EP3819041B1 - Casting method for manufacturing a motor vehicle component - Google Patents

Description

The invention relates to a casting method for producing a motor vehicle component. The motor vehicle component is preferably an exhaust manifold or a cylinder head.

figure 4 shows a device for explaining a casting method known from practice for producing a cylinder head. A first mold 1' and a second mold 2' are attached to one another by means of fastening recesses 2' and fastening projections 5' and glued to one another by means of an adhesive material 7', with the first mold 1' and the second mold 2' forming a receiving space 6' for Recording of cast material is formed. The problem can arise that, because the metering accuracy of the adhesive material 7' cannot always be guaranteed, excess adhesive material X' is pressed out of the fastening recesses 2' by the fastening projections 5' and gets into the receiving space 6' and/or onto an inner surface 8' of a wall 10' of the first mold 1', which can result in imperfections on the cylinder head.

document U.S. 4,632,171 A discloses a thin-walled, resin-bonded sand shell mold for vacuum gravity casting of metal, consisting of upper and lower box halves glued together at a parting line therebetween. The upper box half includes a flange which extends beyond the perimeter of the lower box half, the flange having an upper sealing surface to effect a seal with the opening of the vacuum chamber used to fill the mold.

document U.S. 2014/238574 A1 discloses a method of forming a mold structure with high precision multi-dimensional components.

document DE 10 2004 016 254 A1 discloses a core for an automobile casting with at least a first mold made of a first material and with at least one second mold made of a second material that fits the first mold precisely.

document FR 2 368 323 A1 discloses a multi-part core for metal casting moulds, particularly for the manufacture of cylinder blocks for internal combustion engines, in which the core parts are made of a material resistant to the action of the molten metal and are replaced by a cellular plastic material which under the action of the molten metal evaporates, are kept at the predetermined mutual distances.

It is an object of the invention to create an alternative and/or improved casting method for producing a motor vehicle component, in particular without defects on the motor vehicle component caused by excess adhesive material.

This problem can be solved with the features of the independent claim. Advantageous developments of the invention are disclosed in the dependent claims and the following description.

The invention relates to a casting method for producing a motor vehicle component, e.g. B. an exhaust manifold or a cylinder head.

• ein Bereitstellen einer ersten Form (vorzugsweise Gussform, insbesondere zur Ausbildung des Kraftfahrzeugbauteils), wobei die erste Form eine Wand mit zumindest einer Befestigungsvertiefung aufweist, wobei die zumindest eine Befestigungsvertiefung mit einer zusätzlichen Aussparung (z. B. Vertiefung oder Hohlraum etc.) versehen ist,
• ein Bereitstellen einer zweiten Form (vorzugsweise Gussform, insbesondere zur Ausbildung des Kraftfahrzeugbauteils), wobei die zweite Form zumindest einen Befestigungsvorsprung aufweist, wobei vorzugsweise zwischen der ersten Form und der zweiten Form z. B. ein Aufnahmeraum zur Aufnahme eines Gussmaterials zweckmäßig für das Kraftfahrzeugbauteil gebildet wird, und
• ein in Eingriff bringen der zumindest einen Befestigungsvertiefung und des zumindest einen Befestigungsvorsprungs sowie ein Verkleben der zumindest einen Befestigungsvertiefung und des zumindest einen Befestigungsvorsprungs mittels eines (vorzugsweise zuvor in die zumindest eine Befestigungsvertiefung eingebrachten) Klebematerials, z. B. vorteilhafterweise so, dass (insbesondere überschüssiges) Klebematerial in die Aussparung gedrückt wird und z. B. in der Wand verbleiben kann.

The casting process includes:

• providing a first mold (preferably a casting mold, in particular for forming the motor vehicle component), the first mold having a wall with at least one fastening recess, the at least one fastening recess being provided with an additional recess (e.g. recess or cavity etc.). ,
• providing a second mold (preferably a casting mold, in particular for forming the motor vehicle component), the second mold having at least one fastening projection, with preferably between the first mold and the second mold z. B. a receiving space for receiving a cast material is appropriately formed for the motor vehicle component, and
• bringing the at least one fastening recess and the at least one fastening projection into engagement and gluing the at least one fastening recess and the at least one fastening projection by means of an adhesive material (preferably previously introduced into the at least one fastening recess), e.g. B. advantageously so that (especially excess) adhesive material is pressed into the recess and z. B. can remain in the wall.

This can e.g. B. it can be avoided that (in particular excess) adhesive material is conveyed (e.g. pressed) through the at least one fastening projection out of the at least one fastening recess into the receiving space and/or is conveyed (e.g. pressed) onto an inner surface of the wall .

As a result, defects on the motor vehicle component, which can be caused by excess adhesive material escaping from the at least one fastening recess, can advantageously be avoided.

An exit (e.g. rejects or outflow etc.) of in particular excess adhesive material into the receiving space can thus advantageously be avoided.

The at least one fastening recess can preferably be worked into the first shape, in particular the wall, essentially orthogonally, wherein alternatively or additionally the at least one fastening projection can protrude essentially orthogonally from the second shape.

The combination of mounting recess mounting projection can also z. B. be referred to as adhesive nail connection.

It is possible for the recess to be formed in an end face of the at least one fastening recess.

The recess can z. B. be formed as a through hole in the wall and / or penetrate the wall completely. Alternatively or in addition, the recess can be designed as a blind hole in the wall.

The at least one fastening recess and/or the at least one fastening projection can e.g. B. substantially cylindrical, circular, rectangular or triangular.

It is possible for the at least one fastening recess to be formed and/or enlarged by a projection (e.g. protruding from the wall and/or essentially cylindrical, circular, rectangular or triangular).

It is possible for the second mold to be spaced apart from the first mold by means of the at least one fastening projection, preferably in order to form the receiving space. The at least one fastening projection can thus z. B. serve as spacers.

The first form and/or the second form can e.g. B. trough-shaped (particularly shell-shaped).

It is possible that the wall forms a bottom section, in particular of the first form, and e.g. B. may have an appropriate peripheral flange.

The at least one fastening recess is preferably formed in the base section.

The first mold is preferably a bottom mold.

The second form can B. be used from above in the first form.

The casting material can e.g. B. be introduced from above or from below in the first form.

It is possible for the adhesive material to be filled (e.g. introduced) into the at least one fastening recess before the at least one fastening projection is inserted into the at least one fastening recess.

It is possible for the at least one fastening recess and the at least one fastening projection to be glued to one another on the face side and/or in their circumferential direction.

It is possible that (in particular excess) adhesive material is pressed into the recess by the at least one fastening projection.

The at least one mounting recess and the at least one mounting projection can, for. B. be brought into engagement with each other essentially with a precise fit and/or essentially without play in the circumferential direction.

The motor vehicle component may preferably comprise an exhaust manifold or a cylinder head, e.g. B. a two-cylinder, four-cylinder, six-cylinder, or eight-cylinder head.

It should also be mentioned that several fastening recesses are preferably provided, each of which can have an additional recess. It is also expedient to provide several fastening projections.

FIG. 1

eine schematisierte Schnittdarstellung einer beispielhaften Vorrichtung zur Erläuterung eines Gussverfahrens gemäß einer Ausführungsform der Erfindung;

FIG. 2

eine schematisierte Ansicht von oben auf die Vorrichtung der Figur 1;

FIG. 3

eine Illustration eines Gussverfahrens gemäß einer Ausführungsform der Erfindung; und

FIG. 4

eine schematisierte Schnittdarstellung einer Vorrichtung zur Erläuterung eines Gussverfahrens gemäß Stand der Technik.

The preferred embodiments and features of the invention described above can be expediently combined with one another. Further details and advantages of the invention are described below with reference to the attached figures:

FIG. 1

a schematic sectional view of an exemplary device to explain a casting method according to an embodiment of the invention;

FIG. 2

a schematic view from above of the device figure 1 ;

FIG. 3

an illustration of a casting method according to an embodiment of the invention; and

FIG. 4

a schematic sectional view of a device for explaining a casting method according to the prior art.

figure 1 shows a schematic sectional view of an exemplary device to explain a casting method for manufacturing a motor vehicle component, z. B. an exhaust manifold or a cylinder head, wherein figure 2 a schematic view from above of the device figure 1 indicates.

A first mold 1 (in particular a casting mold) and a second mold 4 (in particular a casting mold) are used to form, in particular to shape, the motor vehicle component.

The first mold 1 , expediently designed as a bottom mold, has three fastening depressions 2 , for example, while the second mold 4 has three fastening projections 5 .

The fastening recesses 2 are formed in a wall 10 having an inner surface 8 .

The fastening projections 5 are engaged with the fastening recesses 2 so that the first mold 1 and the second mold 4 are preferably spaced apart by the fastening projections 5 to form a receiving space 6 for receiving a molding material for the automobile component.

Adhesive material 7 is introduced into the fastening depressions 2 in order to glue the fastening depressions 2 and the fastening projections 5 to one another.

A special feature is that the fastening depressions 2 each have a cutout 3 on their end face, so that in particular any excess adhesive material 7 can be pressed out of the fastening depressions 2 into the cutouts 3 by means of the fastening projections 5 .

This can expediently prevent any excess adhesive material 7 from being transported through the fastening projections 5 from the fastening recesses 2 into the receiving space 6 and/or onto the inner surface 8 of the wall 10, which can lead to defects in the motor vehicle to be manufactured.

At least one recess 3 can, for. B. be formed as a through hole in the wall 10 and in particular penetrate the wall 10 completely. At least one recess 3 can, for. B. be formed as a blind hole in the wall 10. It is possible that one or more fastening depressions 2 are formed and/or enlarged by a projection 9 protruding from the wall 10 . The mounting recesses 2, the mounting projections 5 and the projection 9 can, for. B. substantially cylindrical, circular, rectangular or triangular.

The first form 1 can e.g. B. be trough-shaped, wherein the wall 10 can form a lower bottom portion with a peripheral flange portion 11 expediently.

the FIG. 3 FIG. 11 illustrates a casting method for manufacturing an automotive component according to an embodiment of the invention.

A step S1 includes providing a first mold 1 for forming the motor vehicle component, the first mold 1 preferably having a plurality of fastening recesses 2 . The fastening recesses 2 are each provided with an additional recess 3 . A step S2 includes providing a second mold 4 for forming the motor vehicle component. The second mold 4 preferably comprises a plurality of fastening projections 5. A receiving space 6 for receiving a casting material is formed by the first mold 1 and the second mold 4.

A step S3 comprises bringing the fastening projections 5 and the fastening depressions 2 into engagement and gluing the fastening projections 5 and the fastening depressions 2 by means of an adhesive material 7 that has expediently been introduced into the fastening depressions 2 beforehand, so that in particular excess adhesive material 7 is pressed into the respective recess 3 .

In this way, it can be avoided in particular that any excess adhesive material 7 is transported through the fastening projections 5 out of the fastening recesses 2 into the receiving space 6 and/or onto the inner surface 8 .

A step S4 can include supplying casting material in order to produce the motor vehicle component.

The invention is not limited to the preferred embodiments described above. Rather, a large number of variants and modifications are possible, which also make use of the idea of the invention and therefore fall within the scope of protection.

The invention is defined by the appended claims.

Reference List

1

first mold, preferably cast mold

2

Mounting recess, preferably mounting recesses

3

Recess, preferably recesses

4

second mold, preferably cast mold

5

Fastening projection, preferably fastening projections

6

recording room

7

adhesive material

8th

Inner surface

9

head Start

10

base section

11

flange section

X'

excess adhesive material on inner surface 8'

Claims (15)

1. A casting method for producing a motor vehicle component, comprising:

   - providing a first mould (1), wherein the first mould (1) has a wall (10) having at least one fastening indentation (2), wherein the at least one fastening indentation (2) is provided with an additional cutout (3),

   - providing a second mould (4), wherein the second mould (4) has at least one fastening protrusion (5), wherein a receiving space (6) for receiving a casting material is preferably formed between the first mould (1) and the second mould (4), and

   - bringing the at least one fastening indentation (2) and the at least one fastening protrusion (5) into engagement, and adhesively bonding the at least one fastening indentation (2) and the at least one fastening protrusion (5) by means of an adhesive material (7), such that adhesive material (7) is pushed into the cutout (3), and adhesive material (7) is preferably prevented from being conveyed out of the at least one fastening indentation (2) into the receiving space (6) and/or onto an inner surface (8) of the wall (10) by the at least one fastening protrusion (5).
2. The casting method according to Claim 1, wherein the cutout (3) is configured in an end side of the at least one fastening indentation (2).
3. The casting method according to Claim 1 or 2, wherein the cutout (3)

   - is configured in the form of a through-hole and/or passes completely through the wall (10), or

   - is configured in the form of a blind hole in the wall (10).
4. The casting method according to one of the preceding claims, wherein at least one fastening indentation (2) and/or at least one fastening protrusion (5) are/is of cylindrical, circular, rectangular or triangular configuration.
5. The casting method according to one of the preceding claims, wherein the at least one fastening indentation (2) is formed and/or enlarged by a protrusion (9) which preferably projects from the wall (10).
6. The casting method according to one of the preceding claims, wherein the second mould (4) is spaced apart from the first mould (1) by means of the at least one fastening protrusion (5), preferably such that the at least one fastening protrusion (5) serves as a spacer.
7. The casting method according to one of the preceding claims, wherein the first mould (1) is of trough-like configuration and/or the wall (10) forms an in particular lower bottom portion with a peripheral flange portion (11).
8. The casting method according to one of the preceding claims, wherein the first mould (1) constitutes a bottom casting mould, and the second mould (4) is preferably inserted from above into the first mould (1) .
9. The casting method according to one of the preceding claims, wherein the casting material is introduced from above or from below into the first mould (1).
10. The casting method according to one of the preceding claims, wherein the at least one fastening indentation (2) is filled with the adhesive material (7) before the at least one fastening protrusion (5) is inserted into the at least one fastening indentation (2).
11. The casting method according to one of the preceding claims, wherein the at least one fastening indentation (2) and the at least one fastening protrusion (5) are adhesively bonded to one another on the end side and/or in the peripheral direction thereof.
12. The casting method according to one of the preceding claims, wherein the adhesive material (7) is pushed into the cutout (3) by the at least one fastening protrusion (5).
13. The casting method according to one of the preceding claims, wherein the at least one fastening indentation (2) and the at least one fastening protrusion (5) are brought into engagement with one another in an accurately fitting manner and/or in particular in a play-free manner in the peripheral direction thereof.
14. The casting method according to one of the preceding claims, wherein the motor vehicle component comprises an exhaust manifold or a cylinder head.
15. The casting method according to Claim 14, wherein the cylinder head is a two-cylinder head, four-cylinder head, six-cylinder head or eight-cylinder head.

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