EP0882534A1 - Verfahren zum Herstellen eines Zylinderblockes einer Brennkraftmaschine - Google Patents

Verfahren zum Herstellen eines Zylinderblockes einer Brennkraftmaschine Download PDF

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Publication number
EP0882534A1
EP0882534A1 EP98109853A EP98109853A EP0882534A1 EP 0882534 A1 EP0882534 A1 EP 0882534A1 EP 98109853 A EP98109853 A EP 98109853A EP 98109853 A EP98109853 A EP 98109853A EP 0882534 A1 EP0882534 A1 EP 0882534A1
Authority
EP
European Patent Office
Prior art keywords
preform
protrusion
bore
bore core
cylinder block
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.)
Granted
Application number
EP98109853A
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English (en)
French (fr)
Other versions
EP0882534B1 (de
Inventor
Manabu Fujine
Hikohito Yamazaki
Yoshiaki Kajikawa
Masayuki Hasebe
Masuo Shimizu
Mitsuhiro Karaki
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.)
Toyota Motor Corp
Original Assignee
Toyota Motor Corp
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 Toyota Motor Corp filed Critical Toyota Motor Corp
Publication of EP0882534A1 publication Critical patent/EP0882534A1/de
Application granted granted Critical
Publication of EP0882534B1 publication Critical patent/EP0882534B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form

Definitions

  • the present invention relates to a production method of a cylinder block of an internal combustion engine. More particularly, the present invention relates to a cylinder block having a cylinder bore surface constructed from metal matrix composite (MMC).
  • MMC metal matrix composite
  • a conventional production method for MMC cylinder block includes the steps of: setting a preheated preform (or formed member) 102 having a tapered inside surface and a straight outside surface parallel to an axis of the preform onto a bore core 101 having a tapered outside surface; arranging the bore core such that it is mounted in a cavity 104 defined by a mold 103; injecting molten metal 105 from an injection cylinder 106; and pressing the injected molten metal by a plunger 107, whereby the molten metal is infiltrated (or impregnated) into the preform 102 from the outside surface of the preform 102 only so that the preform changes to an MMC.
  • the cylinder block cast product is taken out of the mold 103 and the bore core 101, and then the MMC cylinder bore surface is machined to a specified diameter to form a straight cylindrical cylinder bore.
  • the clearance 108 between the bore core 101 and the preform 102.
  • the clearance is caused, for example, by a difference between the taper angle of the bore core 101 and the taper angle of the preform 102 and a difference between the temperature of the bore core (for example, 100 - 200 °C) ad the temperature of the preform (for example, 500 - 900 °C).
  • the clearance 108 exists, when the molten aluminum is pressed and is infiltrated into the preform 102 as illustrated in FIG. 13A, cracks such as crack 109 often develop in the preform 102 as illustrated in FIG. 13B.
  • a shear fracture 109 develops along a direction inclined by 45 degrees from the direction of the compression force. Buckling occurs along the fracture surface and causes a local portion of high density of reinforcement fibers.
  • the preform 102 is usually manufactured by dipping an air permeable cylindrical former into a slurry containing reinforcement fibers and particles and aspirating the slurry water from an interior of the former thereby forming a layer of the reinforcement fibers and particles on the outside surface of the former. Then, the former and the layer of the reinforcement fibers and particles are taken out of the slurry and the layer of the reinforcement fibers and particles is dried to form a preform 102 constructed from the reinforcement fibers and particles.
  • the reinforcement fibers extend in directions perpendicular to a radial direction of the preform to form a laminar wall. As a result, the separation resistant strength of one layer from another layer of the laminar wall of the preform is relatively low.
  • the crack 109 tends to change the propagation direction to the circumferential direction of the preform due to the shear stress thereby resulting in a circumferential crack 110 (FIG. 14).
  • the molten aluminum flows into the crack 110 and solidifies, and when the crack portion is exposed to the outside during machining, it causes a portion 111 that has no reinforcement fibers. Such portion 111 will cause excessive abrasive wear and seizure of the piston-ring during actual operation of the engine.
  • the temperature of the preform 102 rapidly decreases.
  • the molten aluminum does not tend to infiltrate smoothly into the preform and the pressure of the molten aluminum rises before the entire portion of the preform is infiltrated with the molten aluminum, whereby the non-infiltrated portion of the preform is compressed (or crushed).
  • the inside surface of the preform is tapered (more than 1 degree). Therefore, as illustrated in FIG. 16, the lower the preform is in the axial direction, the larger the deformation of the preform is due to compression.
  • An object of the present invention is to provide a production method for a cylinder block of an internal combustion engine having a cylinder bore surface constructed from metal matrix composite (MMC) that can solve at least one of the above-described three problems: the occurrence of a shear crack, a circumferential propagation of the shear crack, and compression of a portion of the preform.
  • MMC metal matrix composite
  • a production method for MMC cylinder block of an internal combustion engine includes the steps of: setting a generally cylindrical preform having an inside surface and an outside surface in a cavity defined by a mold and a bore core having an outside surface to form a clearance where molten metal is lead between the inside surface of the preform and the outside surface of the bore core; and supplying molten metal into the cavity so that the molten metal is infiltrated into the preform from both the inside surface and the outside surface of the preform whereby the preform changes to a metal matrix composite.
  • the preform is supported by an upper mold and a lower mold, or is supported by the bore core at the protrusions formed in the bore core.
  • the preform line-contacts the protrusions of the bore core or the upper and lower molds the decrease in temperature of the preform is suppressed.
  • FIGS. 1A - 1D and FIG. 2 illustrate a production method for a cylinder block of an internal combustion engine applicable to any embodiment of the present invention
  • FIGS. 3 - 4 illustrate a method according to a first embodiment of the present invention
  • FIG. 5 illustrates a method according to a second embodiment of the present invention
  • FIG. 6 illustrates a method according to a third embodiment of the present invention
  • FIG. 7 illustrates a fourth embodiment of the present invention
  • FIG. 8 illustrates a fifth embodiment of the present invention
  • FIGS. 9 and 10 illustrate a sixth embodiment of the present invention.
  • Portions common or similar to all of the embodiments of the present invention are denoted with the same reference numerals throughout all of the embodiments of the present invention.
  • FIGS. 1A - 1D and FIG. 2 First, portions common or similar to all of the embodiments of the present invention will be explained with reference to FIGS. 1A - 1D and FIG. 2.
  • a production method for a cylinder block of an internal combustion engine according to the present invention includes a first step and a second step.
  • a generally cylindrical, preheated, preform 2 having an inside surface 2a and an outside surface 2b is set in a cavity 4 defined by a mold 3 which includes a bore core 1 having an outside surface 1a so that a clearance 8 where molten metal is lead is formed between the inside surface 2a of the preform 2 and the outside surface 1a of the bore core 1.
  • the clearance 8 has a thickness equal to or greater than 0.5 mm.
  • the clearance 8 is formed throughout an entire circumference of the inside surface of the preform 2, except portions where protrusions contact the bore core 1 in a case where the preform is supported by the bore core.
  • molten metal 5 (molten aluminum) is supplied into the cavity 4 so that the molten metal 5 is infiltrated into the preform 2 from both the inside surface 2a and the outside surface 2b of the preform 2 whereby the preform 2 changes to a metal matrix composite (MMC).
  • MMC metal matrix composite
  • the production method for a cylinder block according to the present invention may include a third step and a fourth step.
  • a cylinder block cast product 9 is taken out of the mold 3 and the bore core 1 after the molten metal has solidified.
  • a cylinder bore surface of metal matrix composite of each cylinder bore of the cylinder block cast product 9 is machined to a specified diameter.
  • the molten metal is injected into the cavity 4 by an injection cylinder 6 having a plunger tip 7.
  • the bore core 1 and the preform 2 are arranged laterally in the molding apparatus, the bore core 1 and the preform 2 may be arranged vertically.
  • the molten metal is, for example, molten aluminum, though the molten metal is not limited to molten aluminum.
  • the preheating temperature of the preform 2 may be lower than that of the conventional one. More particularly, while the preheating temperature of the conventional method was about 700 °C when the preform was taken out of the preheating furnace or was set to the mold, the preheating temperature of the preform 2 according to the present invention is equal to or higher than 300 °C and lower than 700 °C. Though the temperature of the bore core 1 is lower than the temperature of the preform and is, for example, 100 - 200 °C, since a decrease in the temperature of the preform 2 is delayed due to the clearance 8 between the preform 2 and the bore core 1, the temperature of the preform 2 can be relatively low.
  • FIG. 2 illustrates a relationship between a change in the pressure of the molten metal and beginning and completion of the infiltration of the molten metal into the preform during the second step.
  • a circumferential crack 110 shown in FIG. 14 that initiates at an end of the propagating shear crack will not be caused to occur because the shear crack itself does not occur and because the preform 2 is pressed from both the inside and outside surfaces of the preform and therefore no separating force acting between the layers of the reinforcement fibers will result.
  • the preform has enough strength to endure a pressure equal to or greater than the pressure at the time when infiltration of the molten metal into the preform has just been completed, crushing of the preform will not occur.
  • the pressure at the time when infiltration of the molten metal into the preform has just been completed is high, it is difficult to prevent crushing of the preform. More particularly, when the molten metal is infiltrating the preform, the temperature of the tip portion of the molten metal will be decreased so that the viscosity of the tip portion of the molten metal will be increased.
  • a portion close to the bore core, of the preheated preform is cooled by the bore core and the decrease in temperature of the molten metal at that portion of the preform close to the bore core is large.
  • the molten metal will solidify at that portion of the preform so that a large pressure of the molten metal will act on the radially inner portion of the preform.
  • the preform 2 is supported by and squeezed between a fixed mold 3a and a movable mold 3b of the mold 3.
  • the preform 2 does not contact the bore core 1, and the clearance 8 is formed throughout the entire circumference of the preform 2.
  • the fixed mold 3a includes a cylinder block journal forming portion 3c having opposite surfaces.
  • an opening 3d for introducing a portion of the molten metal 5 to the clearance 8 inside of the preform 2 is formed between an upper end of each of the opposite surfaces of the cylinder block journal forming portion 3c and a lower end of the inside surface of the preform 2.
  • the bore core 1 is supported by the movable mold 3b and is moved together with the movable mold 3b.
  • the bore core 1 has at least one protrusion 11 which protrudes radially outwardly from the outside surface 1a of the bore core 1 and which is integral with the bore core 1.
  • the preform 2 is supported by the bore core 1 at the protrusion 11.
  • the preform 2 and the protrusion 11 line-contact or point-contact with each other.
  • the clearance 8 is interrupted at the protrusion 11.
  • the shape of the protrusion 11 is selected not to prevent the molten metal from filling the clearance 8.
  • the thickness of the clearance 8 can be controlled to about 0.5 mm which is a minimum thickness to ensure smooth filling of the molten metal, whereby the amount of machining of the cylinder bore after casting is minimized.
  • the bore core 1 has a plurality of protrusions which protrude from the outside surface 1a (FIG. 3) of the bore core and which are integral with the bore core 1.
  • the protrusions extend in an axial (longitudinal) direction of the bore core 1.
  • the preform 2 is supported by the bore core 1 via the protrusions 11.
  • the number of the protrusions is equal to or more than three.
  • the preform and the protrusions 11 line-contact with each other.
  • each clearance portion between the protrusions has to communicate with the opening (3d in FIG. 4) for introducing the molten metal to the clearance.
  • the bore core 1 has at least one protrusion 11 protruding radially outwardly from the outside surface 1a of the bore core.
  • the protrusion 11 extends in an axial (longitudinal) direction of the bore core 1.
  • a portion of the bore core facing a cylinder block portion between adjacent cylinder bores is necessarily provided with the at least one protrusion 11.
  • the at least one protrusion 11 is omitted from the outboard portion of each of outboard two bore cores of multi-bore cores arranged in a longitudinal direction of a cylinder block.
  • the preform 2 is supported by the bore core 1 at the at least one protrusion 11.
  • the preform 2 and the at least one protrusion 11 line-contact with each other.
  • the molten metal passes through a portion of the cavity between adjacent cylinder bores, the molten metal is throttled and imposes a greater pressure on the preform 2 at the throttle portion than other portions.
  • the preform 2 is necessarily supported by the protrusion 11, fracture of the preform 2 is prevented.
  • the bore core 1 has a plurality of protrusions 11 protruding radially outwardly from the outside surface 1a of the protrusion 1.
  • the protrusions extend in the axial (longitudinal) direction of the bore core 1.
  • One 11' of the protrusions 11 is also provided at an outboard portion of each of outboard two bore cores of multi-bore cores arranged in a longitudinal direction of a cylinder block.
  • the outboard protrusion 11' has a height that is lower than heights of two protrusions adjacent to the outboard protrusion 11' and that protrudes outboard from a line connecting tips of the two protrusions adjacent to the outboard protrusion 11'.
  • the preform 2 is supported by the bore core 1 at the protrusions 11. There is a clearance 8 except at the protrusions 11.
  • the two outboard protrusions 11' are not used for supporting the preform 2.
  • the protrusions 11 adjacent to the outboard protrusion 11' are used for supporting the preform 2.
  • the outboard protrusion 11' is a dummy protrusion to which molten aluminum is caused to adhere thereby preventing much aluminum from adhering to the protrusions adjacent to the outboard protrusion 11' and preventing an excessive shrinkage force from acting on the protrusions 11 adjacent to the outboard protrusion 11'.
  • the protrusion (protruding member) 11 is formed separately from the bore core 1 and is mounted to the bore core 1 so as to be movable in a radial direction of the bore core 1.
  • a tapered member 12 is provided between the protrusion 11 and a groove formed in the bore core 1 so as to be slidable relative to the bore core 1 and the protrusion 11.
  • the protrusion 11 is adjusted to take a most protruding position. While removing the cast product from the mold and bore core 1, the protrusion 11 is adjusted to take a most receding position, whereby the removing resistance is small and the cast product can be smoothly removed.
  • the clearance 8 is formed between the preform 2 and the core bore 1, the pressures at the inside surface and the outside surface of the preform 2 balance with each other. As a result, a crack due to a shear force is unlikely to be caused in the preform 2, and a circumferential crack initiating a tip of the shear crack will not happen. Further, the molten metal can infiltrate into the preform from the inside and outside surfaces of the preform 2, compression of a portion of the preform in the thickness direction of the preform is unlikely to occur. Furthermore, due to the clearance 8, the temperature decrease of the preform 2 is suppressed and, as a result, the preheating temperature of the preform 2 is allowed to be low compared with the conventional method.
  • the preform 2 does not contact the bore core 1.
  • the preform 2 does not need to be tapered, and the preform 2 is allowed to be formed as thin as possible.
  • the thickness of the clearance 8 can be controlled substantially exactly to a specified thickness.
  • the protrusion 11 extends axially in the bore core 1, the protrusion 11 does not prevent the molten metal from flowing into the clearance 8.
  • the preform 11 is necessarily provided at a portion of the bore core 1 facing a portion of the cylinder block between adjacent cylinder bores, when a relatively large pressure of the molten metal flowing the portion between the cylinder bores acts on the preform 2, the preform can endure the pressure.
  • the protrusion is formed separately from the bore core 1 and is mounted to the bore core 1 so as to be movable in the radial direction relative to the bore core 1, by receding the protrusion during removing the cast product from the bore core 1 and the mold, sticking at the tip of the protrusion can be effectively prevented.
  • a production method for a cylinder block of an internal combustion engine includes a first step and a second step.
  • a preform (2) having an inside surface (2a) and an outside surface (2b) is set to a bore core (1) so that a clearance (8) is formed between the inside surface (2a) of the preform and an outside surface (1a) of the bore core (1).
  • a molten metal (5) is supplied into a cavity (4) so that the molten metal (5) infiltrates into the preform (2) from both the inside surface (2a) and the outside surface (2b) of the preform (2) thereby changing to a metal matrix composite, which constitutes an inside surface of a cast cylinder block.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
EP19980109853 1997-06-02 1998-05-29 Vorrichtung und deren Verwendung zum Herstellen eines Zylinderblockes einer Brennkraftmaschine Expired - Lifetime EP0882534B1 (de)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP14399697 1997-06-02
JP14399697 1997-06-02
JP143996/97 1997-06-02
JP12991098A JPH1147913A (ja) 1997-06-02 1998-05-13 シリンダブロックの製造方法
JP129910/98 1998-05-13
JP12991098 1998-05-13

Publications (2)

Publication Number Publication Date
EP0882534A1 true EP0882534A1 (de) 1998-12-09
EP0882534B1 EP0882534B1 (de) 2002-11-06

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EP19980109853 Expired - Lifetime EP0882534B1 (de) 1997-06-02 1998-05-29 Vorrichtung und deren Verwendung zum Herstellen eines Zylinderblockes einer Brennkraftmaschine

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EP (1) EP0882534B1 (de)
JP (1) JPH1147913A (de)
DE (1) DE69809126T2 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001091947A1 (de) * 2000-05-26 2001-12-06 Audi Ag Zylinderkurbelgehäuse für eine brennkraftmaschine
EP1260293A1 (de) * 2001-05-25 2002-11-27 Alcatel Verfahren zur Herstellung einer Metall-Matrix-Composite Rohr-Platte Anordnung
US6662773B2 (en) 2000-05-26 2003-12-16 Audi Ag Cylinder crankcase for an internal combustion engine
WO2005014205A1 (de) * 2003-07-29 2005-02-17 Hottinger Maschinenbau Gmbh Verfahren und vorrichtung zur positionierung metallischer teile in oder an giessereikernen und giessformen

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7073476B2 (en) * 2004-06-16 2006-07-11 Honda Motor Co., Ltd. Cylinder block
DE102004039306A1 (de) * 2004-08-12 2006-02-23 Bayerische Motoren Werke Ag Verfahren zum Herstellen eines Verbundgussteils
KR20060016694A (ko) * 2004-08-18 2006-02-22 현대자동차주식회사 라이너의 정위치 장치
DE102005043193A1 (de) * 2005-09-09 2007-03-15 Ks Aluminium-Technologie Ag Zylinderkurbelgehäuse für Kraftfahrzeuge

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992015415A1 (en) * 1991-03-05 1992-09-17 Ab Volvo Method of die casting
JPH08197229A (ja) * 1995-01-24 1996-08-06 Honda Motor Co Ltd 繊維強化シリンダブロックの製造方法
EP0744541A1 (de) * 1995-05-26 1996-11-27 Toyota Jidosha Kabushiki Kaisha Verfahren zur Herstellung von Motorzylinderblöcken

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1992015415A1 (en) * 1991-03-05 1992-09-17 Ab Volvo Method of die casting
JPH08197229A (ja) * 1995-01-24 1996-08-06 Honda Motor Co Ltd 繊維強化シリンダブロックの製造方法
EP0744541A1 (de) * 1995-05-26 1996-11-27 Toyota Jidosha Kabushiki Kaisha Verfahren zur Herstellung von Motorzylinderblöcken

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 096, no. 012 26 December 1996 (1996-12-26) *

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001091947A1 (de) * 2000-05-26 2001-12-06 Audi Ag Zylinderkurbelgehäuse für eine brennkraftmaschine
US6662773B2 (en) 2000-05-26 2003-12-16 Audi Ag Cylinder crankcase for an internal combustion engine
DE10026290B4 (de) * 2000-05-26 2007-05-24 Audi Ag Zylinderkurbelgehäuse für eine Brennkraftmaschine
EP1260293A1 (de) * 2001-05-25 2002-11-27 Alcatel Verfahren zur Herstellung einer Metall-Matrix-Composite Rohr-Platte Anordnung
FR2825041A1 (fr) * 2001-05-25 2002-11-29 Cit Alcatel Procede de fabrication d'une structure tube-plaque en materiau composite a matrice metallique
US6595264B2 (en) 2001-05-25 2003-07-22 Alcatel Method of manufacturing a tube-and-plate structure of metal-matrix composite material
WO2005014205A1 (de) * 2003-07-29 2005-02-17 Hottinger Maschinenbau Gmbh Verfahren und vorrichtung zur positionierung metallischer teile in oder an giessereikernen und giessformen

Also Published As

Publication number Publication date
DE69809126T2 (de) 2003-05-08
EP0882534B1 (de) 2002-11-06
JPH1147913A (ja) 1999-02-23
DE69809126D1 (de) 2002-12-12

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