EP3015194A1 - Procédé de fabrication d'un bloc de cylindre - Google Patents

Procédé de fabrication d'un bloc de cylindre Download PDF

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Publication number
EP3015194A1
EP3015194A1 EP15191205.2A EP15191205A EP3015194A1 EP 3015194 A1 EP3015194 A1 EP 3015194A1 EP 15191205 A EP15191205 A EP 15191205A EP 3015194 A1 EP3015194 A1 EP 3015194A1
Authority
EP
European Patent Office
Prior art keywords
pressure
pressure pin
cylinder block
molten metal
manufacturing
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.)
Withdrawn
Application number
EP15191205.2A
Other languages
German (de)
English (en)
Inventor
Yusei Kusaka
Syoichi Tsuchiya
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.)
Toyota Motor Corp
Original Assignee
Toyota Motor Corp
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 Toyota Motor Corp filed Critical Toyota Motor Corp
Publication of EP3015194A1 publication Critical patent/EP3015194A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/22Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/2015Means for forcing the molten metal into the die
    • B22D17/2069Exerting after-pressure on the moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00Special casting characterised by the nature of the product
    • B22D25/02Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02FCYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00Casings, e.g. crankcases or frames
    • F02F7/0043Arrangements of mechanical drive elements
    • F02F7/0053Crankshaft bearings fitted in the crankcase

Definitions

  • the present invention relates to a method for manufacturing a cylinder block, and in particular to a method for manufacturing a cylinder block of an engine for a vehicle.
  • Japanese Unexamined Patent Application Publication No. 2012-179629 discloses a technique used in a method for manufacturing a die-cast article (i.e., a cylinder block) including a semicircular support surface on which a crankshaft is rotatably supported, in which a pressure is locally applied to molten metal located at or near the summit of the semicircular support surface by using a pressure pin. A pressure is applied to molten metal located in an area directly ahead of the pressure pin in its longitudinal direction by that pressure pin. As a result, the formation of blowholes in that area can be reduced.
  • an oil flow channel extends from a main gallery toward the semicircular support surface so that a lubricant can be supplied to the crankshaft.
  • this oil flow channel is connected to a bolt hole for attaching a crank cap due to the formation of a blowhole, an oil leak occurs, thus making the die-cast article defective. That is, there has been a problem that the yield of products deteriorates due to the formation of blowholes.
  • the present invention has been made in view of the above-described problem and an object thereof is to reduce the formation of blowholes in a cylinder block better than the related art does and thereby to improve the yield of products.
  • a first exemplary aspect of the present invention is a method for manufacturing a cylinder block including a semicircular bearing section that rotatably supports a crankshaft, the method including:
  • the pressure pin whose tip protrudes in an arc shape so as to conform to the shape of the bearing section, is slid toward the area where the bearing section is formed in the step for applying a pressure to the molten metal. Therefore, the pressure applied to the molten metal is not only applied to the area located directly ahead of the pressure pin in its longitudinal direction but also applied radially from the center of the tip of the pressure pin. As a result, the formation of blowholes can be reduced in the entire area inside the cylinder block, thus leading to an improvement in the yield of products.
  • the tip of the pressure pin is preferably formed in a semicircular shape. This structure can reduce the machining margin of the bearing section.
  • the tip of the pressure pin is preferably formed in an arc shape shorter than a semicircle, and hence, in the pressure-injecting of the molten metal, no recess is formed in the boundary between the metal mold and the pressure pin. This structure can reduce deformations and cracking on the surface of the bearing section caused by microscopic solidification pieces.
  • notches are formed on both edges of the tip of the pressure pin, which are in contact with the metal mold, so that the boundary between the metal mold and the pressure pin becomes flat without any difference in level formed therein in the pressure-injecting of the molten metal.
  • This structure can reduce deformations and cracking on the surface of the bearing section caused by pulled-in solidification shells.
  • Fig. 1 is a schematic bottom view of the cylinder block manufactured by the manufacturing method according to the first exemplary embodiment.
  • Fig. 2 is a cross section taken along a line II-II in Fig. 1 .
  • Fig. 3 is a cross section taken along a line III-III in Fig. 1 .
  • the cylinder block 1 shown in Fig. 1 is a part of an inline four-cylinder engine in which four cylinder bores 11 each having an axis in parallel with the z-axis are arranged in the x-axis direction.
  • the number of cylinders can be changed as desired.
  • the present invention can also be applied to cylinder blocks of V-type engines and horizontally-opposed cylinder engines as well as inline engines.
  • Figs. 1 to 3 the right-handed xyz-coordinate systems shown in Figs. 1 to 3 are shown just for the sake of convenience for explaining the positional relation among components.
  • the cylinder block 1 is typically mounted on a vehicle in such a manner that the positive direction on the z-axis becomes the vertically upward direction. Therefore, the following explanation with reference to Figs. 1 to 3 is given on the assumption that the positive direction on the z-axis is the vertically upward direction.
  • the cylinder block 1 is a die-cast article made of, for example, an aluminum alloy. As shown in Fig. 2 , the cylinder block 1 includes cylinder sections 10 with cylinder bores 11 formed therein, and skirt sections 20. The skirt sections form a part of a crank case that houses a crankshaft (not shown).
  • a cylinder bore 11 which is a cylindrical hole, is formed in each of the cylinder sections 10.
  • the part of the cylinder section 10 that surrounds the cylinder bore 11 is a cylinder wall 12.
  • a piston (not shown), which performs a reciprocating motion inside the cylinder bore 11, is slid in the cylinder bore 11 while remaining in contact with the inner circumferential surface of the cylinder wall 12.
  • a cylinder liner made of, for example, cast iron having an excellent wear resistance or the like is usually disposed on the inner circumferential surface of the cylinder wall 12 in order to reduce the abrasion caused by the sliding motion of the piston.
  • a cylinder head (not shown) is mounted on the top end (end on the positive side on the z-axis) of the cylinder wall 12, i.e., on the so-called "upper deck". Further, the cylinder bore 11, the piston, and the cylinder head form a combustion chamber. A passage (water jacket) 13 through which a coolant is circulated is formed inside the cylinder wall 12, so that the cylinder section 10 can be cooled to an appropriate temperature.
  • the skirt section 20 includes skirt walls 21 that form an outer shell of the crank case, and bulkheads 22 that partition the crank case into each cylinder bore 11.
  • a pair of the skirt walls 21 are formed so that they seamlessly extend from the cylinder wall 12 and spread in the y-axis direction while being opposed to each other.
  • a plurality of pairs of the skirt walls 21 are arranged in the x-axis direction.
  • the bulkheads 22 are disposed in five places, i.e., between each pair of neighboring cylinder bores of the four cylinder bores 11 (three places) and both sides of the four cylinder bores 11 (two places).
  • each of the bulkheads 22 extends in the y-axis direction so as to straddle a pair of the skirt walls 21.
  • a semicircular bearing section 23 for rotatably supporting a journal (not shown) of the crankshaft is formed at the center of the bottom end (end on the negative side on the z-axis) of each bulkhead 22.
  • Bolt holes 24 for attaching a crank cap (not shown) are formed on both sides of the bearing section 23.
  • an oil flow channel 26 extends from a main gallery 25 toward the bearing section 23 inside each bulkhead 22.
  • the main gallery 25 is disposed in one of the two connecting sections between the cylinder section 10 and the skirt section 20. Further, as shown in Fig. 1 , the main gallery 25 extends in the x-axis direction so as to intersect all of the bulkheads 22.
  • the main gallery 25 is formed by using a core pin when the die-cast article is cast.
  • the oil flow channel 26 is formed by machining after the casting process.
  • a through hole 27 is formed near the center of each bulkhead 22.
  • the through hole 27 is formed to connect the spaces partitioned by the bulkhead 22 with each other.
  • the through hole 27 is formed by using a core pin when the die-cast article is cast.
  • the through hole 27 may be formed by machining after the casting process.
  • Fig. 4 is a schematic cross section showing a method for manufacturing a cylinder block according to the first exemplary embodiment.
  • the cylinder block 1 is manufactured by die casting. Specifically, as shown in Fig. 4 , a movable mold (or movable die) 30 is moved in the positive direction on the z-axis and brought into contact with a fixed mold (or fixed die) 40. Then, molten metal is pressure-injected into a cavity 2 formed in a gap between these molds. As indicated by the xyz-coordinate system in Fig. 4 , the cylinder block 1 shown in Fig.
  • the main gallery 25 is formed by using a core pin 50 that can be moved forward and backward in the x-axis direction, and the through hole 27 is formed by using another core pin 60 that can also be moved forward and backward in the x-axis direction.
  • the bottom surface (surface on the negative side on the z-axis) of the bulkhead 22 of the cylinder block 1 is formed by the front surface (surface on the positive side on the z-axis) of the movable mold 30.
  • pins 34 for forming rough holes (i.e., preparatory holes) for the bolt holes 24 are disposed on and protrude from the front surface of the movable mold 30. The pins 34 are fixed to the movable mold 30.
  • a pressure pin 33 that can be slid in the z-axis direction with respect to the movable mold 30 is disposed in the movable mold 30.
  • the pressure pin 33 forms the bearing section 23 of the bulkhead 22 and can apply a pressure to molten metal. It should be noted that in order to form the bearing section 23, the tip of the pressure pin 33 is formed so as to protrude in an arc shape to conform to the shape of the bearing section 23.
  • the pressure pin 33 When molten metal is injected, the pressure pin 33 is positioned in a retreated position as indicated by a chain double-dashed line in Fig. 4 .
  • the pressure pin 33 disposed in the movable mold 30 is slid forward (in the positive direction on the z-axis), i.e., is moved forward as indicated by a solid line in Fig. 4 , and a pressure is thereby applied to the molten metal. By doing so, the formation of blowholes inside the bulkhead 22 can be reduced.
  • the sliding distance of the pressure pin 33 is, for example, in the order of several millimeters.
  • a pressure pin whose tip is flat is slid toward an area where a bearing section is formed.
  • the pressure pin 33 whose tip protrudes in an arc shape to conform to the shape of the bearing section 23, is slid toward the area where the bearing section 23 is formed. Therefore, the pressure applied to the molten metal is not only applied to the area located directly ahead of the pressure pin 33 in its longitudinal direction (i.e., the area located on the positive side on the z-axis) but also applied radially from the center of the tip of the pressure pin 33.
  • the formation of blowholes can be reduced in the entire area inside the bulkhead 22, thus leading to an improvement in the yield of products.
  • the tip of the pressure pin 33 protrudes in an arc shape to conform to the shape of the bearing section 23, the withdrawal resistance of the pressure pin 33.
  • the bearing section 23 can be formed in a near net shape. That is, the maching margin (excess metal) of the bearing section 23 can be reduced, meaning that the productivity of this exemplary embodiment is superior to the relate art.
  • the width of the pressure pin 33 is roughly equal to the diameter of the semicircular bearing section 23. That is, the tip of the pressure pin 33 is formed in a semicircular shape to conform to the shape of the bearing section 23. Therefore, the maching margin is significantly reduced.
  • the pressure pin is moved forward with a sufficient maching margin.
  • the related art requires more time in a subsequent machining process. Therefore, the productivity of the related art is inferior to that of this exemplary embodiment.
  • the width w of the pressure pin 33 according to this exemplary embodiment is larger than that of a pressure pin in the related art. Provided that the amount of the volume change in the pressurization process in this exemplary embodiment is equal to that in the related art, the traveling distance of the pressure pin 33 can be reduced compared to that in the related art. As a result, the withdrawal resistance of the pressure pin 33 can be reduced.
  • FIG. 5 is a schematic cross section showing a method for manufacturing a cylinder block according to a second exemplary embodiment.
  • Fig. 6 is an enlarged view of an area at or near the tip of the pressure pin 33 shown in Fig. 4 .
  • a wedge-shaped recess is formed between the movable mold 30 and the pressure pin 33 before applying a pressure, i.e., in a state where the pressure pin 33 is in a retreated position. Since molten metal that has gotten into this recess solidifies quickly, microscopic solidification pieces are formed as shown in Fig. 6 . Then, when the pressure pin 33 is moved forward in the pressurization process, these microscopic solidification pieces could be pressed onto and buried into the surface of the bearing section 23 of the cylinder block 1, thus causing a possibility that deformations and cracking occur in the surface of the bearing section 23.
  • the width w of a pressure pin 33a is a size smaller than that of the pressure pin 33 according to the first exemplary embodiment.
  • the width of the pressure pin 33a is smaller than the diameter of the semicircular bearing section 23. That is, the tip of the pressure pin 33a is formed so as to have an arc shape shorter than a semicircle.
  • This structure can reduce deformations and cracking on the surface of the bearing section 23 caused by microscopic solidification pieces because no recess is formed in the boundary between the movable mold 30 and the pressure pin 33a before the pressurization process.
  • the width w of the pressure pin 33a is reduced, the maching margin could increase.
  • Other configurations are similar to those in the first exemplary embodiment, and therefore their explanations are omitted.
  • the method for manufacturing a cylinder block according to the second exemplary embodiment can reduce the formation of blowholes in the entire area inside the bulkhead 22, thus leading to an improvement in the yield of products.
  • FIG. 7 is a schematic cross section showing a method for manufacturing a cylinder block according to a third exemplary embodiment.
  • notches 35 are formed on both edges of the tip of a pressure pin 33b according to the third exemplary embodiment. In particular, these notches 35 are formed in areas of the tip that are in contact with the movable mold 30.
  • the boundary between the movable mold 30 and the pressure pin 33b is flat without any difference in level formed therein before the pressurization process. Therefore, solidification shells that are continuously formed over the movable mold 30 and the pressure pin 33b can be easily sheared (i.e., cut) by moving the pressure pin 33b forward. As a result, deformations and cracking on the surface of the bearing section 23 caused by pulled-in solidification shells can be reduced even better than it is in the second exemplary embodiment. However, since the notches 35 are formed, the maching margin could increase.
  • the method for manufacturing a cylinder block according to the third exemplary embodiment can reduce the formation of blowholes in the entire area inside the bulkhead 22, thus leading to an improvement in the yield of products.
  • the second exemplary embodiment since no recess is formed between the movable mold 30 and the pressure pin 33b before the pressurizing process, deformations and cracking on the surface of the bearing section 23 caused by microscopic solidification pieces can be reduced (or prevented).
  • FIG. 8 is a schematic cross section showing a method for manufacturing a cylinder block according to a fourth exemplary embodiment.
  • a pressure pin 33c according to the fourth exemplary embodiment applies a pressure to the whole area where a crank cap is attached, instead of applying a pressure only to the area where the bearing section 23 is formed. Even when this configuration is employed, the formation of blowholes can be reduced (or prevented) in the entire area inside the bulkhead 22 as in the case of the first exemplary embodiment, thus leading to an improvement in the yield of products.
  • Fig. 9 shows macro-photographs of ingots for explaining effects of pressurization for molten metal.
  • Experiment examples 1 and 2 We have conducted the below-shown Experiment examples 1 and 2 to examine the effects of pressurization for molten metal. The experiment methods of Experiment examples 1 and 2 are explained hereinafter.
  • Experiment example 1 corresponds to an example according to the present invention and Experiment example 2 corresponds to a comparative example.
  • test piece was produced by die casting as an imitation of a bulkhead 22 of a cylinder block as shown in Fig. 9 by pressure-injecting molten metal of an aluminum alloy (ADC12) under a pressure of 25 MPa.
  • ADC12 aluminum alloy
  • the distribution state of blowholes in each of the test pieces was examined by observing its macro-structure. Further, the volume rate of the blowholes was obtained by measuring the specific gravity. Note that any of the bolt hole 24, the main gallery 25, and the through hole 27 was not formed in these test pieces.
  • Casting was performed in the following manner: two seconds after molten metal was pressure-injected in a state where the pressure pin 33 was in a retreated position, the pressure pin 33 was moved forward by 4 mm and a pressure of 160 MPa was thereby applied to the molten metal.
  • Casting was performed by pressure-injecting molten metal in a state where the pressure pin 33 was in a retreated position without moving the pressure pin 33.
  • a method of manufacturing a cylinder block including a semicircular bearing section that rotatably supports a crankshaft includes pressure-injecting molten metal into a cavity formed inside a metal mold, and sliding a pressure pin disposed in the metal mold after the pressure-injecting of the molten metal and thereby applying a pressure to the molten metal injected in the cavity, in which in the applying of the pressure to the molten metal, the pressure pin is slid toward an area where the bearing section is formed, a tip of the pressure pin protruding in an arc shape so as to conform to a shape of the bearing section.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
EP15191205.2A 2014-10-28 2015-10-23 Procédé de fabrication d'un bloc de cylindre Withdrawn EP3015194A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2014219541A JP2016083689A (ja) 2014-10-28 2014-10-28 シリンダブロックの製造方法

Publications (1)

Publication Number Publication Date
EP3015194A1 true EP3015194A1 (fr) 2016-05-04

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EP15191205.2A Withdrawn EP3015194A1 (fr) 2014-10-28 2015-10-23 Procédé de fabrication d'un bloc de cylindre

Country Status (5)

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US (1) US20160114386A1 (fr)
EP (1) EP3015194A1 (fr)
JP (1) JP2016083689A (fr)
CN (1) CN105537557A (fr)
BR (1) BR102015026804A2 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3789134A1 (fr) 2019-09-05 2021-03-10 Nemak, S.A.B. de C.V. Écrasement de métal coulé par un mécanisme de calage

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2537674A (en) * 2015-04-23 2016-10-26 Gm Global Tech Operations Llc Lightweight Internal Cobustion Engine With A Ferrous Reinforced Cylinder Block
JP6696893B2 (ja) * 2016-12-22 2020-05-20 トヨタ自動車株式会社 カムシャフト支持部材
JP2022117565A (ja) * 2021-02-01 2022-08-12 トヨタ自動車株式会社 インサートの接合した鋳造品又は鍛造品の製造方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5568164A (en) * 1978-11-17 1980-05-22 Toyota Motor Corp Die-casting method of cylinder block for engine
JPS6316848A (ja) * 1986-07-09 1988-01-23 Honda Motor Co Ltd Al合金製シリンダブロツクの鋳造方法
EP0465947A1 (fr) * 1990-06-28 1992-01-15 Ube Industries, Ltd. Procédé et dispositif de moulage d'un bloc-moteur
JP2012179629A (ja) 2011-03-01 2012-09-20 Ryobi Ltd ダイカスト品の製造方法

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3808167B2 (ja) * 1997-05-01 2006-08-09 Ykk株式会社 金型で加圧鋳造成形された非晶質合金成形品の製造方法及び装置
CN102909337A (zh) * 2012-11-05 2013-02-06 中钢集团洛阳耐火材料研究院有限公司 一种金属铸造装置

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5568164A (en) * 1978-11-17 1980-05-22 Toyota Motor Corp Die-casting method of cylinder block for engine
JPS6316848A (ja) * 1986-07-09 1988-01-23 Honda Motor Co Ltd Al合金製シリンダブロツクの鋳造方法
EP0465947A1 (fr) * 1990-06-28 1992-01-15 Ube Industries, Ltd. Procédé et dispositif de moulage d'un bloc-moteur
JP2012179629A (ja) 2011-03-01 2012-09-20 Ryobi Ltd ダイカスト品の製造方法

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3789134A1 (fr) 2019-09-05 2021-03-10 Nemak, S.A.B. de C.V. Écrasement de métal coulé par un mécanisme de calage
WO2021044331A1 (fr) 2019-09-05 2021-03-11 Nemak. S.A.B. De C.V. Pressage de métal coulé par l'intermédiaire d'un mécanisme à coin

Also Published As

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JP2016083689A (ja) 2016-05-19
BR102015026804A2 (pt) 2016-08-09
CN105537557A (zh) 2016-05-04
US20160114386A1 (en) 2016-04-28

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