WO2009112177A1 - Carter-moteur et son procédé de fabrication - Google Patents

Carter-moteur et son procédé de fabrication Download PDF

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Publication number
WO2009112177A1
WO2009112177A1 PCT/EP2009/001480 EP2009001480W WO2009112177A1 WO 2009112177 A1 WO2009112177 A1 WO 2009112177A1 EP 2009001480 W EP2009001480 W EP 2009001480W WO 2009112177 A1 WO2009112177 A1 WO 2009112177A1
Authority
WO
WIPO (PCT)
Prior art keywords
cylinder
die
core
casting
cylinder crankcase
Prior art date
Application number
PCT/EP2009/001480
Other languages
German (de)
English (en)
Inventor
Erik Graf
Patrick Izquierdo
Peter Lingl
Peter Ludwig
Christian Schwarz
Guido Söll
Original Assignee
Daimler Ag
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 Daimler Ag filed Critical Daimler Ag
Publication of WO2009112177A1 publication Critical patent/WO2009112177A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/18—Other cylinders
    • F02F1/20—Other cylinders characterised by constructional features providing for lubrication
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • F02F2001/104—Cylinders; Cylinder heads  having cooling means for liquid cooling using an open deck, i.e. the water jacket is open at the block top face

Definitions

  • the invention relates to a method for producing a cylinder crankcase. Furthermore, the invention relates to a cylinder crankcase.
  • the open water jacket leads to a limitation of the mechanical load capacity of the motors. It would be better, therefore, an at least partially closed water jacket ("closed deck” construction), which is not represented in the conventional die-casting process for the reasons mentioned above "Closed deck” - Crankcase in die casting basically possible.
  • closed deck construction an at least partially closed water jacket
  • an additional ring is placed around the cylinder liner, which the Salt core keeps in the distance and positioned in the tool.
  • an iron-based cylinder liner means a significantly increased weight.
  • a cylinder crankcase which has a base material modified by alloying in the region of the cylinder surfaces.
  • the base material is modified by the local introduction of suitable alloying elements so that it withstands higher tribological loads.
  • Object of the present invention is to produce a cylinder crankcase at high cycle times in the "closed deck” method, which has a high mechanical and tribological stability and thereby has a reduced weight.
  • the method according to claim 1 for producing a cylinder crankcase comprises the following steps: Making a core,
  • undercutting can be produced in the die casting process, which enables the representation of a cylinder crankcase in a "closed-deck" construction, resulting in a particularly high mechanical stability of the crankcase compared to conventional open-top cylinder crankcases. Since the die casting technique (or squeeze cast technique) is used, high cycle times can be realized. Compared to conventional cylinder crankcases is dispensed with the use of cylinder liners.
  • a cylinder bore in "open deck” construction with a sprayed layer usually does not provide the mechanical stability, the walls of the cylinder bores are barreled by the high pressures, resulting in a flow of unburned gasoline and increases fuel consumption.
  • the introduction of a mechanically stable and tribologically resistant cylinder liner leads to a significant increase in weight, first through the application of the "closed deck” design using a removable core and bringing a thermal spray coating with the desired tribological stability leads to the desired weight reduction while high mechanical stability.
  • the casting piston speed in a first die casting phase is between 0.08 m / s and 0.2 m / s, preferably between 0.12 m / s and 0.15 m / s.
  • the casting piston speed should be between 4.0 m / s and 4.5 m / s, preferably between 4.2 m / s and 4.4 m / s, in particular 4.3 m / s.
  • the core is least mechanically stressed.
  • an advantageous pressure build-up time is more than 110 ms.
  • the temperature of the light metal alloy is advantageously between 650 0 C and 690 0 C preferably between 670 0 C and 680 0 C.
  • the releasable core forms after casting in the cylinder crankcase a water jacket between a cylinder wall and the rest of the cylinder crankcase.
  • the water jacket serves to cool the cylinder wall.
  • the core preferably has a ring on a cylinder head side. Through-openings can be present in the core underneath the rim, which form webs between the cylinder wall and the remaining crankcase after casting.
  • the arc wire spraying is applied as a thermal spraying process.
  • other spraying methods such as plasma spraying or flame spraying can also be used.
  • the basis for the sprayed layer is a tri-logically stable iron alloy.
  • the cylinder crankcase is made of an aluminum-silicon die-cast alloy, the cylinder crankcase being designed in a "closed-deck" construction Like the rest of the cylinder crankcase and the cylinder walls are coated with an arc wire spraying layer, such a cylinder crankcase has high mechanical strength with high tribological resistance, it is lightweight and economical to produce.
  • Figure 1 is a perspective view of a removable core for insertion into a diecasting tool.
  • Fig. 2 is a perspective view of a cylinder crankcase with a cast-in core according to Fig.l;
  • FIG 3 is a perspective view of a cylinder crankcase in "closed deck” construction with dissolved out core.
  • Fig. 6 is a schematic representation of a single core with conical taper
  • Fig. 7 is a sectional view through the core along the line VII in Fig. 6;
  • FIG. 9 is a sectional view of the core of FIG. 8.
  • a core 4 according to FIG. 1 is inserted into the die casting tool.
  • This core 4 is of course intended for all cylinder bores, in the present figures 1-3 is shown for comparison purposes, however, only a single core.
  • the core 4 preferably consists of a per se known inorganic granules, which is composed essentially of a salt and various binders.
  • the core 4 is produced, for example, by a core shooting method or a pressing method.
  • there are special core tools that can be configured in such a way that, according to the number of cylinders, the corresponding number of cores are pressed in an integral core component (compare FIGS. 8 and 9).
  • the core 4 according to FIG. 1 has a collar 12, which adjoins a core jacket in the area on the cylinder head side.
  • the wreath is preferably inserted into a recess provided for this purpose in a fixed tool side.
  • the core is thus (in contrast to US 4, 446, 906) supported and thus keeps the very high pressure during the casting process without breaking.
  • a core shell 30 extends at a distance of a few millimeters concentric with the quill.
  • the core jacket has a curved lower boundary line 16.
  • the boundary line 16 could also be configured in stages or the like.
  • FIG. 2 shows a crankcase 2 in which a core 4 according to FIG. 1 is cast.
  • the ring 12 of the core 4 can still be seen above the cylinder head end 8 of the left cylinder wall 6.
  • the core 4 is replaced by a liquid medium, for. B. dissolved out with water.
  • the core 4 decays into its granules and is washed out by the water.
  • the core material can be washed out, for example, through the channel 26 (FIGS. 4 and 5) of the cylinder crankcase.
  • Washing remain metallic webs 22 are on the cylinder head end 8 of the cylinder liner 6, which traverse the water jacket 24 and this partially to the cylinder head (not shown) out close (Fig. 3). This is called a "closed deck" cylinder crankcase.
  • the metallic webs 22 are formed by casting metal in the core 4 through vertical openings 14 (FIG. 1) and solidifying.
  • the openings 14 are arranged directly below the cylinder head end 8 of the cylinder wall 6.
  • the geometry of the webs 22 and their number thus depends on the nature of the opening 14 in the core 4. Their design will be discussed later.
  • FIG. 3 two sectional lines IV and V are shown, wherein the line IV extends through the free water jacket 24 and this section is shown schematically in Figure 4.
  • the line V passes through two metallic webs 22, which correlates with the illustration in FIG.
  • the water jacket 24 is open to the cylinder head, allowing a connection of the water circuits from the cylinder head and the crankcase.
  • the core is still included in the cast crankcase in this illustration.
  • the rim 12 of the core 4 is shown above the cylinder liner in dashed lines, although it has already been removed in this cut state of the crankcase 2.
  • FIG. 3 two sectional lines IV and V are shown, wherein the line IV extends through the free water jacket 24 and this section is shown schematically in Figure 4.
  • the line V passes through two metallic webs 22, which correlates with the illustration in FIG.
  • the water jacket 24 is open to the cylinder head, allowing a connection of the water circuits from the cylinder head and the crankcase.
  • the core is still included in the cast crankcase in this illustration
  • the core 4 has already been removed from the crankcase 2, the water jacket 24 which is covered by the webs 22 on the cylinder head end 8 of the cylinder wall 6 is now exposed.
  • the granules have passed through the channel 26.
  • the original position of the ring 12 above the cylinder liner 6 is marked by a dashed line to further understanding.
  • the vertical openings 14 are configured in the form of pendulum bores in FIGS. 6 and 7, which narrow in a manner similar to loopholes from outside to inside. However, it can also be expedient slots long vertically inwardly extending walls.
  • the core 4 according to FIG. 1 has approximately rectangular openings 14. The recess in the region of the rim 12 are caused by the core pressing tool in this core.
  • the core 4 in the described embodiment is inserted into the casting tool, not shown, in a receptacle provided for this purpose.
  • the casting mold is closed and under pressure liquid casting metal, here an aluminum-based die casting alloy (ALSI12) is cast.
  • ALSI12 aluminum-based die casting alloy
  • Diecasting is generally understood to mean a casting process in which, compared to the gravitational pressure, an increased pressure is used for pouring the metal into the usually metallic casting tool. These methods are usually called die casting or squeeze casting, although low pressure casting can be applied.
  • the conventional die casting process involves three phases. In the first phase, a casting piston is moved comparatively slowly until the casting metal has reached a sprue area in the casting tool. In a second phase, the casting piston is accelerated and the casting metal is injected at high speed into a mold cavity of the casting tool. In a subsequent third phase, the mold cavity is filled with casting metal, the piston speed is greatly reduced and the still liquid casting metal is densified to solidification.
  • the thus cast cylinder crankcase whose geometric features are already described in detail to the figures 2-5 is now ejected from the casting mold and placed in a bath in which the core 4 is purged.
  • the cylinder crankcase is further processed, z. B. deburred and surface-treated.
  • a tribologically favorable spray coating is applied to the cylinder wall 6 in a thermal spraying process.
  • the arc wire spraying has been found to be particularly favorable.
  • an iron-based layer can be applied in an economically favorable manner. This iron layer corresponds approximately to the commonly used gray cast cylinder liners of the material composition.
  • the alloy used in the arc wire spraying can be adapted to the tribological requirements.
  • the sprayed layer generally has a precisely set porosity which forms open pores on the layer surface after further mechanical treatment of the sprayed layer. These open pores serve as so-called lubricant pockets in which lubricant reservoirs are formed during the piston movement during engine operation, which ensure optimum lubrication of the piston and avoid abrasion.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un carter-moteur (2) et comprend les étapes suivantes : fabrication d'un noyau (4), mise en place du noyau (4) dans un moule de coulée, coulée du carter-moteur (2) sous pression élevée dans un métal léger, extraction du noyau (4) du carter-moteur (2) moulé, revêtement d'une paroi de cylindre (6) à l'aide d'un procédé de pulvérisation à chaud. L'invention porte également sur un carter-moteur (2) moulé sous pression dans un alliage aluminium-silicium pour coulée sous pression, qui est utilisé dans une architecture dite « closed-deck », et qui est caractérisé par le fait que les parois de cylindre (6) du carter-moteur (2) sont faites dans le même alliage aluminium-silicium pour coulée sous pression que le reste du carter-moteur (2), et que les parois de cylindre (6) sont revêtues à l'aide d'une couche pulvérisée à l'arc.
PCT/EP2009/001480 2008-03-12 2009-03-03 Carter-moteur et son procédé de fabrication WO2009112177A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE200810013813 DE102008013813A1 (de) 2008-03-12 2008-03-12 Zylinderkurbelgehäuse und Verfahren zu dessen Herstellung
DE102008013813.4 2008-03-12

Publications (1)

Publication Number Publication Date
WO2009112177A1 true WO2009112177A1 (fr) 2009-09-17

Family

ID=40677925

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2009/001480 WO2009112177A1 (fr) 2008-03-12 2009-03-03 Carter-moteur et son procédé de fabrication

Country Status (2)

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DE (1) DE102008013813A1 (fr)
WO (1) WO2009112177A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10544751B2 (en) 2015-05-12 2020-01-28 Avl List Gmbh Liquid-cooled internal combustion engine

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT512280B1 (de) * 2012-02-08 2013-07-15 Avl List Gmbh Flüssigkeitsgekühlte brennkraftmaschine
DE102012015405B4 (de) * 2012-08-03 2014-07-03 Federal-Mogul Burscheid Gmbh Zylinderlaufbuchse und Verfahren zu deren Herstellung
DE102013013646A1 (de) 2013-08-16 2015-02-19 Daimler Ag Zylindergehäuse für eine Hubkolben-Verbrennungskraftmaschine, insbesondere eines Kraftwagens
DE102013020835B4 (de) 2013-08-16 2021-11-11 Daimler Ag Zylinderkurbelgehäuse für eine Hubkolben-Verbrennungskraftmaschine
DE102020106059A1 (de) 2020-03-06 2021-09-09 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Herstellen eines Gussbauteils sowie Gießstation

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0734962A (ja) * 1993-07-20 1995-02-03 Hitachi Metals Ltd 軽合金製シリンダブロックとその製造方法
EP0677652A1 (fr) * 1994-03-18 1995-10-18 Yamaha Hatsudoki Kabushiki Kaisha Bloc-cylindres sans fourreaux pour moteurs
EP0927820A1 (fr) * 1996-07-02 1999-07-07 Yamaha Hatsudoki Kabushiki Kaisha Bloc cylindre moulé et procédé de fabricatin
DE10221674A1 (de) * 2002-05-16 2003-12-04 Audi Ag Verfahren zum Herstellen eines Zylindergehäuses und Zylindergehäuse
DE102005022469A1 (de) * 2005-05-14 2007-01-18 Audi Ag Brennkraftmaschine mit einem Zylinderkurbelgehäuse

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4446906A (en) 1980-11-13 1984-05-08 Ford Motor Company Method of making a cast aluminum based engine block
DE19752518A1 (de) 1997-11-27 1999-06-02 Ks Aluminium Technologie Ag Druckgießverfahren
DE102005043193A1 (de) 2005-09-09 2007-03-15 Ks Aluminium-Technologie Ag Zylinderkurbelgehäuse für Kraftfahrzeuge

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0734962A (ja) * 1993-07-20 1995-02-03 Hitachi Metals Ltd 軽合金製シリンダブロックとその製造方法
EP0677652A1 (fr) * 1994-03-18 1995-10-18 Yamaha Hatsudoki Kabushiki Kaisha Bloc-cylindres sans fourreaux pour moteurs
EP0927820A1 (fr) * 1996-07-02 1999-07-07 Yamaha Hatsudoki Kabushiki Kaisha Bloc cylindre moulé et procédé de fabricatin
DE10221674A1 (de) * 2002-05-16 2003-12-04 Audi Ag Verfahren zum Herstellen eines Zylindergehäuses und Zylindergehäuse
DE102005022469A1 (de) * 2005-05-14 2007-01-18 Audi Ag Brennkraftmaschine mit einem Zylinderkurbelgehäuse

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10544751B2 (en) 2015-05-12 2020-01-28 Avl List Gmbh Liquid-cooled internal combustion engine

Also Published As

Publication number Publication date
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