EP3183080B1 - Procédé de fabrication d'un piston pour un moteur à combustion interne - Google Patents

Procédé de fabrication d'un piston pour un moteur à combustion interne Download PDF

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Publication number
EP3183080B1
EP3183080B1 EP15741531.6A EP15741531A EP3183080B1 EP 3183080 B1 EP3183080 B1 EP 3183080B1 EP 15741531 A EP15741531 A EP 15741531A EP 3183080 B1 EP3183080 B1 EP 3183080B1
Authority
EP
European Patent Office
Prior art keywords
casting
melt
groove
collar
feeder
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.)
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Application number
EP15741531.6A
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German (de)
English (en)
Other versions
EP3183080A1 (fr
Inventor
Udo Rotmann
Jürgen GAISSERT
Martin RÜHLE
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.)
Mahle International GmbH
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Mahle International 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 Mahle International GmbH filed Critical Mahle International GmbH
Priority to PL15741531T priority Critical patent/PL3183080T3/pl
Publication of EP3183080A1 publication Critical patent/EP3183080A1/fr
Application granted granted Critical
Publication of EP3183080B1 publication Critical patent/EP3183080B1/fr
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Classifications

    • 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
    • B22C9/088—Feeder heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • 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
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
    • B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure

Definitions

  • the invention relates to a casting tool for producing a piston according to the preamble of claim 1.
  • the invention also relates to a corresponding method for producing such a piston.
  • Fluid energy machines in which pistons in cylinders perform a periodic translational movement transmitted via push rods, are known in mechanical engineering as piston machines.
  • the most common type of piston engine is the reciprocating piston engine, which converts the change in volume of a gas into the linear movement of the piston as described and via a connecting rod and a crank into a rotary movement.
  • the piston comprises a combustion bowl for this purpose.
  • Suitable pistons are regularly manufactured according to the state of the art by means of a master molding process, in particular with the aid of specialized casting techniques.
  • the mold casting method known from metalworking has proven particularly useful, in which a melt is poured into a metal permanent mold called an over-mold and the cavity essentially fills solely as a result of gravity or external pressurization.
  • the bowl rim is also increasingly reinforced by the pouring of ceramic fibers.
  • the squeeze casting process or a robot-assisted medium pressure casting process (“robot-aided medium pressure die casting", RMD) is sometimes used to ensure the complete infiltration of the ceramic fibers by the aluminum melt and thus to promote the integration of the ceramic fibers into the metal structure .
  • a method for producing a piston by means of a multi-part casting tool in which a casting melt is poured into a casting base of the casting tool, the casting melt solidifying in an annular wall which surrounds the feeder in the casting base and is radially spaced therefrom.
  • a corresponding procedure is from the DE 10 2004 052 231 A1 as well as the corresponding revelation of the EP 1 804 985 B1 known.
  • Both documents relate to a method for the series production of a piston, wherein a casting melt is filled via a feed area into a multi-part casting mold with a casting base and at least one feeder, it being provided that after the piston blank has been cast, the opening of the end of the feeder sleeve which is open towards the top is provided is acted upon by a gas pressure acting on the casting melt. The tightness of the feeder is ensured by using a so-called collar feeder.
  • One embodiment of this method is characterized in that after the piston casting tool has been filled, the formation of an edge shell from solidified casting melt is awaited. Due to a special design of the pouring base and feeder sleeve, a collar forms around the feeder in this solidification phase, so that a sealing surface is created between the mouthpiece of the feeder and the collar, which holds the feeder content in position.
  • Dense pressurization of the feeder materials which generally consist of heat-insulating and mechanically unstable materials such as ceramics, has proven to be critical.
  • the formation of an edge shell in the feeder occurs with a function delay compared to the casting tool.
  • the invention is therefore based on the object of providing an improved casting tool in order to produce high-quality pistons in a robust casting process for pistons.
  • the invention is therefore based on the basic idea of supplementing a casting base used in the casting process by a preferably annular groove encircling the feeder or a preferably annular collar encircling the feeder, which collar is also arranged radially spaced from the feeder.
  • the casting melt fed by the feeder or an inlet into the casting mold can, for example, solidify in this groove to form a circumferential sealing rib, the inner flank of which lies sealingly against a corresponding inner flank of the groove.
  • the casting shrinks onto the groove flank, especially when there are different coefficients of thermal expansion, such as between an aluminum melt and a steel mold.
  • the high thermal conductivity of the steel causes the melt to cool and solidify rapidly at the contact points, which can lead to directional solidification with the formation of a fine, columnar, solidified structure.
  • the still liquid part of the casting melt is held in position by the surface contact between the two flanks even when the melt is pressurized by the feeder, but is preferred but not necessary, and exits prematurely the bottom mold hindered.
  • the groove surface acts as a pressure-tight surface when pressure is applied by the feeder.
  • the melt in the feeder has not yet formed a stable edge shell and the liquid melt can thus infiltrate porous inserts, for example for reinforcement of the trough edge, due to the pressurization by the feeder.
  • pressurization of the melt has proven to be advantageous and is preferred, particularly when infiltrating porous inserts, the formation of a combustion chamber trough in a shrunk-on workpiece can also take place without pressurization and, according to the invention, cause directional solidification by rapid cooling.
  • the circumferential groove or collar is radially spaced from the feeder and is arranged separately therefrom, so that the feeder itself is not burdened by shrinking of the pouring melt when the pouring melt solidifies, as is the case, for example at the feeder from the DE 10 2004 052 231 A1 the case is.
  • the casting tool for a piston comprises the above-mentioned casting mold for shaping the piston from the casting melt, the casting base with the centrally arranged feeder for feeding the casting melt into the casting mold and a compressed gas line opening into the feeder for compressing the casting melt within the casting mold.
  • the groove has an inner groove flank for shaping the casting melt into an annular sealing rib in such a way that an inner rib flank of the sealing rib lies sealingly against the inner groove flank when the casting melt solidifies in the groove, whereas the collar has an outer collar flank for shaping the casting melt into one annular sealing groove has that an outer groove flank of the sealing groove lies sealingly against the outer collar flank when the casting melt solidifies.
  • the use of a suitable aluminum alloy as a casting melt can be considered.
  • the choice of specific alloying elements that are introduced into the aluminum liquefied by melting enables properties such as hardness, vibration absorption, toughness and machinability of the piston blank to be influenced in a targeted manner for mechanical processing.
  • an aluminum-silicon alloy for example, has proven itself as a light-metal casting melt which has its eutectic with a mass fraction of approximately 12% silicon.
  • a hypereutectic or slightly hypereutectic mixture ratio is nevertheless recommended, which gives the resulting aluminum alloy a solidification range in which a small proportion of solid phases is already present in addition to the casting melt.
  • the sealing effect of the solidifying rib according to the invention is achieved early in this way.
  • the addition of a mass fraction of up to 6% copper, up to 3% nickel and up to 1% magnesium may also be considered to be expedient in order to additionally increase the strength of the piston blank. All alloy proportions are given in% by weight.
  • the invention is based on the general idea of filling a casting melt via a separate inlet of the casting tool in a method for producing a piston by means of a multi-part casting tool, the Casting melt is pressurized by means of a compressed gas line opening into the feeder within the casting floor.
  • the missing volume due to the shrinkage of the solidifying melt and the infiltration of any porous inserts that may be present is subsequently supplied from the feeder into the casting mold.
  • the pouring melt solidifies in a groove encircling the feeder in the casting base and radially spaced therefrom into an annular sealing rib in such a way that an inner rib flank of the sealing rib lies sealingly against an inner groove flank of the groove from the piston casting tool.
  • a collar can also be provided on the casting base instead of or in addition to the groove, so that the casting melt solidifies to form an annular sealing groove on this circumferential collar which is radially spaced from the feeder in such a way that an outer groove flank of the sealing groove seals on an outer collar flank the collar of the piston mold.
  • At least one insert is placed in the casting mold and infiltrated by means of pressure exerted on the casting melt, the infiltration being supported by generating a negative pressure by means of suction lines.
  • Both embodiments have in common that when the casting melt solidifies, no mechanical stress is exerted on the feeder by shrinking on, but the shrunk-on casting is supported directly on the casting base by a pressure force exerted on the sealing surface and thereby seals along the sealing surface.
  • a particularly favorable design results when the collar of the bottom shape is already as close as possible to the shape of the later combustion bowl, in particular the bowl rim and bowl.
  • the proposed production process is carried out as a gravity mold or low-pressure casting process under a pressure between 0.3 bar and 20 bar.
  • a gravity mold or low-pressure casting process under a pressure between 0.3 bar and 20 bar.
  • a casting tool 1 according to the invention for a piston 2 has a casting mold 3 for forming the piston 2 from a casting melt 4 (cf. Fig. 2 ).
  • the casting mold 3 has a casting base 5 with a preferably centrally arranged feeder 6 for feeding the casting melt 4 into the casting mold 3 and a pressurized gas line 7 opening into the feeder 6 for compressing the casting melt 4 inside the casting mold 3 (cf. Fig. 2 ).
  • the feeder can be made of ceramic, for example.
  • a groove 8, which is arranged in the casting base 5 and has a ring around the feeder 6 and is radially spaced therefrom, is provided with an inner groove flank 9 (cf. Fig.
  • annular collar 12 which is arranged in the casting base 5, surrounds the feeder 6 in a ring shape and is radially spaced from this can be provided (cf. Fig. 3 , 7 and 8th ), with an outer collar flank 13 for shaping the pouring melt 4 into an annular sealing groove 14 such that an outer groove flank 15 of the sealing groove 14 lies sealingly against the outer collar flank 13 when the pouring melt 4 solidifies with shrinkage.
  • the groove 9 or the collar 12 is arranged radially on the outside, whereas it is according to the Fig. 2 and 6 is arranged radially on the inside, that is to say has a smaller radial distance from the feeder 6 than that in FIGS Fig. 1 and 5 shown groove 9.
  • an annular collar 12 may also be provided, as shown in FIGS Fig. 3 and 7 , is shown. It is also conceivable here that the ring collar 12 is arranged further out or further in, there being always a distance from the feeder 6.
  • the groove flank 9 or the collar flank 13 can have an inclination angle ⁇ between 3 ° and 20 °, preferably from 10 ° to 15 °, with respect to a perpendicular 16 on a surface of the casting floor 5.
  • the angle of inclination ⁇ is to be chosen small enough to ensure that the shrunk-on casting is held securely on the sealing surface with regard to the coefficient of friction.
  • the angle of inclination ⁇ should still be sufficiently large to enable the cast piston 2 to be easily stripped out.
  • This geometrical shape also ensures that the sealing rib 10 or sealing groove 14 formed after the casting melt 4 has hardened itself defines an inner rib flank 11 or outer groove flank 15, which lies flat against said inner groove flank 9 or outer collar flank 13 and the casting base 5 or the bottom mold thus seals against a premature and undesired escape of the casting pressure and thus enables the porous inserts to be infiltrated in accordance with the intended purpose.
  • a piston 2 can be produced by means of the casting tool 1 as follows: First, the casting melt 4 is fed via the inlet 21 into the casting base 5 and above into the casting mold 3 of the casting tool 1, the casting melt 4 using the compressed gas line 7 opening into the feeder 6 is pressurized within the casting base 5 in order to avoid the formation of voids and to infiltrate porous pouring parts. When the casting melt 4 is poured into the casting mold 3, it also enters the groove 8, which surrounds the feeder 6 in the casting base 5 in an annular manner and is radially spaced therefrom, and solidifies to form an annular sealing rib 10, the respective inner rib flank 11 of the sealing rib 10 being tight the inner groove flank 9 of the groove 8 (see 1, 2 , 4a, 5 and 6 ).
  • the casting melt 4 can also solidify on the ring collar 12, which surrounds the feeder 6 in the casting floor 5 in a ring shape and is radially spaced therefrom, forming an annular sealing groove 14 in such a way that an outer groove flank 15 of the sealing groove 14 seals against the outer collar flank 13 of the ring collar 12 is present.
  • the casting melt 4 should be pressurized after the casting mold 3 has been filled and before the casting melt has completely solidified, at the earliest after the casting mold 3 has been filled and after the partial solidification of an edge shell of the piston and partial areas of the inlet 21.
  • a porous insert 18 cf. 5 to 8
  • the piston can contain other inserts that are not to be infiltrated, such as ring carriers or salt cores for forming cooling channels.
  • the insert 18, in particular a ring carrier or a trough edge protector can for example be porous and be infiltrated by means of pressure exerted on the casting melt 4. At the same time, the infiltration can be supported by generating a negative pressure by means of suction lines 20.
  • a near-eutectic aluminum alloy is particularly suitable for the casting melt 4, which comprises a mass fraction of 10% to 14% silicon and / or a further mass fraction of up to 6% copper, up to 3% nickel and / or up to 1% magnesium.
  • other elements such as V and Zr (each ⁇ 0.2%) can be added to increase the heat resistance, and Ti ( ⁇ 0.2%) and P ( ⁇ 0.01%) for grain refinement.
  • a near-eutectic or even under-eutectic design of the AlSi alloys has proven to be advantageous for the infiltrability of the porous inserts.
  • a casting melt is preferred that is largely free of contamination by low-melting elements with a Melting point ⁇ 490 ° C, such as Pb, Bi, Sn, Zn, the concentrations of these elements individually being below 0.01%.
  • the pistons 2 are cast by gravity die casting or low-pressure casting, and the casting melt solidifies in the casting mold, in particular under a pressure between 0.3 bar and 20 bar.
  • the described casting melt 4 is poured into the casting tool 1 via the inlet 21, so that the free areas of the casting mold 3 are filled with casting melt 4 around a core 19, which later forms the small connecting rod eye of the piston 2.
  • the special design of the pouring base 5 and feeder 6 allows the formation of the sealing rib 10 or sealing groove 14, which holds the feeder content in position, if the casting tool is opened according to the method to achieve short cycle times at a time when the contents of the feeder 6 are still partially liquid inside can be.
  • the stabilizing effect of the sealing rib 10 or sealing groove 14 is supported by the groove 8 encircling the feeder 6 in the casting base 5 or, in the complementary embodiment, by the annular collar 12, within which the casting melt 4 forms the annular sealing rib 10 or Sealing groove 14 solidifies.
  • the pouring melt 4 can rise to a desired level within the feeder 6, so that above the poured pouring melt 4, after the supply of pouring melt 4 has ended, there is a free space within the feeder 6, via which the pouring melt 4 with a gas pressure between 0. 3 bar and 20 bar is applied.
  • the gas for pressurization will fed to the feeder 6 via the compressed gas line 7, which is open to the environment during the pouring process of the casting melt 4, so that pressure equalization can take place (cf. Fig. 2 ).
  • the compressed gas line 7 is only in for the sake of simplicity Fig. 2 and the inlet 21 and the sleeve 22 are only in Fig. 8 drawn in, it being clear that these may also be present in other embodiments.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (7)

  1. Procédé de fabrication d'un piston (2) au moyen d'un outil de coulée (1) en plusieurs parties, selon lequel
    - une masse fondue de coulée (4) est versée au moyen d'une entrée (21) dans un fond de coulée (5) de l'outil de coulée (1),
    caractérisé en ce que
    - la masse fondue de coulée (4) se solidifie, dans une gorge (8) de préférence annulaire, faisant le tour de la masselotte (6) dans le fond de coulée (5) et distante radialement de celle-ci, en une nervure d'étanchéité (10) de préférence annulaire de telle sorte qu'un flanc de nervure (11) intérieur de la nervure d'étanchéité (10) s'appuie de manière à assurer l'étanchéité contre un flanc de nervure (9) intérieur de la gorge (8), et/ou
    - la masse fondue de coulée (4) se solidifie, contre un collet (12) de préférence annulaire, faisant le tour de la masselotte (6) dans le fond de coulée (5) et distant radialement de celle-ci, en formant une gorge d'étanchéité (14) de préférence annulaire de telle sorte qu'un flanc de gorge (15) extérieur de la gorge d'étanchéité (14) s'appuie de manière à assurer l'étanchéité contre un flanc de collet (13) extérieur du collet (12),
    - au moins une pièce insérée (18) est insérée dans le moule de coulée (3) et est infiltrée au moyen d'une pression exercée sur la masse fondue de coulée (4),
    - l'infiltration est soutenue par la production d'une dépression au moyen de conduites d'aspiration (20).
  2. Procédé selon la revendication 1, caractérisé en ce que la gorge (8) et/ou le collet (12) sont refroidis par passage d'un fluide de refroidissement à travers des canaux qui sont agencés dans le fond de coulée dans la zone de la gorge (8) et/ou du collet (12).
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que la masse fondue de coulée (4) est soumise à une pression à l'intérieur du fond de coulée (5).
  4. Procédé selon la revendication 3, caractérisé en ce que, après le remplissage du moule de coulée (3) et après la solidification partielle, la masse fondue de coulée (4) est soumise à une pression comprise entre 0,35 bar et 20 bar.
  5. Procédé selon l'une quelconque des revendications 1 à 4, caractérisé en ce que la masse fondue de coulée (4) comprend une masse fondue d'aluminium avec une part de 10% à 14% en masse de silicium et une autre part allant jusqu'à 6 % en masse de cuivre, jusqu'à 3 % en masse de nickel et/ou jusqu'à 1 % en masse de magnésium.
  6. Procédé selon la revendication 5, caractérisé en ce que des impuretés présentes dans la masse fondue de coulée (4) sont des éléments à bas point de fusion avec un point de fusion <490 °C dans une proportion à chaque fois inférieure à 0,01 %.
  7. Procédé selon l'une quelconque des revendications 1 à 6, caractérisé en ce que le procédé est mis en œuvre dans le procédé de coulée en coquille par gravité ou de coulée sous basse pression.
EP15741531.6A 2014-08-20 2015-07-21 Procédé de fabrication d'un piston pour un moteur à combustion interne Active EP3183080B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL15741531T PL3183080T3 (pl) 2014-08-20 2015-07-21 Sposób wytwarzania tłoka silnika spalinowego

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014216517.2A DE102014216517A1 (de) 2014-08-20 2014-08-20 Gießwerkzeug und Verfahren zur Herstellung eines Kolbens für einen Verbrennungsmotor
PCT/EP2015/066598 WO2016026638A1 (fr) 2014-08-20 2015-07-21 Outil de coulée et procédé de fabrication d'un piston pour un moteur à combustion interne

Publications (2)

Publication Number Publication Date
EP3183080A1 EP3183080A1 (fr) 2017-06-28
EP3183080B1 true EP3183080B1 (fr) 2020-06-03

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Application Number Title Priority Date Filing Date
EP15741531.6A Active EP3183080B1 (fr) 2014-08-20 2015-07-21 Procédé de fabrication d'un piston pour un moteur à combustion interne

Country Status (8)

Country Link
US (1) US11623272B2 (fr)
EP (1) EP3183080B1 (fr)
JP (1) JP6568930B2 (fr)
CN (1) CN106573296B (fr)
BR (1) BR112017002972B1 (fr)
DE (1) DE102014216517A1 (fr)
PL (1) PL3183080T3 (fr)
WO (1) WO2016026638A1 (fr)

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CN107598088A (zh) * 2017-09-25 2018-01-19 泰州康乾机械制造有限公司 一种提升薄壁异型铝合金铸件出品率的方法
USD872781S1 (en) 2018-04-13 2020-01-14 Foseco International Limited Breaker core
CN112719222A (zh) * 2020-12-30 2021-04-30 安徽省恒泰动力科技有限公司 一种双喇叭口陶瓷纤维冒口套及其制备方法

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Also Published As

Publication number Publication date
PL3183080T3 (pl) 2020-11-02
WO2016026638A1 (fr) 2016-02-25
JP6568930B2 (ja) 2019-08-28
BR112017002972B1 (pt) 2021-08-31
CN106573296A (zh) 2017-04-19
BR112017002972A2 (pt) 2017-12-12
US11623272B2 (en) 2023-04-11
US20180361470A1 (en) 2018-12-20
JP2017528324A (ja) 2017-09-28
DE102014216517A1 (de) 2016-02-25
EP3183080A1 (fr) 2017-06-28
CN106573296B (zh) 2020-10-27

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