EP2569121A1 - Procédé pour conférer à des pistons de moteurs à combustion interne une géométrie de conception quelconque - Google Patents

Procédé pour conférer à des pistons de moteurs à combustion interne une géométrie de conception quelconque

Info

Publication number
EP2569121A1
EP2569121A1 EP11704548A EP11704548A EP2569121A1 EP 2569121 A1 EP2569121 A1 EP 2569121A1 EP 11704548 A EP11704548 A EP 11704548A EP 11704548 A EP11704548 A EP 11704548A EP 2569121 A1 EP2569121 A1 EP 2569121A1
Authority
EP
European Patent Office
Prior art keywords
piston
working cathode
elysieren
cooling
passage opening
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.)
Ceased
Application number
EP11704548A
Other languages
German (de)
English (en)
Inventor
Michael Albert Janssen
Volker Gniesmer
Karl Dieffenbach
Gerhard Luz
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.)
KS Kolbenschmidt GmbH
Original Assignee
KS Kolbenschmidt GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by KS Kolbenschmidt GmbH filed Critical KS Kolbenschmidt GmbH
Publication of EP2569121A1 publication Critical patent/EP2569121A1/fr
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/10—Supply or regeneration of working media
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/006—Cavity sinking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/14—Making holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/10—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass 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
    • F02F3/00—Pistons 
    • F02F3/0015—Multi-part pistons
    • F02F3/003—Multi-part pistons the parts being connected by casting, brazing, welding or clamping
    • 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
    • F02F3/00—Pistons 
    • F02F3/16—Pistons  having cooling means
    • F02F3/18—Pistons  having cooling means the means being a liquid or solid coolant, e.g. sodium, in a closed chamber in piston
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/49274—Piston ring or piston packing making
    • Y10T29/49275—Piston ring or piston packing making including forging or hammering
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/49274—Piston ring or piston packing making
    • Y10T29/49277—Piston ring or piston packing making including casting or molding

Definitions

  • the invention relates to a method for processing a one-piece or built, liquid-cooled piston of an internal combustion engine, which comprises a piston piston upper part and a piston piston lower part.
  • a method for processing a one-piece or built, liquid-cooled piston of an internal combustion engine which comprises a piston piston upper part and a piston piston lower part.
  • an electrochemical process is used, with which a metallic material can be removed.
  • pistons for internal combustion engines have been used to represent a free-form surface topography known forming methods such as casting and forging.
  • casting this involves complicated tools, in particular casting cores, and draft angles for the forging tool to be considered in the case of forging.
  • These primary molding processes are also subject to the disadvantage of a rough surface structure.
  • the geometries of finished pistons to be produced by mechanical machining of surfaces currently extend to rotationally symmetrical measures such as turning and drilling or plane milling operations. Regardless of the mechanical measures used, these require complex deburring.
  • Electrochemical material removal corresponds to that of an electrolytic cell in which a system of workpiece electrolytic tool forms the electrolytic cell in which the anode goes into solution due to charge exchange processes when using suitable electrolyte solutions.
  • electrolyte solution Between the anode (workpiece) and the cathode (tool) flows through a machining gap, the electrolyte solution, wherein at the cathode hydrogen ions are discharged.
  • the metal ions formed at the anode react with corresponding reactants to form metal hydroxides, which are carried along by the flowing electrolyte and transported away.
  • Elysizing is a reversal of electroplating.
  • the object of the invention is to provide a method by means of which arbitrarily designed topographies can be generated on finished piston components or a finished piston by an electrochemical method, the Elysieren.
  • the solution to the problem consists in an Elysier method, which is applied after the respective completion of the piston upper part or piston lower part or after assembly of these piston components or after completion of the one-piece piston.
  • the method allows a material removal on a finished piston or finished piston component to create any geometrically designed topographies executed as a recess, passage opening, bore, oil pocket, contour or surface in or on the piston. This method advantageously takes place without mechanical damage to the surrounding surfaces of the components produced by a casting or forging process.
  • a further advantage of the method used is the high degree of dimensional stability and surface quality as well as a material removal that is accurate to the final contour.
  • This electrochemical machining which can be implemented with low process times, can be used both for cooling areas and for non-cooling areas of the piston.
  • a particular advantage is that a good reproducibility is achieved in a single operation with high dimensional accuracy and high surface quality, with no tool wear sets.
  • the cold material removal of the Elysiervons also causes no thermal or deformation-induced microstructural influence.
  • neither appreciable machining forces nor bracing forces in the piston occur at the same time completely free of degree of machining.
  • the outstanding properties of the process also known as ECM (Electro Chemical Machining), offer great design freedom, even for complex spatial forms.
  • the method allows a flexible design in the design of measures that are provided for coolant supply and / or coolant to the piston, which can be realized without Gestaltfestmaschinebuchnere that were not or only partially implemented.
  • the method used requires no additional Entgratungsetzwand and the result is a reduction in manufacturing costs.
  • cooling channels, cooling chambers or oil pockets with local extensions for cooling optimization of the piston can be produced, with all transitions being rounded for the first time.
  • Holes, passages or recesses for supplying or discharging coolant can optionally be curved, out-of-round, oval, oblong hole-shaped.
  • the cross section of an opening or bore can change over its longitudinal extent. Through the process used, all edges are rounded and thus the risk of structural strength compared to the mechanical processing is significantly reduced.
  • the thereby achievable surface structure favors the flow of a coolant, so that this processing is advantageously used to create passages, openings or recesses through which a lubricant or cooling medium flows or is discharged.
  • oil drain pockets with free shaping on the groove flanks einbringbar These pockets are characterized in that the transitions on the groove flank and toward the groove bottom are completely rounded. If necessary, the shape of the Zuntenground is included, so that the oil behind the ring can be removed through the bag. Furthermore, the pockets can be designed as a complete breakthrough through the last ring land. Another feature is the oil pockets with free shaping in the bolo area, as well as the oil grooves in the bolt area to ensure optimum lubrication of the bolt.
  • the ECM process also allows the creation of complex, three-dimensional freeform surfaces on the finished piston. As a result, the piston can be adapted with respect to its function to specific requirements, such as optimization of the cooling function, flow optimization of the cooling medium, weight optimization. This is achieved by a less expensive and less restricted process compared to the alternative manufacturing possibilities.
  • inventive use of the electro-chemical removal advantageously allows a great deal of freedom in terms of the orientation, the course and the size of free-form surfaces, recesses or contours.
  • a particular advantage is that there is no restriction on the geometric shape.
  • the method used also allows the creation of trumpet-shaped, not rotationally symmetrical holes.
  • the realizable shaping is determined by the feed direction of the working cathode (electrode), which after completion of the created topography has to be moved in the opposite direction again.
  • this direction of feed can also be irregular or curved, as a result of which contours with undercuts can advantageously be produced by the method used.
  • a piston production which uses the Elysier Kunststoffmaschinen for targeted removal of the material on or in a piston, takes place in the following steps.
  • a forging or casting process is preferably used as the primary molding process.
  • the piston component is cleaned of lubricants and / or coolants used in mechanical processing to remove, for example, adhering chips.
  • the Elysier method is used to finish or finish individual surfaces or to create geometrically shaped recesses, openings or contours.
  • the assembly of the lower piston part and the upper piston part takes place, which are supported via a joining zone and connected in a force-fitting manner by means of a weld material fit or by means of a screw connection.
  • the Elysier Kunststoffe for example, a passage opening between the cooling chamber and a cooling channel after assembly of the piston lower part and the piston upper part, and thus introduce in the finished part.
  • the Elysier process includes the following steps. First, a manual or automated introduction of the piston or the piston component takes place in a device in which the piston is calibrated, aligned to a zero position and fixed.
  • a lowering and aligning of the working cathode is carried out on the piston area to be machined.
  • the further process steps see the creation a voltage or a current and the flushing or flushing of the working cathode with an electrolyte medium, wherein the applied current or the applied voltage can be controlled in time over the course of the process.
  • the working cathode is introduced, for example, along a continuously curved infeed line to the piston or the piston component for the purpose of removal of material, to display the predetermined geometry or topography.
  • a particular advantage of the Elysier method used is that this is used for piston components or the entire piston regardless of the manufacturing process, forging or casting process and the metallic materials used. Consequently, piston components can be machined from the same or different materials or materials in which z. B. aluminum and / or steel form the main alloy element or a piston part made of steel is combined with another piston part made of light metal.
  • the electrochemical process can preferably be used to produce simple or complicated free-form surfaces on piston components. Likewise, it lends itself to use the method to introduce recesses, openings or holes between a cooling chamber and the cooling channel in the piston upper part or in the piston lower part or to increase the size of cold storage or to optimize. Furthermore, recesses or oil pockets can be created by Elysieren in the refrigerator or in the region of the pin bore of the piston base. The Elysieren can also be used for a rework or finishing of already introduced in a piston part openings, holes or contours.
  • a device is suitable in which the piston is fixed and the working cathode is received in a holder and displaceable is guided. Between the anode connected to the workpiece, the piston and the tool, the working cathode (electrode) is provided a gap for the flow of an electrolyte solution.
  • An electrochemical removal of the material takes place after application of an electrical voltage or current between the anode and the insulated, the shaping, for example, to be created recess working cathode.
  • the working cathode is continuously tracked during the removal process.
  • the working cathode is advantageously used in a holder that a controlled, the removal process takes place corresponding adjustment.
  • a spring means causes a spring-assisted displacement of the working cathode.
  • the holder also includes openings for entry and exit for the electrolyte solution.
  • the working cathode are assigned to the anode facing the end non-conductive spacers.
  • a linear drive or a numerically controlled drive can also be used.
  • FIG. 1 shows a first embodiment of a piston in a sectional view with an inventively prepared passage opening in the piston upper part
  • Fig. 3 a third embodiment with respect to FIG. 2 alternatively
  • Fig. 4 a fourth embodiment with an inventively designed Refrigerator
  • Fig. 5 a fifth embodiment with an inventively prepared
  • Fig. 5a In a single part drawing, the working cathode to create the
  • FIG. 5b shows a further view of the working cathode according to FIG. 5a, FIG.
  • FIG. 6 shows a sixth embodiment with a cooling channel according to the invention
  • Fig. 7 a seventh embodiment with two differently executed
  • FIG. 1 shows a sectional view of a piston 1 constructed as a cooling channel piston, comprising a piston upper part 2 and a piston lower part 7.
  • a piston upper part 2 of the piston 1 is closed off by a piston head 3 in which a combustion bowl 4 is centrally inserted.
  • the upper piston part 2 is surrounded by a top land 5 and a subsequent ring field 6.
  • the upper piston part 2 is adjoined by the lower piston part 7, which forms a piston shaft 8, which comprises certain diametrically opposite pin bores 9 for receiving a piston pin not shown in FIG.
  • the components which are preferably produced by a casting method or by a forging process, the piston upper part 2 and the piston lower part 7, are supported via a joining plane 10 and connected in a materially bonded manner, in particular by means of a weld.
  • a radially encircling cooling channel 11 is integrated in the piston upper part 2, which is preferably produced by a detachable casting core, in particular a salt or sand core is.
  • a made of a temperature-resistant sheet metal insert 25 is used for sealing an outer circumferential annular gap 24, which adjusts between the annular field 6 and the piston lower part 7, a made of a temperature-resistant sheet metal insert 25 is used.
  • the piston 1 In the operating state, the piston 1 is acted upon by a coolant, in particular the lubricating oil of the internal combustion engine, via a spray nozzle, not shown in FIG.
  • the coolant is injected to a central cooling chamber 13 of the piston 1 and passes through at least one passage opening 12 in the cooling channel 11.
  • the coolant can be injected directly from the spray nozzle via a not shown inlet opening into the cooling channel 11.
  • the exit of the coolant from the cooling channel 11 via at least one not shown outlet opening.
  • a corresponding shaping and installation position of the cooling channel 11 extends at least partially in matching intervals to the ring field 6 and the combustion bowl 4.
  • the lower piston part 7 is positioned in a device 14, which comprises a holder 15, in which a working cathode 16 is displaceably guided.
  • the outside of the course of the passage opening 12 in accordance arcuately shaped working cathode 16 is adjustable on a with the radius of curvature of the passage opening 12 extending infeed line 17.
  • the device 14 may be equipped with a plurality of correspondingly positioned working cathodes 16.
  • FIGS. 2 to 7 show alternative embodiments of pistons designed according to the invention with differently designed topographies produced by elytra. It is understood that details and areas which have equivalent functions to previously described details and areas, the same reference numerals bear and are not explained again in detail.
  • FIG. 2 shows, in a half section, the piston 1, in which local oil pockets 21 are introduced into the upper piston part 2 after the production process and before assembly with the lower piston part 7 by the Elysiervon.
  • the circumferentially distributed in the cooling channel 11 arranged oil pockets 21 cause enlargement of the cooling channel 11 in the direction of the piston head 3.
  • the piston upper part 2 comprises in the lower groove wall 23 pointing to the piston shaft 8 a plurality of oil drain holes 22 produced by an Elysiervon.
  • the piston 1 according to Figure 3 comprises the cooling channel 1 1, the piston bottom side forms a corrugated running profile 26, which, for example. has different depths between a measure "x" and "y". Furthermore, in the region of the cooling space 13 illustrated as an alternative to FIG. 1, the piston 1 comprises at least one trough-shaped recess 27 separated by a rib 28. To illustrate the profile 26 and the recess 27, which are introduced into the piston upper part 2 prior to assembly, becomes also used an Elysier vide.
  • the piston 1 shows the piston 1 with a conically tapered and arcuate passage opening 29 between the cooling chamber 13 and the cooling channel 1 1 in the region of the piston upper part 2.
  • the lower piston part 7 includes in the direction of the pin bore 9 extending oil pockets 33a, 33b.
  • a through-opening 34 extending from the cooling channel 11 to the cooling space 13 is provided in the piston lower part 7.
  • the delivery line 36 illustrates the delivery of the working cathode 35 for producing the inflow line 34.
  • Figures 5a, 5b show the working cathode 35, which is designed according to the course of the geometric shape of the passage opening 34.
  • the trumpet-shaped working cathode 35 forms a standing oval-shaped cross-sectional profile, which tapers from a largest diameter "x" to a small diameter "y". Accordingly, the enveloping edge curves of the working cathode 35 are related, according to which Ai ⁇ A 2 ⁇ A 3 is designed.
  • FIG. 6 A further application of the Elysiervons to create targeted recesses in the piston 1 is shown in FIG 6. Thereafter, the cooling channel 11 is provided with arcuately extending in the direction of the piston crown 3, mutually offset oil pockets 37 are provided. The working cathode 38 used to create the oil pocket 37 is guided on a correspondingly curved delivery line 39.
  • the piston bottom part 7 of the piston 1 further includes trough-shaped recesses 40 introduced by an Elysiervon, which are separated by a rib 41.
  • FIG. 7 shows openings and bores which, after assembly, are produced by the piston upper part 2 and piston bottom part 7 by an elliptical method on the finished piston 1.
  • an arcuate and conically extending passage opening 43 is provided between a piston interior 42 and the cooling channel 11, on the one hand.
  • the opposite to the passage opening 43 introduced passage opening 44 shows an alternative design.
  • the course of these passage openings 43,44 takes place in consideration of a possible delivery of the working cathodes used, which are characterized by the associated arcuate delivery lines 45, 46.
  • the oil drain holes 22 in the groove wall 23 are introduced by the Elysier vide to the finished piston 1 in the region of the ring field 6. List of reference signs piston

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)

Abstract

L'invention concerne un procédé pour usiner un piston (1) assemblé refroidi par liquide d'un moteur à combustion interne, qui comprend une partie supérieure de piston (2) et une partie inférieure de piston (7), lesquelles sont soutenues par un plan d'assemblage (10) et sont reliées l'une à l'autre par liaison de matière. Pour former une ouverture de passage (12) ou un trou dans le piston (1), un procédé électrochimique est prévu : l'usinage électrochimique. Avec ce procédé, on effectue un enlèvement de matière ciblé après l'achèvement respectif de la partie supérieure de piston (2), de la partie inférieure de piston (7) ou du piston (1) après un assemblage des deux composants de piston. L'usinage électrochimique permet la création d'une topographie conçue de façon quelconque d'un point de vue géométrique, comprenant au moins une ouverture de passage (12), un évidement ou une poche d'huile dans des zones de refroidissement ou des zones de non-refroidissement sur le piston (1).
EP11704548A 2010-05-11 2011-02-12 Procédé pour conférer à des pistons de moteurs à combustion interne une géométrie de conception quelconque Ceased EP2569121A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010020227.4A DE102010020227B4 (de) 2010-05-11 2010-05-11 Verfahren zur Erzeugung einer beliebig gestalteten Geometrie an Kolben von Brennkraftmaschinen und eine Vorrichtung zur Durchführung des Verfahrens
PCT/EP2011/000664 WO2011141071A1 (fr) 2010-05-11 2011-02-12 Procédé pour conférer à des pistons de moteurs à combustion interne une géométrie de conception quelconque

Publications (1)

Publication Number Publication Date
EP2569121A1 true EP2569121A1 (fr) 2013-03-20

Family

ID=43728860

Family Applications (1)

Application Number Title Priority Date Filing Date
EP11704548A Ceased EP2569121A1 (fr) 2010-05-11 2011-02-12 Procédé pour conférer à des pistons de moteurs à combustion interne une géométrie de conception quelconque

Country Status (4)

Country Link
US (2) US20130062218A1 (fr)
EP (1) EP2569121A1 (fr)
DE (1) DE102010020227B4 (fr)
WO (1) WO2011141071A1 (fr)

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See also references of WO2011141071A1 *

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DE102010020227B4 (de) 2023-10-26
DE102010020227A1 (de) 2011-11-17
US20130062218A1 (en) 2013-03-14
US20150224589A1 (en) 2015-08-13
WO2011141071A1 (fr) 2011-11-17

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