EP2340901B9 - Method for making a cast component - Google Patents

Method for making a cast component Download PDF

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Publication number
EP2340901B9
EP2340901B9 EP10194254.8A EP10194254A EP2340901B9 EP 2340901 B9 EP2340901 B9 EP 2340901B9 EP 10194254 A EP10194254 A EP 10194254A EP 2340901 B9 EP2340901 B9 EP 2340901B9
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EP
European Patent Office
Prior art keywords
feeder
casting
core
engine block
mold
Prior art date
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Application number
EP10194254.8A
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German (de)
French (fr)
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EP2340901A1 (en
EP2340901B1 (en
Inventor
Thomas Schwabl
Richard Schächtl
Josef Gibis
Stefan Schmidberger
Thomas Heller
Andreas Fent
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Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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Publication of EP2340901A1 publication Critical patent/EP2340901A1/en
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Publication of EP2340901B9 publication Critical patent/EP2340901B9/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/108—Installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product

Definitions

  • the invention relates to a method for producing a casting, in particular an engine block, comprising the steps of: producing a feeder core, inserting the feeder core into a casting mold and filling the casting mold with a liquid metal.
  • crankcases and engine blocks are manufactured in various casting processes known in the art.
  • Highly stressed crankcases or engine blocks used in engines such as diesel engines or turbocharged supercharged engines are manufactured in low pressure, core packaged, or gravity casting. In these methods, the solidification of the liquid material from the cylinder head side to the crank chamber side or from the crank chamber side of the engine block to the cylinder head side.
  • the US 1,670,725 shows a method and apparatus for casting wheel hubs.
  • the JP 57 103 755 shows a method for producing cast components with a feeder core, in which the outlet opening of the feeder is optimized from the feeder core by suitable geometrical measures.
  • crankcase side bearing block or the combustion chamber web on the cylinder head solidifies faster than the respective other, opposite end of the engine block by the described solidification course.
  • the solidification time is significantly involved in achieving favorable material properties of the engine block.
  • engine blocks or crankcases produced by the method according to the prior art are either cylinder headboards or high-strength storage chairs.
  • Another disadvantage of the known methods is that the solidification of the tool from one end region to another end region leads to high solidification times and thus to long process times. Furthermore, high mold temperatures are required, resulting in a particularly high wear of the tool.
  • the present invention has for its object to provide a method with improved properties, which overcomes the above-mentioned disadvantages of the prior art.
  • a method for producing a casting comprises the steps of: producing a feeder core, inserting the feeder core into a casting mold and filling the casting mold with a liquid metal. Furthermore, the method may include the step of positioning the feeder core inside the mold. Such a positioning of the feeder core causes the feeding to take place from a central area during the production of the casting.
  • the method may include the step of: creating a recess in the casting by positioning the feeder core at a predetermined position inside the casting mold. Due to the positioning of the feeder core in the interior of the casting mold and thus also in the interior of the cast part to be produced, the feeder core cools down last and thus maintains as long as possible a high component temperature. This allows the feeder to be kept in a liquid to semi-liquid or doughy state for a long time, thereby ensuring that the casting is fed with liquid metal during solidification.
  • a predetermined position we enter Area preferred, which is arranged centrally in the longitudinal, transverse and vertical direction of the casting and thus corresponds to a central area.
  • the method may be characterized in that, after complete filling of the casting mold with liquid metal, the casting is cooled substantially simultaneously, opposite outer regions to the inner region.
  • edge regions of the casting which extend from the surface to the component center.
  • the outer regions preferably correspond to an area where a cylinder head is connected, an area where a crankcase is connected to the engine block, or an area where the crankshaft is supported to the engine block.
  • the method may be characterized in that the casting is removable from the mold when a feeder is inside the feeder core after cooling at least in a partially dough-like state.
  • the method may be characterized in that the feeder is arranged in the interior of at least one cylinder of an engine block to be produced, wherein the feeder is connected to a predetermined area on an inner wall of the cylinder.
  • the invention relates to a casting, in particular a motor block with at least one recess, which in the interior of the Casting is arranged and at least one feeder. Furthermore, the feeder can be provided in the interior of the recess.
  • the recess may have an inner wall, wherein the inner wall is connected in at least one predetermined area with the feeder.
  • FIGS. 1 to 3 show a casting 10 according to the invention, which is shown by way of example in the form of a cylinder block.
  • FIG. 1 shows a plan view of a first outer region 12 of the casting 10.
  • This first outer region 12 corresponds to an upper end portion of the cylinder block 10, on which a cylinder head of the engine can be mounted.
  • the upper outer region 12 thus corresponds to the cylinder head web.
  • two recesses 15 are shown by way of example and not by way of limitation. These recesses 15 are cylinders 15 in which the pistons of the engine are later installed. In the casting 10, these recesses 15 may be provided as through openings with a circular, oval or polygonal cross-section. Alternatively, in the casting 10 immediately after removal from a mold, the recesses 15 may be formed as blind holes with round, oval or polygonal cross-sectional shapes. In both the through-hole embodiment and the blind-hole embodiment, the recesses 15 may have a tapered, prismatic, or cylindrical shape from the cylinder head end to a crankshaft end of the engine block.
  • each feeder 13 are shown, which are arranged substantially coaxially in the recesses 15.
  • the feeders 13 are connected to the cylinder block 10 via feed connections 13a.
  • the recesses 15 have an inner wall 15a, which tapers from the cylinder head side to the crankshaft side of the engine block 10 and in this direction has a tapered, circular cross-section.
  • the feeder connections 13a are connected to the inner wall 15a of the recess 15 in a predetermined area 15b.
  • the predetermined area 15b is located in the region of the casting longitudinal axis, which corresponds to the section line AA at the level of two tie rods 17, which are adjacent in the transverse direction of the engine block, as shown FIG. 1 is recognizable.
  • FIG. 2 is a vertical direction of the casting 10 defined by the arrow Z.
  • the above-mentioned predetermined areas of the memory connection 13b are in casting upright Z below water jackets 14, as shown FIG. 2 seen.
  • the feeder connections 13a extend in the engine block longitudinal direction, namely below the deepest region of the water jackets 26.
  • the water jackets form recesses in the engine block, which are used as cooling channels.
  • these predetermined areas may also extend in the transverse direction of the cylinder block, i. in a direction corresponding to the section lines B-B and C-C.
  • the feeder connections 13a extend substantially perpendicular to the longitudinal direction of the engine block 10, between two longitudinally adjacent tie rods 17, and are connected below the water jacket cores 26 to an inner wall 15a of the recess 15. A diagonal orientation of the feeder connections 13a is also conceivable.
  • the tie-rod regions 17 are regions of material accumulation used during the casting process for distributing liquid metal to achieve better filling of the casting mold 20. In these areas, which can thus be used as channels later holes are provided with threads to which the cylinder head of a motor is screwed.
  • the casting mold 20 comprises at least two side parts 21 a and 21 b, a lower part or a base part 22 and a top part 23. These parts are shaping the outer casting contour and are preferably made of steel.
  • a feeder core 24 is provided inside the casting mold 20, as shown FIG. 4 seen.
  • the FIG. 4 represents a sectional view through a mold along the line BB of the casting 10 from FIG. 1 In other words, one would make the mold 20 for the production of the casting 10 from FIG. 1 Cut along the section BB, so you would make the presentation FIG. 4 receive.
  • the same applies to the presentation FIG. 5 with the difference that the FIG.
  • FIG. 5 a sectional view along the interface CC FIG. 1 equivalent.
  • the tool part is cut in a region between two cylinders adjacent to one another in the longitudinal direction of the engine block.
  • the casting mold 20 has feeds 16 in the lower region. These inlets represent sprues 16, via which the liquid metal is introduced into the mold 20 during the casting process.
  • FIG. 6 shows a sectional view along the section line AA FIG. 1 through the casting mold 20.
  • the feeder cores 24 are arranged centrally in an inner region of the engine block, ie in the transverse direction, and are clamped between the upper part 23 and the lower part 22.
  • the feeder cores 24 have passages 25 through which the liquid metal can flow into a cavity 27.
  • the feeders 13 are formed during the casting process and the feed connections 13a are formed in the passages 25.
  • the feeder core 24 is produced. This has a quill shape, with an inner cavity 27 and is preferably formed of sand.
  • the mold 20 is assembled, wherein the side parts 21 a, 21 b, the lower part 22 and the upper part 23 are aligned and fixed in a predetermined arrangement to each other.
  • the feeder cores 24 are attached at predetermined positions in the mold 20.
  • Water jacket cores 26 are produced in parallel and likewise introduced into the casting mold 20.
  • the water jacket cores 26 are, as well as the feeder cores, formed of sand and serve to hold in the later casting 10 openings that are used as cooling channels. These cooling channels are then flushed in the running engine with a fluid, preferably a cooling liquid or a cooling gas to keep the running engine at operating temperature.
  • the casting mold 20 is filled with liquid metal in the subsequent step.
  • the liquid metal enters the interior via the sprues 16, i. in the inner cavities of the mold 20 and is distributed in the mold 20, where it flows through the passages 25 into the cavity 27 of the feeder cores 24 and forms the feeder 13.
  • the cooling takes place.
  • the casting mold 20 is cooled substantially simultaneously from the upper outer region 12 and from the lower outer region 11.
  • the cylinder head land area 12 and the bearing seat area 11 cool rapidly and thus obtain particularly high strength characteristics. Consequently, in the casting 10, a solidification direction or a course of solidification results, which runs from the cylinder head region 12 and the bearing block region 11, or the region at which the crankcase is screwed, to the center of the casting 10.
  • the feeder 13 acts as a thermal heat storage and solidifies as the last portion of the casting.
  • the casting 10 can also be removed more quickly from the casting mold 20. Since the surface or the outer edge regions are already cooled when the casting 10 is removed, the risk of cracking during removal from the mold 20 is reduced. The complete cooling of the casting 10, or the residual cooling of the feeder 13, can then take place in the ambient air.
  • the method according to the invention provides a significantly shorter demolding time and thus a much shorter cycle time compared to the methods known from the prior art.
  • the positioning of the feeders in a central region of the mold further results in the advantage that smaller feeders can be used so that the circulation material is reduced.
  • the loop material is the material that must be removed from the casting immediately after the casting process, such as sprues, feeders, or machining allowances. These are usually melted down and reused. The smaller the feeders, the lower the circulation material in the process chain, which reduces the energy requirement of the process.
  • the feeder core 24 and the water jacket cores 26 are removed and the feeder 13 and the feeder connections 13a are cut away. Even though reference has been made above to a feeder 13 and a feeder core 24, the same applies to embodiments in which a plurality of feeder cores are used.
  • AlSi7, AlSi8, gray cast iron or any other metal is particularly suitable as material for the engine block or crankcase produced according to the invention.
  • the casting process preferably takes place in the down process, wherein for the filling of the mold 20, in particular the furnace filling level, the component height of the casting mold and the relative arrangement of component and furnace are essential factors.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Gussteils, insbesondere eines Motorblocks, mit den Schritten Erzeugen: eines Speiserkerns, Einsetzen des Speiserkerns in eine Gussform und Befüllen der Gussform mit einem Flüssigmetall.The invention relates to a method for producing a casting, in particular an engine block, comprising the steps of: producing a feeder core, inserting the feeder core into a casting mold and filling the casting mold with a liquid metal.

Derzeit werden Kurbelgehäuse und Motorblöcke in verschiedenen Gießverfahren hergestellt, die aus dem Stand der Technik bekannt sind. Hochbeanspruchte Kurbelgehäuse bzw. Motorblöcke, die in Motoren, wie beispielsweise Dieselmotoren oder mittels Turboladern aufgeladenen Motoren Verwendung finden, werden im Niederdruckguss-, im Corepackage- oder im Schwerkraftgussverfahren hergestellt. Bei diesen Verfahren läuft die Erstarrung des flüssigen Materials von der Zylinderkopfseite zur Kurbelraumseite oder von der Kurbelraumseite des Motorblocks zur Zylinderkopfseite.Currently, crankcases and engine blocks are manufactured in various casting processes known in the art. Highly stressed crankcases or engine blocks used in engines such as diesel engines or turbocharged supercharged engines are manufactured in low pressure, core packaged, or gravity casting. In these methods, the solidification of the liquid material from the cylinder head side to the crank chamber side or from the crank chamber side of the engine block to the cylinder head side.

Die US 1,670,725 zeigt ein Verfahren und eine Vorrichtung zum Gießen von Radnaben.The US 1,670,725 shows a method and apparatus for casting wheel hubs.

Aus der EP 0 933 151 ist eine Gießform und ein Verfahren zur Herstellung von Gussstücken bekannt, wobei ein Gießlauf an einer in Schwerkraftrichtung tiefsten Stelle des Formhohlraums durch diesen hindurch in Form eines Kanals und die Öffnung des Gießlaufes an einer in Schwerkraftrichtung tiefsten Stelle des Kanals ausgebildet ist.From the EP 0 933 151 a mold and a method for the production of castings is known, wherein a casting run is formed at a lowest point in the gravitational direction of the mold cavity therethrough in the form of a channel and the opening of the casting run in a gravitational direction deepest point of the channel.

Aus der DE 10 2007 002 208 ist ein Zylinderblockgießteil mit einem Trennwandfenster bekannt, wobei das Trennwandfenster durch ein Einstellkern ausgebildet wird, der in einen Kokillenaufbau oder einem einstückigen Stabkurbelgehäuse eines Formpakets aufgenommen wird.From the DE 10 2007 002 208 a Zylinderblockgießteil with a partition wall window is known, wherein the partition wall window through a Adjusting core is formed, which is received in a mold assembly or a one-piece rod crankcase a mold package.

Die JP 57 103 755 zeigt ein Verfahren zum Herstellen von Gussbauteilen mit einem Speiserkern, bei dem die Austrittsöffnung des Speisers aus dem Speiserkern durch geeignete geometrische Maßnahmen optimiert wird.The JP 57 103 755 shows a method for producing cast components with a feeder core, in which the outlet opening of the feeder is optimized from the feeder core by suitable geometrical measures.

Solche Verfahren weisen jedoch den Nachteil auf, dass durch den beschriebenen Erstarrungsverlauf entweder der kurbelraumseitige Lagerstuhl oder der Brennraumsteg am Zylinderkopf schneller erstarrt als das jeweilige andere, gegenüberliegende Ende des Motorblocks. Die Erstarrungszeit ist maßgeblich beteiligt an der Erzielung günstiger Materialeigenschaften des Motorblocks. Dabei sind besonders gute Materialeigenschaften zur erzielen, je schneller das Werkstück erstarrt. Folglich weisen Motorblöcke bzw. Kurbelgehäuse, die mit dem Verfahren nach dem Stand der Technik hergestellt sind, entweder Zylinderkopfstege oder Lagerstühle mit hohen Festigkeitswerten auf. Ein weiterer Nachteil der bekannten Verfahren liegt darin, dass die Erstarrung des Werkzeuges von einem Endbereich zu einem anderen Endbereich hin zu hohen Erstarrungszeiten und damit zu langen Prozesszeiten führt. Ferner werden auch hohe Werkzeugtemperaturen benötigt, wodurch sich ein besonders hoher Verschleiß des Werkzeuges ergibt.However, such methods have the disadvantage that either the crankcase side bearing block or the combustion chamber web on the cylinder head solidifies faster than the respective other, opposite end of the engine block by the described solidification course. The solidification time is significantly involved in achieving favorable material properties of the engine block. Here are particularly good material properties to achieve, the faster the workpiece solidifies. Consequently, engine blocks or crankcases produced by the method according to the prior art are either cylinder headboards or high-strength storage chairs. Another disadvantage of the known methods is that the solidification of the tool from one end region to another end region leads to high solidification times and thus to long process times. Furthermore, high mold temperatures are required, resulting in a particularly high wear of the tool.

Die vorliegende Erfindung macht es sich zur Aufgabe, ein Verfahren anzugeben, mit verbesserten Eigenschaften, welche die oben genannten Nachteile des Standes der Technik überwindet.The present invention has for its object to provide a method with improved properties, which overcomes the above-mentioned disadvantages of the prior art.

Die Lösung der Aufgabe erfolgt mit den Merkmalen der unabhängigen Ansprüche. Bevorzugte Ausführungsformen und Weiterbildungen der Erfindung sind Gegenstand der Unteransprüche.The object is achieved by the features of the independent claims. Preferred embodiments and further developments of the invention are subject of the dependent claims.

Gemäß der Erfindung umfasst ein Verfahren zur Herstellung eines Gussteils, insbesondere eines Motorblocks, die Schritte: Erzeugen eines Speiserkerns, Einsetzen des Speiserkerns in eine Gussform und Befüllen der Gussform mit einem Flüssigmetall. Weiterhin kann das Verfahren den Schritt umfassen, dass der Speiserkern im Inneren der Gussform positioniert wird. Durch eine solche Positionierung des Speiserkerns erfolgt die Speisung während der Erzeugung des Gussteils aus einem mittleren Bereich heraus.According to the invention, a method for producing a casting, in particular an engine block, comprises the steps of: producing a feeder core, inserting the feeder core into a casting mold and filling the casting mold with a liquid metal. Furthermore, the method may include the step of positioning the feeder core inside the mold. Such a positioning of the feeder core causes the feeding to take place from a central area during the production of the casting.

Darüber hinaus kann das Verfahren den Schritt aufweisen: Erzeugen einer Ausnehmung in dem Gussteil durch die Positionierung des Speiserkerns an einer vorbestimmten Position im Inneren der Gussform. Durch die Positionierung des Speiserkerns im Inneren der Gussform und damit auch im Inneren des zu erzeugenden Gussteils kühlt der Speiserkern als letztes ab und behält somit möglichst lang eine hohe Bauteiltemperatur. Dadurch kann der Speiser lange in einem flüssigen bis semiflüssigen oder teigförmigen Zustand gehalten werden, wodurch sicherstellt wird, dass das Gussteil während der Erstarrung mit Flüssigmetall gespeist wird. Als vorbestimmte Position wir ein Bereich bevorzugt, der in Läng-, Quer- sowie Hochrichtung des Gussteils mittig angeordnet ist und somit einem zentralen Bereich entspricht.In addition, the method may include the step of: creating a recess in the casting by positioning the feeder core at a predetermined position inside the casting mold. Due to the positioning of the feeder core in the interior of the casting mold and thus also in the interior of the cast part to be produced, the feeder core cools down last and thus maintains as long as possible a high component temperature. This allows the feeder to be kept in a liquid to semi-liquid or doughy state for a long time, thereby ensuring that the casting is fed with liquid metal during solidification. As a predetermined position we enter Area preferred, which is arranged centrally in the longitudinal, transverse and vertical direction of the casting and thus corresponds to a central area.

Weiterhin kann das Verfahren dadurch gekennzeichnet sein, dass nach dem vollständigen Befüllen der Gussform mit flüssigem Metall das Gussteil im Wesentlichen zeitgleich, voneinander gegenüberliegenden Außenbereichen zum Innenbereich, abgekühlt wird. Hieraus ergibt sich der Vorteil, dass durch die starke Abkühlung der Außenbereiche diese gute Materialkennwerte, insbesondere hohe Festigkeitskennwerte, erreichen. Außenbereich sind im Sinnen der Erfindung als Randbereiche des Gussteils zu verstehen, die sich von der Oberfläche zum Bauteil Zentrum hin erstrecken. Wenn das Gussteil als ein Motorblock ausgebildet ist, entsprechen die Außenbereiche bevorzugt einem Bereich an dem ein Zylinderkopf angeschlossen wird, einem Bereich an dem ein Kurbelwellengehäuse an den Motorblock angeschlossen wird oder einem Bereich an dem die Kurbelwelle an dem Motorblock gelagert wird.Furthermore, the method may be characterized in that, after complete filling of the casting mold with liquid metal, the casting is cooled substantially simultaneously, opposite outer regions to the inner region. This results in the advantage that due to the strong cooling of the outer areas, these good material properties, in particular high strength characteristics, can be achieved. Outside are to be understood in the sense of the invention as edge regions of the casting, which extend from the surface to the component center. When the casting is formed as an engine block, the outer regions preferably correspond to an area where a cylinder head is connected, an area where a crankcase is connected to the engine block, or an area where the crankshaft is supported to the engine block.

Ferner kann das Verfahren dadurch gekennzeichnet sein, dass das Gussteil aus der Gussform entnehmbar ist, wenn sich ein Speiser im Inneren des Speiserkerns nach dem Abkühlen zumindest in einem teilweise teigförmigen Zustand befindet. Dies bietet den Vorteil, dass die Entformungszeit des Gussteils, d.h. die Zeit ab Gießstart bis zur Entnahme aus der Form reduziert wird und damit die Gesamttaktzeit des Gießprozesses erniedrigt wird.Further, the method may be characterized in that the casting is removable from the mold when a feeder is inside the feeder core after cooling at least in a partially dough-like state. This offers the advantage that the demolding time of the casting, i. the time from casting start is reduced until removal from the mold and thus the total cycle time of the casting process is lowered.

Weiterhin kann das Verfahren dadurch gekennzeichnet sein, dass der Speiser im Inneren mindestens eines Zylinders eines zu erzeugenden Motorblocks angeordnet ist, wobei der Speiser mit einem vorbestimmten Bereich an einer Innenwand des Zylinders verbunden ist.Furthermore, the method may be characterized in that the feeder is arranged in the interior of at least one cylinder of an engine block to be produced, wherein the feeder is connected to a predetermined area on an inner wall of the cylinder.

In einem weiteren Aspekt betrifft die Erfindung ein Gussteil, insbesondere einen Motorblock mit mindestens einer Ausnehmung, die im Inneren des Gussteils angeordnet ist und mindestens einem Speiser. Weiterhin kann der Speiser im Inneren der Ausnehmung vorgesehen sein.In a further aspect, the invention relates to a casting, in particular a motor block with at least one recess, which in the interior of the Casting is arranged and at least one feeder. Furthermore, the feeder can be provided in the interior of the recess.

Darüber hinaus kann die Ausnehmung eine Innenwand aufweisen, wobei die Innenwand in mindestens einem vorbestimmten Bereich mit dem Speiser verbunden ist.In addition, the recess may have an inner wall, wherein the inner wall is connected in at least one predetermined area with the feeder.

Nachfolgend ist ein besonders zu bevorzugendes Ausführungsbeispiel der Erfindung unter Bezugnahme auf Figuren näher erläutert. Dabei zeigen schematisch, beispielhaft und nicht einschränkend:

Figur 1
eine Draufsicht auf ein erfindungsgemäßes Gussteil;
Figur 2
eine Schnittansicht des erfindungsgemäßen Gussteils entlang der Schnittlinie B-B aus Figur 1;
Figur 3
eine Schnittansicht des erfindungsgemäßen Gussteils entlang der Schnittlinie A-A aus Figur 1;
Figur 4
eine Schnittansicht durch eine Gussform, zur Erstellung eines Gussteils nach Figur 1, entlang der Schnittlinie B-B aus Figur 1;
Figur 5
einen Schnitt durch eine Gussform, zur Erstellung eines Gussteils nach Figur 1, entlang der Schnittlinie C-C aus Figur 1; und
Figur 6
eine Schnittansicht durch eine Gussform, zur Herstellung eines Gussteils nach Figur 1, entlang der Schnittlinie A-A aus Figur 1.
Hereinafter, a particularly preferred embodiment of the invention is explained in more detail with reference to figures. Shown schematically, by way of example and not limitation:
FIG. 1
a plan view of a casting according to the invention;
FIG. 2
a sectional view of the casting according to the invention along the section line BB FIG. 1 ;
FIG. 3
a sectional view of the casting according to the invention along the section line AA FIG. 1 ;
FIG. 4
a sectional view through a mold, for creating a casting after FIG. 1 , along the section line BB FIG. 1 ;
FIG. 5
a section through a mold to create a casting after FIG. 1 , along the section line CC off FIG. 1 ; and
FIG. 6
a sectional view through a mold, for producing a casting after FIG. 1 , along the section line AA FIG. 1 ,

Die Figuren 1 bis 3 zeigen ein erfindungsgemäßes Gussteil 10, das beispielhaft in Form eines Zylinderblocks dargestellt ist.The FIGS. 1 to 3 show a casting 10 according to the invention, which is shown by way of example in the form of a cylinder block.

Figur 1 zeigt eine Draufsicht auf einen ersten Außenbereich 12 des Gussteils 10. Dieser erste Außenbereich 12 entspricht einem oberen Endbereich des Zylinderblocks 10, an dem ein Zylinderkopf des Motors montiert werden kann. Der obere Außenbereich 12 entspricht damit dem Zylinderkopfsteg. Mittig befinden sich in dieser Darstellung beispielhaft und nicht einschränkend zwei Ausnehmungen 15. Bei diesen Ausnehmungen 15 handelt es sich um Zylinder 15, in denen später die Kolben des Motors eingebaut werden. In dem Gussteil 10 können diese Ausnehmungen 15 als durchgehende Öffnungen vorgesehen sein mit kreisrundem, ovalen oder mehreckigem Querschnitt. Alternativ dazu können im Gussformteil 10 unmittelbar nach der Entnahme aus einer Gussform die Ausnehmungen 15 als Sacklöcher ausgebildet sein mit runden, ovalen oder mehreckigen Querschnittsformen. Sowohl in der Ausführungsform mit durchgehenden Löchern, wie auch in der Ausführungsform mit Sacklöchern, können die Ausnehmungen 15 ausgehend von dem zylinderkopfseitigen Ende zu einem kurbelwellenseitigen Ende des Motorblocks eine konisch zulaufende, prismische oder zylindrische Form aufweisen. FIG. 1 shows a plan view of a first outer region 12 of the casting 10. This first outer region 12 corresponds to an upper end portion of the cylinder block 10, on which a cylinder head of the engine can be mounted. The upper outer region 12 thus corresponds to the cylinder head web. In the middle of this illustration, two recesses 15 are shown by way of example and not by way of limitation. These recesses 15 are cylinders 15 in which the pistons of the engine are later installed. In the casting 10, these recesses 15 may be provided as through openings with a circular, oval or polygonal cross-section. Alternatively, in the casting 10 immediately after removal from a mold, the recesses 15 may be formed as blind holes with round, oval or polygonal cross-sectional shapes. In both the through-hole embodiment and the blind-hole embodiment, the recesses 15 may have a tapered, prismatic, or cylindrical shape from the cylinder head end to a crankshaft end of the engine block.

In den Ausnehmungen 15 in Figur 1 sind jeweils Speiser 13 dargestellt, die im Wesentlichen koaxial in den Ausnehmungen 15 angeordnet sind. Die Speiser 13 sind über Speiseranbindungen 13a mit dem Zylinderblock 10 verbunden. Die Ausnehmungen 15 weisen eine Innenwand 15a auf, die von der Zylinderkopfseite zu der Kurbelwellenseite des Motorblocks 10 konisch zuläuft und in dieser Richtung einen sich verjüngenden, kreisrunden Querschnitt aufweist. Die Speiseranbindung 13a sind in einem vorbestimmten Bereich 15b mit der Innenwand 15a der Ausnehmung 15 verbunden. Der vorbestimmte Bereich 15b befindet sich dabei im Bereich der Gussteillängsachse, die der Schnittlinie A-A entspricht auf Höhe zweier Zuganker 17, die in Querrichtung des Motorblocks benachbart sind, wie aus Figur 1 erkennbar ist.In the recesses 15 in FIG. 1 each feeder 13 are shown, which are arranged substantially coaxially in the recesses 15. The feeders 13 are connected to the cylinder block 10 via feed connections 13a. The recesses 15 have an inner wall 15a, which tapers from the cylinder head side to the crankshaft side of the engine block 10 and in this direction has a tapered, circular cross-section. The feeder connections 13a are connected to the inner wall 15a of the recess 15 in a predetermined area 15b. The predetermined area 15b is located in the region of the casting longitudinal axis, which corresponds to the section line AA at the level of two tie rods 17, which are adjacent in the transverse direction of the engine block, as shown FIG. 1 is recognizable.

In Figur 2 ist eine Hochrichtung des Gussteils 10 definiert durch den Pfeil Z. Die oben genannten vorbestimmten Bereiche der Speicheranbindung 13b befinden sich in Gussteilhochrichtung Z unterhalb von Wassermänteln 14, wie aus Figur 2 ersichtlich. Mit anderen Worten, die Speiseranbindungen 13a erstrecken sich in Motorblocklängsrichtung und zwar unterhalb des tiefsten Bereichs der Wassermäntel 26. Die Wassermäntel bilden Aussparungen im Motorblock, die als Kühlkanäle genutzt werden.In FIG. 2 is a vertical direction of the casting 10 defined by the arrow Z. The above-mentioned predetermined areas of the memory connection 13b are in casting upright Z below water jackets 14, as shown FIG. 2 seen. In other words, the feeder connections 13a extend in the engine block longitudinal direction, namely below the deepest region of the water jackets 26. The water jackets form recesses in the engine block, which are used as cooling channels.

In einer weiteren, nicht dargestellten Ausführungsform der Erfindung, können diese vorbestimmten Bereiche sich auch in Querrichtung des Zylinderblocks erstrecken, d.h. in einer Richtung, die der Schnittlinien B-B und C-C entspricht. In dieser Ausführungsform verlaufen die Speiseranbindungen 13a im Wesentlichen senkrecht zur Längsrichtung des Motorblocks 10, zwischen zwei in Längsrichtung benachbarten Zugankern 17, und sind unterhalb der Wassermantelkerne 26 mit einer Innenwand 15a der Ausnehmung 15 verbunden. Eine diagonale Ausrichtung der Speiseranbindungen 13a ist ebenfalls denkbar.In a further, not shown embodiment of the invention, these predetermined areas may also extend in the transverse direction of the cylinder block, i. in a direction corresponding to the section lines B-B and C-C. In this embodiment, the feeder connections 13a extend substantially perpendicular to the longitudinal direction of the engine block 10, between two longitudinally adjacent tie rods 17, and are connected below the water jacket cores 26 to an inner wall 15a of the recess 15. A diagonal orientation of the feeder connections 13a is also conceivable.

In beiden Ausführungsformen stellen die Zugankerbereiche 17 Bereiche dar mit Materialanhäufung, die während des Gussprozesses verwendet werden zur Verteilung von Flüssigmetall, um eine bessere Füllung der Gussform 20 zu erreichen. In diesen Bereichen, die somit als Kanäle genützt werden können, werden später Bohrungen mit Gewinden vorgesehen, an die der Zylinderkopf eines Motors geschraubt wird.In both embodiments, the tie-rod regions 17 are regions of material accumulation used during the casting process for distributing liquid metal to achieve better filling of the casting mold 20. In these areas, which can thus be used as channels later holes are provided with threads to which the cylinder head of a motor is screwed.

Im Folgenden soll nun der Aufbau einer Gussform 20 sowie das erfindungsgemäße Gießverfahren anhand der Figuren 4 bis 6 beschrieben werden. Die Gussform 20 umfasst zumindest zwei Seitenteile 21 a bzw. 21 b, ein Unterteil bzw. ein Grundteil 22 und ein Oberteil 23. Diese Teile sind formgebend für die äußere Gussteilkontur und bestehen vorzugsweise aus Stahl. Im Inneren der Gussteilform 20 ist ein Speiserkern 24 vorgesehen, wie aus Figur 4 ersichtlich. Die Figur 4 stellt dabei eine Schnittansicht durch eine Gussform entlang der Linie B-B des Gussteils 10 aus Figur 1 dar. Mit anderen Worten, würde man die Gussform 20 zur Herstellung des Gussteils 10 aus Figur 1 entlang der Schnittlinie B-B schneiden, so würde man die Darstellung aus Figur 4 erhalten. Selbiges gilt für die Darstellung aus Figur 5, mit dem Unterschied, dass die Figur 5 einer Schnittdarstellung entlang der Schnittstelle C-C aus Figur 1 entspricht. In der Schnittansicht aus Figur 5 wird das Werkzeugteil in einem Bereich zwischen zwei, in Längsrichtung des Motorblocks benachbarte Zylindern geschnitten. Wie aus dieser Schnittansicht erkennbar, weist die Gussform 20 im unteren Bereich Zuläufe 16 auf. Diese Zuläufe stellen Angüsse 16 dar, über die das Flüssigmetall während des Gießprozesses ins Innere der Form 20 eingebracht wird.The construction of a casting mold 20 and the casting method according to the invention will now be described with reference to FIG FIGS. 4 to 6 to be discribed. The casting mold 20 comprises at least two side parts 21 a and 21 b, a lower part or a base part 22 and a top part 23. These parts are shaping the outer casting contour and are preferably made of steel. Inside the casting mold 20, a feeder core 24 is provided, as shown FIG. 4 seen. The FIG. 4 represents a sectional view through a mold along the line BB of the casting 10 from FIG. 1 In other words, one would make the mold 20 for the production of the casting 10 from FIG. 1 Cut along the section BB, so you would make the presentation FIG. 4 receive. The same applies to the presentation FIG. 5 , with the difference that the FIG. 5 a sectional view along the interface CC FIG. 1 equivalent. In the sectional view FIG. 5 the tool part is cut in a region between two cylinders adjacent to one another in the longitudinal direction of the engine block. As can be seen from this sectional view, the casting mold 20 has feeds 16 in the lower region. These inlets represent sprues 16, via which the liquid metal is introduced into the mold 20 during the casting process.

Figur 6 zeigt eine Schnittansicht entlang der Schnittlinie A-A aus Figur 1 durch die Gussform 20. Die Speiserkerne 24 sind in einem Innenbereich des Motorblocks, d.h. in Querrichtung mittig angeordnet und zwischen dem Oberteil 23 und dem Unterteil 22 eingespannt. Die Speiserkerne 24 weisen Durchlässe 25 auf, durch die das flüssige Metall in einen Hohlraum 27 fließen kann. In den Hohlräumen 27 bilden sich während dem Gießverfahren die Speiser 13 und in den Durchlässen 25 die Speiseranbindungen 13a aus. FIG. 6 shows a sectional view along the section line AA FIG. 1 through the casting mold 20. The feeder cores 24 are arranged centrally in an inner region of the engine block, ie in the transverse direction, and are clamped between the upper part 23 and the lower part 22. The feeder cores 24 have passages 25 through which the liquid metal can flow into a cavity 27. In the cavities 27, the feeders 13 are formed during the casting process and the feed connections 13a are formed in the passages 25.

Im Folgenden soll der Ablauf des erfindungsgemäßen Verfahrens beispielhaft erläutert werden. In einem ersten Schritt wird zuerst der Speiserkern 24 hergestellt. Dieser weist eine Pinolenform auf, mit einem inneren Hohlraum 27 und ist vorzugsweise aus Sand ausgebildet.In the following, the course of the method according to the invention will be explained by way of example. In a first step, first the feeder core 24 is produced. This has a quill shape, with an inner cavity 27 and is preferably formed of sand.

Anschließend wird die Gussform 20 zusammengesetzt, wobei die Seitenteile 21 a, 21 b, das Unterteil 22 und das Oberteil 23 in einer vorbestimmten Anordnung zueinander ausgerichtet und fixiert werden. Es bilden sich vorbestimmte Hohlräume in der Gussform 20, die die Form des späteren Gussteils 10 vorgeben. Dabei werden die Speiserkerne 24 an vorbestimmten Positionen in der Gussform 20 angebracht. Parallel dazu werden Wassermantelkerne 26 hergestellt und ebenfalls in die Gussform 20 eingebracht. Die Wassermantelkerne 26 sind, wie auch die Speiserkerne, aus Sand ausgebildet und dienen dazu, im späteren Gussteil 10 Öffnungen vorzuhalten, die als Kühlkanäle verwendet werden. Diese Kühlkanäle werden dann im laufenden Motor mit einem Fluid, vorzugsweise einer Kühlflüssigkeit oder auch einem Kühlgas durchspült, um den laufenden Motor auf Betriebstemperatur zu halten.Subsequently, the mold 20 is assembled, wherein the side parts 21 a, 21 b, the lower part 22 and the upper part 23 are aligned and fixed in a predetermined arrangement to each other. There are formed predetermined cavities in the mold 20, which dictate the shape of the subsequent casting 10. At this time, the feeder cores 24 are attached at predetermined positions in the mold 20. Water jacket cores 26 are produced in parallel and likewise introduced into the casting mold 20. The water jacket cores 26 are, as well as the feeder cores, formed of sand and serve to hold in the later casting 10 openings that are used as cooling channels. These cooling channels are then flushed in the running engine with a fluid, preferably a cooling liquid or a cooling gas to keep the running engine at operating temperature.

Nachdem die Gussform 20 vollständig zusammengesetzt ist mit den darin angeordneten Speiserkernen 24 und den Wassermantelkernen 26, wird im darauffolgenden Schritt die Gussform 20 mit Flüssigmetall befüllt. Das Flüssigmetall tritt dabei über die Angüsse 16 in den Innenbereich, d.h. in die inneren Hohlräume der Gussform 20 ein und verteilt sich in der Gussform 20, wobei es über die Durchlässe 25 in den Hohlraum 27 der Speiserkerne 24 fließt und den Speiser 13 ausbildet.After the casting mold 20 is completely assembled with the feeder cores 24 and the water jacket cores 26 arranged therein, the casting mold 20 is filled with liquid metal in the subsequent step. The liquid metal enters the interior via the sprues 16, i. in the inner cavities of the mold 20 and is distributed in the mold 20, where it flows through the passages 25 into the cavity 27 of the feeder cores 24 and forms the feeder 13.

Nachdem das Flüssigmetall sich vollständig in der Gussform 20 verteilt hat, und die Gussform 20 folglich vollständig gefüllt ist erfolgt die Abkühlung. Dabei wird im Wesentlichen zeitgleich vom oberen Außenbereich 12 und von dem unteren Außenbereich 11 die Gussform 20 abgekühlt. Dies hat zur Folge, dass der Zylinderkopfstegbereich 12 und der Lagerstuhlbereich 11 schnell abkühlen und dadurch besonders hohe Festigkeitskennwerte erhalten. Folglich ergibt sich in dem Gussteil 10 eine Erstarrungsrichtung bzw. ein Erstarrungsverlauf, der von dem Zylinderkopfbereich 12 und dem Lagerstuhlbereich 11, bzw. dem Bereich an dem das Kurbelgehäuse verschraubt wird, zur Mitte des Gussteils 10 verläuft. Mit anderen Worten, der Speiser 13 fungiert als thermischer Wärmespeicher und erstarrt als letzter Bereich des Gussteils.After the liquid metal has been completely distributed in the mold 20, and the mold 20 is thus completely filled, the cooling takes place. In this case, the casting mold 20 is cooled substantially simultaneously from the upper outer region 12 and from the lower outer region 11. This has the consequence that the cylinder head land area 12 and the bearing seat area 11 cool rapidly and thus obtain particularly high strength characteristics. Consequently, in the casting 10, a solidification direction or a course of solidification results, which runs from the cylinder head region 12 and the bearing block region 11, or the region at which the crankcase is screwed, to the center of the casting 10. In other words, the feeder 13 acts as a thermal heat storage and solidifies as the last portion of the casting.

Der Speiser 13, der sich in einem zentralen Bereich des Gussteils befindet, bleibt deswegen möglichst lange in einem flüssigen bzw. teigförmigen Zustand. Schrumpfungseffekte, die in den abgekühlten Bereichen des Gussteils entstehen, können dadurch verringert werden, da aus dem noch im Wesentlichen flüssigen Speiser 13 Material in diese Bereiche nachfließen kann. Folglich wird durch dieses Verfahren die Gefahr der Bildung von Lunkern oder Lufteinschlüssen erheblich reduziert. Zudem kann vorteilhafter Weise das Gussteil 10 auch schneller aus der Gussform 20 entfernt werden. Da die Oberfläche bzw. die äußeren Randbereiche bereits abgekühlt sind wenn das Gussteil 10 entnommen wird, wird die Gefahr von Rissbildung beim Entfernen aus der Gussform 20 verringert. Die vollständige Abkühlung des Gussteils 10, bzw. die Restabkühlung des Speisers 13, kann dann an der Umgebungsluft erfolgen. Folglich bietet das Verfahren gemäß der Erfindung eine erheblich kürzere Entformungszeit und damit auch eine wesentlich kürzere Taktzeit, verglichen mit den Verfahren die aus dem Stand der Technik bekannt sind. Aus der Positionierung der Speiser in einem zentralen Bereich der Gussform ergibt sich weiterhin Vorteil das kleinere Speiser verwendet werden können, so dass sich das Kreislaufmaterial reduziert. Das Kreislaufmaterial ist das Material das von dem Gussteil unmittelbar nach dem Gießprozess entfernt werden muss, wie beispielsweise Angüsse, Speiser oder Bearbeitungsaufmaße. Diese werden üblicherweise eingeschmolzen und wiederverwendet. Je kleiner die Speiser, desto geringer ist das Kreislaufmaterial in der Prozesskette wodurch der Energiebedarf des Prozesses reduziert wird.The feeder 13, which is located in a central region of the casting, therefore remains as long as possible in a liquid or dough-shaped state. Shrinkage effects, which arise in the cooled areas of the casting, can be reduced because of the still in the Essentially liquid feeder 13 material can flow into these areas. Consequently, this method significantly reduces the risk of the formation of voids or air pockets. In addition, advantageously, the casting 10 can also be removed more quickly from the casting mold 20. Since the surface or the outer edge regions are already cooled when the casting 10 is removed, the risk of cracking during removal from the mold 20 is reduced. The complete cooling of the casting 10, or the residual cooling of the feeder 13, can then take place in the ambient air. Consequently, the method according to the invention provides a significantly shorter demolding time and thus a much shorter cycle time compared to the methods known from the prior art. The positioning of the feeders in a central region of the mold further results in the advantage that smaller feeders can be used so that the circulation material is reduced. The loop material is the material that must be removed from the casting immediately after the casting process, such as sprues, feeders, or machining allowances. These are usually melted down and reused. The smaller the feeders, the lower the circulation material in the process chain, which reduces the energy requirement of the process.

Nachdem das Gussteil 10 vollständig abgekühlt ist, werden der Speiserkern 24 und die Wassermantelkerne 26 entfernt und der Speiser 13 sowie die Speiseranbindungen 13a abgefräst bzw. herausgesägt. Selbst wenn im Vorgehenden auf einen Speiser 13 bzw. einen Speiserkern 24 Bezug genommen wurde, so gilt gesagtes auch für Ausführungsformen in denen mehrere Speiser bzw. Speiserkerne verwendet werden.After the casting 10 has cooled completely, the feeder core 24 and the water jacket cores 26 are removed and the feeder 13 and the feeder connections 13a are cut away. Even though reference has been made above to a feeder 13 and a feeder core 24, the same applies to embodiments in which a plurality of feeder cores are used.

Als Material für den gemäß der Erfindung erstellten Motorblock oder des Kurbelgehäuses kommt insbesondere AlSi7, AlSi8, Grauguss oder ein sonstiges Metall in Betracht. Der Gießprozess findet dabei vorzugsweise im Niedergussverfahren statt, wobei für die Füllung der Gussform 20, insbesondere der Ofenfüllstand, die Bauteilhöhe der Gussform sowie die relative Anordnung von Bauteil und Ofen wesentliche Faktoren sind.AlSi7, AlSi8, gray cast iron or any other metal is particularly suitable as material for the engine block or crankcase produced according to the invention. The casting process preferably takes place in the down process, wherein for the filling of the mold 20, in particular the furnace filling level, the component height of the casting mold and the relative arrangement of component and furnace are essential factors.

Claims (6)

  1. A method for producing an engine block (10), comprising the steps:
    - producing a feeder core (24),
    - inserting the feeder core (24) into a casting mould (20),
    - filling the casting mould (20) with a liquid metal,
    characterised in that
    - the feeder core (24) is positioned in the interior of the casting mould (20), wherein a feeder (13) is provided in the feeder core (24) and the feeder (13) is arranged inside at least one cylinder (15) of the engine block (10), wherein the feeder (13) is connected to a predetermined region on an inner wall (15a) of the cylinder (10), the feeder core (24) has a sleeve form with an inner cavity (27), wherein
    a feeder connection (13a) to the engine block (10) is provided at the height of the tie rod (17).
  2. A method for producing an engine block (10), comprising the steps:
    - producing a feeder core (24),
    - inserting the feeder core (24) into a casting mould (20),
    - filling the casting mould (20) with a liquid metal,
    characterised in that
    - the feeder core (24) is positioned in the interior of the casting mould (20), wherein a feeder (13) is provided in the feeder core (24) and the feeder (13) is arranged inside at least one cylinder (15) of the engine block (10), wherein the feeder (13) is connected to a predetermined region on an inner wall (15a) of the cylinder (10), the feeder core (24) has a sleeve form with an inner cavity (27), wherein
    the feeder is connected (13b) below water jackets (14).
  3. A method according to claim 1, characterised in that
    the feeder connection (13a) is provided between two adjacent tie rods (17).
  4. A method according to claim 1 or claim 2, characterised in that
    - a recess is produced in the engine block (10), by the positioning of the feeder core (24) in a predetermined position in the interior of the casting mould (20).
  5. A method according to any one of the preceding claims, characterised in that
    - after the casting mould (24) has been completely filled with liquid metal, the engine block (10) is cooled substantially simultaneously from mutually opposite outer regions (11, 12) to the inner region.
  6. A method according to any one of the preceding claims, characterised in that
    - the engine block (10) can be removed from the casting mould when a feeder (13) in the interior of the feeder core (24) is at least in a partly pasty form after cooling.
EP10194254.8A 2009-12-17 2010-12-09 Method for making a cast component Active EP2340901B9 (en)

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EP2340901B1 EP2340901B1 (en) 2017-03-15
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CN103212669A (en) * 2012-01-20 2013-07-24 天津市瑞普天晟汽车零部件制造有限公司 Lost-foam casting model of engine cylinder body and casting method
DE102012101887B4 (en) 2012-03-06 2018-04-19 Ks Huayu Alutech Gmbh Device for producing a cylinder crankcase in V-design
CN103521716B (en) * 2013-10-11 2015-09-23 黄石新兴管业有限公司 The casting method of a kind of high-quality ship use intermediate speed serial diesel engine front end casing
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US1670725A (en) * 1926-05-28 1928-05-22 Wanner Malleable Castings Comp Method and apparatus for forming castings
JPS57103755A (en) * 1980-12-18 1982-06-28 Hitachi Metals Ltd Mold
DE19803866A1 (en) * 1998-01-31 1999-08-05 Volkswagen Ag Casting mold and process for making castings
ES2653521T3 (en) * 2003-07-18 2018-02-07 Man Truck & Bus Ag Casting process for alternative piston combustion engine block
US7438117B2 (en) * 2006-01-19 2008-10-21 Gm Global Technology Operations, Inc. Cylinder block casting bulkhead window formation
DE102008019200A1 (en) * 2008-04-17 2009-10-22 Honsel Ag Method for casting and die casting of cylindrical light metal cylinder housing in a casting mold, comprises mounting a core for forming cylinder hollow area by internal cooled barrel in wall of the mold before filling the light metal melt

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DE102009058730B4 (en) 2021-03-25
PL2340901T3 (en) 2017-09-29
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DE102009058730A1 (en) 2011-06-22
DE102009058730B8 (en) 2021-05-20
HUE034264T2 (en) 2018-02-28

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