JPH1119762A - Manufacturing method of fiber reinforced parts - Google Patents

Abstract

(57) [Problem] To provide a method of manufacturing a fiber reinforced component in which bending of a drill and breakage of a drill during drilling of a fiber reinforced portion are prevented. SOLUTION: A plurality of fiber moldings having notched grooves provided on an outer peripheral surface are arranged in a mold adjacent to each other so that the notched grooves face each other to form a tubular hollow portion, and a molten metal is injected into the mold. Then, the fiber molded body is stuffed into a casting having a composite portion of the fiber molded body and the metal, and a columnar metal portion filled with metal in the tubular hollow portion, and the columnar metal portion in the casting is drilled. . Or, cast-in a fiber molded body having a tubular hollow portion, a composite portion of the fiber molded body and metal, to create a cast-in piece having a columnar metal portion filled with metal tubular hollow portion,
The cast metal piece is placed at a predetermined position in the mold, and the cast-in piece is further formed into an integrated casting, and the columnar metal portion in the casting is drilled.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced component such as a fiber-reinforced cylinder block of an internal combustion engine such as an automobile engine, and more particularly to a reinforcing fiber / metal composite portion between cylinder bores having a small cooling hole formed by drilling. The present invention relates to a method of manufacturing a fiber-reinforced component such as a fiber-reinforced cylinder block in which a fiber-reinforced portion includes a drill hole.

[0002]

2. Description of the Related Art In recent years, in order to reduce the weight and size of an engine, in addition to the use of a fiber-reinforced cylinder block, the overall length of the engine has been shortened. Tend to be thinner. When the thickness between the cylinder bores is reduced, the temperature between the bores tends to increase during operation of the engine, the bore deformation due to thermal stress increases, the friction between the cylinder and the piston increases, engine performance decreases, and oil consumption increases. And various problems occur, such as deterioration of head gasket sealing performance.

In order to avoid such a problem, appropriate cooling is required so as not to increase the temperature between the bores. Conventionally, in order to cool the space between the bores, (a) a method in which a slit is formed in the upper surface between the bores, (b) a method in which the corner R between the bores is made as small as possible to allow the cooling water to enter deeply between the bores, and (c).
A method of providing a cooling hole (cooling water circulation hole) by drilling between the bores and the like have been performed.

[0004] Among them, (a) has a problem in head gasket sealability and workability depending on the dimension between bores.
In addition, the method (c) is considered to be the most promising because the method (b) has the drawback that the life of the rough material die at the time of casting is short and the cooling performance is lower than that of the methods (a) and (c). However, because the thickness between the bores is thin, the cooling holes have a very small diameter of 2φ and 3φ, and from the geometrical shape of drilling holes from both sides into the hole between the bores corresponding to the valley bottom sandwiched between the cylinder outer surfaces. The protruding amount of the drill during drilling is increased (for example, 50
mm or more). As a result, drill bending is likely to occur, resulting in uneven dimensions between bores and breakage of the drill. For this reason, the thickness between the bores cannot be made very thin, which has been one of the limits to the compactness of the cylinder block.

[0005] In particular, when a fiber-reinforced cylinder block is used to reduce the engine weight, there is a problem that drill bending or drill breakage is liable to occur because the hardness is high because the space between the bores is also fiber-reinforced.

[0006]

SUMMARY OF THE INVENTION The present invention relates to a method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, such as a fiber reinforced cylinder block including a cooling hole between cylinder bores. An object of the present invention is to provide a method of manufacturing a fiber reinforced component in which occurrence of breakage is prevented.

It is another object of the present invention to provide a method of manufacturing a fiber reinforced component in which bending of a drill and breakage of a drill are prevented by intentionally disposing a fiber reinforced portion at a portion where a small diameter drill is to be drilled in an alloy member.

[0008]

According to the present invention, there is provided, in accordance with the present invention, a method of manufacturing a fiber reinforced part including a drilled portion in a fiber reinforced portion, the fiber having a hollow tubular portion. Forming a molded body, placing the fiber molded body in a mold, injecting a molten metal into the mold and casting the fiber molded body with the metal, thereby forming the fiber molded body and the metal. Forming a unitary casting having a composite part of the above and a tubular metal part filled with the metal in the tubular hollow part, and a step of drilling the columnar metal part in the casting. A method for producing a fiber reinforced component is provided.

According to a first aspect of the present invention, there is provided a method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, wherein a plurality of fiber molded bodies each having a cutout groove on an outer peripheral surface are formed. Arranging a plurality of fiber molded bodies in a mold adjacent to each other so that the notched grooves face each other to form a tubular hollow portion, injecting a molten metal into the mold to form the fiber molded bodies; Forming an integral casting having a composite portion of the fiber molded body and the metal and a columnar metal portion filled with the metal by filling the tubular hollow portion with the metal by casting the metal; A method of manufacturing a fiber-reinforced component, the method including a step of drilling a hole in the columnar metal portion in the inside.

According to a second aspect of the present invention, there is provided a method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, wherein a fiber molded body having a tubular hollow portion is made of a first metal. A step of producing a cast-in piece having a composite part of the fiber molded body and the first metal and a columnar metal part filling the tubular hollow part with the first metal by casting; Disposing the cast-in piece at a predetermined position in the mold, pouring a molten metal of a second metal into the mold, and further casting the cast-in piece with the second metal to form an integrated casting. A method for producing a fiber reinforced component is provided, comprising a step of forming and a step of drilling the columnar metal portion in the casting.

According to the present invention, the object of drilling is a low-hardness metal portion filled with a hollow fiber portion that is not fiber-reinforced, and at the same time, a high-hardness metal portion that is reinforced with a fiber molded body having a hollow tube portion. Since the composite portion guides the drill by surrounding the metal portion in a cylindrical shape, drilling such as formation of a small-diameter water cooling hole between the cylinder bores can be performed without causing bending or breakage of the drill.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A typical example of an embodiment according to the first aspect of the present invention is a method of manufacturing a fiber reinforced cylinder block having a cooling hole penetrating a reinforcing fiber / metal composite portion between cylinder bores. Producing a reinforcing fiber molded body having a cylindrical body having an inner peripheral surface defining the cylinder bore, the outer surface having a cutout groove extending in a direction transverse to the cylindrical axis; Arranging a plurality of the moldings in parallel and adjacent to each other in a mold so that the notch grooves of the body face each other to define a hollow portion, injecting a molten metal into the mold, And a composite part of the metal and
A method of manufacturing a fiber-reinforced cylinder block, the method including a step of forming a casting having a metal part in which the hollow part is filled with the metal, and a step of drilling the metal part of the casting to form a through hole. Provided.

According to this embodiment, since the diameter of the water cooling hole can be reduced as compared with the prior art, the gap between the bores can be further reduced, and the cylinder block can be further compacted. As a typical example of the embodiment according to the second aspect of the present invention, the above-described insert piece is further inserted into a normal aluminum alloy part such as a cylinder head, and a small-diameter deep hole is drilled. Use as a guide can prevent drill bending and breakage.

[Embodiment 1] An example of an embodiment according to the first aspect of the present invention will be described. FIG. 1 shows a partial cross-sectional view of a fiber-reinforced cylinder block according to the present invention, and FIG.
1 shows a cross-sectional view taken along line AA in FIG. The four cylinder barrels 1 (of which three are shown) are water-cooled by a water jacket 3 between the cylinder barrel 1 and the outer shell 2. The cylinder barrel 1 is a cast body obtained by casting a reinforcing fiber molded body with a metal such as an aluminum alloy. An inner peripheral side defining a cylinder bore 4 has a composite portion 5 of a reinforcing fiber and a cast metal and a water jacket 3. The outer peripheral side that comes into contact is the metal portion 6 made of only cast-in metal. A cooling hole 8 extends from one end X to the other end Y between the adjacent cylinder bores 4 and 4. Portions other than the reinforcing fiber / metal composite portion 5 of the cylinder block (such as the outer shell 2 of the cylinder block and the outer peripheral portion 6 of the cylinder barrel 1) are metal portions made only of an aluminum alloy.

The fiber reinforced cylinder block shown in FIGS. 1 and 2 is manufactured by the method of the present invention in the following procedure. As shown in FIG. 3A, a reinforcing fiber molded body 5A of the present invention used for the composite portion 5 of the cylinder block shown in FIGS. The molded body 5A is a cylindrical body having an inner peripheral surface that defines the cylinder bore 4, and has a cutout groove 9 that extends in a direction transverse to the cylindrical axis L on the outer surface.

The notch groove 9 has a semicircular cross-sectional profile as shown in FIG. 3 (2), and when a plurality of compacts 5A are arranged adjacent to each other in a mold in parallel with each other, the notch grooves of the adjacent compacts are formed. 9
They are arranged so that they face each other and define a hollow portion 10A as shown in FIG. In this state, the molten metal is poured into the mold, and as shown in FIG. 4A, the composite portion 5 of the reinforcing fiber molded body and the metal, and the metal portion 10 in which the hollow portion 10A is filled with the metal, After forming a casting having
As shown in (2), the metal portion 10 of the cast body is drilled to form a through hole 8, which is used as a cooling hole.

At this time, the object to be drilled is a low-hardness metal portion 10 that is not fiber-reinforced, and at the same time, the high-hardness composite portion 5 that is fiber-reinforced surrounds the metal portion 10 in a cylindrical shape and guides the drill. Therefore, the water cooling hole 8 having a small diameter can be formed between the bores 7 without causing bending or breakage of the drill. In this embodiment, the cross-sectional shape of the cutout groove 9 is semicircular, and the cross-sectional shape of the tubular hollow portion 10A is circular. However, the cross-sectional shape of the cutout groove 9 and the tubular hollow portion 10A need not be limited to these. Absent.

The role of the notch groove or the tubular hollow portion is to form a low-hardness columnar metal portion which can be easily drilled, and to appropriately guide the drill by the fiber reinforced portion surrounding the metal portion, thereby preventing bending or breakage of the drill. To prevent drilling of small diameters. Therefore, the cross-sectional shape of the notch groove or the tubular hollow portion does not need to be particularly limited as long as the above-described effects can be obtained.

For example, the notch groove 9 may be a V-shaped groove, and as a result, the tubular hollow portion 10A may have a rhombic cross section, or the notched groove 9 may be a U-shaped groove, and as a result, the tubular hollow portion 10A may be an oval shape. It may be a cross section. In addition, other cross-sectional shapes can be adopted as long as the above-described effects can be obtained.

[Embodiment 2] An example of an embodiment according to the second aspect of the present invention will be described. As shown in FIG. 5A, the fiber molded body 11 having the tubular hollow portion 11A is
As shown in (2), the composite part 15 of the fiber molded body 11 and the first metal is formed by casting with the first metal.
And a cast-in piece having a tubular metal part 16 in which the tubular hollow portion 11A is filled with the first metal, and the cast-in piece is disposed at a predetermined position in the mold, and a second piece is formed in the mold. A molten metal is poured, and the cast piece is further cast with a second metal to form an integral casting, and then the columnar metal portion in the casting is drilled. Accordingly, the high-hardness composite portion surrounding the columnar metal portion guides the drill, thereby preventing bending or breakage of the drill when drilling a small-diameter deep hole.

This embodiment can be applied to, for example, a case where a cooling hole between cylinder bores is drilled in the production of a cylinder block in which the cylinder barrel is not fiber-reinforced. In addition, as described above, in the usual aluminum alloy parts such as the cylinder head, the above-mentioned insert piece is further inserted and used as a guide when drilling a small diameter deep hole, thereby preventing drill bending and breakage it can.

The first metal for making the insert and the second metal for further casting the insert are generally the same metal or alloy, but are undesirable between the two metals. It is also possible to select a different metal as long as the reaction does not occur. Furthermore, a mode in which different types of metals are intentionally combined so that the machinability of the drilled portion is higher than that of other portions is also conceivable.

In the above example, the fiber-reinforced part to be manufactured has only the fiber-reinforced part of the cast-in piece,
By arranging and casting a fiber molded body other than the stuffed piece in the mold, a necessary portion other than the stuffed piece can also be fiber-reinforced.

[0024]

As described above, according to the present invention,
In the manufacture of a fiber reinforced component including a drilled portion in a fiber reinforced portion, such as a fiber reinforced cylinder block including a cooling hole between cylinder bores, a method of manufacturing a fiber reinforced component in which drill bending and drill breakage are prevented during drilling Is provided. Further, there is provided a method of manufacturing a fiber reinforced component in which bending and drill breakage of a drill are prevented by intentionally disposing a fiber reinforced portion at a portion where a small diameter drill is to be drilled in an alloy member.

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional view of a cylinder block according to the present invention.

FIG. 2 is a cross-sectional view taken along line AA of FIG.

3 (1) is a perspective view of a fiber molded body used in the present invention, FIG. 3 (2) is a cross-sectional view taken along line CC of FIG. 3 (1), and FIG. 3 (3) is FIG. It is sectional drawing of the contact part which arranged the fiber molding of 1) adjacently.

FIG. 4 is a cross-sectional view corresponding to the position of line BB in FIG. 2, showing (1) a state before drilling and (2) a state after drilling.

FIG. 5 is a perspective view of (1) a fiber molded body having a tubular hollow portion used in the present invention, and (2) a perspective view of a stuffed piece obtained by casting the fiber molded body with metal.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Cylinder barrel 2 ... Outer shell 3 ... Water jacket 4 ... Cylinder bore 5 ... Composite part (Inner peripheral part of cylinder barrel 1) 5A ... Fiber molded body 6 ... Metal part (Outer peripheral part of cylinder barrel 1) 7 ... Bore Between 8 ... Cooling hole 9 ... Notch groove 10 ... Columnar metal part 10A ... Tubular hollow part 11 ... Fiber molded body 11A ... Tubular hollow part 15 ... Composite part 16 ... Columnar metal part

Claims (3)

[Claims] 1. A method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, the method comprising: forming a fiber molded body having a tubular hollow portion; arranging the fiber molded body in a mold; By pouring a molten metal into the mold and casting the fibrous body with the metal, a composite part of the fibrous body and the metal, and a columnar metal part filled with the metal in the tubular hollow part A method of manufacturing a fiber reinforced component, comprising: a step of forming an integral casting having: and a step of drilling the columnar metal portion in the casting. 2. A method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, the method comprising: forming a plurality of fiber molded bodies having notched grooves on an outer peripheral surface thereof, wherein the notched grooves face each other. A step of arranging the plurality of fiber molded bodies in a mold adjacent to each other so as to form a tubular hollow portion, by pouring a molten metal into the mold and casting the fiber molded body with the metal, Forming an integral casting having a composite portion of the fibrous formed body and the metal and a columnar metal portion filling the tubular hollow portion with the metal; drilling the columnar metal portion in the casting; A method for producing a fiber-reinforced component, comprising: 3. A method of manufacturing a fiber reinforced component including a drilled portion in a fiber reinforced portion, wherein the fiber formed body having a tubular hollow portion is formed by casting a first metal into the fiber formed body. A step of producing a stuffed piece having a composite part with the first metal and a columnar metal part filling the tubular hollow part with the first metal; disposing the stuffed piece at a predetermined position in a mold Forming a one-piece casting by injecting a second metal melt into the mold and further casting the stuffed piece with the second metal; and forming the columnar shape in the casting. A method for producing a fiber-reinforced component, comprising a step of drilling a metal part.