JPS62248554A - Production of closed-deck type cylinder block - Google Patents

Abstract

PURPOSE:To surely meld a strengthened cylindrical body and molten metal, which is divided and led a gap between a sand core and the strengthened cylindrical body, by arranging the sand core for water jacket and the strengthened cylindrical body, having the molten metal dividing flow part at the end part and inserting loosely the molten metal dividing flow part to a gate connecting to a cavity. CONSTITUTION:Each fiber forming body F is laid in the upper mold 9 and each core l9, and sand core 39 is laid in the lower mold 11 to close the molds. Each fiber forming body F is inserted loosely in each cylindrical part of the sand core 39 and a space S2 for Siamese cylinder barrel forming between the fiber forming body F and the sand core 39 and a space S3 for cylinder block outer wall forming between each side mold 101-102 and the sand core 39, are formed. Next, the molten metal is poured from runner 15 to gate 16, and then divided into the both spaces S2, S3 by the molten metal dividing flow part 42b of the sand core 39, and as the molten metal is positively led to the space S2 of the fiber forming body F side and the running state in the space S2 is good, the molten metal and the fiber forming body F is surely welded.

Description

Detailed Description of the Invention A0 Object of the Invention (11 Industrial Field of Application) The present invention relates to a closed deck type cylinder block, particularly a cylinder barrel having a reinforcing cylinder defining a cylinder bore, and a cylinder block surrounding the cylinder barrel. an outer wall, and a water jacket located between the cylinder barrel and the cylinder block outer wall and facing the outer periphery of the cylinder barrel;
A plurality of reinforcing deck portions that partially connect the cylinder barrel and the outer wall of the cylinder block at the end of the water jacket on the side where the cylinder head is joined, and a cylinder head side communication port located between adjacent reinforcing deck portions. The present invention relates to a method of manufacturing a product comprising:

(2) Prior Art Conventionally, in the casting process of the cylinder block material, no means has been adopted to actively introduce molten metal into the space between the sand core and the reinforcing cylinder in the cavity.

(3) Problems to be Solved by the Invention As a result, there is a problem in that the flow of the metal into the space is poor, resulting in poor welding between the molten metal and the reinforcing cylinder, and the casting quality of the cylinder block material is degraded.

An object of the present invention is to provide the manufacturing method capable of solving the above problems.

B0 Structure of the Invention 11) Means for Solving Problems The present invention provides a sand core for a water jacket, which is provided with a protrusion for forming a communication port having a molten metal distribution portion at the tip on the end face on the cylinder head joint surface side; The reinforcing cylindrical body surrounded by the sand core is installed in a cavity of a mold, and the molten metal distribution part is loosely inserted into a gate communicating with the cavity, and the end face of the sand core and the end face are connected to each other. forming a space for forming a reinforcing deck part between opposing inner surfaces of the cavity; pouring metal into the cavity through the gate to cast a cylinder block material; incorporating the molten metal distribution part in correspondence with the gate; The method is characterized by using the steps of: removing an appendage molded in such a manner from the cylinder block material to obtain the communication port and the reinforcing deck portion.

(2) Effect When the protrusion of the sand core is provided with a molten metal distribution part as described above, the molten metal separated by the molten metal distribution part is actively guided into the space between the sand core and the reinforcing cylinder. This improves the ability to run the hot water in the space.

In addition, since the attachment molded to accommodate the molten metal diverting part in correspondence with the gate is removed from the cylinder block material to obtain the communication port and reinforcing deck part, even if the molten metal diverting part is provided in the sand core, the cylinder will not work. It does not change the shape of the block in any way.

(3) Examples 1 to 3 show a Siamese-type cylinder block S made of fiber-reinforced aluminum alloy obtained by the present invention,
The cylinder block S has four cylinder barrels 11
-1. It is equipped with a Siamese cylinder barrel l formed by coupling each other, a cylinder block outer wall 2 surrounding the Siamese cylinder barrel 1, and a crankcase 3 connected to the lower edge of the Siamese cylinder barrel 1 and the cylinder block outer wall 2. There is. Each cylinder barrel 11
14 is a fiber-reinforced composite cylinder 1 made of a cylindrical fiber molded body F (FIG. 11) as a reinforcing cylinder defining the cylinder bore 4 and an aluminum alloy as a matrix.
a and an aluminum alloy cylindrical body 1b surrounding the cylindrical body 1a.

A water jacket 6 facing the outer periphery of the Siamese cylinder barrel 1 is formed between the Siamese cylinder barrel 1 and the cylinder block outer wall 2. At the end of the water jacket 6 on the cylinder head joint surface a side, the Siamese cylinder barrel l and the cylinder block outer wall 2 are partially connected by a plurality of reinforcing deck parts 8. There is a lower communicating with the head side. As a result, the cylinder block S is configured into a closed deck type.

Figures 5 to 8 show the cylinder block material S shown in Figure 4.
The device is equipped with a metal mold M as a casting mold, and the metal mold M has an upper mold 9 that can be raised and lowered, and is disposed below the upper mold 9. In FIG. 6, the first and second side molds 10 are divided into left and right halves. ．． 10. and bilateral type 1
It is composed of a lower die 11 on which a weight of 0+ and 10g is slidably placed.

7th. As clearly shown in FIG. 8, a sump 1 receives molten aluminum alloy from a melting furnace (not shown) in a lower mold 11.
2, a hot water supply cylinder 13 communicating with the hot water reservoir 12,
a plunger 14 that is slid into the hot water cylinder 13;
A runner 15 extending from the sump 12 and having an annular shape is provided.

A first cavity C3 for molding the Siamese cylinder barrel 1 and the cylinder block outer wall 2 is defined by the upper surface of the lower mold 11 surrounded by the runner 15 and the opposing surfaces of both molds LO+ and lQz. Lower mold 11
On the top surface, each gate 1 is installed at a location corresponding to each communication lower.
The distal end of each gate 16 is located, and the proximal end of each gate 16 is located at the runner 1.
Connects to 5.

The upper mold 9 has a molding block 18 projecting downward, and the molding block 18 has both molds 10. ．． 103 to define a second cavity C2 for molding the crankcase 3. The lower end of the cavity C2 communicates with the upper end of the first cavity C3.

The molding block 18 includes four tall semi-cylindrical first molding parts 181 formed at predetermined intervals, and the outermost brush 1 molding part 18 between the adjacent first molding parts 183. and a convex-shaped second molded part 18 □ located on the outside of each first molded part 18 . is used to form the crank pin and crank arm rotation space 20 (Figs. 2 and 3),
The second molded part 18□ is the bearing holder 2 of the crank journal.
1 (Figures 2 and 3).

A columnar cylinder barrel molding core 19 is protruded from the lower surface of each first molding section 181, and the lower end of the fiber molded body F is fitted into the lower die 11 facing the lower end surface of the core 19. A positioning protrusion 22 is provided to protrude.

A recess 23 is formed at the center of the positioning protrusion 22, and the recess 23 is adapted to fit into the protrusion 19a of the core 19. In addition, two first molding parts 181 located on both sides
, the lower mold 1 is positioned on both sides of the positioning protrusion 22.
1, through holes 24 are formed, and these through holes 24
A pair of temporary installation pins 25 are slid together. The lower ends of these temporary installation pins 25 are as follows:
It is fixed to a mounting plate 26 arranged in the empty space of the lower mold 11.

Two support rods 27 are inserted through the mounting plate 26, and a coil spring 28 is compressed between the lower part of each support rod 27 and the lower surface of the mounting plate 26.

When the mold is opened, the mounting plate 26 receives the elastic force of each coil spring 28 and rises until it comes into contact with the stopper 27a at the tip of each support rod 27, so that the tip of each temporary installation pin 25 protrudes from the upper surface of the lower mold. There is.

A recess 25a is formed on the tip end surface of each temporary installation pin 25 to engage with the lower edge of the sand core.

In addition, a through hole 29 is formed in the lower mold l at a trisecting position between both through holes 24, and the through hole 29 has a
An operating pin 30 whose lower end is fixed to the mounting plate 26 is slid together. When the mold is opened, the tip of the operating pin 30 protrudes into the recess 23, and when the mold is closed, the tip of the operating pin 30 protrudes into the cylinder bore forming core 19.
This causes both plate installation pins 25 to be retracted from the upper surface of the lower mold 11.

Core holders 31 for actually installing sand cores are provided at two locations in the central portions of the walls defining the first cavities CI in the first and second side molds 101.10□. Each core holder 31 has an engagement hole 31a for positioning the sand core, and a clamping surface 31b formed on the outer periphery of the opening to clamp the sand core.
It becomes more.

Each first molding part 18 in the upper mold 9. At the base on both sides of
A plurality of third cavities C3 are formed to communicate with the cavity C2 and allow the molten metal to overflow, and the upper mold 9
A gas vent hole 32 communicating with each third cavity C3 is formed in the third cavity C3.

Closing pins 34 are loosely inserted into these gas vent holes 32, and the upper ends of these closing pins 34 are fixed to a mounting plate 36 disposed above the upper die 9.

A small diameter portion 32a of the gas vent hole 32 that extends upward over a predetermined length from the end communicating with the cavity C1 is adapted to fit with the lower end of the closing pin 34 to close the third cavity C1. .

A hydraulic cylinder 37 is interposed between the upper surface of the upper mold 9 and the mounting plate 36, and the operation of the hydraulic cylinder 37 raises and lowers the mounting plate 36 to open and close the small diameter portion 32a using each closing bin 34. 38 is a guide rond for the mounting plate 36.

9, 9A, and 10 show a sand core 39 for a water jacket, and the sand core 39 has four cylindrical portions 40 corresponding to the four cylinder barrels 11 to 14 of the cylinder block S.
．． - 404 and are omitted from surrounding walls that overlap their adjacent ones, and the core body 41 is designed to form a communicating lower that communicates the water jacket 6 with the water jacket of the cylinder head. Cylinder head joint surface a
A plurality of protrusions 42 protruding from the side end surface 41a and two cylindrical portions 40 located in the middle! , 403, and baseboards 43 protruding from both outer surfaces of the baseboards 403, respectively. As clearly shown in FIG. 9A, each protrusion 42 has a base end 42a that is straightly connected to the end surface 41a of the core body 41 to define the inner circumferential surface of the communicating lower, and a base end 42a of the base end 42a. Cylindrical part 4 at the tip
01 to 404, which are diagonally connected in series so as to protrude outward. Each baseboard 43 has a core body 4
1, and a small diameter portion 43b protruding from the end surface thereof.

FIG. 11 shows a cylindrical fiber molded body F formed from a mixed fiber of carbon fiber and alumina fiber, and its dimensions are 89 m in outer diameter, 78 m in inner diameter, 152 m in height, and its bulk density is 0. 3 g/Ql'', the fiber molded body F is made of carbon fibers (short fibers) with an average diameter of 18 μm and an average length of 0.8 m, and alumina fibers with an average diameter of 3 to 4 μm and an average length of 0.5 m. 1a (short fibers) at a ratio of 1:3, silica sol is added as a binder to the mixed fibers, and molded by applying a suction adhesion molding method.In this case, alumina sol alone is used instead of silica sol. , or it is possible to use a mixture of silica sol and alumina sol.

The above-mentioned suction adhesion molding method is a method in which a cylindrical mold with air permeability with both ends sealed is erected in a tank containing the mixture of the mixed fibers and silica sol, and a suction action is applied to the inside of the cylindrical mold. A method in which a mixture is adsorbed onto the outer surface of a cylindrical shape.

The fiber molded body formed by the above method is used after being released from the mold and subjected to a drying and firing process.

Next, the casting operation of the cylinder block material Sm by the casting apparatus using the fiber molded body F will be explained.

First, as shown in FIG. 5, the upper mold 9 is raised and the molds 101 and 102 on both sides are moved apart from each other to open the mold.The hydraulic cylinder 37 on the upper mold 9 is operated to remove the mounting plate. 36, the closing pin 34 is raised to open the upper opening of the small diameter portion 32a communicating with the third cavity C1, and the plunger 14 in the hot water supply cylinder 12 is lowered.

Each fiber molded body F is attached to each core 19, and the upper end opening of the fiber molded body F is brought into contact with the lower surface of the first molded part 181.

Fifth. 8th. As shown in FIG. 10, the cylindrical portions 4G, 40. on both sides of the sand core 39. The sand core 39 is temporarily installed by engaging the lower edge with the recess 25a of each temporary installation pin 25 of the lower mold 11. The molten metal distribution portion 42b in each protrusion 42 of the sand core 39 is formed by the sixth. Each game (as shown in Figures 6A and 8)
16, and a reinforcing deck part molding space s is formed between the end surface 41a of the sand core 39 and the inner surface of the first cavity C1, and thus the upper surface of the lower mold 11.

As shown in FIG. 6, the two-sided molds 10+ and 10z are moved a predetermined distance in the direction in which they approach each other, and each core receiver 31
and each baseboard 43 to perform the actual installation of the sand core 39,
That is, the sand core 39 is positioned by fitting the small diameter portion 43b of each skirting board 43 in the sand core 39 into the engagement hole 31a of each core receiver 31, and also aligning the cylinder barrel arrangement direction of each large diameter portion 43a. The sand core 39 is clamped by the clamping surfaces 31b of each core holder 31 by abutting the end surfaces parallel to the clamping surfaces 31b of each core holder 31.

Next, the upper mold 9 is lowered to close the mold, and as a result of this mold closing, each fiber molded body F is attached to each cylindrical portion 40 of the sand core 39. ~4
04, and the lower end of each fiber molded body F fits into the positioning protrusion 22. As a result, the first cavity CI includes a Siamig cylinder barrel molding space S2 existing between the fiber molded body F and the sand core 39, and a both-side mold 10+, 1
A cylinder block outer wall forming space S exists between the zero layer and the sand core 39. Also, the convex portion 1 of the core 19
9a fits into the recess 23 of the lower mold 11, so the operating pin 3
0 is pushed down, each temporary installation pin 25 descends, and the lower mold 11
Pull in from the top.

A molten metal made of aluminum alloy (JIS ADC12) at a temperature of 730 to 740°C is supplied from a melting furnace to the sump 12 of the lower mold 11, and the plunger 14 is heated to a height of 0.08 to 0.3 m.
/sec, and as shown in FIG. 12, the molten metal is injected from the lower part of the first cavity CI through the gate 16 from the runner 15 with the pressure p1 into the cavities C1 and the second cavity C2.
The gas such as air in the t is pushed up by the molten metal and flows into the third
The upper mold 9 passes through the gas vent hole 32 communicating with the cavity C3.
passes above.

In this case, the molten metal flow in each game) 16 is divided into rain spaces 3□+33 by the molten metal distribution part 42b of the sand core 39, as shown in FIG. 6A, and thereby the space on the fiber molded body F side Since the molten metal is actively guided to S2, the space S2
Improves the running properties of hot water.

By applying this push-up method, the first. second cavity C1,
C! As the scene rises in a substantially horizontal state, gas entrainment into the molten metal is prevented and the formation of cavities is thus avoided. The pressure p is 10 to 50 ksr/-, and the molten metal is substantially filled into the fiber molded body F under this pressure.

When the molten metal is completely poured into the third cavity C1,
The hydraulic cylinder 37 on the upper mold 9 is operated to lower the mounting plate 36, and the closing pin 34 closes the small diameter portion 32a communicating with the third cavity C1.

After that, plunger 14 is adjusted to 0.14 to 0.18 m/sec.
The molten metal is raised at a speed of The aim is to improve its strength by making it denser. As mentioned above, since the hot water circulation in space st is good,
The fiber molded body F is sufficiently infiltrated with the molten metal, thereby obtaining a fiber-reinforced composite cylinder 1a free from casting defects.

Further, the weldability between the cylindrical body 1a and the aluminum alloy cylindrical body 1b surrounding it is also good.

During the casting operation, the sand core 39 is passed through each baseboard 43 of the sand core 39 to the mold 10 on both sides. ．． Since the sand core 39 is held in an accurate position by the sand core 39, the sand core 39 does not float up when pouring the molten metal into the first cavity C1 and when pressurizing the molten metal in the cavity C3. Also, each baseboard 43
Since the end face of the large diameter portion 43a of the two-sided mold 10+ and 10g abuts against the clamping surfaces 31b of the core receiver 31, when the sand core 39 tends to swell, the deformation force is applied to each clamping surface 31.
b, thereby preventing deformation of the sand core 39 and providing a Siamese cylinder barrel l with uniform wall thickness around each cylinder bore 4.

After the molten metal has completely solidified, the mold is opened to obtain the cylinder block material Sm shown in FIG. 4.

This cylinder block material Sm has appendages 44, to 4 corresponding to the sump 12, runner 15, and each gate 16.
4. Since each attachment 44. is attached, each attachment 44. ~443 is removed. Each appendage 44 has a built-in molten metal distribution part 42b corresponding to each gate 16. When removed, each communicating lower is formed by the base end 42a of each protrusion 42 of the sand core 39, and a reinforcing deck portion 8 is formed between adjacent communicating lowers. In this way, each appendage 44. If each communicating lower and each reinforcing deck part 8 are obtained by removing , the shape of the cylinder block S will not be changed even if the molten metal distribution part 42b is provided in the sand core 39. A water jacket 6 is obtained by removing sand, and the inner circumferential surface of each cylinder bore 4 is machined into a perfect circle. Furthermore, by performing other predetermined processing, a cylinder block S shown in FIGS. 1 to 3 is obtained. is obtained.

Note that the fiber molded body F may be molded from one type of reinforcing fiber. Furthermore, it is also possible to use a cast iron sleeve as the reinforcing cylinder, and in this case as well, the molten metal and the sleeve can be reliably welded because the flowability in the space Sfi is good.

In addition to the aluminum alloy, copper is used as the matrix.
Magnesium alloy or the like is used.

C0 Effects of the Invention According to the present invention, since the casting work is performed with the molten metal distribution part of the communication port forming projection loosely inserted into the gate, molten metal is actively poured into the space existing between the sand core and the reinforcing cylinder. As a result, the molten metal and the reinforcing cylindrical body can be reliably welded by improving the flowability in the space, and a cylinder block material with excellent casting quality can be obtained.

In addition, since the attachment molded to accommodate the molten metal diverting part in correspondence with the gate is removed from the cylinder block material to obtain the communication port and reinforcing deck part, even if the molten metal diverting part is provided in the sand core, the cylinder will not work. There is no need to make any changes to the shape of the pro-tsuku, and furthermore, the long way entrance and reinforcing deck can be easily manufactured.

[Brief explanation of drawings]

1 to 3 show a Siamese type cylinder block made of the material obtained according to the present invention, FIG. 1 is a perspective view seen from above, FIG. 2 is a sectional view taken along the line X-X in FIG.
The figures are a sectional view taken along the line X-X in Figure 9, Figure 3 is a perspective view seen from below, Figure 4 is a perspective view of the Siamese type cylinder block material seen from above, and Figure 5 is when the mold of the casting machine is opened. 6 is a vertical sectional front view of the casting device when the mold is closed, FIG. 6A is an enlarged view of the main part of FIG. 6, FIG. 7 is a sectional view taken along the line X-X in FIG. 9, and FIG. is a sectional view taken along line X-X in Figure 9, Figure 9 is a perspective view of the sand core seen from below, and Figure 9A is Figure 9 IXa-I.
An enlarged cross-sectional view taken along the Xa line; FIG. 10 is a cross-sectional view taken along the line X-X in FIG.
FIG. 11 is a perspective view of the fiber molded body, and FIG. 12 is a graph showing the relationship between molten metal pressure and time. a... Cylinder head joint surface, C1... First cavity, F... Fiber molded body, M... Mold 1 as a mold, Sm... Siamese type cylinder pro V-shaped material,
S2...Space, II-14...Cylinder barrel, l
a... Fiber-reinforced composite cylinder as a reinforcing cylinder, 2...
Cylinder block outer wall, 4... cylinder bore, 6...
・Water jacket, 7...Communication port, 8...Reinforced deck part, 16...Gate, 39...Sand core, 41a...
・End face, 42... Protrusion, 42b... Molten metal distribution part, 4
4. ...Applicant for Permission to Hold Attachments Person Honda Motor Co., Ltd. Illustration procedure amendment (.issued) Showa 6? October 14, 2015 1. Display of the case 1986 Patent Application No. 91857 3. Person making the amendment Relationship to the case Patent applicant name (532) Honda Motor Co., Ltd. 4, Representative
Director 〒105 5 "Detailed Description of the Invention" column of the specification subject to amendment and Figure 7 of the drawings 1 Correct Contents 1, Page 7 of the Specification, Line 16, ``And, both sides type 10..10 □” should be corrected as follows. "And in Figure 7, the third and fourth halves of the left and right halves
Side type 10. ．． 10. and each side mold 10. ~10,'' 2. On page 8, line 8 of the specification, the phrase ``opposing surfaces of both side molds 101 and 10g'' is corrected to read ``the lower half of each side mold 102 to 104''. 3. In the specification, No. 1O, line 16.17, "both sides mold 10+, 10tJ" is corrected to "the upper half of each side mold 10. to 104". 4. Lines 2 to 4 of page 10 of the specification are corrected as follows. "The lower mold 11 has through holes 2 that penetrate the lower mold 11 on both sides of the positioning projections 22 at positions facing the two first molding parts +8 located on both sides."5. Line 7 of page 15 of the specification is corrected as follows. ``Also, opposing both sides type 101.10□ 1103.1
6. On the last line of page 16 of the specification, after the words "is", the following is added. "The other double-sided molds 10s and IO2 are also moved in the same way." 7. In the specification, page 17, line 7, "both-sided molds 10+, 10tJ" is corrected to "each side mold 101 to 104." 8. Lines 13 on page 18 of the specification to line 1 on page 19 are corrected as follows. ``Also, since the opening of the small diameter part 32a of the gas vent 32 is narrow, when pouring the molten metal into the first and second cavities CI+02, back pressure is generated in the cavity CI+02. The back pressure acts evenly on the entire scene.As a result, the scene rises almost horizontally with less ripples, which prevents gas from being entrained in the molten metal, and also allows for efficient degassing, which eliminates cavities. Due to the back pressure, the first and second cavities C+, C
As shown in FIG. 12, the injection pressure of the molten metal in Z is a pressure 1) higher than atmospheric pressure, for example, 2 to 5 kg/c+d. Furthermore, since the fiber molded body F is preheated to the above temperature,
The molten metal around the fibrous molded body F is kept warm, thereby preventing the molten metal from adhering to the fibrous molded body F. 9. In the specification, page 19, line 9, next to "rp, bottom", add ", that is, under a pressure of 400 kg/-". 10. On page 19, line 12 of the specification, after the words "to plan," the following is added. "During this process of increasing the pressure of the molten metal, the pressure of the molten metal is 5 to 20
The molten metal is filled into the fiber molded body F at 1/cd. In this way, since the filling pressure of the molten metal is low, the fiber molded product F
is not destroyed by molten metal. 11. As shown in the attached drawing, the reference numeral r in Figure 7 of the drawing
Correct lO,J to rlo,j, and use the sign rloffJ
join. that's all

Claims (1)

[Claims] a cylinder barrel having a reinforcing cylindrical body defining a cylinder bore; a cylinder block outer wall surrounding the cylinder barrel; a water jacket located between the cylinder barrel and the cylinder block outer wall and facing the outer periphery of the cylinder barrel; At the end of the jacket on the side facing the cylinder head,
In manufacturing a closed deck type cylinder block comprising a plurality of reinforcing deck parts that partially connect the cylinder barrel and the outer wall of the cylinder block, and a cylinder head side communication port between adjacent reinforcing deck parts. A sand core for a water jacket, which has a protrusion for forming a communication port with a molten metal distribution part at the tip on the end face on the cylinder head joint surface side, and the reinforcing cylindrical body surrounded by the sand core are inserted into the cavity of the mold. and loosely inserting the molten metal distribution part into a gate communicating with the cavity, and forming a space for forming a reinforcing deck part between the end surface of the sand core and the inner surface of the cavity facing the end surface. ; pouring metal into the cavity through the gate to cast a cylinder block material; and removing from the cylinder block material an accessory molded to accommodate the molten metal distribution part corresponding to the gate. A method for manufacturing a closed deck type cylinder block, comprising: obtaining the communication port and the reinforcing deck portion.