are that it can be easily picked up by the core tool and can be well integrated in the core production or mold production. Of course, the single tube holder could also be designed differently, e.g. a single body made of a welded or cast construction, each of which is integrated into the outer mold or core mold at a single location (i.e., where the pipe is to be held in position).

Vorteilhaft ist es, wenn der Verankerungsabschnitt der Rohrhalterung direkt bei der Herstellung der Außenform bzw. der Kernform in die Außenform bzw. Kernform eingebracht wird (z.B. eingeschossen wird), da dadurch eine feste, spielfreie Verankerung erzeugt wird. Ein nachträgliches Einbringen der Rohrhalterung in die Außenform bzw. Kernform ist ebenfalls möglich, aber aufwändiger. Die Rohrhalterung wird in der Außenform bzw. in der Kernform bei der Herstellung der Außenform bzw. Kernform vorteilhafterweise dreidimensional lagegenau positioniert. Dafür weist die Rohrhalterung mindestens eine Anlage (z.B. eine umlaufende Anlage), vorzugsweise mehrere Anlagen, Anlagestellen, Anlagefläche oder dergleichen, auf.It is advantageous when the anchoring portion of the pipe holder is introduced directly into the outer mold or core mold (eg injected) directly in the production of the outer mold or the core mold, as a solid, backlash-free anchoring is generated. Subsequent insertion of the pipe holder in the outer mold or core shape is also possible, but more complex. In the outer shape or in the core shape in the production of the outer shape or core shape, the tube holder is advantageously aligned in three dimensions positioned. For this purpose, the pipe support has at least one installation (eg a peripheral installation), preferably several installations, installations, contact surface or the like.

Um die Stabilität der Kernform bzw. der Außenform nicht durch das Einbringen der Rohrhalterung zu schwächen, ist an der Rohrhalterung vorteilhafterweise mindestens eine Ausnehmung ausgebildet worden. Die Kernformfestigkeit bzw. Kernfestigkeit bleibt somit trotz eingebrachter Rohrhalterung erhalten.In order not to weaken the stability of the core shape or the outer shape by the introduction of the pipe holder, at least one recess has been advantageously formed on the pipe support. The core form strength or core strength thus remains despite inserted pipe holder.

In einer bevorzugten Weiterbildung des erfindungsgemäßen Verfahrens werden nach dem Gießen des Bauteiles nicht eingegossene Teile der Rohrhalterung entfernt. Hierfür ist es vorteilhaft, wenn eine Rohrhalterung eingegossen wird, die in mindestens einem vorgegebenen Bereich bzw. mindestens einer definierten Stelle mindestens eine Sollbruchstelle aufweist. Dabei kann es sich beispielsweise um eine örtlich eingeprägte Einkerbung handeln. Durch diese einfache Maßnahme können nach dem Gießen des Bauteiles im Rahmen von Putzbearbeitung nicht eingegossene Bereiche der Rohrhalterung, wobei es sich insbesondere um die während des Gießens in der Form befindlichen Verankerungsabschnitte handelt, unaufwändig aus dem Bauteil entfernt werden.In a preferred development of the method according to the invention, non-cast-in parts of the pipe holder are removed after the casting of the component. For this purpose, it is advantageous if a pipe holder is cast, which has at least one predetermined breaking point in at least one predetermined area or at least one defined location. This may be, for example, a locally impressed notch. As a result of this simple measure, non-cast-in regions of the pipe holder, in particular casting elements that are in the mold during casting, can be easily removed from the component after the component has been cast.

Je nach Konstruktion der zu gießenden Bauteile und dem dazu entsprechenden Formaufbau, d.h. der Außenform, und dem erforderlichen Kernaufbau, d.h. der Innenform, sind die Rohrhalterungen in ihrer Ausführung unterschiedlich und den jeweiligen Bedürfnissen angepasst. Wenn beispielsweise gemäß einer vorteilhaften Variante mehrere Rohre eingegossen und während des Gießens positionsgenau gelagert werden sollen, kann vorteilhaft eine Rohrhalterung mit mehreren entsprechenden Halteabschnitten eingesetzt werden.Depending on the construction of the components to be cast and the corresponding shape structure, ie the outer shape, and the required core structure, ie the inner shape, the pipe supports are different in their design and adapted to the respective needs. If, for example, according to an advantageous variant, several tubes are to be cast and stored in a positionally accurate position during casting, it is advantageous to use a tube holder with a plurality of corresponding holding sections.

Gemäß einer vorteilhaften Weiterbildung des erfindungsgemäßen Verfahrens wird das eingegossene Rohr im Zuge der mechanischen Bearbeitung des gegossenen Bauteiles an einer vorgegebenen Stelle geöffnet, d.h. durchtrennt oder - was vorteilhaft realisierbar ist - randlich angeschnitten. Für derartige Ausführungen ist das erfindungsgemäße Herstellungsverfahren besonders gut geeignet. Die erfindungsgemäße Verwendung einer erfindungsgemäßen Rohrhalterung bzw. mehrerer erfindungsgemäßer Rohrhalterungen ermöglicht erstmals mit einer unaufwändigen Maßnahme das exakte, positionsgenaue Eingießen von Rohren in ein gegossenes Bauteil. Trotz der auf das Rohr beim Eingießen einwirkenden Kräfte befindet sich das eingegossene Rohr in dem gegossenen Bauteil genau in der Lage, in der es für die anschließende mechanische Bearbeitung benötigt wird. Aufgrund der erfindungsgemäß erzielten Positionsgenauigkeit des eingegossenen Rohres ist es vorteilhaft erstmals möglich, im Zuge einer mechanischen Bearbeitung das eingegossene Rohr gezielt lediglich randlich anzuschneiden. Je nach gegossenem Bauteil kann es sich bei der mechanischen Bearbeitung beispielsweise um das Einbringen einer Hauptölbohrung, das Einbringen einer Bohrung für Einspritzdüsen bzw. Einsteckpumpen etc. handeln. Die in dem Schnittbereich der mechanischen Bearbeitung zu dem eingegossenen Rohr erforderliche sehr hohe Positionsgenauigkeit wird durch das erfindungsgemäße Verfahren erreicht. Vorzugsweise wird die Rohrhalterung, bezogen auf den Formaufbau, im Zentrum der geplanten mechanischen Bearbeitung positioniert, da das eingegossene Rohr dort mit der höchsten Genauigkeit anzutreffen ist.According to an advantageous embodiment of the method according to the invention, the cast-in tube is opened in the course of the mechanical processing of the cast component at a predetermined location, i. severed or - which is advantageous feasible - marginal cut. For such embodiments, the manufacturing method according to the invention is particularly well suited. The use according to the invention of a pipe holder according to the invention or of a plurality of pipe holders according to the invention makes it possible, for the first time with an uncomplicated measure, to accurately pour positionally precise pipes into a cast component. Despite the forces acting on the tube during pouring, the cast-in tube in the cast component is precisely in the position in which it is needed for subsequent mechanical processing. Due to the positional accuracy of the cast-in tube obtained according to the invention, it is advantageously possible for the first time to selectively cut the cast-in tube only marginally in the course of a mechanical processing. Depending on the cast component, mechanical machining may be, for example, the introduction of a main oil bore, the introduction of a bore for injection nozzles or plug-in pumps, etc. The very high position accuracy required in the cutting region of the mechanical processing to the cast-in tube is achieved by the method according to the invention. Preferably, the pipe support, based on the mold design, positioned in the center of the planned mechanical processing, since the cast-in pipe is encountered there with the highest accuracy.

Vorteilhafterweise kann in dem Verfahren ein Zylinderkopf, ein Kurbelgehäuse oder ein Anbauteil des Kurbelgehäuses, insbesondere ein Getriebegehäuse, ein Rädergehäuse, eine Ölwanne oder dergleichen, gegossen werden, wobei mindestens ein Rohr als Kraftstoffleitung, Schmiermittelleitung oder als Versorgungsleitung für ein anderes fluides Medium eingegossen wird. Die genannten Bauteile, bei denen die Innenkonturen durch Kernformen gebildet sind, können eine Vielzahl unterschiedlicher Versorgungsleitungen aufweisen. Lagegenau eingegossene Rohre, die teilweise an vorgegebenen Stellen mechanisch geöffnet (durchtrennt bzw. angeschnitten) werden, bieten hier somit viele Vorteile. In einer vorteilhaften Weiterbildung werden hierfür je nach Bedarf in Kernformen bzw. in Einzelkerne, die jeweils eine Ausnehmung freisparen (beispielsweise in Pumpenkerne, Düsenkerne, Kanalkerne, Wassermantelkerne, Kurbelraumkerne, Bohrungskerne usw.) Rohrhalterungen mit jeweils einem oder mehreren Halteabschnitt(en) integriert. Ein Rohr oder mehrere Rohre wird/werden in die Halteabschnitte eingesetzt, und nach dem Gießen des Bauteiles werden nicht eingegossene Bereiche der Rohrhalterungen entfernt. Im Zuge einer mechanischen Bearbeitung des Bauteiles werden die Rohre - falls erforderlich - in den Bereichen der freigesparten Ausnehmungen oder an anderen Stellen geöffnet, insbesondere durch eine mechanische Zerspanung.Advantageously, in the method, a cylinder head, a crankcase or an attachment of the crankcase, in particular a transmission housing, a gear housing, an oil pan or the like, wherein at least one tube is poured as a fuel line, lubricant line or as a supply line for another fluid medium. The components mentioned, in which the inner contours are formed by core shapes, can have a multiplicity of different supply lines. Precisely cast-in pipes, which are partially mechanically opened (cut or cut) at predetermined points, thus offer many advantages. In an advantageous development, tube holders with in each case one or more holding sections are integrated as required in core molds or in individual cores, each of which frees a recess (for example in pump cores, nozzle cores, channel cores, water jacket cores, crankcase cores, bore cores, etc.). One or more tubes are inserted into the holding portions, and after casting of the component, non-poured portions of the tube holders are removed. In the course of a mechanical machining of the component, the pipes are opened, if necessary, in the areas of the recessed openings or at other locations, in particular by mechanical machining.

Die oben genannte Aufgabe wird ferner gelöst durch ein gegossenes Bauteil einer Brennkraftmaschine mit den Merkmalen des Anspruches 13.The above object is further achieved by a cast component of an internal combustion engine with the features of claim 13.

Das gemäß der Erfindung ausgebildete gegossene Bauteil einer Brennkraftmaschine zeichnet sich dadurch aus, dass es einen eingegossenen Halteabschnitt einer Rohrhalterung oder einen Teil davon aufweist, der örtlich an dem Außenumfang des eingegossenen Rohres angeordnet ist. Dabei hatte die in die Außenform bzw. in die Kernform integriert gewesene Rohrhalterung während des Gießens des Bauteiles dazu gedient, das Rohr derart zu lagern, dass es sich in Achsrichtung ausdehnen konnte, jedoch in radialen Richtungen gegen durch die Auftriebskräfte des flüssigen Gussmaterials bedingte Verschiebungen gesichert war. Das erfindungsgemäße gegossene Bauteil weist somit ein positionsgenau eingegossenes Rohr auf, was beispielsweise Voraussetzung ist, wenn das Rohr im Zuge einer mechnischen Bearbeitung an einer genau vorgegebenen Stelle gezielt geöffnet werden soll oder an einer vorgegebenen Stelle eben nicht durch eine eingebrachte Bohrung getroffen werden soll.The molded component of an internal combustion engine formed according to the invention is characterized in that it has a cast-in holding portion of a pipe holder or a part thereof, which is arranged locally on the outer circumference of the cast-in tube. In this case, the tube holder integrated into the outer mold or into the core mold had served during the casting of the component, the pipe in such a way to store that it could extend in the axial direction, but was secured in radial directions against displacements caused by the buoyancy forces of the liquid casting material. The cast component according to the invention thus has a positionally cast-in pipe, which is a prerequisite, for example, if the pipe is to be selectively opened in the course of a mechanical processing at a precisely predetermined location or just not to be hit by a hole introduced at a predetermined location.

Gemäß einer vorteilhaften Ausführung handelt es sich bei dem eingegossenen Rohr um eine Kraftstoffleitung. Auch eine als Rohr eingegossene Schmiermittelleitung oder eine Leitung für ein anderes fluides Medium ist vorteilhaft realisierbar. Bei dem gegossenen Bauteil kann es sich vorteilhaft um einen Zylinderkopf handeln. Aufgrund der eingangs beschriebenen engen Platzverhältnisse in einem derartigen Bauteil bietet sich die erfindungsgemäße Lösung hier an. Alternativ kann es sich bei dem gegossenen Bauteil vorteilhaft um ein Kurbelgehäuse oder um ein Anbauteil des Kurbelgehäuses, insbesondere um ein Getriebegehäuse, ein Rädergehäuse, eine Ölwanne oder dergleichen, handeln.According to an advantageous embodiment, the cast-in tube is a fuel line. Also, a cast as a pipe lubricant line or a conduit for another fluid medium is advantageously feasible. The cast component may advantageously be a cylinder head. Due to the tight space conditions in such a component described above, the solution according to the invention offers here. Alternatively, the cast component can advantageously be a crankcase or an attachment of the crankcase, in particular a transmission housing, a wheel housing, an oil sump or the like.

Darüber hinaus wird die eingangs genannte Aufgabe gelöst durch eine Gießform mit den Merkmalen des Anspruches 17.In addition, the object mentioned above is achieved by a casting mold having the features of claim 17.

Vorteilhafte Ausführungen der Gießform sind in den Unteransprüchen angegeben. Die einzelnen Merkmale und Vorteile der im Rahmen der Erfindung eingesetzten Rohrhalterung wurden bereits im Zusammenhang mit dem erfindungsgemäßen Verfahren beschrieben. Zur Vermeidung von Wiederholungen wird diesbezüglich auf die entsprechenden obigen Ausführungen verwiesen.Advantageous embodiments of the mold are given in the dependent claims. The individual features and advantages of the pipe holder used in the context of the invention have already been described in connection with the method according to the invention. To avoid repetition, reference is made in this regard to the corresponding statements above.

In den Zeichnungen sind gegossene Bauteile und Rohrhalterungen zur Verdeutlichung der Erfindung schematisch dargestellt. Es zeigen:

Fig. 1
einen Querschnitt durch einen erfindungsgemäß gegossenen Zylinderkopf mit einer ersten Ausführung einer erfindungsgemäßen Rohrhalterung,
Fig. 2
die Rohrhalterung aus Fig. 1,
Fig. 3
eine zweite Ausführung einer erfindungsgemäßen Rohrhalterung,
Fig. 3a
ein Detail aus Fig. 3,
Fig. 4
einen ausschnittsweisen Querschnitt durch ein erfindungsgemäß gegossenes Kurbelgehäuse mit einer dritteln Ausführung einer erfindungsgemäßen Rohrhalterung und
Fig. 5
die Rohrhalterung aus Fig. 4.
In the drawings, molded components and pipe supports are shown schematically to illustrate the invention. Show it:
Fig. 1
a cross section through an inventive cast cylinder head with a first embodiment of a pipe support according to the invention,
Fig. 2
the pipe holder off Fig. 1 .
Fig. 3
a second embodiment of a pipe holder according to the invention,
Fig. 3a
a detail from Fig. 3 .
Fig. 4
a fragmentary cross section through an inventively cast crankcase with a third embodiment of a pipe support according to the invention and
Fig. 5
the pipe holder off Fig. 4 ,

Fig. 1 ist eine schematische Darstellung und zeigt unterschiedliche Stadien bei der erfindungsgemäßen Herstellung eines erfindungsgemäßen gegossenen Bauteiles 1 einer Brennkraftmaschine mit einem eingegossenen Rohr 3 als Versorgungsleitung. Bei dem dargestellten, bereits mechanisch bearbeiteten Bauteil handelt es sich exemplarisch um einen Zylinderkopf 2, der in einem Gießverfahren mit verlorenen Formen und Dauermodell oder einem Gießverfahren mit Dauerformen, bei welchem jeweils eine feste Kernform 4 in einer geteilten Außenform gelagert wird, hergestellt wurde. Bei der dargestellten Versorgungsleitung handelt es sich in diesem Beispiel um eine Kraftstoffleitung. Fig. 1 is a schematic representation and shows different stages in the inventive production of a cast component 1 of an internal combustion engine according to the invention with a cast-in pipe 3 as a supply line. The illustrated, already mechanically machined component is exemplarily a cylinder head 2, which was produced in a casting process with lost molds and permanent model or a casting process with permanent molds, in each of which a solid core mold 4 is stored in a divided outer mold. The illustrated supply line in this example is a fuel line.

Das Rohr 3 wurde mittels einer erfingungsgemäßen Rohrhalterung 5, die in Fig. 2 separat dargestellt ist, positionsgenau in dem Zylinderkopf 2 eingegossen. Dafür wurde vor dem Gießen in eine Kernform 4 (hier in einen Einzelkern, der eine Ausnehmung für eine Einspritzdüse freispart) die Rohrhalterung 5 integriert. Bei dem als Ausführungsbeispiel dargestellten Zylinderkopf 2 wurde in mehrere Kernformen 4, die jeweils eine Einspritzdüsen-Ausnehmung freisparen, jeweils eine Rohrhalterung 5 integriert. Das einzugießende Rohr 3 wurde in Halteabschnitte 6 der Rohrhalterungen 5, deren Ausbildung und Funktion weiter unten beschrieben wird, im Zuge der Kernmontage eingesetzt. Nach dem Zusammenbau der Kernformen 4 zur kompletten Innenform, die die Innenkontur des Bauteiles 1 bildet, und der Montage der Innenform in die jeweilige einfach oder mehrfach geteilte Außenform, die die Außenkontur des Bauteiles bildet, wurde der Zylinderkopf 2 mit dem jeweiligen Verfahren gegossen. - In Abhängigkeit von der jeweiligen Konstuktion des zu gießenden Zylinderkopfes könnte(n) der Kern bzw. die Kerne für die Einspritzdüsen-Ausnehmung(en) alternativ auch in einem Haubenkern oder in einer Außenformhälfte gelagert sein.The tube 3 was by means of a pipe holder according to the invention 5, which in Fig. 2 is shown separately, accurately cast in the cylinder head 2. This was done before pouring in a core mold 4 (here in a single core, which frees a recess for an injection nozzle), the pipe holder 5 is integrated. In the case of the cylinder head 2 shown as an exemplary embodiment, a pipe holder 5 has been integrated into a plurality of core molds 4, each of which has an injection nozzle recess. The einzugießende tube 3 was in holding sections 6 of the pipe supports 5, the training and function will be described below, used in the course of core assembly. After assembly of the core molds 4 to the complete inner mold, which forms the inner contour of the component 1, and the assembly of the inner mold in the respective single or multiple divided outer mold, which forms the outer contour of the component, the cylinder head 2 was cast with the respective method. Depending on the particular construction of the cylinder head to be cast, the core or cores for the injection nozzle recess (s) could alternatively also be mounted in a hood core or in an outer mold half.

Die in den Fig. 1 und 2 dargestellte Rohrhalterung 5 ist in diesem Ausführungsbeisiel als plattenartiges Element 5a ausgebildet und wurde beispielsweise aus einem Stahlblech gefertigt. Sie weist einen Verankerungsabschnitt 7, der in der in Fig. 1 zu erkennenden Kernform 4 spielfrei verankert ist, und einen Halteabschnitt 6 zur Aufnahme des einzugießenden Rohres 3 auf. Der Halteabschnitt 6 ist derart ausgebildet, dass er - wie in Fig. 2 zu erkennen ist - örtlich den Außenumfang 8 des Rohres 3 mindestens teilweise und mit geringem Spiel (hier umlaufend vorzugsweise 0,2 mm) umgibt. Dadurch wird erreicht, dass sich das Rohr 3 beim Gießen in Achsrichtung ausdehnen kann, jedoch gegen durch die Auftriebskräfte des flüssigen Gussmaterials bedingte Verschiebungen in radialen Richtungen gesichert ist. Der Halteabschnitt 6 ist hier vorteilhaft bügelartig ausgebildet und umfasst zur Sicherung des Rohres nach innen eine Rohranlagestelle 9.The in the Fig. 1 and 2 illustrated pipe holder 5 is formed in this Ausführungsbeisiel as a plate-like element 5a and was made for example of a steel sheet. It has an anchoring portion 7, which in the in Fig. 1 to recognize core shape 4 is anchored backlash-free, and a holding section 6 for receiving the einzugießenden tube 3. The holding portion 6 is formed such that it - as in Fig. 2 can be seen - locally surrounds the outer circumference 8 of the tube 3 at least partially and with little play (here circumferentially preferably 0.2 mm). It is thereby achieved that the tube 3 can expand during casting in the axial direction, but is secured against caused by the buoyancy forces of the liquid casting material displacements in the radial directions. The holding section 6 is here advantageous bow-like formed and includes to secure the pipe inside a pipe abutment point. 9

Bei der in den Fig. 1 und 2 dargestellten Ausführung wurde die Rohrhalterung 5, und zwar der Verankerungsabschnitt 7, direkt bei der Herstellung der Kernform 4 in diese eingebracht (z.B. in den Kern eingeschossen). Um die Rohrhalterung 5 in dem Kernwerkzeug bei der Herstellung der Kernform 4 dreidimensional in der erforderlichen Stellung zu halten und damit positionsgenau in die Kernform 4 einzubringen, weist der Verankerungsabschnitt 7 eine Anlage 10, vorteilhafterweise mindestens zwei Anlagen 10 (Anlagestellen, Anlageflächen etc.), auf. Um die Anzahl an Anlagen 10 und damit den Aufwand für eine exakte Positionierung gering zu halten, bildet der Halteabschnitt 6 der Rohrhalterung 5 hier vorteilhafterweise eine Zentrierstelle 11, indem beispielsweise in dem Kernwerkzeug ein Dorn in den Halteabschnitt 6 eingreift. Durch die Anlagen 10 und die Zentrierstelle 11 wird die Rohrhalterung 5 positionsgenau in die Kernform 4 eingebracht, was dafür sorgt, dass das Rohr positionsgenau in das Bauteil eingegossen werden kann. Die räumlichen Parameter für das Rohr im späteren Gussstück sind auf diese Weise im Vorfeld genau vorgegeben.In the in the Fig. 1 and 2 As shown embodiment, the pipe holder 5, namely the anchoring portion 7, directly in the production of the core mold 4 introduced into this (eg injected into the core). In order to hold the pipe holder 5 in the core tool in the production of the core mold 3 three-dimensionally in the required position and thus accurately position in the core mold 4, the anchoring section 7 has a system 10, advantageously at least two systems 10 (contact points, contact surfaces, etc.), on. In order to keep the number of systems 10 and thus the effort for an exact positioning low, the holding portion 6 of the pipe holder 5 advantageously forms a centering point 11, for example, by a mandrel engages in the holding portion 6 in the core tool. By the systems 10 and the centering point 11, the pipe holder 5 is accurately positioned in the core mold 4, which ensures that the tube can be poured accurately positioned in the component. The spatial parameters for the tube in the later casting are predetermined in this way in advance.

Um die Kernform 4 durch den eingebrachten Verankerungsabschnitt 7 nicht zu schwächen, d.h. ein Auseinanderfallen der Kernform 4 zu verhindern, weist die Rohrhaltung 5 mindestens eine Freisparung 12 auf. Bei dem dargestellten Ausführungsbeispiel sind drei derartige Freisparungen 12 in dem Verankerungsabschnitt 7 ausgebildet.In order not to weaken the core mold 4 by the introduced anchoring section 7, i. to prevent falling apart of the core mold 4, the pipe holder 5 has at least one cutout 12. In the illustrated embodiment, three such recesses 12 are formed in the anchoring portion 7.

Nach dem Gießen des Bauteiles 1 und Entsanden des Rohgussstückes (d.h. dem Entfernen von Kern- bzw. Formstoff) werden im Rahmen von Putzmaßnahmen nicht eingegossene Bereiche der Rohrhalterung 5, insbesondere die in die Kernform 4 integriert gewesenen Verankerungsabschnitte 7, entfernt. Es verbleiben somit nur die in das Gussstück eingegossenen Bereiche der Rohrhalterung 5 (insbesondere Teile der Halteabschnitte 6) in dem gegossenen Bauteil 1. An den eingegossenen Halteabschnitten 6 bzw. deren Teilen, die am Außenumfang 8 des Rohres 3 angeordnet sind, ist zu erkennen, dass das gegossene Bauteil 1 mit dem erfindungsgemäßen Verfahren hergestellt wurde.After casting the component 1 and Entsanden the Rohgussstückes (ie the removal of core or molding material) are in the context of cleaning measures not poured areas of Pipe holder 5, in particular the integrated into the core mold 4 anchoring sections 7, removed. Thus, only the areas of the tube holder 5 cast into the casting remain (in particular, parts of the holding sections 6) in the cast component 1. The cast-in holding sections 6 or their parts, which are arranged on the outer circumference 8 of the tube 3, show that the cast component 1 was produced by the method according to the invention.

In Fig. 1 ist zu erkennen, dass das positionsgenau in den Zylinderkopf 2 eingegossene Rohr 3 (die Kraftstoffleitung) im Zuge der mechanischen Bearbeitung des gegossenen Bauteiles 1 an einer vorgegebenen Stelle geöffnet wird. Und zwar wird das Rohr beim Einbringen der abgestuften Einspritzdüsen-Bohrung 13 randlich angeschnitten. - Ferner sind in dem Bauteil 1 weitere durch Kerne gebildete Hohlräume 14 und nachträglich eingebrachte Bohrungen 15, von denen einige exemplarisch mit Bezugszeichen versehen sind, zu erkennen.In Fig. 1 It can be seen that the tube 3 (the fuel line), which has been cast into position accurately in the cylinder head 2, is opened at a predetermined point in the course of the mechanical machining of the cast component 1. Namely, the pipe is cut marginal in the introduction of the stepped injection nozzle bore 13. - Further, in the component 1 further formed by cores cavities 14 and subsequently introduced holes 15, some of which are exemplarily provided with reference numerals to recognize.

Der Durchmesser der Einspritzdüsen-Bohrung 13 im Bereich des eingegossenen Rohres 3 ist in Fig. 2 mit D angegeben. Hier ist nochmals vergrößert zu erkennen, wie das Rohr 3 für die Versorgung einer später in die Einspritzdüsen-Bohrung 13 eingesetzten Einspritzdüse tangential geöffnet wird.The diameter of the injection nozzle bore 13 in the region of the cast-in tube 3 is in Fig. 2 indicated by D. Here it is once again enlarged to see how the tube 3 is opened tangentially for the supply of an injection nozzle used later in the injection nozzle bore 13.

Vorstehend wurde exemplarisch das positionsgenaue Eingießen einer Kraftstoffleitung als Rohr in einen Zylinderkopf erläutert. Mit der dargestellten oder einer entsprechend abgewandelten Rohrhalterung lassen sich selbstverständlich auch andere Versorgungsleitungen (z.B. für Schmiermittel, Wasser oder ein anderes fluides Medium) in einen Zylinderkopf oder in ein anderes gegossenes Bauteil einer Brennkraftmaschine (z.B. Kurbelgehäuse, Rädergehäuse, Getriebegehäuse etc.) eingießen.In the above example, the positionally accurate pouring of a fuel pipe as a pipe into a cylinder head has been explained. Of course, other supply lines (eg for lubricant, water or another fluid medium) can also be poured into a cylinder head or into another cast component of an internal combustion engine (eg crankcase, wheel housing, gear housing, etc.) using the illustrated or a correspondingly modified pipe mount.

Die Fig. 3 zeigt eine zweite Ausführung einer erfindungsgemäßen Rohrhalterung 5. Gleiche Merkmale sind mit denselben Bezugszeichen wie in Fig. 2 bezeichnet. Die Rohrhalterung 5 weist mehrere Halteabschnitte 6 (exemplarisch dargestellt sind hier 3 Halteabschnitte, selbstverständlich sind auch andere Anzahlen möglich) auf, so dass mit einer solchen in eine Kernform 3 oder eine Außenform eingebrachten Rohrhalterung 5 mehrere Rohre 3 während des Gießens des Bauteiles 1 positionsgenau gelagert werden können. Die Rohrhalterung 5 weist mehrere Anlagen 10 auf. Ein Halteabschnitt 6 ist eine Zentrierstelle 11 der Halterung 5 während des Einbringens in die Kernform 4.The Fig. 3 shows a second embodiment of a pipe support according to the invention 5. The same features are denoted by the same reference numerals as in Fig. 2 designated. The tube holder 5 has a plurality of holding sections 6 (shown by way of example here are 3 holding sections, of course, other numbers are possible), so that a plurality of tubes 3 are mounted with exact positioning during the casting of the component 1 with such a tube holder 5 introduced into a core mold 3 or an outer mold can be. The pipe holder 5 has several systems 10. A holding section 6 is a centering point 11 of the holder 5 during insertion into the core mold 4.

Die Rohrhalterung 5 in Fig. 3 weist Sollbruchstellen 16 auf. Durch diese Maßnahme ist es möglich, auf unaufwändige Weise nach dem Gießen und Entsanden des Bauteiles 1 den nicht eingegossenen Teil der Rohrhalterung 5 aus der durch die Kernform 4 erzeugten Aussparung zu entfernen. Das Prinzip einer Sollbruchstelle ist in Fig. 3a dargestellt, und zwar handelt es sich beispielsweise um eine lokal in die Rohrhalterung 5 in einem vorgegebenen Bereich eingeprägte Einkerbung 16a. Durch Biegen kann die Rohrhalterung 5 an diesen Stellen abgebrochen werden. Selbstverständlich sind auch andere Arten einer Sollbruchstelle möglich.The pipe holder 5 in Fig. 3 has predetermined breaking points 16. By this measure, it is possible to remove the non-cast part of the pipe holder 5 from the recess produced by the core mold 4 in an unobtrusive manner after the casting and sanding of the component 1. The principle of a predetermined breaking point is in Fig. 3a illustrated, and it is, for example, a locally impressed in the pipe holder 5 in a predetermined region notch 16a. By bending the pipe bracket 5 can be stopped at these points. Of course, other types of breaking point are possible.

In den Fig. 4 und 5 wird ein zweites Ausführungsbeispiel eines mit dem erfindungsgemäßen Verfahren gegossenen erfindungsgemäßen Bauteiles 1 für eine Brennkraftmaschine mit mehreren positionsgenau eingegossenen Rohren 3 als Versorgungsleitungen dargestellt. Es handelt sich hier um einen Ausschnitt aus einem gegossenen Kurbelgehäuse 17.In the 4 and 5 A second exemplary embodiment of a component 1 according to the invention cast by the method according to the invention for an internal combustion engine with a plurality of precisely cast-in tubes 3 as supply lines is shown. This is a section of a cast crankcase 17th

Die vier zu erkennenden Rohre 3 wurden mittels einer erfindungsgemäßen Rohrhalterung 5, die in Fig. 5 separat dargestellt ist, positionsgenau in das Kurbelgehäuse 17 eingegossen. Dafür wurde vor dem Gießen in eine Kernform 4 (hier in einen Einzelkern, der eine Ausnehmung für eine Kraftstoffpumpe freispart) die Rohrhalterung 5 integriert. Bei der Herstellung des Kurbelgehäuses wurde in mehrere Kernformen 4, die jeweils eine Kraftstoffpumpen-Aussparung freisparen, jeweils eine Rohrhalterung 5 integriert. Die einzugießenden Rohre 3 wurden in die Halteabschnitte 6 der Rohrhalterungen 5, deren Ausbildung und Funktion weiter unten beschrieben wird, im Zuge der Kernmontage eingesetzt. Nach dem Einbau der Kernformen 4 in die Außenform, wobei die Kernformen 4 hier Teilbereiche der Außenkontur des Bauteiles 1 bilden, und der Montage der Innenform in die jeweilige einfach oder mehrfach geteilte Außenform, die die Außenkontur des Bauteiles bildet, wurde das Kurbelgehäuse 17 mit dem jeweiligen Verfahren gegossen.The four tubes 3 to be recognized by means of a pipe holder 5 according to the invention, which in Fig. 5 is shown separately, accurately cast in the crankcase 17. For this purpose, the pipe holder 5 was integrated before casting into a core mold 4 (here in a single core, which frees a recess for a fuel pump). In the production of the crankcase, in each case a tube holder 5 was integrated into a plurality of core molds 4, each of which has a fuel pump recess. The einzugießenden tubes 3 were in the holding sections 6 of the pipe supports 5, the training and function will be described below, used in the course of core assembly. After installation of the core molds 4 in the outer mold, the core molds 4 here form part of the outer contour of the component 1, and the assembly of the inner mold into the respective single or multiple divided outer mold, which forms the outer contour of the component, the crankcase 17 with the cast in each case.

Die in den Fig. 4 und 5 dargestellte Rohrhalterung 5 ist in diesem Ausführungsbeisiel als plattenartiges Element 5a ausgebildet und wurde beispielsweise aus einem Stahlblech gefertigt. Sie weist hier stegartige Verankerungsabschnitte 7, die in der in Fig. 4 zu erkennenden Kernform 4 spielfrei verankert sind, und vier Halteabschnitt 6 zur Aufnahme der einzugießenden Rohre 3 auf. Die Halteabschnitte 6 sind derart ausgebildet, dass sie - wie in Fig. 5 zu erkennen ist - örtlich den Außenumfang 8 des jeweiligen Rohres 3 hier vollständig und mit geringem Spiel (hier umlaufend vorzugsweise 0,2 mm) umgeben. Dadurch wird erreicht, dass sich die Rohre 3 beim Gießen in Achsrichtung ausdehnen können, jedoch gegen durch die Auftriebskräfte des flüssigen Gussmaterials bedingte Verschiebungen in radialen Richtungen gesichert sind. Die Halteabschnitte 6 sind hier vorteilhaft ringartig ausgebildet. Selbstverständlich sind andere Anzahlen, Ausbildungen und Anorndungen von Halteabschnitten an der Rohrhalterung möglich, z.B. Bereiche, in denen der Halteabschnitt ein Rohr nicht vollständig umgibt.The in the 4 and 5 illustrated pipe holder 5 is formed in this Ausführungsbeisiel as a plate-like element 5a and was made for example of a steel sheet. It has here web-like anchoring sections 7, which in the in Fig. 4 to be recognized core shape 4 anchored backlash, and four holding section 6 for receiving the pipes 3 zuzugießenden. The holding portions 6 are formed such that they - as in Fig. 5 can be seen - locally the outer circumference 8 of the respective tube 3 here completely and with little play (here circumferentially preferably 0.2 mm) surrounded. It is thereby achieved that the tubes 3 can expand during casting in the axial direction, but are secured against movements caused by the buoyancy forces of the liquid casting material in the radial directions. The holding portions 6 are advantageously formed like a ring here. Of course Other numbers, configurations and Anorndungen of holding sections on the pipe support are possible, for example, areas in which the holding portion does not completely surround a pipe.

Mittels der beispielhaft dargestellten Anlagen 10 und der Zentrierstelle 11 wurde die Rohrhalterung 5 positionsgenau in die Kernform 4 eingebracht.By means of the systems 10 and the centering point 11 shown by way of example, the pipe holder 5 has been positioned accurately in the core mold 4.

In dem Ausführungsbeispiel ist das von der Kernform 4 umgebene Rohr 3a eine Kraftstoffleitung. Im Zuge der mechanischen Bearbeitung werden nach dem Gießen und Entsanden des gegossenen Bauteiles 1 die nicht eingegossenen Bereiche der Rohrhaltung 5 entfernt. Hier werden z.B. bei der Bearbeitung der durch die Kernform 4 freigesparten Kraftstoffpumpen-Ausnehmung beim Einbringen der Pumpenbohrung 19 die Verankerungsabschnitte 7 und der Halteabschnitt 6 des zentralen Rohres 3a entfernt und dabei das Rohr 3a durchtrennt. Das eingegossene Rohr 3b bildet z.B. eine Kraftstoffrücklaufleitung. Bei dem eingegossenen Rohr 3c kann es sich um eine Schmiermittelleitung handeln. Das untere Rohr 3d, das hier durch eine mechanisch eingebrachte Bohrung 18 seitlich angeschnitten wurde, kann Schmiermittel leiten und eine Anschlussstelle für die Schmiermittelversorgung zu einem Anbauteil des Kurbelgehäuses 17 bilden.In the embodiment, the pipe 3a surrounded by the core mold 4 is a fuel pipe. In the course of the mechanical processing, the non-cast-in areas of the tube holder 5 are removed after the casting and sanding of the cast component 1. Here, e.g. in the processing of the freed by the core mold 4 fuel pump recess during insertion of the pump bore 19, the anchoring portions 7 and the holding portion 6 of the central tube 3a and thereby removes the tube 3a is severed. The cast-in tube 3b forms e.g. a fuel return line. The cast-in pipe 3c may be a lubricant line. The lower tube 3d, which has been cut laterally here by a mechanically introduced bore 18, can guide lubricant and form a connection point for the lubricant supply to an attachment of the crankcase 17.

Anhand der Figuren 4 und 5 wurde vorstehend exemplarisch das positionsgenaue Eingießen von Versorgungsleitungen als Rohre in ein Kurbelgehäuse beschrieben. Mit der dargestellten oder einer entsprechend abgewandelten Rohrhalterung lassen sich selbstverständlich auch andere mit einem fluiden Medium belegte Versorgungsleitungen in ein Kurbelgehäuse oder in ein anderes gegossenes Bauteil einer Brennkraftmaschine (z.B. Rädergehäuse, Getriebegehäuse, Zylinderkopf etc.) eingießen. In welchen Kernform-Typ oder an welchen Stellen der Außenform die jeweilige Rohrhalterung dabei eingebracht wird, hängt von dem zu gießenden Bauteil und den konstruktiven Gegebenheiten ab. Das erfindungsgemäße Verfahren lässt sich auch auf gegossene Bauteile, insbesondere auf solche mit kerngebildeten Innenkonturen, übertragen, die nicht im Rahmen einer Brennkraftmaschine stehen, z.B. auf gegossene Bauteile, die in der Installationstechnik zum Einsatz kommen.Based on FIGS. 4 and 5 has been described above by way of example the positionally accurate pouring of supply lines as pipes in a crankcase. With the illustrated or a correspondingly modified pipe holder can of course also other occupied with a fluid medium supply lines in a crankcase or in another cast component of an internal combustion engine (eg, gear housing, gear housing, cylinder head, etc.) pour. In which core shape type or at which points of the outer shape the respective pipe holder is introduced, depends on the component to be cast and the structural conditions. The method according to the invention can also be applied to cast components, in particular those with core-formed inner contours, which are not part of an internal combustion engine, for example cast components that are used in installation technology.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
gegossenes Bauteilcast component
22
Zylinderkopfcylinder head
33
Rohrpipe
3a3a
Rohrpipe
3b3b
Rohrpipe
3c3c
Rohrpipe
3d3d
Rohrpipe
44
Kernformcore shape
55
Rohrhalterungpipe support
5a5a
plattenartige Rohrhalterungplate-like pipe holder
66
Halteabschnitt von 5Holding section of 5
77
Verankerungsabschnitt von 5Anchoring section of 5
88th
Außenumfang von 3Outer circumference of 3
99
RohranlagestellePipe plant site
1010
Anlageinvestment
1111
Zentrierstellecentering point
1212
Freisparungcutout
1313
Einspritzdüsen-BohrungInjector bore
1414
Hohlraumcavity
1515
Bohrungdrilling
1616
SollbruchstelleBreaking point
16a16a
Einkerbungnotch
1717
Kurbelgehäusecrankcase
1818
Bohrungdrilling
1919
Pumpenbohrungpump bore
DD
Durchmesserdiameter

Claims (23)

  1. A method for producing a cast component (1) of an internal combustion engine with a cast-in pipe (3) in a casting process with expendable moulds and a permanent pattern or in a casting process with permanent moulds in which a solid core mould (4) is mounted in a split outer mould,
    characterised in
    that a separate pipe holder (5) is integrated in the outer mould or the core mould (4),
    that the pipe (3) is inserted in a retaining section (6) of the pipe holder (5), which is configured in such a manner that it locally surrounds the outer circumference (8) of the pipe (3) at least in part and with little play so that the pipe (3) can expand in the axial direction during casting but is secured against displacements in radial directions caused by buoyancy forces of the liquid casting material and
    that the component (1) is cast by the respective method.
  2. The method according to claim 1,
    characterised in
    that the pipe holder (5) consists of a material which is related to the casting material of the cast component (1).
  3. The method according to claim 1 or 2,
    characterised in
    that a plate-like element (5a) is integrated as a pipe holder (5) in the outer mould or the core mould (4).
  4. The method according to one of the preceding claims,
    characterised in
    that an anchoring section (7) of the pipe holder (5) is incorporated into the outer mould or the core mould (4) directly during manufacture of the outer mould or the core mould (4).
  5. The method according to one of the preceding claims,
    characterised in
    that the pipe holder (5) is positioned positionally accurately in the outer mould or in the core mould (4) with the aid of at least one abutting piece (10) which was provided on the pipe holder (5).
  6. The method according to one of the preceding claims,
    characterised in
    that a clearance (12) has been formed in the pipe holder (5).
  7. The method according to one of the preceding claims,
    characterised in
    that non-cast-in regions of the pipe holder (5) are removed after casting.
  8. The method according to claim 7,
    characterised in
    that a predetermined breaking point (16) is provided on the pipe holder (5) in a predetermined region.
  9. The method according to one of the preceding claims,
    characterised in
    that a plurality of pipes to be cast in (3, 3a, 3b, 3c, 3d) are mounted positionally accurately during casting by means of the same pipe holder (5), for which this has a plurality of retaining sections (6).
  10. The method according to one of the preceding claims,
    characterised in
    that in the course of the mechanical processing of the cast component (1), the cast-in pipe (3) is opened at a predetermined point.
  11. The method according to one of the preceding claims,
    characterised in
    that a cylinder head (1), a crankcase (17) or an attachment part of the crankcase, in particular a gear case, a chain case, an oil pan or the like, is cast and that at least one pipe (3) is cast in as a fuel line, lubricant line or as a supply line for another fluid medium.
  12. The method according to claim 11,
    characterised in
    that pipe holders (5) with respectively one or more retaining section(s) (6) are integrated in core moulds (4) and/or in individual cores which each leave open a recess in the component (1),
    that a pipe (3) or a plurality of pipes (3) is/are inserted in the retaining sections (6),
    that after casting the component (1), non-cast-in regions of the pipe holders (5) are removed and
    that in the course of mechanical treatment of the component (1), the pipe (3) or the pipes (3), if necessary, is/are mechanically opened in the regions of the left-open recesses or in other regions.
  13. A cast component of an internal combustion engine with a cast-in pipe (3), wherein the component (1) is produced in a casting process with expendable moulds and a permanent pattern or in a casting process with permanent moulds in which a solid core mould (4) is mounted in a split outer mould,
    characterised in
    that the cast component (1) comprises a cast-in retaining section (6) of a pipe holder (5) or a part thereof, which is arranged locally on the outer circumference (8) of the cast-in pipe (3), wherein the pipe holder (5) which was integrated in the outer mould or in the core mould (4) during casting of the component (1) has served to mount the pipe (3) in such a manner that it could expand in the axial direction but was secured against displacements in radial directions caused by buoyancy forces of the liquid casting material.
  14. The cast-in component according to claim 13,
    characterised in
    that the cast-in pipe (3) is a fuel line, a lubricant line or a line for another fluid medium.
  15. The cast-in component according to claim 13 or 14,
    characterised in
    that the cast component is a cylinder head (1).
  16. The cast-in component according to claim 13 or 14,
    characterised in
    that the component is a crankcase (17) or an attachment part of the crankcase, in particular a gear case, a chain case, an oil pan or the like.
  17. A casting mould comprising a split outer mould forming the outer contour of the component (1) to be cast, in which a core mould (4) is inserted for shaping the inner contour of the component (1),
    characterised in
    that an anchoring section (7) of a pipe holder (5) is integrated in the outer mould or in the core mould (4) and the pipe holder (5) has a retaining section (6) for receiving and positionally accurate mounting of a pipe (3) to be cast in during casting, wherein the retaining section (6) is configured in such a manner that it locally surrounds the outer circumference (8) of the inserted pipe (3) at least in part and with little play.
  18. The casting mould according to claim 17,
    characterised in
    that the pipe holder (5) consists of a material which is related to the casting material of the cast component (1).
  19. The casting mould according to claim 17 or 18,
    characterised in
    that the pipe holder (5) is a plate-like element (5a).
  20. The casting mould according to one of claims 17 to 19,
    characterised in
    that the pipe holder (5) has at least one abutting piece (10) for accurate positioning of the pipe holder (5) in the core mould (4) or in the outer mould.
  21. The casting mould according to one of claims 17 to 20,
    characterised in
    that the pipe holder (5) has at least one recess (12) on the anchoring section (7).
  22. The casting mould according to one of claims 17 to 21,
    characterised in
    that the pipe holder (5) has a predetermined breaking point (16) in a predetermined region.
  23. The casting mould according to one of claims 17 to 22,
    characterised in
    that the pipe holder (5) has a plurality of retaining sections (6).
EP07785637A 2006-07-23 2007-07-13 Method for producing a cast component with a cast-in pipe Not-in-force EP1919644B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006034341A DE102006034341A1 (en) 2006-07-23 2006-07-23 Method for producing a cast component with a cast-in pipe
PCT/DE2007/001265 WO2008011863A1 (en) 2006-07-23 2007-07-13 Method for producing a cast component with a cast-in pipe

Publications (2)

Publication Number Publication Date
EP1919644A1 EP1919644A1 (en) 2008-05-14
EP1919644B1 true EP1919644B1 (en) 2009-04-08

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP07785637A Not-in-force EP1919644B1 (en) 2006-07-23 2007-07-13 Method for producing a cast component with a cast-in pipe

Country Status (8)

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US (1) US8176967B2 (en)
EP (1) EP1919644B1 (en)
AT (1) ATE427800T1 (en)
BR (1) BRPI0714670B1 (en)
DE (2) DE102006034341A1 (en)
ES (1) ES2323097T3 (en)
MX (1) MX2009000630A (en)
WO (1) WO2008011863A1 (en)

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DE102010030499A1 (en) * 2010-06-24 2011-12-29 Man Diesel & Turbo Se Cylinder head and thus equipped internal combustion engine
US8714232B2 (en) * 2010-09-20 2014-05-06 GM Global Technology Operations LLC Method of making a brake component
GB2492101B (en) * 2011-06-21 2014-12-10 Jaguar Land Rover Ltd Apparatus and method for embedding an element
EP2777843B1 (en) * 2013-03-15 2015-09-30 ZF Friedrichshafen AG Method and device for the method for producing a cast workpiece
US9303595B2 (en) 2013-08-27 2016-04-05 Deere & Company Exhaust gas recirculation cooler mount
FR3051129B1 (en) * 2016-05-12 2018-05-18 Peugeot Citroen Automobiles Sa LOST MODEL STRATE FOR USE IN FOUNDRIES
DE102017206372A1 (en) * 2017-04-13 2018-10-18 Zf Friedrichshafen Ag Metallic cast component for a housing with a cast-in pipe and gap drainage, as well as manufacturing methods and housings, in particular gearbox housings
JP6242533B1 (en) * 2017-08-22 2017-12-06 真辺工業株式会社 Hollow part and manufacturing method thereof
DE102017217387A1 (en) * 2017-09-29 2019-04-04 Zf Friedrichshafen Ag Cast component with cast-in pipe and method of manufacture
DE102020004388A1 (en) 2020-07-22 2022-01-27 Deutz Aktiengesellschaft Cylinder crankcase with foreign body inclusion for cast reduction and for better cleanliness of the component
CN113560536B (en) * 2021-07-30 2023-05-30 共享装备股份有限公司 Casting deformation preventing device

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DE3013745C2 (en) * 1980-04-10 1982-03-25 Zahnradfabrik Friedrichshafen Ag, 7990 Friedrichshafen Cast part with channels, as well as process and casting mold for the production of this cast part
DE3300924A1 (en) * 1983-01-13 1984-07-19 Volkswagenwerk Ag, 3180 Wolfsburg Device for the cooling of cylinder lands
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DE4226207C1 (en) * 1992-08-07 1993-09-30 Siemens Nixdorf Inf Syst Device for holding meandering tubing inside mould during casting - has side plates held together by support keys which lock plates together when turned
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BRPI0714670A2 (en) 2013-03-26
ES2323097T3 (en) 2009-07-06
ATE427800T1 (en) 2009-04-15
EP1919644A1 (en) 2008-05-14
DE502007000583D1 (en) 2009-05-20
US8176967B2 (en) 2012-05-15
DE102006034341A1 (en) 2008-01-31
WO2008011863A1 (en) 2008-01-31
US20090233116A1 (en) 2009-09-17
MX2009000630A (en) 2009-01-28
BRPI0714670B1 (en) 2016-03-08

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