EP1556585B1 - Method for producing a device for converting a rotatory motion into a translatory motion, and a corresponding device produced according thereto - Google Patents

Method for producing a device for converting a rotatory motion into a translatory motion, and a corresponding device produced according thereto Download PDF

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Publication number
EP1556585B1
EP1556585B1 EP03798177A EP03798177A EP1556585B1 EP 1556585 B1 EP1556585 B1 EP 1556585B1 EP 03798177 A EP03798177 A EP 03798177A EP 03798177 A EP03798177 A EP 03798177A EP 1556585 B1 EP1556585 B1 EP 1556585B1
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EP
European Patent Office
Prior art keywords
functional layer
layers
ceramic
region
camshaft
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Expired - Lifetime
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EP03798177A
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German (de)
French (fr)
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EP1556585A1 (en
Inventor
Ralf Lang
Michael Seifert
Roman Zieris
Lutz-Michael Berger
Steffen Nowotny
Erwin Trageser
Reinhard Wolf
Reimund Neugebauer
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Htm Haertetechnik & Metallbearbeitung GmbH
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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Htm Hartetechnik & Metallbearbeitung GmbH
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L1/00—Valve-gear or valve arrangements, e.g. lift-valve gear
    • F01L1/02—Valve drive
    • F01L1/04—Valve drive by means of cams, camshafts, cam discs, eccentrics or the like
    • F01L1/047—Camshafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2301/00—Using particular materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2301/00—Using particular materials
    • F01L2301/02—Using ceramic materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2303/00—Manufacturing of components used in valve arrangements

Definitions

  • the invention relates to a method for producing a device for converting a rotary into a translatory movement and a device produced according to this method.
  • the present invention relates to a camshaft, preferably for engines of motor vehicles.
  • the present invention also relates to similar elements or assemblies, which implement a rotational movement in a translational movement, in particular a lifting movement, for example by running lifting elements on rotating (curved) discs with different curvature and are moved counter to the direction of rotation.
  • cam gears preferably also be mentioned cam gears.
  • camshafts Preferably, however, used in the field of Rollenschlepphebelsysteme, but also built camshafts begin to prevail.
  • the fixation of the cam on the shaft for example, by pressing and / or by partial expansion of the shaft body directly under the cam.
  • the cams are individually and sequentially connected to the shaft.
  • the built camshafts are limits in the design freedom set. In addition, there is only a non-positive or positive connection of the cam with the shaft. In addition, the built camshafts are relatively expensive to manufacture, so the cost is about 30 percent higher compared to a conventional cast shaft.
  • the assembled camshafts are usually only used when the material casting reaches its technical limits.
  • built-in camshafts are used for weight reduction.
  • the realizable weight savings compared to solid cast camshafts is 20-40%.
  • a method for producing a camshaft and a camshaft produced therewith wherein the camshaft is produced by hydroforming and then in the region of the running surfaces a layer of wear-resistant material is applied by the action of a charge carrier beam.
  • a band-shaped or wire-shaped wear-resistant material is introduced in a vacuum into the energy field of the electron beam at a defined speed, melted and transferred to the running surface of a cam of the camshaft. Subsequently, the treads are machined to a desired final dimension.
  • cored wires and sheets also greatly limits the available material range for the coating.
  • the method described is unsuitable for application of non-conductive materials, such as ceramics.
  • the process for producing defined structures (which can result in layers of composite materials such as metal ceramics (hard metals)) is unsuitable when using the cored wires.
  • This object is achieved in procedural perspective according to the invention by a method for producing a device for converting a rotary into a translational movement, wherein at least partially, at least one functional layer of a ceramic, metal-ceramic or metallic material is applied with mechanical interlocking with a surface of the device.
  • the method according to the invention makes it possible to apply a wear-resistant layer to the device for converting a rotary into a translational movement without thermal distortion of the device occurring.
  • the inventive method allows a further reduction in weight and friction over the prior art by the use of wear-resistant ceramic, metal-ceramic and metallic layers.
  • a hollow shaft having at least one lifting element is (at least) produced in a hydroforming process ("hydroforming process").
  • hydroforming process it is advantageous if the at least one functional layer is applied in the region of a running surface of the at least one lifting element and / or in the region of bearing surfaces of the hollow shaft.
  • the functional layers applied in the region of the running surface of the at least one lifting element and / or in the region of bearing surfaces of the hollow shaft are made of identical or different materials and in each case in one or more embodiments be formed several layers.
  • a method from the group of methods of thermal spraying is used for producing the at least one functional layer made of a ceramic, metal-ceramic or metallic material while being clamped to the surface of the hollow shaft.
  • the at least one lifting element and / or the bearing surfaces are formed with a circumferential recess, which form a receptacle for the functional layer to be applied.
  • the functional layer is designed as a wear-resistant layer and / or as a friction-influencing layer.
  • the surfaces of the device in particular a camshaft, at least in the region of the applied functional layer (before application of the same) roughened, in particular sandblasted.
  • the above object is achieved in device-technical view according to the invention by a device for implementing a rotational in a translational movement produced by the above method.
  • the device is designed as a hollow, by means of hydroforming (IHU method) camshaft with at least one cam, wherein a running surface of the at least one cam and / or bearing surfaces of the camshaft wear-resistant ceramic, metal-ceramic or have metallic functional layers, which are connected to it with mechanical clamping.
  • hydroforming IHU method
  • ceramic coatings or metal-ceramic layers or metal-ceramic hard metal layers or metallic layers are applied by thermal spraying.
  • cams and / or the bearing surfaces have a circumferential Have trough, which serve as a bed for the functional layer to be applied.
  • the camshaft 1 shown by way of example in a longitudinal section in FIG. 1 with a cam 2 is an intake camshaft 1 made of the material St 52 produced by hydroforming (hydroforming) for a three-cylinder four-valve engine.
  • the complete camshaft has 6 cams.
  • cams 2 of the intake camshaft 1 Of the individual cams 2 of the intake camshaft 1, only one is shown in the sectional view for reasons of simplification, wherein all of the cams 2 of the intake camshaft 1 or some of the cams or one of the cams 2 are provided with a functional layer 3 and in the one shown in FIG may be formed below described type.
  • camshaft 1 can also be provided with a functional layer 3.
  • bearing surfaces of the camshaft 1 can be provided with such a functional layer 3.
  • the individual functional surfaces 3 (on the cams 2 or at other locations of the camshaft 1, in particular the bearing surfaces) can be made of the same or similar or equivalent materials or of different materials.
  • the choice of material is due in particular to the individual technical use (for example wear protection or friction improvement) and also to the technical boundary conditions.
  • the cams 2 each have a circumferential recess, wherein the recess has a substantially flat depression and two raised, radiused edge regions.
  • the present invention is not limited to the shape of the trough shown in FIG. Rather, this depends on the intended use, the shape of the functional surface to be produced, the respective coating method and the respective material of the functional surface dependent. For example, it is also possible to provide a plurality of essentially flat depressions, each with these limiting raised and radiused edge regions.
  • the material of the functional layer 3 completely fills the trough, wherein the functional layer is formed precisely with the raised edge regions of the trough. This results in a flat cam surface.
  • a depth of the well of 1 mm has proven to be particularly advantageous.
  • a width of the trough corresponds to a width of an associated roller cam follower of the engine, but the present invention is not limited thereto.
  • This mechanical clamping may preferably be assisted by providing the camshaft with a preliminary, roughening surface treatment, e.g. by sandblasting, possibly even only in the area of the troughs, is subjected. This increases the micro-surface of the camshaft and thereby the adhesion surface between the camshaft surface and the applied hard wear upper layer and increases the bonding strength between the sprayed-on layer and the cam surface.
  • the intake camshaft 1 was coated by means of atmospheric plasma spraying with a plant MF-P-1000 GTV mbH / Luckenbach.
  • a metal ceramics (hard metal) (Ti, Mo) (C, N) - 37% Ni, Co was used as the coating powder.
  • an Ar / H 2 plasma 50 l / min Ar, 11 l / min H 2 ) at a current of 630 A was used. The spray distance was 110 mm.
  • coating methods can be used, in which the layer deposition is based at least substantially on a mechanical clamping of the layer on the substrate and cause only a small thermal energy input.
  • Such coating methods are preferably found in the process group of thermal spraying, so in particular, in addition to plasma spraying and high-speed flame spraying (HVOF).
  • the cams are ground to final dimensions, resulting in the running surface of the cam 2.
  • a production of a (still uncoated) camshaft takes place by means of the hydroforming process.
  • the layer deposition takes place by such methods, which are based essentially on a mechanical clamping of the layer on the substrate and which cause only a small thermal energy input, preferably from the process group of thermal spraying (eg plasma spraying, high-velocity flame spraying (HVOF), etc.).
  • thermal spraying eg plasma spraying, high-velocity flame spraying (HVOF), etc.
  • the above embodiments have a high flexibility through the use of different materials, which can be adapted to the requirements of the camshaft in the different engines.
  • up to 1.5 mm thick wear protection layers can be produced with new metallic, ceramic or metal-ceramic materials in a simple manner and without major technical effort.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Valve-Gear Or Valve Arrangements (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Noodles (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Measurement Of Resistance Or Impedance (AREA)
  • Control Of Electric Motors In General (AREA)
  • Manipulator (AREA)
  • Ceramic Products (AREA)

Abstract

The invention relates to a method for producing a device for converting a rotatory motion into a translatory motion during which at least one functional layer (3) made of a ceramic, metal-ceramic or metallic material is applied at least in sections while clamping it in a predominantly mechanical manner to a surface of the device. The invention also relates to the corresponding device for converting a rotatory motion into a translatory motion.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung einer Einrichtung zur Umsetzung einer rotatorischen in eine translatorische Bewegung und eine gemäß diesem Verfahren hergestellte Einrichtung.The invention relates to a method for producing a device for converting a rotary into a translatory movement and a device produced according to this method.

Insbesondere betrifft die vorliegende Erfindung eine Nockenwelle, vorzugsweise für Motoren von Kraftfahrzeugen. Darüber hinaus betrifft die vorliegende Erfindung auch ähnliche Elemente oder Baugruppen, welche eine Rotationsbewegung in eine translatorische Bewegung, insbesondere eine Hubbewegung umsetzen, indem beispielsweise Hubelemente auf rotierenden (Kurven-)Scheiben mit unterschiedlicher Krümmung laufen und entgegen der Drehrichtung bewegt werden. Hierbei sind vorzugsweise auch Kurvengetriebe anzuführen.In particular, the present invention relates to a camshaft, preferably for engines of motor vehicles. In addition, the present invention also relates to similar elements or assemblies, which implement a rotational movement in a translational movement, in particular a lifting movement, for example by running lifting elements on rotating (curved) discs with different curvature and are moved counter to the direction of rotation. In this case, preferably also be mentioned cam gears.

Der gegenwärtige Stand der Herstetlungsprozesse zur Nockenwellenfertigung, insbesondere in der Grosserienfertigung ist überwiegend geprägt von Schalenhartgußwellen, welche teilweise nachträglich ausgebohrt werden oder auch hohl gegossen sind. Für höhere Festigkeitsanforderungen gibt es geschmiedete Varianten.The current state of the manufacturing processes for camshaft production, especially in mass production, is predominantly characterized by shell casting shafts, which are sometimes bored out later or are also hollow cast. For higher strength requirements, there are forged variants.

Die am Markt eingeführten Verfahren der als massiv bezeichneten Nockenwellen dominieren wegen des Preises, in Anbetracht des immer abzuwägenden technischen Kompromisses zwischen Herstellungskosten und technischen Leistungsparametem (wie Festigkeit und Verschleiß), sowie der vorliegenden langjährigen Erfahrungen bei der Massenfertigung derselben.The introduced on the market procedures of the designated as massive camshafts dominate because of the price, in view of the always to be weighed technical compromise between production costs and technical Leistungsparametem (such as strength and wear), as well as the existing many years of experience in mass production thereof.

Vorzugsweise im Bereich der Rollenschlepphebelsysteme eingesetzt, beginnen sich jedoch auch gebaute Nockenwellen durchzusetzen. Bei diesen erfolgt die Fixierung der Nocken auf der Welle beispielsweise durch Aufpressen oder/und durch partielles Aufweiten des Wellenkörpers direkt unter dem Nocken. Dabei werden die Nocken einzeln und nacheinander mit der Welle verbunden.Preferably, however, used in the field of Rollenschlepphebelsysteme, but also built camshafts begin to prevail. In these, the fixation of the cam on the shaft, for example, by pressing and / or by partial expansion of the shaft body directly under the cam. The cams are individually and sequentially connected to the shaft.

Den gebauten Nockenwellen sind allerdings Grenzen in der konstruktiven Gestaltungsfreiheit gesetzt. Außerdem besteht lediglich eine kraft- oder formschlüssige Verbindung der Nocken mit der Welle. Außerdem sind die gebauten Nockenwellen in ihrer Herstellung vergleichsweise teuer, so sind die Kosten verglichen mit einer konventionellen Gusswelle um ca. 30 Prozent höher.However, the built camshafts are limits in the design freedom set. In addition, there is only a non-positive or positive connection of the cam with the shaft. In addition, the built camshafts are relatively expensive to manufacture, so the cost is about 30 percent higher compared to a conventional cast shaft.

Daher kommen die gebauten Nockenwellen meist nur dann zum Einsatz, wenn der Werkstoff Guss seine technischen Grenzen erreicht. Insbesondere werden gebaute Nockenwellen zur Gewichtsreduktion eingesetzt. Die realisierbare Gewichtseinsparung gegenüber massiv gegossenen Nockenwellen liegt bei 20-40%.Therefore, the assembled camshafts are usually only used when the material casting reaches its technical limits. In particular, built-in camshafts are used for weight reduction. The realizable weight savings compared to solid cast camshafts is 20-40%.

Aus der Druckschrift DE 199 07 258 C 1 ist ein Verfahren zur Herstellung einer Nockenwelle und eine mit diesem hergestellte Nockenwelle bekannt, wobei die Nockenwelle durch Innenhochdruck-Umformen hergestellt und danach im Bereich der Laufflächen eine Schicht aus verschleißfestem Material durch Einwirkung eines Ladungsträgerstrahls aufgebracht wird. Hierbei wird ein bandförmiges bzw. drahtförmiges verschleißfestes Material im Vakuum in das Energiefeld des Elektronenstrahls mit definierter Geschwindigkeit eingebracht, aufgeschmolzen und auf die Lauffläche eines Nocken der Nockenwelle übertragen. Anschließend erfolgt eine Bearbeitung der Laufflächen auf ein gewünschtes Endmaß.From the document DE 199 07 258 C 1 a method for producing a camshaft and a camshaft produced therewith is known, wherein the camshaft is produced by hydroforming and then in the region of the running surfaces a layer of wear-resistant material is applied by the action of a charge carrier beam. Here, a band-shaped or wire-shaped wear-resistant material is introduced in a vacuum into the energy field of the electron beam at a defined speed, melted and transferred to the running surface of a cam of the camshaft. Subsequently, the treads are machined to a desired final dimension.

Beim Aufschmelzen und Übertragen des verschleißfesten Materials entsteht jedoch eine hohe thermische Belastung. Diese führt dazu, daß (auch) Werkstoff der Nocken zumindest partiell aufgeschmolzen wird, wodurch es zu Verzugserscheinung der Hohlwelle kommt. Eine notwendige nachträgliche Korrektur des entstehenden Verzuges bedingt umfangreiche Nacharbeiten. Weiterhin wird durch die hohe thermische Belastung die durch den Prozess des Innenhochdruck-Umformens (IHU-Verfahren) erzeugte wünschenswerte Kaltverfestigung zumindest teilweise wieder aufgehoben.When melting and transferring the wear-resistant material, however, creates a high thermal load. This leads to (at least) the material of the cams being melted at least partially, which leads to distortion of the hollow shaft. A necessary subsequent correction of the resulting delay requires extensive rework. Furthermore, due to the high thermal load, the desirable work hardening produced by the hydroforming process (hydroforming process) is at least partially canceled out.

Die Verwendung von Fülldrähten und Blechen schränkt zudem die verfügbare Werkstoffpalette für die Beschichtung stark ein. Insbesondere ist das beschriebene Verfahren zu einem Auftragen von nicht-leitenden Werkstoffen, wie Keramiken, ungeeignet. Ebenso ist das Verfahren zur Herstellung von definierten Strukturen (welche sich bei Schichten aus Kompositwerkstoffen wie Metallkeramiken (Hartmetallen) ergeben können) bei Verwendung der Fülldrähte ungeeignet.The use of cored wires and sheets also greatly limits the available material range for the coating. In particular, the method described is unsuitable for application of non-conductive materials, such as ceramics. Likewise, the process for producing defined structures (which can result in layers of composite materials such as metal ceramics (hard metals)) is unsuitable when using the cored wires.

Es ist daher eine Aufgabe der vorliegenden Erfindung, ein Verfahren zur Herstellung einer Einrichtung zur Umsetzung einer rotatorischen in eine translatorische Bewegung und eine gemäß diesem Verfahren hergestellte Einrichtung anzugeben, mit denen eine verschleißfeste Schicht auftragbar ist, ohne daß ein wesentlicher thermischer Verzug entsteht.It is therefore an object of the present invention to provide a method for producing a device for converting a rotary into a translatory movement and a device produced according to this method, with which a wear-resistant layer can be applied without causing a significant thermal distortion.

Diese Aufgabe wird in verfahrenstechnischer Sicht erfindungsgemäß gelöst durch ein Verfahren zur Herstellung einer Einrichtung zur Umsetzung einer rotatorischen in eine translatorische Bewegung, wobei zumindest abschnittsweise, zumindest eine Funktionsschicht aus einem keramischen, metallkeramischen oder metallischen Werkstoff unter mechanischer Verklammerung mit einer Oberfläche der Einrichtung aufgetragen wird.This object is achieved in procedural perspective according to the invention by a method for producing a device for converting a rotary into a translational movement, wherein at least partially, at least one functional layer of a ceramic, metal-ceramic or metallic material is applied with mechanical interlocking with a surface of the device.

Das erfindungsgemäße Verfahren ermöglicht das Aufbringen einer verschleißfesten Schicht auf die Einrichtung zur Umsetzung einer rotatorischen in eine translatorische Bewegung, ohne daß ein thermischer Verzug der Einrichtung entsteht. Außerdem ermöglicht das erfindungsgemäße Verfahren eine weitere Gewichts- und Reibungsreduzierung gegenüber dem bekannten Stand der Technik durch den Einsatz verschleißfester keramischer, metallkeramischer und metallischer Schichten.The method according to the invention makes it possible to apply a wear-resistant layer to the device for converting a rotary into a translational movement without thermal distortion of the device occurring. In addition, the inventive method allows a further reduction in weight and friction over the prior art by the use of wear-resistant ceramic, metal-ceramic and metallic layers.

Da bei dem erfindungsgemäßen Verfahren Keramiken bzw. Kompositwerkstoffe zum Einsatz kommen können, ergibt sich ein zusätzliches Verbesserungspotential hinsichtlich einer weiteren Gewichtsreduzierung, einer Verringerung der Reibungsverluste, eines Verschleißes und der Fertigungskosten. Die Gewichtsreduzierung und die Verringerung der Reibungsverluste bedingt zudem eine Abnahme des Kraftstoffverbrauches der entsprechenden Motoren.Since ceramics or composite materials can be used in the method according to the invention, there is an additional potential for improvement with regard to a further reduction in weight, a reduction in the friction losses, a wear and the production costs. The weight reduction and the reduction of friction losses also causes a decrease in the fuel consumption of the corresponding engines.

Gemäß einem bevorzugten Ausführungsbeispiel des Verfahrens wird (zunächst) eine zumindest ein Hubelement aufweisende Hohlwelle in einem Innenhochdruck-Umformverfahren ("IHU-Verfahren") hergestellt. Hierbei ist es vorteilhaft, wenn die zumindest eine Funktionsschicht im Bereich einer Lauffläche des zumindest einen Hubelementes und/oder im Bereich von Lagerflächen der Hohlwelle aufgetragen wird. Weiterhin ist es vorteilhaft, wenn die im Bereich der Lauffläche des zumindest einen Hubelementes und/oder im Bereich von Lagerflächen der Hohlwelle aufgetragenen Funktionsschichten aus gleichen oder unterschiedlichen Werkstoffen und jeweils in einer oder mehreren Lagen ausgebildet werden.According to a preferred exemplary embodiment of the method, a hollow shaft having at least one lifting element is (at least) produced in a hydroforming process ("hydroforming process"). In this case, it is advantageous if the at least one functional layer is applied in the region of a running surface of the at least one lifting element and / or in the region of bearing surfaces of the hollow shaft. Furthermore, it is advantageous if the functional layers applied in the region of the running surface of the at least one lifting element and / or in the region of bearing surfaces of the hollow shaft are made of identical or different materials and in each case in one or more embodiments be formed several layers.

Gemäß einem weiteren bevorzugten Ausführungsbeispiel wird ein Verfahren aus der Verfahrensgruppe des thermischen Spritzens, insbesondere Plasmaspritzen oder Hochgeschwindigkeitsflammspritzen, zur Herstellung der zumindest einen Funktionsschicht aus einem keramischen, metallkeramischer oder metallischen Werkstoff unter Verklammerung mit der Oberfläche der Hohlwelle genutzt.According to a further preferred embodiment, a method from the group of methods of thermal spraying, in particular plasma spraying or high-speed flame spraying, is used for producing the at least one functional layer made of a ceramic, metal-ceramic or metallic material while being clamped to the surface of the hollow shaft.

Außerdem ist es besonders vorteilhaft, wenn das zumindest eine Hubelement und/oder die Lagerflächen mit einer umlaufenden Vertiefung ausgebildet werden, die eine Aufnahme für die aufzubringende Funktionsschicht bilden.Moreover, it is particularly advantageous if the at least one lifting element and / or the bearing surfaces are formed with a circumferential recess, which form a receptacle for the functional layer to be applied.

Weiterhin ist es vorteilhaft, wenn die Funktionsschicht als Verschleißschutzschicht und/oder als Reibungsbeeinflussungsschicht ausgebildet wird.Furthermore, it is advantageous if the functional layer is designed as a wear-resistant layer and / or as a friction-influencing layer.

Bevorzugterweise werden die Oberflächen der Einrichtung, insbesondere einer Nockenwelle, zumindest im Bereich der aufzubringenden Funktionsschicht (vor Aufbringung derselben) aufgeraut, insbesondere sandgestrahlt.Preferably, the surfaces of the device, in particular a camshaft, at least in the region of the applied functional layer (before application of the same) roughened, in particular sandblasted.

Die vorgenannte Aufgabe wird in vorrichtungstechnischer Sicht erfindungsgemäß gelöst durch eine Einrichtung zur Umsetzung einer rotatorischen in eine translatorische Bewegung hergestellt nach dem vorstehenden Verfahren.The above object is achieved in device-technical view according to the invention by a device for implementing a rotational in a translational movement produced by the above method.

Gemäß einem besonders zu bevorzugenden Ausführungsbeispiel der erfindungsgemäßen Einrichtung ist die Einrichtung als hohle, mittels Innenhochdruck-Umformen (IHU-Verfahren) hergestellte Nockenwelle mit zumindest einem Nocken ausgebildet, wobei eine Lauffläche des zumindest einen Nocken und/oder Lagerflächen der Nockenwelle verschleißfeste keramische, metallkeramische oder metallische Funktionsschichten aufweisen, die unter mechanischer Verklammerung mit diesen verbunden sind.According to a particularly preferable embodiment of the device according to the invention, the device is designed as a hollow, by means of hydroforming (IHU method) camshaft with at least one cam, wherein a running surface of the at least one cam and / or bearing surfaces of the camshaft wear-resistant ceramic, metal-ceramic or have metallic functional layers, which are connected to it with mechanical clamping.

Vorteilhafterweise sind durch thermisches Spritzen keramische Schichten oder metallkeramische Schichten oder metallkeramische Hartmetallschichten oder metallische Schichten aufgetragen.Advantageously, ceramic coatings or metal-ceramic layers or metal-ceramic hard metal layers or metallic layers are applied by thermal spraying.

Weiterhin ist es vorteilhaft, wenn die Nocken und/ oder die Lagerflächen eine umlaufende Mulde besitzen, die als Bett für die aufzubringende Funktionsschicht dienen.Furthermore, it is advantageous if the cams and / or the bearing surfaces have a circumferential Have trough, which serve as a bed for the functional layer to be applied.

Die vorliegende Erfindung wird nachfolgend anhand bevorzugter Ausführungsbeispiele in Verbindung mit der beigefügten Zeichnung näher erläutert.

  • Figur 1 zeigt eine Teilschnittdarstellung entlang einer Längsachse einer Nockenwelle im Bereich eines Nockens.
The present invention will be explained in more detail below with reference to preferred embodiments in conjunction with the accompanying drawings.
  • Figure 1 shows a partial sectional view along a longitudinal axis of a camshaft in the region of a cam.

Bei der in Figur 1 in einer Längsschnittdarstellung exemplarisch gezeigten Nockenwelle 1 mit einem Nocken 2 handelt es sich um eine durch Innenhochdruck-Umformen (IHU-Verfahren) hergestellte Einlaßnockenwelle 1 aus dem Werkstoff St 52 für einen Dreizylinder-Vierventil-Motor. Die komplette Nockenwelle hat also 6 Nocken.The camshaft 1 shown by way of example in a longitudinal section in FIG. 1 with a cam 2 is an intake camshaft 1 made of the material St 52 produced by hydroforming (hydroforming) for a three-cylinder four-valve engine. The complete camshaft has 6 cams.

Von den einzelnen Nocken 2 der Einlaßnockenwelle 1 ist aus Vereinfachungsgründen lediglich eine in der Schnittdarstellung dargestellt, wobei sämtliche der Nocken 2 der Einlassnockenwelle 1 oder einige der Nocken oder einer der Nocken 2 mit einer Funktionsschicht 3 versehen und in der in Figur 1 gezeigten bzw. der nachstehend beschriebenen Art ausgebildet sein können.Of the individual cams 2 of the intake camshaft 1, only one is shown in the sectional view for reasons of simplification, wherein all of the cams 2 of the intake camshaft 1 or some of the cams or one of the cams 2 are provided with a functional layer 3 and in the one shown in FIG may be formed below described type.

Weiterhin können auch weitere in Fig. 1 nicht gezeigte Bereiche der Nockenwelle 1 mit einer Funktionsschicht 3 versehen werden. Insbesondere können Lagerflächen der Nockenwelle 1 mit einer solchen Funktionsschicht 3 versehen werden.Furthermore, other areas of the camshaft 1 not shown in FIG. 1 can also be provided with a functional layer 3. In particular, bearing surfaces of the camshaft 1 can be provided with such a functional layer 3.

Die einzelnen Funktionsflächen 3 (an den Nocken 2 oder an anderen Stellen der Nockenwelle 1, insbesondere die Lagerflächen) können aus gleichen bzw. gleichartigen bzw. gleichwirkenden Werkstoffen oder auch aus verschiedenen Werkstoffen hergestellt werden. Die Werkstoffauswahl ist insbesondere durch den einzelnen technischen Verwendungszweck (z.B. Verschleißschutz oder Reibungsverbesserung) und auch durch die technischen Randbedingungen bedingt.The individual functional surfaces 3 (on the cams 2 or at other locations of the camshaft 1, in particular the bearing surfaces) can be made of the same or similar or equivalent materials or of different materials. The choice of material is due in particular to the individual technical use (for example wear protection or friction improvement) and also to the technical boundary conditions.

Die Nocken 2 weisen in dem in Fig. 1 gezeigten Ausführungsbeispiel jeweils eine umlaufende Mulde auf, wobei die Mulde eine im wesentlichen ebene Vertiefung und zwei erhöhte, mit Radien versehene Randbereiche aufweist. Die vorliegende Erfindung ist jedoch nicht auf die in Fig. 1 gezeigte Form der Mulde beschränkt. Vielmehr ist diese abhängig vom Verwendungszweck, der herzustellenden Form der Funktionsfläche, dem jeweiligen Beschichtungsverfahren sowie dem jeweiligen Werkstoff der Funktionsfläche abhängig. Beispielsweise können auch mehrere im wesentlichen ebene Vertiefungen mit jeweils diese begrenzenden erhöhten und mit Radien versehenen Randbereichen vorgesehen werden.In the exemplary embodiment shown in FIG. 1, the cams 2 each have a circumferential recess, wherein the recess has a substantially flat depression and two raised, radiused edge regions. However, the present invention is not limited to the shape of the trough shown in FIG. Rather, this depends on the intended use, the shape of the functional surface to be produced, the respective coating method and the respective material of the functional surface dependent. For example, it is also possible to provide a plurality of essentially flat depressions, each with these limiting raised and radiused edge regions.

Diese umlaufende Mulde dient als Aufnahmebett für die aufzubringende Funktionsschicht 3. Wie in Fig. 1 gezeigt, füllt hierbei der Werkstoff der Funktionsschicht 3 die Mulde vollständig aus, wobei die Funktionsschicht eben mit den erhöhten Randbereichen der Mulde ausgebildet ist. Hierdurch ergibt sich eine ebene Nockenlauffläche.As shown in FIG. 1, in this case the material of the functional layer 3 completely fills the trough, wherein the functional layer is formed precisely with the raised edge regions of the trough. This results in a flat cam surface.

In dem in Fig. 1 gezeigten Anwendungsfall hat sich eine Tiefe der Mulde von 1 mm als besonders vorteilhaft erwiesen. Außerdem hat es sich als ausreichend herausgestellt, wenn eine Breite der Mulde einer Breite eines zugeordneten Rollenschlepphebels des Motors entspricht, wobei die vorliegende Erfindung allerdings nicht hierauf beschränkt ist.In the application shown in Fig. 1, a depth of the well of 1 mm has proven to be particularly advantageous. In addition, it has been found to be sufficient if a width of the trough corresponds to a width of an associated roller cam follower of the engine, but the present invention is not limited thereto.

Eine Beschichtung der Einlaßnockenwelle 1 mit der Funktionsschicht 3 erfolgt über die Einlagerung eines verschleißfesten keramischen, metallkeramischen oder metallischen Werkstoffes unter mechanischer Verklammerung mit einer Oberfläche der Einlassnockenwelle 1 im Bereich der Mulde und durch die Ausfüllung der Mulde mit diesem Werkstoff. Diese mechanische Verklammerung kann vorzugsweise dadurch unterstützt werden, daß die Nockenwelle einer vorbereitenden, aufrauenden Oberflächenbehandlung, z.B. durch Sandstrahlen, ggf. auch nur im Bereich der Mulden, unterzogen wird. Hierdurch wird die Mikrooberfläche der Nockenwelle und dadurch die Haftfläche zwischen Nockenwellenoberfläche und der aufgebrachten, harten Verschleißoberschicht vergrößert und die Verbindungsfestigkeit zwischen aufgespritzter Schicht und der Nockenoberfläche erhöht.A coating of the intake camshaft 1 with the functional layer 3 via the incorporation of a wear-resistant ceramic, metal-ceramic or metallic material with mechanical interlocking with a surface of the intake camshaft 1 in the trough and by filling the trough with this material. This mechanical clamping may preferably be assisted by providing the camshaft with a preliminary, roughening surface treatment, e.g. by sandblasting, possibly even only in the area of the troughs, is subjected. This increases the micro-surface of the camshaft and thereby the adhesion surface between the camshaft surface and the applied hard wear upper layer and increases the bonding strength between the sprayed-on layer and the cam surface.

Im konkreten Anwendungsfall wurde die Einlaßnockenwelle 1 mittels atmosphärischem Plasmaspritzen mit einer Anlage MF-P-1000 der Firma GTV mbH/ Luckenbach beschichtet. Als Beschichtungspulver wurde eine Metallkeramik (Hartmetall) (Ti, Mo)(C, N) - 37% Ni, Co verwendet. Zum Spritzen wurde ein Ar/H2- Plasma (50 l/min Ar, 11 I/min H2) bei einer Stromstärke von 630 A verwendet. Der Spritzabstand betrug 110 mm.In concrete application, the intake camshaft 1 was coated by means of atmospheric plasma spraying with a plant MF-P-1000 GTV mbH / Luckenbach. As the coating powder, a metal ceramics (hard metal) (Ti, Mo) (C, N) - 37% Ni, Co was used. For spraying, an Ar / H 2 plasma (50 l / min Ar, 11 l / min H 2 ) at a current of 630 A was used. The spray distance was 110 mm.

Neben dem beschriebenen atmosphärischen Plasmaspritzen mit den genannten exemplarischen Versuchsparametem sind weitere solche Beschichtungsverfahren nutzbar, bei denen die Schichtabscheidung zumindest im wesentlichen auf einer mechanischen Verklammerung der Schicht auf der Unterlage beruht und die nur einen geringen thermischen Energieeintrag bewirken. Solche Beschichtungsverfahren finden sich vorzugsweise in der Prozessgruppe des thermischen Spritzens, also insbesondere neben Plasmaspritzen auch das Hochgeschwindigkeitsflammspritzen (HVOF).In addition to the described atmospheric plasma spraying with the mentioned exemplary Experimental parameters are further such coating methods can be used, in which the layer deposition is based at least substantially on a mechanical clamping of the layer on the substrate and cause only a small thermal energy input. Such coating methods are preferably found in the process group of thermal spraying, so in particular, in addition to plasma spraying and high-speed flame spraying (HVOF).

Anschließend an den Beschichtungsvorgang werden die Nocken auf Endmaß geschliffen, wodurch sich die Lauffläche der Nocken 2 ergibt.Subsequent to the coating process, the cams are ground to final dimensions, resulting in the running surface of the cam 2.

Hieran anschließend wurde ein Test der so erzeugten Nockenwelle 1 durchgeführt. Dieser Test erfolgte auf einem speziellen Prüfstand mit einer Flächenpressung von 1400 N/mm2, einer Drehzahl von 3500 U/min, einer Öltemperatur von 100 °C und Motorenöl Esso Ultron SAE 5W40.Subsequently, a test of the thus produced camshaft 1 was performed. This test was carried out on a special test bench with a surface pressure of 1400 N / mm 2 , a speed of 3500 rpm, an oil temperature of 100 ° C and engine oil Esso Ultron SAE 5W40.

Dabei ergab sich auch nach einer Laufzeit von 500 Std. (übliche Testzeit) kein Schichtausfall (sog. "Pittingbildung").After a running time of 500 hours (usual test time), there was no stratum failure (so-called "pitting formation").

Bei den vorstehend beschriebenen Ausführungsbeispielen erfolgt zunächst eine Herstellung einer (noch unbeschichteten) Nockenwelle mittels des IHU-Verfahrens. Daran anschließend erfolgt die Schichtabscheidung durch solche Verfahren, die im wesentlichen auf einer mechanischen Verklammerung der Schicht auf der Unterlage beruhen und die nur einen geringen thermischen Energieeintrag bewirken, vorzugsweise aus der Prozessgruppe des thermischen Spritzens (z. B. Plasmaspritzen, Hochgeschwindigkeitsflammspritzen (HVOF), u.a.).In the exemplary embodiments described above, first of all a production of a (still uncoated) camshaft takes place by means of the hydroforming process. Subsequently, the layer deposition takes place by such methods, which are based essentially on a mechanical clamping of the layer on the substrate and which cause only a small thermal energy input, preferably from the process group of thermal spraying (eg plasma spraying, high-velocity flame spraying (HVOF), etc.).

Die vorstehenden Ausführungsbeispiele weisen eine hohe Flexibilität durch den Einsatz verschiedenster Werkstoffe auf, wobei diese an die Anforderungen an die Nockenwelle in den unterschiedlichen Motoren angepasst werden können. Insbesondere können auch auf einfache Art und Weise und ohne größeren technischen Aufwand bis zu 1,5 mm dicke Verschleißschutzschichten mit neuen metallischen, keramischen oder metallkeramischen Werkstoffen erzeugt werden.The above embodiments have a high flexibility through the use of different materials, which can be adapted to the requirements of the camshaft in the different engines. In particular, up to 1.5 mm thick wear protection layers can be produced with new metallic, ceramic or metal-ceramic materials in a simple manner and without major technical effort.

Beispiele derartiger Werkstoffe sind:

  • Mo und Mo-selbstfließende Legierung als metallische Schichten,
  • WC-Co, WC-CoCr, (Ti,Mo)(C,N)-NiCo als metallkeramische (Hartmetall-) Schichten, oder
  • Al2O3-TiO2, Cr2O3, Tin-2Cr2O2n-1 als keramische Schichten.
Examples of such materials are:
  • Mo and Mo self-fluxing alloy as metallic layers,
  • WC-Co, WC-CoCr, (Ti, Mo) (C, N) -NiCo as metal-ceramic (hard metal) layers, or
  • Al 2 O 3 -TiO 2 , Cr 2 O 3 , Ti n-2 Cr 2 O 2n-1 as ceramic layers.

Bei den vorstehenden Ausführungsbeispielen kommt es nicht zu einem Verziehen der Nockenwelle, d.h. ein nachträgliches Richten der Welle ist nicht erforderlich. Außerdem werden durch den Einsatz neuer Werkstoffe (metallische, keramische oder metallkeramische bis 1,5 mm dicke Verschleißschutzschichten) die Verschleißfestigkeit und gleichzeitig auch die Reibungsverhältnisse auf dem Nocken verbessert. Der Einsatz keramischer Schichten bewirkt zusätzlich eine Gewichtreduzierung. Verminderung der Fertigungs- und Materialkosten im Vergleich zum Einsatz von Tragringen, z.B. aus 100 Cr6.In the above embodiments, there is no warping of the camshaft, i. a subsequent straightening of the shaft is not required. In addition, the use of new materials (metallic, ceramic or metal-ceramic up to 1.5 mm thick wear protection layers) improves the wear resistance and at the same time the friction conditions on the cam. The use of ceramic layers additionally causes a weight reduction. Reduction of manufacturing and material costs compared to the use of support rings, e.g. made of 100 Cr6.

Claims (9)

  1. Process for producing a hollow shaft (3), wherein at least one lifting element (2) is produced in a hydroforming process with a circumferential depression, wherein the depression is defined by two edge regions provided with radii, and wherein at least one functional layer (3) of a ceramic, cermet or metallic material is applied while filling the depression and being mechanically interlocked with a surface of the depression, after which the lifting element is reworked in the region of the functional layer to form a functional surface.
  2. Process according to Claim 1, characterised in that the at least one functional layer (3) is applied in the region of a running surface of the at least one lifting element (2) and/or in the region of bearing surfaces of the hollow shaft (1).
  3. Process according to Claim 2, characterised in that the functional layers (3) which are applied in the region of the running surface of the at least one lifting element (2) and/or in the region of bearing surfaces of the hollow shaft (1) are formed from the same or different materials and in each case in one or a plurality of layer(s).
  4. Process according to at least one of Claims 1 to 3, characterised in that a process from the process group of thermal spraying, in particular plasma spraying or high-speed flame spraying, is used to produce the at least one functional layer (3) of a ceramic, cermet or metallic material while interlocking it with the surface of the device (1).
  5. Process according to at least one of Claims 1 to 4, characterised in that the functional layer (3) is formed as an antiwear layer and/or as a friction influencing layer.
  6. Process according to at least one of Claims 1 to 5, characterised in that the surfaces of the hollow shaft, in particular camshaft, are roughened, in particular sand-blasted, at least in the region of the functional layer.
  7. Camshaft (1) with at least one cam (2), produced according to a process according to at least one of Claims 1 to 6, wherein a running surface of the at least one cam (2) and/or bearing surfaces of the camshaft (1) comprise wear-resistant ceramic, cermet or metallic functional layers (3) which are joined to these by mechanical interlocking, wherein the cams and/or the bearing surfaces comprise a circumferential trough with a circumferential, substantially plane depression and two elevated edge regions which are provided with radii and serve as a bed for the functional layer which is to be applied.
  8. Device according to Claim 7, characterised in that ceramic layers or cermet layers or cermet hard metal layers or metallic layers are applied by thermal spraying.
  9. Device according to Claim 8, characterised in that hard metal layers are applied by means of high-speed flame spraying.
EP03798177A 2002-09-23 2003-09-23 Method for producing a device for converting a rotatory motion into a translatory motion, and a corresponding device produced according thereto Expired - Lifetime EP1556585B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10244151A DE10244151A1 (en) 2002-09-23 2002-09-23 Coated hollow camshaft
DE10244151 2002-09-23
PCT/EP2003/010581 WO2004029421A1 (en) 2002-09-23 2003-09-23 Method for producing a device for converting a rotatory motion into a translatory motion, and a corresponding device produced according thereto

Publications (2)

Publication Number Publication Date
EP1556585A1 EP1556585A1 (en) 2005-07-27
EP1556585B1 true EP1556585B1 (en) 2006-04-12

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EP03798177A Expired - Lifetime EP1556585B1 (en) 2002-09-23 2003-09-23 Method for producing a device for converting a rotatory motion into a translatory motion, and a corresponding device produced according thereto

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EP (1) EP1556585B1 (en)
AT (1) ATE323216T1 (en)
AU (1) AU2003275979A1 (en)
DE (2) DE10244151A1 (en)
ES (1) ES2262023T3 (en)
WO (1) WO2004029421A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102004025553B4 (en) * 2004-05-25 2006-04-20 Daimlerchrysler Ag Camshaft and a method for its production
DE102009025023A1 (en) 2009-06-10 2010-12-16 Neumayer Tekfor Holding Gmbh Method for producing a camshaft and corresponding camshaft

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB859327A (en) * 1957-12-12 1961-01-18 Maybach Motorenbau Gmbh Improvements in and relating to shafts
DE1082461B (en) * 1957-12-12 1960-05-25 Maybach Motorenbau Gmbh Shaft, especially camshaft
DE3303629C2 (en) * 1982-02-26 1986-04-10 Kokan Kako Co., Ltd., Yokohama, Kanagawa Method for manufacturing a camshaft with at least one eccentric cam
DE3342316A1 (en) * 1983-11-23 1985-05-30 Bayerische Motoren Werke AG, 8000 München Camshaft for internal combustion engines
DE19545991A1 (en) * 1995-12-09 1997-06-12 Eckel Gmbh & Co Kg Heinrich Lightweight camshaft with at least partly non-cylindrical outer surface
DE19617593A1 (en) * 1996-05-02 1998-01-29 Haerle Hans A Dipl Ing Hollow camshaft produced out of a length of pipe
JPH11241605A (en) * 1998-02-24 1999-09-07 Tube Foming Co Ltd Hollow integrated cam shaft and manufacture thereof
DE19907258C1 (en) * 1999-02-21 2000-09-07 Saechsische Elektronenstrahl G Camshaft for motor vehicle engines
DE20121375U1 (en) * 2001-10-11 2002-08-08 Salzgitter Antriebstechnik Gmb Camshaft designed as a hollow shaft

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AU2003275979A8 (en) 2004-04-19
AU2003275979A1 (en) 2004-04-19
ES2262023T3 (en) 2006-11-16
DE50302979D1 (en) 2006-05-24
ATE323216T1 (en) 2006-04-15
WO2004029421A1 (en) 2004-04-08
DE10244151A1 (en) 2004-04-08
EP1556585A1 (en) 2005-07-27

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