JP4617806B2 - Thermal spray pretreatment method - Google Patents

Thermal spray pretreatment method Download PDF

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JP4617806B2
JP4617806B2 JP2004281554A JP2004281554A JP4617806B2 JP 4617806 B2 JP4617806 B2 JP 4617806B2 JP 2004281554 A JP2004281554 A JP 2004281554A JP 2004281554 A JP2004281554 A JP 2004281554A JP 4617806 B2 JP4617806 B2 JP 4617806B2
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broaching
cylinder bore
pretreatment method
thermal spraying
blade
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JP2006097045A (en
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智浩 近藤
雅彦 飯泉
崇 荻野
公男 西村
英爾 塩谷
秀夫 高橋
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Nissan Motor Co Ltd
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Description

本発明は、溶射皮膜を形成する前の基材表面を粗面に形成する溶射前処理方法に関する。 The present invention relates to a thermal spraying preprocessing method for forming the substrate surface before the formation of the thermal spray coating to the roughened surface.

自動車用エンジンの重量低減および排気処理対応に効果のあるライナレスアルミシリンダブロックのシリンダボア内面に対して溶射皮膜を形成する際に、その前工程として、溶射皮膜の密着性を高める目的でシリンダボア内面を粗面に形成する必要がある。   When forming a thermal spray coating on the cylinder bore inner surface of a linerless aluminum cylinder block, which is effective for reducing the weight of an automobile engine and dealing with exhaust treatment, as a pre-process, the inner surface of the cylinder bore is improved for the purpose of improving the adhesion of the thermal spray coating. It is necessary to form on a rough surface.

例えば、下記特許文献１には、シリンダボア内面に対し、ボーリング加工を行ってねじ状の凹部を形成するとともに、このとき発生する切削片によって、凹部相互間の凸部を除去して微細凹凸部となる破断面を形成している。
特開２００２−１５５３５０号公報 For example, in Patent Document 1 below, a cylindrical recess is formed on the inner surface of a cylinder bore by forming a screw-like recess, and a projection between the recesses is removed by a cutting piece generated at this time, Forming a fracture surface.
JP 2002-155350 A

ところが、上記した従来の溶射前処理方法では、ボーリング加工に時間がかかり、加工能率が低下するという問題がある。   However, the conventional thermal spraying pretreatment method described above has a problem that it takes time for boring and the machining efficiency is lowered.

そこで、本発明は、基材表面を短時間で粗面化できるようにすることを目的としている。   Then, this invention aims at enabling it to roughen the base-material surface in a short time.

本発明は、溶射皮膜を形成する前の基材表面を粗面に形成する溶射前処理方法において、前記基材表面に対しブローチ加工を行って凹凸部を形成し、この凹凸部における凸部先端を破壊して破断面を形成する際に、前記凸部先端を、ワイヤブラシで擦ることで破壊することを最も主要な特徴とする。 The present invention provides a thermal spraying pretreatment method for forming a rough surface of a base material before forming a sprayed coating, and performing a broaching process on the base material surface to form a concavo-convex portion. When forming a fractured surface by breaking the surface, the most important feature is to break the tip of the convex portion by rubbing with a wire brush .

本発明によれば、基材表面に対しブローチ加工を行って凹凸部を形成した後、その凸部を破壊して破断面を形成するようにしたので、ボーリング加工による場合に比較して、基材表面を短時間で粗面化することができる。
また、上記凹凸部の凸部先端をワイヤブラシで擦ることで、破断面が安定化したものとなる。 According to the present invention, after forming the concavo-convex portion by performing broaching on the surface of the base material, the convex portion is broken to form the fractured surface. The surface of the material can be roughened in a short time.
Further, the fracture surface is stabilized by rubbing the tip of the convex portion of the concave and convex portion with a wire brush.

以下、本発明の実施の形態を図面に基づき説明する。   Hereinafter, embodiments of the present invention will be described with reference to the drawings.

図１は、本発明の一実施形態に係わる溶射前処理方法におけるブローチ加工を行っている状態を示す断面図である。溶射皮膜を形成する前の基材表面として、ここでは例えばエンジンのシリンダブロック１における円筒内面となるシリンダボア内面３とする。上記したシリンダブロック１は、アルミ合金（ＡＤＣ１２材）からなるダイカスト製であり、シリンダボア内面３は、一定の精度で加工してある。このシリンダボア内面３を粗面に形成した後、鉄系材料からなる溶射用材料をシリンダボア内面３に溶射して溶射皮膜を形成する。   FIG. 1 is a cross-sectional view showing a state in which broaching is performed in a thermal spraying pretreatment method according to an embodiment of the present invention. Here, for example, a cylinder bore inner surface 3 which is a cylindrical inner surface in the cylinder block 1 of the engine is used as the base material surface before the thermal spray coating is formed. The cylinder block 1 described above is made of die-casting made of an aluminum alloy (ADC12 material), and the cylinder bore inner surface 3 is processed with a certain accuracy. After the cylinder bore inner surface 3 is formed into a rough surface, a spraying material made of an iron-based material is sprayed onto the cylinder bore inner surface 3 to form a sprayed coating.

上記したシリンダボア内面３を粗面化する際に、図２に拡大して示すようなブローチ工具５を使用する。図２（ａ）はブローチ工具の正面図、図２（ｂ）は同平面図である。   When the above-described cylinder bore inner surface 3 is roughened, a broach tool 5 as shown in an enlarged view in FIG. 2 is used. FIG. 2A is a front view of the broach tool, and FIG. 2B is a plan view thereof.

このブローチ工具５は、図示しないブローチ盤の主軸６に装着するブローチ刃支持部７に、図２中で下部側から、いずれも星形形状で、最も小径の第１荒加工用ブローチ刃９，第１荒加工用ブローチ刃９より大径の第２荒加工用ブローチ刃１１，第２荒加工用ブローチ刃１１よりさらに大径の仕上げ加工用ブローチ刃１３を順次取り付けてある。   This broaching tool 5 is connected to a broaching blade support 7 mounted on a main shaft 6 of a broaching machine (not shown) from the lower side in FIG. A second roughing broaching blade 11 having a larger diameter than the first roughing broaching blade 9 and a finishing broaching blade 13 having a larger diameter than the second roughing broaching blade 11 are sequentially attached.

次に作用を説明する。図示しないブローチ盤の駆動により、上記したブローチ工具５を、図１に示すように、シリンダブロック１の上方からシリンダボア内に挿入することで、第１荒加工用ブローチ刃９および第２荒加工用ブローチ刃１１が、シリンダボア内面３を順次荒加工によるブローチ加工を行い、続いて仕上げ加工用ブローチ刃１３が、仕上げブローチ加工を行う。   Next, the operation will be described. By driving a broaching machine (not shown), the broaching tool 5 described above is inserted into the cylinder bore from above the cylinder block 1 as shown in FIG. The broach blade 11 sequentially performs broaching by roughing on the cylinder bore inner surface 3, and then the finishing broaching blade 13 performs finish broaching.

図３は、上記したブローチ加工後のシリンダボア内面３の形状を示す斜視図であり、シリンダボアの軸方向（図３中で上下方向）に延びる凹部１５および凸部１７からなる凹凸部１９が形成されている。   FIG. 3 is a perspective view showing the shape of the cylinder bore inner surface 3 after broaching as described above, in which a concavo-convex portion 19 including a concave portion 15 and a convex portion 17 extending in the axial direction (vertical direction in FIG. 3) of the cylinder bore is formed. ing.

図４（ａ）は、その凹凸部１９の一部を拡大して示した斜視図であり、ブローチ加工後は、ブローチ工具５をシリンダボア内から引き抜いた後、図５に示すように、ワイヤブラシ２１をシリンダボア内に対し、回転させつつ挿入する。ワイヤブラシ２１は、図示しない駆動装置の主軸に２３に取り付けられ、軸部２５と、軸部２５の外周面に設けた多数の金属製のピン状部材２７とをそれぞれ備えている。   FIG. 4A is a perspective view showing a part of the uneven portion 19 in an enlarged manner. After broaching, after the broach tool 5 is pulled out from the cylinder bore, as shown in FIG. 21 is inserted into the cylinder bore while being rotated. The wire brush 21 is attached to a main shaft 23 of a drive device (not shown) and includes a shaft portion 25 and a number of metal pin-like members 27 provided on the outer peripheral surface of the shaft portion 25.

上記した図示しない駆動装置に駆動により、ワイヤブラシ２１を回転させつつシリンダボア内に挿入することで、シリンダボア内面３は、図４（ａ）の状態から、凹凸部１９における凸部１７の先端を破壊して除去し、これにより図４（ｂ）に示すような破断面２９を形成する。   By inserting the wire brush 21 into the cylinder bore while rotating the wire brush 21 by driving the driving device (not shown), the cylinder bore inner surface 3 breaks the tip of the convex portion 17 in the concave and convex portion 19 from the state of FIG. Thus, the fracture surface 29 as shown in FIG. 4B is formed.

この結果、シリンダボア内面３を、所望の粗面形状とすることができる。このようなシリンダボア内面３に対する粗面化加工は、ブローチ加工を行って凹凸部１９を形成した後、その凸部１７を破壊して破断面２９を形成すればよいので、ボーリング加工によって粗面化する場合に比較して短時間で行うことができ、加工能率を向上させることができる。   As a result, the cylinder bore inner surface 3 can be formed into a desired rough surface shape. The roughening process for the cylinder bore inner surface 3 is performed by broaching to form the concavo-convex part 19 and then breaking the convex part 17 to form the fracture surface 29. Compared with the case where it does, it can carry out in a short time and can improve processing efficiency.

また、得られる粗面形状も、特にその凸部１７を破壊して得る破断面２９については、ボーリング加工時に切削片によって凸部を破壊する場合に比較して、ワイヤブラシ２１を用いることから安定化し、また工具についても、ボーリング加工時の場合のような鋳巣による破損なども回避でき、工具の長寿命化も達成することができる。   In addition, the roughened surface shape obtained is stable because the wire brush 21 is used for the fractured surface 29 obtained by breaking the convex part 17 as compared with the case where the convex part is broken by a cutting piece during boring. In addition, the tool can be prevented from being damaged by a cast hole as in the case of boring, and the tool life can be extended.

また、ブローチ工具５は、仕上げ加工用ブローチ刃１３に加え、第１，第２荒加工用ブローチ刃１１，１３を備えているので、粗面化加工に先立つシリンダボアのラフボーリング加工やファインボーリング加工工程を削減することができる。   Further, since the broach tool 5 is provided with first and second roughing broaching blades 11 and 13 in addition to the finishing broaching blade 13, rough boring and fine boring of the cylinder bore prior to roughening. The number of processes can be reduced.

なお、上記した基材表面としては、エンジンのシリンダブロックにおけるシリンダボア内面３に限ることはなく、他の円筒内面に対してこの発明を適用可能であり、また円筒内面に限ることもない。   The above-described base material surface is not limited to the cylinder bore inner surface 3 in the engine cylinder block, and the present invention can be applied to other cylindrical inner surfaces, and is not limited to the cylindrical inner surface.

また、上記のようにして溶射前処理加工したシリンダボア内面３の粗面形状については、レーザなどの被接触型の形状測定機などにより形状を測定し、その精度を保証している。   Moreover, about the rough surface shape of the cylinder bore inner surface 3 processed by thermal spraying pretreatment as described above, the shape is measured by a contact-type shape measuring machine such as a laser and the accuracy is guaranteed.

図６は、シリンダボア内面３を粗面化した後に溶射皮膜を形成するための溶射装置の概略を示す全体構成図である。この溶射装置は、シリンダボア内の中心に、ガス溶線式の溶射ガン３１を挿入し、その溶射口３１ａから溶射用材料として溶融した鉄系金属材料を溶滴３３として溶射してシリンダボア内面３に溶射皮膜３２を形成する。   FIG. 6 is an overall configuration diagram showing an outline of a thermal spraying apparatus for forming a thermal spray coating after roughening the cylinder bore inner surface 3. In this thermal spraying apparatus, a gas spray type spray gun 31 is inserted into the center of the cylinder bore, and an iron-based metal material melted as a thermal spraying material is sprayed from the thermal spray port 31a as a spray 33 to spray onto the inner surface 3 of the cylinder bore. A film 32 is formed.

溶射ガン３１は、溶線送給機３５から溶射用材料として鉄系金属材料の溶線３７の送給を受けるとともに、アセチレンまたはプロパンあるいはエチレンなどの燃料を貯蔵した燃料ガスボンベ３９および酸素を貯蔵した酸素ボンベ４１から、配管４３および４５を介して燃料ガスおよび酸素の供給をそれぞれ受ける。   The thermal spray gun 31 is supplied with a molten metal 37 of an iron-based metal material as a thermal spray material from a thermal feeder 35, and also has a fuel gas cylinder 39 storing fuel such as acetylene, propane or ethylene, and an oxygen cylinder storing oxygen. The fuel gas and oxygen are supplied from the pipe 41 through the pipes 43 and 45, respectively.

上記した溶線３７は、溶射ガン３１に対し、中央部の上下に貫通する溶線送給孔４７の上端から下方に向けて送給する。また、燃料および酸素は、溶線送給孔４７の外側の円筒部４９に、上下方向に貫通して形成してあるガス案内流路５１に供給する。この供給した燃料および酸素の混合ガスは、ガス案内流路５１の図６中で下端開口部５１ａから流出し、点火されることで燃焼炎５３が形成される。   The above-mentioned molten wire 37 is fed to the thermal spray gun 31 downward from the upper end of the molten wire feed hole 47 penetrating vertically in the central portion. Further, the fuel and oxygen are supplied to the gas guide channel 51 formed in the cylindrical portion 49 outside the melt feed hole 47 so as to penetrate in the vertical direction. The supplied mixed gas of fuel and oxygen flows out from the lower end opening 51 a in FIG. 6 of the gas guide channel 51 and is ignited to form a combustion flame 53.

前記円筒部４９の外周側には、アトマイズエア流路５５を設けてあり、さらにその外周側には、いずれも円筒形状の隔壁５７と外壁５９との間に形成したアクセラレータエア流路６１を設けてある。   An atomizing air flow channel 55 is provided on the outer peripheral side of the cylindrical portion 49, and an accelerator air flow channel 61 formed between the cylindrical partition wall 57 and the outer wall 59 is provided on the outer peripheral side thereof. It is.

アトマイズエア流路５５を流れるアトマイズエアは、燃焼炎５３の熱を前方（図６中で下方）へ送って周辺部に対する冷却を行うとともに、溶融した溶線３７を同前方へ送る。一方、アクセラレータエア流路６１を流れるアクセラレータエアは、上記前方へ送られ溶融した溶線３７を、この送り方向と交差するように前記シリンダボア内面３に向けて溶滴３３として送り、シリンダボア内面３に溶射皮膜３２を形成する。   The atomizing air flowing through the atomizing air flow channel 55 sends the heat of the combustion flame 53 forward (downward in FIG. 6) to cool the peripheral portion, and sends the molten wire 37 forward. On the other hand, the accelerator air flowing through the accelerator air flow path 61 sends the molten wire 37 fed forward and melted as the droplet 33 toward the cylinder bore inner surface 3 so as to intersect the feed direction, and sprayed onto the cylinder bore inner surface 3. A film 32 is formed.

アトマイズエア流路５５には、アトマイズエア供給源６７から、減圧弁６９を備えたエア供給管７１を通してアトマイズエアを供給する。一方、アクセラレータエア流路６１には、アクセラレータエア供給源７３から、減圧弁７５およびマイクロミストフィルタ７７をそれぞれ備えたエア供給管７９を通してアクセラレータエアを供給する。   Atomized air is supplied to the atomized air flow channel 55 from an atomized air supply source 67 through an air supply pipe 71 provided with a pressure reducing valve 69. On the other hand, accelerator air is supplied from the accelerator air supply source 73 to the accelerator air flow channel 61 through an air supply pipe 79 provided with a pressure reducing valve 75 and a micro mist filter 77.

アトマイズエア流路５５とアクセラレータエア流路６１との間の隔壁５７は、図６中で下部側の先端部に、外壁５９に対しベアリング８１を介して回転可能となる回転筒部８３を備えている。この回転筒部８３の上部外周に、アクセラレータエア流路６１に位置する回転翼８５を設けてある。回転翼８５に、アクセラレータエア流路６１を流れるアクセラレータエアが作用することで、回転筒部８３が回転する。   The partition wall 57 between the atomizing air flow channel 55 and the accelerator air flow channel 61 is provided with a rotating cylinder portion 83 that can rotate with respect to the outer wall 59 via a bearing 81 at the lower end portion in FIG. Yes. A rotating blade 85 located in the accelerator air flow path 61 is provided on the outer periphery of the upper portion of the rotating cylinder portion 83. When the accelerator air flowing through the accelerator air flow path 61 acts on the rotary blade 85, the rotary cylinder portion 83 rotates.

回転筒部８３の先端（下端）面８３ａには、回転筒部８３と一体となって回転する先端部材８７を固定してある。先端部材８７の周縁の一部には、前記したアクセラレータエア流路６１にベアリング８１を通して連通する噴出流路８９を備えた突出部９１を設けてあり、噴出流路８９の先端に、溶滴３３を噴出させる前記した溶射口３１ａを設けている。   A tip member 87 that rotates integrally with the rotary cylinder 83 is fixed to the tip (lower end) surface 83 a of the rotary cylinder 83. A protrusion 91 having an ejection flow path 89 communicating with the accelerator air flow path 61 through the bearing 81 is provided at a part of the peripheral edge of the distal end member 87, and the droplet 33 is formed at the distal end of the ejection flow path 89. The above-described thermal spraying port 31a is provided for jetting.

溶射口３１ａを備える先端部材８７が回転筒部８３と一体となって回転しつつ溶射ガン３１をシリンダボアの軸方向に移動させることで、シリンダボア内面３のほぼ全域に溶射皮膜３２形成する。   The tip member 87 including the spray port 31a rotates integrally with the rotary cylinder portion 83 while moving the spray gun 31 in the axial direction of the cylinder bore, so that the spray coating 32 is formed on almost the entire area of the cylinder bore inner surface 3.

本発明の一実施形態に係わる溶射前処理方法におけるブローチ加工を行っている状態を示す断面図である。It is sectional drawing which shows the state which is performing the broaching in the thermal spraying pretreatment method concerning one Embodiment of this invention. （ａ）は図１の実施形態におけるブローチ工具の正面図、（ｂ）は同平面図である。(A) is the front view of the broach tool in embodiment of FIG. 1, (b) is the top view. 図１の実施形態によるブローチ加工後のシリンダボア内面の形状を示す斜視図である。It is a perspective view which shows the shape of the cylinder bore inner surface after broaching by embodiment of FIG. （ａ）はブローチ加工後のシリンダボア内面の凹凸部の一部を拡大して示す斜視図、（ｂ）はブローチ加工後にワイヤブラシで凹凸部の凸部を除去した状態を示す斜視図である。(A) is a perspective view which expands and shows a part of uneven part of the cylinder bore inner surface after broaching, (b) is a perspective view which shows the state which removed the convex part of the uneven part with the wire brush after broaching. ブローチ加工後にワイヤブラシにより加工を行っている状態を示す断面図である。It is sectional drawing which shows the state currently processed with the wire brush after broaching. 溶射装置の概略を示す全体構成図である。It is a whole block diagram which shows the outline of a thermal spraying apparatus.

符号の説明Explanation of symbols

１ シリンダブロック
３ シリンダボア内面（基材表面，円筒内面）
５ ブローチ工具
９ 第１荒加工用ブローチ刃
１１ 第２荒加工用ブローチ刃
１３ 仕上げ加工用ブローチ刃
１７ 凸部
１９ 凹凸部
２１ ワイヤブラシ
２９ 破断面
３２ 溶射皮膜 1 Cylinder block 3 Cylinder bore inner surface (base material surface, cylindrical inner surface)
DESCRIPTION OF SYMBOLS 5 Broach tool 9 1st roughing broaching blade 11 2nd roughing broaching blade 13 Finishing broaching blade 17 Convex part 19 Concave part 21 Wire brush 29 Fracture surface 32 Thermal spray coating

Claims (3)

溶射皮膜を形成する前の基材表面を粗面に形成する溶射前処理方法において、前記基材表面に対しブローチ加工を行って凹凸部を形成し、この凹凸部における凸部先端を破壊して破断面を形成する際に、前記凸部先端を、ワイヤブラシで擦ることで破壊することを特徴とする溶射前処理方法。   In the thermal spraying pretreatment method for forming the base material surface before forming the spray coating on a rough surface, the base material surface is broached to form an uneven portion, and the tip of the convex portion in the uneven portion is destroyed. A thermal spraying pretreatment method characterized in that, when forming a fractured surface, the tip of the convex portion is destroyed by rubbing with a wire brush. 前記基材表面を円筒内面としてこの円筒内面に対して前記ブローチ加工を行って前記凹凸部を形成し、この凹凸部における前記凸部先端の破壊を、前記ワイヤブラシを回転させて行うことを特徴とする請求項１に記載の溶射前処理方法。   The substrate surface is a cylindrical inner surface, the broaching process is performed on the cylindrical inner surface to form the uneven portion, and the tip of the convex portion in the uneven portion is broken by rotating the wire brush. The thermal spraying pretreatment method according to claim 1. 前記ブローチ加工を行う際に使用するブローチ工具に、荒加工用ブローチ刃および仕上げ加工用ブローチ刃を軸方向に沿ってそれぞれ設け、前記ブローチ工具の軸方向移動によって、前記荒加工用ブローチ刃による荒加工に続いて前記仕上げ加工用ブローチ刃による仕上げ加工を連続して行うことを特徴とする請求項１または２に記載の溶射前処理方法。   The broaching tool used when performing the broaching is provided with a roughing broaching blade and a finishing broaching blade along the axial direction, respectively, and the roughing broaching blade by the roughing broaching blade is moved by the axial movement of the broaching tool. The thermal spraying pretreatment method according to claim 1, wherein the finishing process is continuously performed by the finishing broaching blade following the processing.
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