EP3099436B1 - Device for producing a cylinder crankcase using the low-pressure or gravity casting method - Google Patents
Device for producing a cylinder crankcase using the low-pressure or gravity casting method Download PDFInfo
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- EP3099436B1 EP3099436B1 EP15701711.2A EP15701711A EP3099436B1 EP 3099436 B1 EP3099436 B1 EP 3099436B1 EP 15701711 A EP15701711 A EP 15701711A EP 3099436 B1 EP3099436 B1 EP 3099436B1
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- casting method
- cylinder
- producing
- low
- cylinder crankcase
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- 238000005266 casting Methods 0.000 title claims description 70
- 238000000034 method Methods 0.000 title claims description 40
- 230000005484 gravity Effects 0.000 title claims description 23
- 229910000831 Steel Inorganic materials 0.000 claims description 4
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- 229910010293 ceramic material Inorganic materials 0.000 claims description 3
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- 238000009413 insulation Methods 0.000 claims description 3
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- 239000012778 molding material Substances 0.000 claims 1
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- 238000001816 cooling Methods 0.000 description 18
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- 238000007711 solidification Methods 0.000 description 12
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- 238000002485 combustion reaction Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000007712 rapid solidification Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
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- 238000003860 storage Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000035508 accumulation Effects 0.000 description 1
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- 230000001174 ascending effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
-
- 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
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- 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
- B22D15/04—Machines or apparatus for chill casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/02—Top casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
Definitions
- the invention relates to a device for producing a cylinder crankcase in the low-pressure or gravity casting with an outer mold with moldings that form a casting mold the outer contour of the cylinder crankcase mold cavity in the assembled state, a metering furnace containing liquid metal and at least one gate, which geodetically below the mold cavity is arranged and via which the metering furnace is fluidically connectable to the mold cavity.
- each gate is connected to a sprue bush, which projects into a cylinder space of the cylinder crankcase forming portion of the mold cavity, is achieved that a directional solidification in the range of massive sections, such as the bearing block and the Screw pipes is achieved, so that in these areas high strength results from low Dendritenarmabnies. At the same time these areas can also be refilled during solidification through the direct connection to the sprue, so that voids are avoided by shrinkage during cooling.
- the sprue bushes are designed as lost sprue bushes, which are expressed after casting from the crankcase side.
- the lost sprue bushings are made of fiber materials, ceramic materials, foundry mold materials or a combination of these materials. This results in a simple and cost-effective production of sprue bushes.
- the sprue bushings have a cylindrical channel from which channels extend at an angle through the side walls delimiting the sprue bushing. Through these channels, the connection takes place a directed filling and feeding of the massive sections of the cylinder crankcase, with high strength values are achieved.
- channels are formed as transverse channels, which extend perpendicular to the cylindrical channel.
- the arrangement of the channels preferably takes place in such a way that the channels are directed in the direction of massive casting areas of the cylinder crankcase, whereby the make-up of these areas is optimized.
- the sprue bushings are arranged on a cylindrical part delimiting the cylinder deck, wherein the side walls thereof at least partially serve as a boundary wall for forming the cylinder space.
- the side walls thereof at least partially serve as a boundary wall for forming the cylinder space.
- the sprue bushes are fastened in a holding mold part extending into the cylinder space, which at least partially serves to form a boundary wall of the cylinder space.
- the placement of the sprue bushes is simplified and done with high precision and good durability.
- cooling molds protrude at least in areas of each cylinder space, which are arranged close to the cylinder deck or on the webs. In this way, a directed rapid solidification of the melt can be additionally achieved in these strength-critical areas and thus a fine structure with high strength can be achieved.
- These cooling molds can be mounted as a cooling iron in the sprue bushes and used with these in the mold.
- the holding moldings are designed as cooling molds that hold the sprue.
- the holding moldings are designed as cooling molds that hold the sprue.
- a further improvement results when the cylinder-top-side molded part is made of steel and can be cooled in chill casting.
- a directed solidification by a short cooling time of the melt can be achieved on the cylinder deck, so that fine structures with high strength are the result.
- the holding mold members each have four axially extending arms which form a circumferentially interrupted cylinder, the arms being uniformly distributed about the circumference.
- the sprue bushing can be fastened easily and reliably.
- this body is easy to manufacture.
- an insulation insert is arranged in the radially inner region of the arms, which has openings corresponding to the interruptions between the arms, over which the filling of the mold takes place.
- the interruptions are diagonal to the screw pipes, which on the one hand good filling and feeding of these areas is ensured and on the other hand, a cooling of the land area between the cylinders is ensured on the holding moldings, so that good strength values are achieved here.
- the casting filter is arranged directly under the gate or in the sprue bush, so that no oxides or other impurities get into the casting.
- the device Components on which the mold or the core package after filling with the molten metal can be rotated by 180 ° and decoupled from the metering furnace.
- the temperature gradient generated by the mold filling supports directional solidification.
- the apparatus shown has an outer mold 10 consisting of a plurality of molded parts made of steel or foundry mold materials, which has a lower part 12, two side parts 14, 16 and an upper part 18, in their interior after the molding or closing of the molded parts 12, 14, 16, 18 a mold cavity 20 is formed, which is an outer contour of a cylinder crankcase 22, the cylinder chambers 24 have geodetically facing down, while the bearing block 25 facing upward.
- an outer mold 10 consisting of a plurality of molded parts made of steel or foundry mold materials, which has a lower part 12, two side parts 14, 16 and an upper part 18, in their interior after the molding or closing of the molded parts 12, 14, 16, 18 a mold cavity 20 is formed, which is an outer contour of a cylinder crankcase 22, the cylinder chambers 24 have geodetically facing down, while the bearing block 25 facing upward.
- the lower mold part 12 has a filling system 26, via which the mold cavity 20 is connected to a metering furnace 28, which is arranged below the mold 10. It is a low-pressure casting machine, so that the promotion of the molten aluminum alloy from the metering furnace 28 into the mold cavity 20 by generating a pressure difference, which causes the melt is lifted from the bottom to the top.
- the filling system 26 extends from the metering furnace 28 to a plurality of gates 30, wherein a gate 30 is formed per cylinder, which is arranged in each case centrally below each cylinder chamber 24 of the cylinder crankcase 22.
- a casting filter 32 is arranged so that there is a 90 ° deflection of the melt stream during the mold filling in front of the casting filters 32 or in the casting filter.
- Each gate 30 is connected to a sprue bushing 34, which in the embodiment according to the FIG. 1 has a cylindrical shape and thus substantially the cylinder chamber 24 or boundary walls 35 of the cylinder maps.
- These sprue bushes 34 are made of a ceramic material, fiber material or a foundry material such as foundry sand or salt or a combination of these substances and aligned and fixed on the lower part 12 accordingly.
- a cylindrical channel 36 In its interior, a cylindrical channel 36 extending along the cylinder center axis is formed. From the channel 36 extend in the present embodiment, four transverse channels 38 through the side walls 40 of the sprue bushings 34, which open into the mold cavity 20. These transverse channels 38 are distributed over the circumference according to the mass accumulations on the component and extend in the direction of screw pipes 42 of the cylinder crankcase 22, that is aligned obliquely offset from the non-visible cylinder webs of the cylinder crankcase 22. The transverse channels 38 open above cores 46 to produce a coolant jacket of the cylinder crankcase 22 in the mold cavity 20.
- melt is lifted from the metering furnace 28 by the generation of pressure via the gate 30 in the sprue bushing 34, this melt flows through the transverse channels 38 in the mold cavity 20 and fills first the region of the downwardly facing cylinder deck 52, at which thus rapid solidification is achieved because no material in flows in this area.
- the further filling is now increasing from bottom to top.
- the main bearings 50 as the highest-lying parts are filled last, so that when these areas of the cylinder crankcase 22, the melt is already in the eutectic temperature and thus rapidly solidifies, whereby fine structure can be achieved with small Dendritenarmabnote, resulting in high strengths.
- the entire solidification direction is thus from outside to inside.
- FIGS. 2 and 3 An additional improvement of this casting result can with an embodiment according to the FIGS. 2 and 3 be achieved, wherein the same reference numerals are used below for the same components.
- This embodiment differs from the above-described in that the lower part 12 of the casting mold 10 is made of steel and can be cooled, that is, for example, 12 cooling channels are arranged in the interior of the lower part.
- These consist of four evenly distributed over the circumference arms 56, which serve as a chill 58, record the sprue bush 34 radially and determine the height and width of the boundary wall 35 of the cylinder during casting as in FIG. 3 can be seen.
- the arms 56 respectively form a cylinder with circumferentially distributed interruptions 60.
- the breaks 60 are equally distributed around the circumference as the transverse channels 38 of the sprue bushing 34.
- an insulating insert 62 again with corresponding recesses to allow the Filling and feeding, through which a heat transfer is reduced between acting asmékokillen 58 arms 56 and the sprue bushing 34.
- the filling of the mold cavity 20 is now carried out in the same manner as described in the first embodiment.
- even finer microstructures on the cylinder deck 52 and in the region of the cylinder webs are achieved, since these areas are cooled directly and thus the solidification times are shortened.
- an additional active cooling can be carried out, which leads to reduced Dendritenarmabracen and increased strength on the bearing block 25 in comparison to the already achievable by the directed filling structures.
- a Sandgussformbyte is used as a mold 10.
- a cooling mold 64 which is held by a cover core 66 as an additional molding.
- the lower part 12 is formed as a bottom core, in which a casting run 68 of the filling system 26 and the leading to the sprue bushings 34 gates 30 are formed.
- cooling molds 58 are formed in the region of the cylinder deck 52.
- transverse runs 70 extending from the casting run 68, which lead to auxiliary gates 72, via which lateral cylinder walls can be additionally filled.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Description
Die Erfindung betrifft eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses im Niederdruck- oder Schwerkraftgießverfahren mit einer äußeren Gießform mit Formteilen, die im zusammengesetzten Zustand einen die Außenkontur des Zylinderkurbelgehäuses gießtechnisch abbildenden Formhohlraum bilden, einem Dosierofen, der flüssiges Metall beinhaltet und zumindest einem Anschnitt, welcher geodätisch unterhalb des Formhohlraums angeordnet ist und über den der Dosierofen mit dem Formhohlraum fluidisch verbindbar ist.The invention relates to a device for producing a cylinder crankcase in the low-pressure or gravity casting with an outer mold with moldings that form a casting mold the outer contour of the cylinder crankcase mold cavity in the assembled state, a metering furnace containing liquid metal and at least one gate, which geodetically below the mold cavity is arranged and via which the metering furnace is fluidically connectable to the mold cavity.
Verbrennungsmotoren mit V-förmig oder reihenförmig zueinander angeordneten Zylinderbänken aus Leichtmetalllegierungen werden häufig mittels Niederdruck-Kokillengussverfahren oder im Schwerkraftgussverfahren hergestellt. Üblicherweise erfolgt die Füllung bei stehendem Kurbelgehäuse mit oben liegenden Zylinder und unten angeordnetem Lagerstuhl. Zusätzlich ist es bekannt, die Zylinderkurbelgehäuse beim Gießen liegend anzuordnen und die Anschnitte seitlich anzuordnen, um Lagerstühle und Zylinderwände zur Verbesserung des Gefüges kühlen zu können, wie dies beispielsweise in der
Beim Gießen im stehenden Zustand erfolgt die Erstarrung der Schmelze entweder von der Zylinderkopfseite zum Kurbelraum oder umgekehrt, je nachdem von wo aus die Schmelze in den Hohlraum der Gießform eingeführt wird. Dabei erstarrt entweder das Zylinderdeck oder die Lagerstühle langsamer als der jeweils andere Bereich, was zu einem gröberen Gefüge mit verringerten Festigkeiten in den langsamer erstarrenden Bereichen führt. Des Weiteren ergeben sich relativ lange Erstarrungswege aufgrund der Anordnung der Anschnitte und daraus hohe notwendige Werkzeugtemperaturen, um eine korrekte Füllung der Form ohne Lunkerbildung sicherzustellen. Bei der Auslegung ergibt sich auch die Schwierigkeit, nicht den Speisungsweg durch die innenliegenden Kerne beim Gießen vollständig abzuschnüren, deren Anzahl und Komplexität in modernen Verbrennungsmotoren zunehmen.When casting in the stationary state, the solidification of the melt takes place either from the cylinder head side to the crank chamber or vice versa, depending on where the melt is introduced into the cavity of the mold. This solidifies either the cylinder deck or the Storage chairs slower than the other area, resulting in a coarser structure with reduced strength in the slower solidifying areas. Furthermore, there are relatively long solidification paths due to the arrangement of the gates and hence high necessary tool temperatures to ensure a correct filling of the mold without voids formation. In the design, there is also the difficulty not completely cut off the feed path through the inner cores during casting, the number and complexity of which increase in modern internal combustion engines.
Um eine möglichst gute Lagerstuhlfestigkeit durch kurze Erstarrungszeiten gewährleisten zu können, wurde daher vorgeschlagen, dass Zylinderkurbelgehäuse bei Verwendung des Niederdruckverfahrens von unten zu füllen, wobei das Zylinderdeck unten angeordnet ist und der Lagerstuhl im oberen Bereich. So wird in der
Des Weiteren ist aus der
Entsprechend besteht das Problem, dass kein Verfahren bekannt ist, bei dem sowohl kleine Dedritenarmabstände im Bereich des Lagerstuhls und der Zylinderlaufflächen an den Stegbereichen als auch eine hohe Festigkeit durch Vermeidung von Lunkern im Bereich der Schraubenpfeifen erreicht werden kann.Accordingly, there is the problem that no method is known in which both small Dedritenarmabstände in the area of the bearing block and the cylinder surfaces at the web areas as well as high strength can be achieved by avoiding voids in the screw pipes.
Es stellt sich daher die Aufgabe, eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses im Niederdruck- oder Schwerkraftgießverfahren zu schaffen, mit der optimale Gefügeeigenschaften im Lagerstuhlbereich und im Bereich der Zylinderstege als auch im Bereich der Schraubenpfeifen und des Zylinderecks erreichbar sind.It is therefore the object to provide an apparatus for producing a cylinder crankcase in the low-pressure or gravity casting, can be achieved with the optimal structural properties in the bearing block area and in the area of the cylinder webs and in the field of screw pipes and the cylinder corner.
Diese Aufgabe wird durch eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses im Niederdruck- oder Schwerkraftgießverfahren mit den Merkmalen des Hauptanspruchs gelöst.This object is achieved by a device for producing a cylinder crankcase in the low-pressure or gravity casting with the features of the main claim.
Dadurch, dass jeder Anschnitt mit einer Angussbuchse verbunden ist, die in einen Zylinderraum des Zylinderkurbelgehäuses bildenden Bereich des Formhohlraums ragt, wird erreicht, dass eine gerichtete Erstarrung im Bereich massereicher Abschnitte, wie dem Lagerstuhl und den Schraubenpfeifen erreicht wird, so dass in diesen Bereichen hohe Festigkeitswerte durch geringe Dendritenarmabstände entsteht. Gleichzeitig können diese Bereiche bei der Erstarrung durch die direkte Anbindung zum Angussrohr über dieses auch nachgespeist werden, wodurch Lunker durch Schrumpfung beim Abkühlen vermeiden werden.The fact that each gate is connected to a sprue bush, which projects into a cylinder space of the cylinder crankcase forming portion of the mold cavity, is achieved that a directional solidification in the range of massive sections, such as the bearing block and the Screw pipes is achieved, so that in these areas high strength results from low Dendritenarmabstände. At the same time these areas can also be refilled during solidification through the direct connection to the sprue, so that voids are avoided by shrinkage during cooling.
Vorteilhafterweise sind die Angussbuchsen als verlorene Angussbuchsen ausgeführt, welche nach dem Gießen von der Kurbelraumseite ausgedrückt werden. Dabei werden die verlorenen Angussbuchsen aus Fasermaterialien, keramischen Werkstoffen, Gießereiformstoffen oder aus einer Kombination dieser Werkstoffe hergestellt. Es ergibt sich eine einfache und kostengünstige Herstellung der Angussbuchsen.Advantageously, the sprue bushes are designed as lost sprue bushes, which are expressed after casting from the crankcase side. The lost sprue bushings are made of fiber materials, ceramic materials, foundry mold materials or a combination of these materials. This results in a simple and cost-effective production of sprue bushes.
In einer besonders vorteilhaften Ausbildung der Erfindung weisen die Angussbuchsen einen zylindrischen Kanal auf, von dem aus sich Kanäle unter einem Winkel durch die die Angussbuchse begrenzenden Seitenwände erstrecken. Über diese Kanäle erfolgt die Anbindung erfolgt eine gerichtete Füllung und Speisung der massereichen Abschnitte des Zylinderkurbelgehäuses, wobei hohe Festigkeitswerte erzielt werden.In a particularly advantageous embodiment of the invention, the sprue bushings have a cylindrical channel from which channels extend at an angle through the side walls delimiting the sprue bushing. Through these channels, the connection takes place a directed filling and feeding of the massive sections of the cylinder crankcase, with high strength values are achieved.
Eine besonders einfache Herstellung ergibt sich, wenn die Kanäle als Querkanäle ausgebildet sind, die sich senkrecht zum zylindrischen Kanal erstrecken.A particularly simple production results when the channels are formed as transverse channels, which extend perpendicular to the cylindrical channel.
Dabei erfolgt die Anordnung der Kanäle vorzugsweise derart, dass die Kanäle in Richtung massereicher Gussbereiche des Zylinderkurbelgehäuses gerichtet sind, wodurch die Nachspeisung dieser Bereiche optimiert wird.In this case, the arrangement of the channels preferably takes place in such a way that the channels are directed in the direction of massive casting areas of the cylinder crankcase, whereby the make-up of these areas is optimized.
In einer spezifischen vorteilhaften Ausgestaltung weisen die Kanäle in Richtung von Schraubenpfeifen und/oder Hauptölkanälen und/oder den Verbindungsabschnitten zwischen den Hauptlagerstellen und den Zylinderräumen des Zylinderkurbelgehäuses, so dass in diesen Bereichen eine gerichtete Füllung und Nachspeisung entsteht und ein Zylinderkurbelgehäuse mit geringen Dendritenarmabständen hergestellt wird.In a specific advantageous embodiment, the channels in the direction of screw pipes and / or main oil channels and / or the Connecting portions between the main bearings and the cylinder chambers of the cylinder crankcase, so that in these areas a directional filling and make-up arises and a cylinder crankcase is made with low Dendritenarmabständen.
Vorzugsweise sind die Angussbuchsen auf einem das Zylinderdeck begrenzenden Formteil angeordnet, wobei deren Seitenwände zumindest teilweise als Begrenzungswand zur Bildung des Zylinderraums dienen. So kann aufgrund der Gießlage eine einfache exakte Platzierung der Angussbuchsen erfolgen.Preferably, the sprue bushings are arranged on a cylindrical part delimiting the cylinder deck, wherein the side walls thereof at least partially serve as a boundary wall for forming the cylinder space. Thus, due to the casting position, a simple exact placement of the sprue bushes can be done.
Alternativ sind die Angussbuchsen in einem sich in den Zylinderraum erstreckenden Halteformteil befestigt, welches zumindest teilweise zur Bildung einer Begrenzungswand des Zylinderraums dient. Die Platzierung der Angussbuchsen wird so vereinfacht und erfolgt mit hoher Präzision und guter Haltbarkeit.Alternatively, the sprue bushes are fastened in a holding mold part extending into the cylinder space, which at least partially serves to form a boundary wall of the cylinder space. The placement of the sprue bushes is simplified and done with high precision and good durability.
Dabei ist es besonders vorteilhaft, wenn Kühlkokillen zumindest in Bereiche jedes Zylinderraums ragen, die nahe am Zylinderdeck oder an den Stegen angeordnet sind. Auf diese Weise kann zusätzlich in diesen festigkeitskritischen Bereichen eine gerichtete schnelle Erstarrung der Schmelze erreicht werden und somit ein feines Gefüge mit hoher Festigkeit erzielt werden. Diese Kühlkokillen können als Kühleisen auch in den Angussbuchsen befestigt sein und mit diesen in die Form eingesetzt werden.It is particularly advantageous if cooling molds protrude at least in areas of each cylinder space, which are arranged close to the cylinder deck or on the webs. In this way, a directed rapid solidification of the melt can be additionally achieved in these strength-critical areas and thus a fine structure with high strength can be achieved. These cooling molds can be mounted as a cooling iron in the sprue bushes and used with these in the mold.
In einer alternativen Ausbildung sind die Halteformteile als Kühlkokillen ausgebildet, die das Angussrohr halten. Durch diese Ausführung wird eine besonders einfache Anbindung des Angussrohres erreicht.In an alternative embodiment, the holding moldings are designed as cooling molds that hold the sprue. Through this design, a particularly simple connection of the sprue is achieved.
Eine weitere Verbesserung ergibt sich, wenn das zylinderdeckseitige Formteil aus Stahl ist und im Kokillenguss kühlbar ist. So kann auch am Zylinderdeck eine gerichtete Erstarrung durch eine kurze Abkühlzeit der Schmelze erreicht werden, so dass feine Strukturen mit hoher Festigkeit die Folge sind.A further improvement results when the cylinder-top-side molded part is made of steel and can be cooled in chill casting. Thus, a directed solidification by a short cooling time of the melt can be achieved on the cylinder deck, so that fine structures with high strength are the result.
In einer bevorzugten Ausführungsform weisen die Halteformteile jeweils vier sich axial erstreckende Arme auf, die einen über den Umfang unterbrochenen Zylinder bilden, wobei die Arme gleichmäßig über den Umfang verteilt sind. In einem derart ausgebildeten Halteformteil kann die Angussbuchse einfach und zuverlässig befestigt werden. Zusätzlich ist dieser Körper einfach herzustellen.In a preferred embodiment, the holding mold members each have four axially extending arms which form a circumferentially interrupted cylinder, the arms being uniformly distributed about the circumference. In a holding mold part designed in this way, the sprue bushing can be fastened easily and reliably. In addition, this body is easy to manufacture.
Damit eine einfache Entformung der Angussbuchse erfolgen kann und eine gute Kühlung über die Arme erfolgen kann, ist im radial innen liegenden Bereich der Arme ein Isolationseinsatz angeordnet, der zu den Unterbrechungen zwischen den Armen korrespondierende Öffnungen aufweist, über die die Füllung der Form erfolgt.So that a simple demolding of the sprue bushing can take place and good cooling can take place via the arms, an insulation insert is arranged in the radially inner region of the arms, which has openings corresponding to the interruptions between the arms, over which the filling of the mold takes place.
Vorzugsweise weisen die Unterbrechungen diagonal zu den Schraubenpfeifen, wodurch einerseits eine gute Füllung und Speisung dieser Bereiche sichergestellt wird und andererseits über die Haltformteile eine Kühlung des Stegbereiches zwischen den Zylindern sichergestellt wird, so dass hier gute Festigkeitswerte erzielt werden.Preferably, the interruptions are diagonal to the screw pipes, which on the one hand good filling and feeding of these areas is ensured and on the other hand, a cooling of the land area between the cylinders is ensured on the holding moldings, so that good strength values are achieved here.
Vorteilhaft ist es, wenn der Gießfilter unmittelbar unter dem Anschnitt oder in der Angussbuchse angeordnet ist, so dass keine Oxide oder sonstige Verunreinigungen in das Gussteil gelangen.It is advantageous if the casting filter is arranged directly under the gate or in the sprue bush, so that no oxides or other impurities get into the casting.
Zur nochmaligen Verbesserung der Formfüllung und Speisung beim Kernpaket- und Kokillengießverfahren weist die Vorrichtung vorzugsweise Bauteile auf, mit welcher die Gießform beziehungsweise das Kernpaket nach dem Befüllen mit der Metallschmelze um 180° drehbar und von dem Dosierofen abkoppelbar ist. Der durch die Formfüllung erzeugte Temperaturgradient unterstützt die gerichtete Erstarrung.For further improvement of the mold filling and feeding in Kernpaket- and Kokillengießverfahren preferably, the device Components on which the mold or the core package after filling with the molten metal can be rotated by 180 ° and decoupled from the metering furnace. The temperature gradient generated by the mold filling supports directional solidification.
Es wird somit eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses für Verbrennungsmotoren geschaffen, mit der eine gerichtete Erstarrung zum Erhalt optimaler Gefügestrukturen und somit Festigkeiten in den festigkeitskritischen Bereichen, also im Bereich des Lagerstuhls, der Schraubenpfeifen sowie der Stegbereiche der Zylinder sichergestellt wird. Die Abkühlung kann fast vollständig von außen nach innen beziehungsweise von außen in Richtung der Angüsse erfolgen, wobei hierdurch die Erstarrungszeiten minimiert werden. Gleichzeitig werden Gefügefehler im Innenbereich durch die Speiserfunktion der Angussbuchse vermieden.It is thus an apparatus for producing a cylinder crankcase for internal combustion engines created with the directional solidification to maintain optimum microstructures and thus strength in the strength-critical areas, ie in the area of the bearing block, the screw pipes and the web portions of the cylinder is ensured. The cooling can be almost completely from outside to inside or from outside in the direction of the sprues, whereby the solidification times are minimized. At the same time structural defects in the interior are avoided by the feed function of the sprue bush.
Drei Ausführungsbeispiele erfindungsgemäßer Vorrichtungen zur Herstellung eines Zylinderkurbelgehäuses in Reihenbauweise sind schematisch in den Figuren dargestellt und werden nachfolgend beschrieben.
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Figur 1 zeigt eine Seitenansicht eines Ausschnitts einer ersten erfindungsgemäßen Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses in geschnittener Darstellung. -
Figur 2 zeigt eine Seitenansicht eines Ausschnitts einer alternativen erfindungsgemäßen Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses in geschnittener Darstellung. -
Figur 3 zeigt eine Draufsicht entlang der Schnittlinie inFigur 2 auf die Angussbuchse und das Halteformteil. -
Figur 4 zeigt eine Seitenansicht eines Ausschnitts einer dritten erfindungsgemäßen Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses in geschnittener Darstellung.
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FIG. 1 shows a side view of a section of a first device according to the invention for producing a cylinder crankcase in a sectional view. -
FIG. 2 shows a side view of a section of an alternative device according to the invention for producing a cylinder crankcase in a sectional view. -
FIG. 3 shows a plan view along the section line inFIG. 2 on the sprue bushing and the holding mold part. -
FIG. 4 shows a side view of a section of a third device according to the invention for producing a cylinder crankcase in a sectional view.
Die in
Das untere Formteil 12 weist ein Füllsystem 26 auf, über die der Formhohlraum 20 mit einem Dosierofen 28 verbunden ist, der unterhalb der Gießform 10 angeordnet ist. Es handelt sich um eine Niederdruckgießanlage, so dass die Förderung der geschmolzenen Aluminium-Legierung aus dem Dosierofen 28 in den Formhohlraum 20 durch Erzeugen einer Druckdifferenz erfolgt, die dazu führt, dass die Schmelze von unten nach oben gehoben wird.The
Das Füllsystem 26 erstreckt sich vom Dosierofen 28 zu mehreren Anschnitten 30, wobei pro Zylinder ein Anschnitt 30 ausgebildet ist, der jeweils zentral unterhalb jedes Zylinderraumes 24 des Zylinderkurbelgehäuses 22 angeordnet ist. Im Bereich jedes Anschnitts 30 beim Kokillenguss beziehungsweise vor dem Eintritt in den Gießlauf beim Sandguss ist ein Gießfilter 32 angeordnet, so dass vor den Gießfiltern 32 oder im Gießfilter eine 90°-Umlenkung des Schmelzestroms bei der Formfüllung erfolgt.The filling
Jeder Anschnitt 30 ist mit einer Angussbuchse 34 verbunden, welche in der Ausführung gemäß der
In ihrem Innern ist ein zylindrischer Kanal 36, der sich entlang der Zylindermittelachse erstreckt, ausgebildet. Vom Kanal 36 aus erstrecken sich im vorliegenden Ausführungsbeispiel vier Querkanäle 38 durch die Seitenwände 40 der Angussbuchsen 34, die in den Formhohlraum 20 münden. Diese Querkanäle 38 sind entsprechend der Masseanhäufungen am Bauteil über den Umfang verteilt und erstrecken sich in Richtung von Schraubenpfeifen 42 des Zylinderkurbelgehäuse 22, sind also schräg versetzt zu den nicht sichtbaren Zylinderstegen des Zylinderkurbelgehäuses 22 ausgerichtet. Die Querkanäle 38 münden oberhalb von Kernen 46 zur Erzeugung eines Kühlmittelmantels des Zylinderkurbelgehäuses 22 in den Formhohlraum 20. Somit weisen diese Querkanäle 38 in Richtung der massereichen Bereiche des Zylinderkurbelgehäuses 22, wie den Schraubenpfeifen 42, den Hauptölkanälen 48, die ebenfalls durch entsprechende eingelegte Kerne gebildet werden, sowie den Anbindungen des Lagerstuhls 25 mit den Hauptlagerstellen 50 der Kurbelwelle.In its interior, a
Wird nun Schmelze aus dem Dosierofen 28 durch Erzeugung von Druck über den Anschnitt 30 in die Angussbuchse 34 gehoben, strömt diese Schmelze über die Querkanäle 38 in den Formhohlraum 20 und füllt zunächst den Bereich des nach unten weisenden Zylinderdecks 52, an dem somit eine schnelle Erstarrung erreicht wird, da kein Material in diesen Bereich nachströmt. Die weitere Füllung erfolgt nun steigend von unten nach oben. Die Hauptlagerstellen 50 als höchstliegende Teile werden zuletzt befüllt, so dass sich bei Erreichen dieser Bereiche des Zylinderkurbelgehäuses 22 die Schmelze bereits im Bereich der eutektischen Temperatur befindet und somit schnell erstarrt, wodurch feine Gefüge mit kleinen Dendritenarmabstände erreicht werden, was zu hohen Festigkeiten führt. Die gesamte Erstarrungsrichtung ist somit von außen nach innen. Die massereichen Bereiche der Schraubenpfeifen 42 und der Anbindung zum Lagerstuhl 25 bleibt in Kontakt zu den Querkanälen 38, so dass über diese bei Abkühlung von außen nach innen eine Nachspeisung erfolgt, die eine Lunkerbildung durch die Schrumpfung zuverlässig verhindert. Es erfolgt somit eine gerichtete Füllung und Erstarrung mit guten Festigkeitswerten.If now melt is lifted from the
Eine zusätzliche Verbesserung dieses Gießergebnisses kann mit einer Ausführung gemäß der
Die Füllung des Formhohlraums 20 erfolgt nun in gleicher Weise wie im ersten Ausführungsbeispiel beschrieben. Jedoch werden noch feinere Gefüge am Zylinderdeck 52 und im Bereich der Zylinderstege erreicht, da diese Bereiche direkt gekühlt werden und somit die Erstarrungszeiten verkürzt werden. Auch im Bereich der Hauptlagerstellen 50 kann eine zusätzliche aktive Kühlung vorgenommen werden, was zu verringerten Dendritenarmabständen und erhöhten Festigkeiten am Lagerstuhl 25 im Vergleich zu den bereits durch die gerichtete Füllung erzielbaren Gefügen führt.The filling of the
Beim Ausführungsbeispiel gemäß der Figur wird ein Sandgussformpaket als Gießform 10 verwendet. Im Vergleich zum Ausführungsbeispiel gemäß
Es werden somit Vorrichtungen zur Verfügung gestellt, mit denen ein Zylinderkurbelgehäuse im Niederdruckgussverfahren hergestellt werden kann, bei dem einerseits hohe Festigkeiten an den hochbelasteten Bereichen erreicht werden und andererseits reduzierte Zykluszeiten erzielt werden können, da sich kurze Abkühlzeiten und eine gerichtete Füllung ergibt. Zusätzlich besteht die Möglichkeit einer Nachspeisung massereicher Partien, so dass Lunkerbildungen entgegengewirkt wird.There are thus provided devices with which a cylinder crankcase are manufactured in the low pressure casting process can, on the one hand high strengths on the highly stressed areas can be achieved and on the other hand reduced cycle times can be achieved, since there are short cooling times and a directional filling. In addition, there is the possibility of replenishment of massive lots, so that cavities are counteracted.
Es sollte deutlich sein, dass der Schutzbereich nicht auf die beschriebenen Ausführungsbeispiele begrenzt ist. Es besteht eine Eignung auch für das Schwerkraftgießen oder zur Herstellung von Motoren mit V-förmig angeordneten Zylindern. Weitere konstruktive Änderungen der Angussbuchse oder der Halteformteile sind selbstverständlich ebenso denkbar, wie die Herstellung der Formteile aus unterschiedlichen gekühlten oder nicht gekühlten Materialien. Auch die Position und Anzahl der Querkanäle oder deren Ausrichtung ist änderbar, so dass diese beispielsweise unterhalb der Wassermantelkerne münden können.It should be clear that the scope of protection is not limited to the described embodiments. It is also suitable for gravity casting or for the production of engines with V-shaped cylinders. Other structural changes of the sprue bushing or retaining moldings are of course conceivable as well as the production of moldings from different cooled or non-cooled materials. Also, the position and number of transverse channels or their orientation is changeable, so that they can open, for example, below the water jacket cores.
Claims (17)
- A device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method, comprising:an outer casting mold (10) comprising mold parts (12, 14, 16, 18) which, in an assembled state, form a mold cavity (20) that forms, for casting purposes, an outer contour of the cylinder crankcase (22);a dosing furnace (28) configured to contain a liquid metal;at least one gate (30) arranged geodetically below the mold cavity (20) and via which the dosing furnace (28) can be fluidically connected to the mold cavity (20)characterized in thateach gate (30) is connected to a sprue bushing (34) configured to project into a region of the mold cavity (20) that forms the cylinder space (24) of the cylinder crankcase (22).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 1, characterized in that the sprue bushings (34) are lost sprue bushings (34).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 2, characterized in that the lost sprue bushings (34) are made of a fiber material, a ceramic material, a foundry molding material, or a combination thereof.
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that the sprue bushings (34) comprise a cylindrical channel (36) from which channels (38) extend at an angle through the side walls (40) defining the sprue bushings (34).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 4, characterized in that the channels are formed as transversal channels (38) which extend orthogonally to the cylindrical channel (36).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in one of claims 4 or 5, characterized in that the channels (38) are directed towards high-mass casting regions of the cylinder crankcase (22).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 6, characterized in that the channels (38) are directed towards at least one of bolt bosses (42), main oil channels (48) and connecting sections between main bearing sites (50) and the cylinder spaces (24) of the cylinder crankcase (22).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that the sprue bushings (34) are arranged on a mold part (12) which delimits a cylinder deck (52), wherein the side walls (40) of the sprue bushings in part serve as a delimiting wall (35) for forming the cylinder space (24).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in one of the preceding claims 1 to 7, characterized in that the sprue bushes (34) are fastened in a holding mold part (54) configured to extend into the cylinder space (24) and to at least in part form the delimiting wall (35) of the cylinder space (24).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that chill molds (58) protrude at least into regions of the cylinder space (24) arranged near the cylinder deck (52) or the cylinder webs.
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 9, characterized in that the holding mold parts (54) are designed as chill molds (58),
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that the mold part (12) on the cylinder deck side is made of steel and is configured to be cooled.
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in one of claims 9 to 12, characterized in that each of the holding mold parts (54) comprises four axially extending arms (56) forming a cylinder with interruptions over the circumference thereof, the arms (56) being regularly distributed over the circumference.
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in claim 13, characterized in that an insulation insert is arranged in a radially inner region of the arms (56), the insulation insert comprising recesses (64) which correspond to the interruptions (60) between the arms (56).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in one of claims 13 or 14, characterized in that the interruptions (60) are directed diagonally towards the bolt bosses (42).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that a casting filter (32) is arranged immediately below the gate (30) or in the sprue bushing (34).
- The device for producing a cylinder crankcase (22) using a low-pressure casting method or a gravity casting method as recited in of one of the preceding claims, characterized in that the device comprises components which are configured so that, after a filling with the metal melt, a core package (10) can be turned by 180° and be decoupled from the dosing furnace (28).
Priority Applications (1)
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PL15701711T PL3099436T3 (en) | 2014-01-29 | 2015-01-15 | Device for producing a cylinder crankcase using the low-pressure or gravity casting method |
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DE102014101080.9A DE102014101080B3 (en) | 2014-01-29 | 2014-01-29 | Device for producing a cylinder crankcase in low-pressure or gravity casting |
PCT/EP2015/050639 WO2015113821A1 (en) | 2014-01-29 | 2015-01-15 | Device for producing a cylinder crankcase using the low-pressure or gravity casting method |
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EP3099436A1 EP3099436A1 (en) | 2016-12-07 |
EP3099436B1 true EP3099436B1 (en) | 2017-12-27 |
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US (1) | US9718124B2 (en) |
EP (1) | EP3099436B1 (en) |
JP (1) | JP6324520B2 (en) |
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CN (1) | CN106029253B (en) |
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DE (1) | DE102014101080B3 (en) |
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2012
- 2012-09-11 NO NO12775075A patent/NO2756167T3/no unknown
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2014
- 2014-01-29 DE DE102014101080.9A patent/DE102014101080B3/en not_active Expired - Fee Related
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MX2016009775A (en) | 2017-01-26 |
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KR101962525B1 (en) | 2019-07-17 |
JP6324520B2 (en) | 2018-05-16 |
JP2017505234A (en) | 2017-02-16 |
RU2016130851A (en) | 2018-03-05 |
HUE038110T2 (en) | 2018-09-28 |
CN106029253A (en) | 2016-10-12 |
DE102014101080B3 (en) | 2015-07-30 |
NO2756167T3 (en) | 2018-06-16 |
PL3099436T3 (en) | 2018-06-29 |
RU2660449C2 (en) | 2018-07-06 |
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