WO2005102560A2 - Procede et appareil de moulage de blocs moteur en aluminium avec passage pour refroidissement de liquide dans des bandes de chemisage ultrafines - Google Patents

Procede et appareil de moulage de blocs moteur en aluminium avec passage pour refroidissement de liquide dans des bandes de chemisage ultrafines Download PDF

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Publication number
WO2005102560A2
WO2005102560A2 PCT/IB2005/002331 IB2005002331W WO2005102560A2 WO 2005102560 A2 WO2005102560 A2 WO 2005102560A2 IB 2005002331 W IB2005002331 W IB 2005002331W WO 2005102560 A2 WO2005102560 A2 WO 2005102560A2
Authority
WO
WIPO (PCT)
Prior art keywords
casting
sand
core
interliner
strip
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.)
Ceased
Application number
PCT/IB2005/002331
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English (en)
Other versions
WO2005102560A3 (fr
Inventor
Oscar Gerardo Cantu-Gonzalez
Ismael Ramirez-Alvarez
Alvaro Ramirez-Morales
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.)
Nemak SAB de CV
Original Assignee
Tenedora Nemak SA de CV
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 Tenedora Nemak SA de CV filed Critical Tenedora Nemak SA de CV
Publication of WO2005102560A2 publication Critical patent/WO2005102560A2/fr
Publication of WO2005102560A3 publication Critical patent/WO2005102560A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • B22C1/14—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for separating the pattern from the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/106—Vented or reinforced cores
    • 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

Definitions

  • the invention broadly relates to the art of manufacturing narrow passages in thin walled castings and is particularly useful for the manufacture of cast aluminum automotive engine blocks with very thin interliner walls for providing cooling liquid passages therein, preferably using essentially conventional sand core techniques. BACKGROUND OF THE INVENTION The description will be mainly in terms of its applicability to aluminum engine blocks (typically with iron cylinder liners).
  • the design of the engine blocks has been changing over the time with a tendency to increase the power of engines while reducing size and weight.
  • the dimensions of the motor blocks tend to be fixed by the dimensions of the car body.
  • the blocks need to accommodate cylinders of larger volume, meaning larger diameter, within the same block volume.
  • Patent no. 4,917,169 teaches an expensive ceramic form (having a width "of the minute thickness of 1.5 to 3.0 mm") to use during casting to create the interliner water cooling passages. Removal of the ceramic form from the subsequently hardened casting requires a separate sandblasting step.
  • 5,217,059 itself, proposes use of a metal support element 64 covered with a removable woven refractory (fiberglass) sleeve 66 as the casting form for the interliner water cooling passage.
  • This has the distinct disadvantage of requiring the element 64 to extend out the side of the resulting cast block, thus leaving an external hole in the block through into the water jacket, that must be plugged.
  • the apparently expendable woven refractory 66 is again relatively expensive (an important consideration in a mass production operations).
  • Patent no. 4,693,294 will be understood by those skilled in the art to be relevant to an iron casting (not aluminum). It discusses employing special sand cores (unsupported) for use in forming the water channels bridging through the webs separating adjacent cylinders.
  • cooling passage reduces the aluminum wall thickness in such passages to about only 1 mm or less.
  • the wall thickness of the cooling passages needs to be sufficient to prevent leaks (and thus should not touch the liner walls).
  • the present invention also avoids another current practice involving casting a solid section between the cylinder liners and then opening or machining a very thin gap which is later sealed by welding the top of the gap closed, thus forming a passage. This procedure requires expensive precision cutting/machining equipment and tools.
  • the present invention overcomes the above drawbacks of the current art by introducing a pre-formed reinforced core, with the required shape to fit in the narrowest space between the adjacent pairs of cylinder liners, typically iron, in an aluminum engine casting.
  • a pre-formed reinforced core with the required shape to fit in the narrowest space between the adjacent pairs of cylinder liners, typically iron, in an aluminum engine casting.
  • it can be used with engine blocks where the liners can be press fit after casting of the engine block (such as when AA 319 or AA 356 alloy is used).
  • the insert can be between the cylinder bores in aluminum engine blocks made with a high strength high silicon alloy (or equivalent), where iron liners are not needed, but the need for cooling passages in the narrow gaps remain.
  • This core is made of a supportive very thin reinforcing element, preferably in the form of a rectangular metal strip, such as steel (or other material that withstands the casting process), with a thin coating layer that protects such element and permits its ready removal after formation of the casting, which layer may advantageously and inexpensively be formed of conventional casting sand with a typical binder.
  • the coating layer may be formed by anything serving the same function.
  • a refractory coating maybe used of the type long employed to prevent aluminum from sticking to molds, ladles, and the like (but which apparently have never been put to the unexpected use of aiding in the formation of water passages, especially in the interliner webs of aluminum engine blocks).
  • a refractory coating When used such a refractory coating has been applied either with a brush or a pneumatic pistol.
  • refractory coatings known in the art include: DAG 193 and ISOL BM manufactured by ACHESON and Delta Cast 696 by FORDATH.
  • Other appropriate coating layers may be used which serve to prevent the sticking of the thin reinforcing strip to the aluminum as it cools from the liquid to solid state, and allow convenient removal of the strip from the cooling passage formed, and, if needed, to help prevent the melting or warping of the thin strip.
  • the strip from the pre-formed core insert is easily removed after the casting sand has been loosened and the water jacket core thus removed from the solidified casting.
  • Figure 2 shows a top stylized view of an engine cylinder block with a cylindrical iron insert closely fitted into each of the cylinder bores (showing the relationship of engine parts in which the invention can effectively be practiced), the core of Figures la-c would have been positioned to below the surface of the block paralleling line B-B.
  • Figure 3 shows a stylized vertical section (similar to a view as though taken along section line A-A of Figure 2) of a engine cylinder block (but without a cylindrical iron insert having been press fit in place yet into each of the cylinder bores) and showing core support strip (as in Figures la-c) still surrounded by sand as positioned prior to removal in the newly created cooling flow passage in each of the interliner gaps.
  • Figure 3 A shows an enlarged sectional view taken from a portion of Figure 3 showing a core of slightly modified shape (in the upper part of the insert including a cooling flow passage sandwiched between two cylinder liners).
  • Figure 4 shows a stylized vertical section (as along section line B-B of Figure 2) of a engine cylinder block with its internal water jacket cooling passages including a connecting cooling flow passage through the interliner space between two adjacent cylinder liners (not visible in this view).
  • Figure 4A shows an enlarged sectional view taken from the portion of Figure 4 showing the connecting cooling flow passage through the interliner space.
  • Figure 5 is an isometric view of the main water jacket core of a mold for forming the cooling passages of an engine block incorporating three reinforced bridging cores (according to one preferred embodiment of the present invention), with each such reinforced bridging core being joined with the main water jacket core at the respective interliner positions.
  • Figure 6 shows a stylized vertical view of an exemplary rotary clamp-and-pick mechanism for automatically extracting the metal strip from the core of Figures la-c that remains after the casting has been formed and the sand coating loosened.
  • the reinforced core 10 shown in Figures la-c serves to overcome the drawbacks of the prior art by being able to maintain the required shape when sized to fit in the narrowed space between the adjacent pairs of cylinder liners 6 in an aluminum engine casting 8.
  • This is a combination of a very thin metal support strip 12 that is coated with thin layer 14 preferably of bound sand to form a reinforced sand core 10 (the combined width of which is on the order of as small as 1 mm, and for most purposes is less than 3 mm wide, and with a vertical dimension on the order of 10-15 mm).
  • the composition of the layer 14 can even be the same as that of the water jacket mold core 16.
  • the support strip 12 is about 0.8 mm wide by 8 to 12 mm high and 20 cm long (more or less, depending upon the dimensions of the block), with a coating of sand of about 0.2 mm thick.
  • the walls of the liners 6 are typically 3 to 6 mm thick.
  • the reinforced core 10 in this first embodiment thus comprises fabricating a sand core 10 of the desired shape (for example a rectangular shape as shown in the figures) and having internally a thin steel sheet or bar 12, or may be a stiff element made of any other material so that the thin sand core maintains its shape while the mold is filled with liquid aluminum.
  • the thin reinforcing element 12 is preferably placed in a centered position within the sand core 10, or even a plurality of said elements 12 (not shown) may be used in several positions within the sand core, to provide strength to said core.
  • the mold assembly (not shown, but including the water jacket mold 16) may comprise as many of the reinforced cores 10 in each of the interbore walls 18 as are deemed desirable.
  • the molten aluminum is poured.
  • the bound sand structure forming the cores and the molds of the cooling channels is destroyed and eliminated by the heat of the molten aluminum whereby the channels 20 for coolant circulation is formed, including channel 20' in the thin interbore wall 18.
  • the metallic reinforcing element 12 remaining loosely contained together with loose sand within the water passage 20' that it helped form is easily removed after the casting is solidified. This removal can be done in a number of ways; as will be understood by those skilled in the art, including such as by a jet of fluid (if the relative dimensions are appropriatae) or by the mechanism 22 shown in Figure 6.
  • This mechanism 22 includes a guide rail 24 along which a clamping, rotating, & lifting device 26 rides in moving from the illustrated lowered clamping position to the remote "discarding" position (shown as device 26', in dotted outline).
  • a clamping, rotating, & lifting device 26 rides in moving from the illustrated lowered clamping position to the remote "discarding" position (shown as device 26', in dotted outline).
  • the jaws 28 of the clamping head 30 fastens onto the exposed end of the strip 12, the head 30 then rotates to pull the strip 12 from the passage 20' by twisting it into a coil 12'.
  • the device 26 lifts the clamping head 30 with the coil 12' secured in the jaws 28, and then is free to travel to and drop the coil 12' at the discarding position.
  • the narrow passages 20' formed webs 18 by the present invention are illustrated in Figures 3 and 6 as being adjacent the top of the cylinder liners 6, it will be understood that there can be one or more such passages 20' in each web 18 and can be placed as needed anywhere along the height of the web 18.
  • the coating layer 14 of the core 10 need not be formed of a conventional sand and binder, but can instead be a refractory or other coating that does not stick to the solidified aluminum and preferably after performing its mold function (as shown in Figure 3 A) is easily crumbled to permit easy removal of the now-loose layer 14' and the strip 12 from the newly formed passage 20'.
  • the present invention can be practiced, for example, in a current process and equipment which comprises a holding furnace for liquid aluminum alloy, a source of pressurized gas, normally nitrogen, which is injected into said holding furnace for pushing upwardly said liquid aluminum alloy through a suitable connecting conduit into a gate of a mold placed on top of said holding furnace.
  • a suitable device for example a slide valve or gate and said mold is then disconnected from the holding furnace and the process is repeated for a subsequent mold to be filled up.
  • Webs 18 having minimum widths of less than 3 mm is a preferred condition for using this invention, but the method applies as well to thicker interliner dimensions when there is a need to provide interliner flow passages by means of reinforced cores according to the present invention when conventional unreinforced cores are not effective or for any of the other reasons discussed above.
  • *** Those skilled in the art will recognize, or be able to ascertain without undue experimentation any of the numerous equivalents to the embodiments of the invention described herein. All such equivalents are considered to be within the scope of the instant invention and are encompassed by the claims that follow. Unless otherwise explained, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs.

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

Abstract

L'invention se rapporte à un procédé et à un appareil de moulage permettant de former des passages de refroidissement de fluide dans les bandes présentant une dimension minimale inférieure ou égale à 3 mm entre des chemises de cylindre en fer dans des blocs moteur en aluminium au moyen de noyaux renforcés, préformés, très minces, insérés entre des chemises adjacentes et assemblés au noyau de chemise d'eau externe. Le noyau renforcé est constitué d'un élément de renforcement et de support très mince, se présentant de préférence sous la forme d'une bande métallique rectangulaire, ou d'une autre matière résistant au processus de moulage, avec une couche d'un revêtement mince qui protège ledit élément et permet facilement sont retrait après formation du moule, ladite couche pouvant de manière avantageuse et peu onéreuse être composée d'un sable de moulage classique associé à un liant type.
PCT/IB2005/002331 2004-04-20 2005-04-20 Procede et appareil de moulage de blocs moteur en aluminium avec passage pour refroidissement de liquide dans des bandes de chemisage ultrafines Ceased WO2005102560A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US56398504P 2004-04-20 2004-04-20
US60/563,985 2004-04-20

Publications (2)

Publication Number Publication Date
WO2005102560A2 true WO2005102560A2 (fr) 2005-11-03
WO2005102560A3 WO2005102560A3 (fr) 2006-06-29

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012110258A1 (de) 2012-10-26 2014-04-30 Ks Aluminium-Technologie Gmbh Verfahren zur Herstellung eines Zylinderkurbelgehäuses
EP2727668A1 (fr) * 2012-11-06 2014-05-07 Martinrea Honsel Germany GmbH Procédé de fabrication d'un bloc moteur et agencement de coulage pour un bloc moteur
DE102014109598A1 (de) * 2014-07-09 2016-01-14 Tenedora Nemak, S.A. De C.V. Gießkern, Verwendung eines Gießkerns und Verfahren zur Herstellung eines Gießkerns
DE102015012554A1 (de) 2015-09-25 2017-03-30 Neue Halberg-Guss Gmbh Gusskörper eines Zylinderkurbelgehäuses und Verfahren zur Herstellung mit Verwendung einer Gießform mit filigranem einstückigen Einsatzkern
CN110947904A (zh) * 2019-11-27 2020-04-03 山东联诚精密制造股份有限公司 一种商用车转向器壳体制备方法
CN113231602A (zh) * 2018-08-01 2021-08-10 中国兵器工业第五九研究所 一种具有高性能的铝合金铸造用复合铸型

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JP2007514550A (ja) * 2003-12-18 2007-06-07 テネドーラ ネマク エス．エー．デ シー．ヴイ． 丈夫な薄壁付き鋳造品を製造するための方法および装置
WO2009149567A1 (fr) * 2008-06-12 2009-12-17 Bühler Druckguss AG Noyau perdu avec élément d'armature pour son élimination
US8555950B2 (en) 2011-10-25 2013-10-15 Ford Global Technologies, Llc Organic-like casting process for water jackets
US9162280B2 (en) * 2013-07-23 2015-10-20 Southwest Research Institute Hybrid ceramic/sand core for casting metal engine parts with passages or holes having a cross section too small for sand casting
DE102014221359A1 (de) * 2014-10-21 2016-04-21 Volkswagen Aktiengesellschaft Verfahren zur Herstellung eines metallischen Druckgussbauteils unter Verwendung eines Salzkerns mit integrierter Stützstruktur und hiermit hergestelltes Druckgussbauteil
CN104308088A (zh) * 2014-10-30 2015-01-28 沈阳工业大学 一种采用铸造方式制备方形孔的方法
DE102015201994A1 (de) * 2015-02-05 2016-08-11 Ford Global Technologies, Llc Hubkolbenmotor, Kraftfahrzeug
US10113504B2 (en) * 2015-12-11 2018-10-30 GM Global Technologies LLC Aluminum cylinder block and method of manufacture

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* Cited by examiner, † Cited by third party
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DE102012110258A1 (de) 2012-10-26 2014-04-30 Ks Aluminium-Technologie Gmbh Verfahren zur Herstellung eines Zylinderkurbelgehäuses
EP2727668A1 (fr) * 2012-11-06 2014-05-07 Martinrea Honsel Germany GmbH Procédé de fabrication d'un bloc moteur et agencement de coulage pour un bloc moteur
DE102014109598A1 (de) * 2014-07-09 2016-01-14 Tenedora Nemak, S.A. De C.V. Gießkern, Verwendung eines Gießkerns und Verfahren zur Herstellung eines Gießkerns
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DE102015012554A1 (de) 2015-09-25 2017-03-30 Neue Halberg-Guss Gmbh Gusskörper eines Zylinderkurbelgehäuses und Verfahren zur Herstellung mit Verwendung einer Gießform mit filigranem einstückigen Einsatzkern
CN113231602A (zh) * 2018-08-01 2021-08-10 中国兵器工业第五九研究所 一种具有高性能的铝合金铸造用复合铸型
CN110947904A (zh) * 2019-11-27 2020-04-03 山东联诚精密制造股份有限公司 一种商用车转向器壳体制备方法
CN110947904B (zh) * 2019-11-27 2021-07-27 山东联诚精密制造股份有限公司 一种商用车转向器壳体制备方法

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WO2005102560A3 (fr) 2006-06-29

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