EP1713603A2 - Procede et appareil pour fabriquer des moulages a parois minces tres resistants - Google Patents

Procede et appareil pour fabriquer des moulages a parois minces tres resistants

Info

Publication number
EP1713603A2
EP1713603A2 EP04816622A EP04816622A EP1713603A2 EP 1713603 A2 EP1713603 A2 EP 1713603A2 EP 04816622 A EP04816622 A EP 04816622A EP 04816622 A EP04816622 A EP 04816622A EP 1713603 A2 EP1713603 A2 EP 1713603A2
Authority
EP
European Patent Office
Prior art keywords
casting
block
interliner
mold
insert
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.)
Withdrawn
Application number
EP04816622A
Other languages
German (de)
English (en)
Inventor
Oscar Gerardo Cantu-Gonzalez
Ismael Ramirez-Al Varez
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 EP1713603A2 publication Critical patent/EP1713603A2/fr
Withdrawn legal-status Critical Current

Links

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

Definitions

  • the invention broadly relates to the art of manufacturing thin-walled castings and is particularly useful for the manufacture of cast aluminum automotive engine blocks with very thin interliner walls.
  • the design of the engine blocks has been changing over the time with a tendency to increase the power of engines.
  • 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.
  • These designs pose a challenging problem to block manufacturers, because the cylinder liners (usually made of iron) are sought to be so close together that the aluminum wall formed as a web in the gap between said cylinder liners is becoming ever thinner (less than about 3 mm). With the gap between adjacent pairs of cylinder liners being so thin, the liquid aluminum volume filling such interliner cavity is relatively small and rapidly loses heat upon contacting said iron liners and consequently solidifies prematurely thus plugging the cavity and preventing liquid aluminum from filling the rest of said cavity.
  • This insert is preferably made of aluminum of the same alloy or optionally of a different alloy or even of some other suitable material (such as bronze or copper) and is positioned in the desired place at the same time that the sand core defining the water jacket of the block is produced.
  • This insert can have an hourglass shape similar to the pre-formed core discussed in U.S. Patent No. 6,298,899 and also similarly has the advantage of avoiding the "angle of inclination" discussed therein. Though similar in shape due to its positioning, the '899 core serves a very different purpose (involving a different concept). The applicants' pre-formed insert is significantly different with many more advantages.
  • the '899 core is an impermanent sand core
  • Applicants' pre-formed insert is a permanent solid structure that effectively remains in place as part of the casting after the water jacket core is removed.
  • the Applicants' pre-formed insert can be a solid, or can additionally incorporate a thin- walled pipe, or preferably can alternatively have an integrally formed passage in it. The pipe or passage in such an insert is thus able to provide an effective stable cooling fluid passage through the ultra-nanow interliner gap.
  • a method of casting a cast product comprising pre-formed solid elements having at least one dimension thinner than about 3mm and separately casting thereafter the rest of the product with liquid metal with the pre-formed elements already in place thereby to form the final cast product.
  • a method of manufacturing an engine block of aluminum alloy having cylinder liners comprising providing a mold for casting said engine block; inserting pre-formed solid elements each between a pair of said cylinder liners and filling said mold with molten aluminum alloy to form said motor block.
  • an engine block made of aluminum alloy is provided, comprising relatively stress-free pre-formed solid elements between said cylinder liners and the rest of said engine block being cast from said aluminum alloy forming an integral block after solidification of said casting.
  • the solid elements can incorporate a cooling passage pipe, or the pre-formed solid insert can have a cooling passage already formed therein (optionally with an in-place removable core).
  • Figure 1 is an isometric view of the core of a mold for forming the water jacket (i.e. cooling passages) of an aluminum engine block incorporating three pre-formed solid aluminum inserts (according to one prefened embodiment of the present invention), with each such insert having a bridging cooling passage core and each being incorporated by means of the bridging core with the jacket core at a respective interliner gap position
  • Figure 2 shows a top stylized view of an engine cylinder block with a cylindrical iron liner closely fitted into each of the cylinder bores and with a solid aluminum insert (having no passages therein) positioned in the interliner gap of each pair of liners in the finished block (thus showing the relationship of engine parts in which the invention can effectively be practiced).
  • Figure 3 shows a stylized vertical section taken along section line A- A of Figure 2.
  • Figure 4 shows a top stylized view similar to figure 2, but according to a different prefened embodiment of the present invention wherein the pre-formed inserts each incorporate a bridging cooling fluid flow passage (shown in dotted lines).
  • Figure 5 shows a stylized vertical section taken along section line A-A of Figure 4..
  • Figure 6 is an isometric view a solid pre-formed insert showing two bridging cores, passing through and extending out from either end of the upper portion of the pre-formed insert, for forming interliner-gap-bridging cooling-fluid flow passages.
  • Figure 7 is an isometric view showing two iron liners mounted on the core of a mold with a solid pre-formed insert (according to the prefened embodiment of figures 2 and 3) fitted in the interliner gap.
  • a solid pre-formed insert according to the prefened embodiment of figures 2 and 3 fitted in the interliner gap.
  • the solution to the problems of filling a casting mold for an engine-block 8 having thin interliner walls 9 with a liquid aluminum alloy comprises incorporating a solid insert 10 made of a suitable material, for example the same aluminum alloy which will form the rest of the cast block.
  • suitable materials for the pre-formed insert include, for example, bronze, copper and alloys and equivalents thereof.
  • the pre-formed insert (designated generally by reference number 10) may be forged or extruded.
  • the pre-formed insert 10 is placed between the cylinder liners 12 before introducing the liquid aluminum alloy into said mold.
  • the insert 10 will be contained and locked in place by the liquid aluminum which solidifies forming the rest of the block 8.
  • the perform insert (see inserts 10a or 10b) has grooves 14 to engage the liquid aluminum, thereby providing a better bond between the insert and the aluminum when the liquid aluminum cools and sets. Bonding may also occur from surface melting of the insert 10 during the casting pour. This may be aided by the addition of a bonding agent such as low melting zinc.
  • one of the advantages of the present invention is that the pre-formed inserts 10 do not result in residual tension.
  • the inserts 10 are not made of the same alloy, little or no thermal stresses are induced in the pre-formed inserts 10 due to shrinking of aluminum or due to expansion of the iron cylinder liners 12 (since the inserts 10 are already cooled to solid stress free form).
  • the invention advantageously resists tensions or cracking caused by post-machining, procedures such as boring.
  • a cooling-liquid passage 15 is preferably formed in or as part of a pre-formed insert 10; for example, by placing an insert 10b or 10c with a conduit for said cooling-fluid having the required shape to fit in the gap between the cylinder liners.
  • the passage 15 can take the form of an embedded thin walled pipe 17 (made of steel or the like), see Figure 1 , or may be integrally form with the insert by use of a bridging core 16, see Figure 6.
  • the removable bridging core 16 when used to form the passage 15 in the pre-formed insert 10b will remain in place until after the casting of the engine block is completed (and thereafter be removed with the removal of the jacket core 6).
  • Known examples of such bridging cores include salt, carbon, or glass (see U.S. Patent No. 6,205,959).
  • the present invention can be practiced, for example, with cunent processes and equipment, which can comprise 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 by a subsequent mold to be filled up.
  • a mass of a heat-absorbing material also known as a chill (or a heat sink device) can be cunently placed under a proprietary process of the assignee of this application in contact with the liquid aluminum alloy in order to direct the solidification in the desired direction in order to produce good-quality castings.
  • Such controlled cooling can be disrupted by the small interliner gaps that are now encountered in modern aluminum automotive engine blocks; but are overcome by use of the present invention.
  • Less than 3 mm is a prefened condition for using this invention, but the method applies as well to thicker interliner dimensions when there is a need to provide interliner cross sections with reduced residual stresses due to the solidification process or for any of the other reasons discussed above.

Landscapes

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

Abstract

L'invention concerne un procédé et un appareil permettant de former des parties jointives de bonne qualité et très résistantes présentant une dimension minimale inférieure ou égale à 3 mm entre les chemises en fonte grise dans les blocs-cylindres en aluminium en recourant à des inserts métalliques préformés adjoints au noyau de la chemise d'eau extérieure, lesdits inserts étant de préférence pourvus de passages de liquide de refroidissement assurant la jonction avec la chemise d'eau extérieure et conformés de préférence pour remplir l'espace interchemise, et constitués du même alliage que le reste du bloc.
EP04816622A 2003-12-18 2004-12-20 Procede et appareil pour fabriquer des moulages a parois minces tres resistants Withdrawn EP1713603A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US53127803P 2003-12-18 2003-12-18
PCT/IB2004/004401 WO2005060343A2 (fr) 2003-12-18 2004-12-20 Procede et appareil pour fabriquer des moulages a parois minces tres resistants

Publications (1)

Publication Number Publication Date
EP1713603A2 true EP1713603A2 (fr) 2006-10-25

Family

ID=34710217

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04816622A Withdrawn EP1713603A2 (fr) 2003-12-18 2004-12-20 Procede et appareil pour fabriquer des moulages a parois minces tres resistants

Country Status (5)

Country Link
US (1) US20050173091A1 (fr)
EP (1) EP1713603A2 (fr)
JP (1) JP2007514550A (fr)
CA (1) CA2550033A1 (fr)
WO (1) WO2005060343A2 (fr)

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US20100044003A1 (en) * 2008-08-25 2010-02-25 Mark A. Baumgarten Insert molding
DE102010047325B4 (de) * 2010-10-01 2021-11-18 Daimler Ag Brennkraftmaschine mit einem Zylindergehäuse aus Leichtmetallguss und mit Zylinderlaufbuchsen aus Rauguss
CN103541828B (zh) * 2012-07-17 2014-10-08 安徽华菱汽车有限公司 发动机及其缸套缸体的冷却结构
DE102012025333B4 (de) * 2012-12-21 2021-09-30 Audi Ag Kurbelgehäuse einer Brennkraftmaschine sowie Verfahren zum Herstellen eines Kurbelgehäuses
US9416749B2 (en) 2013-12-09 2016-08-16 Ford Global Technologies, Llc Engine having composite cylinder block
US9341136B2 (en) 2013-12-09 2016-05-17 Ford Global Technologies, Llc Engine having composite cylinder block
US10113504B2 (en) * 2015-12-11 2018-10-30 GM Global Technologies LLC Aluminum cylinder block and method of manufacture
US10781769B2 (en) * 2018-12-10 2020-09-22 GM Global Technology Operations LLC Method of manufacturing an engine block
US11174813B1 (en) * 2020-09-30 2021-11-16 Caterpillar Inc. Liner for engine block and systems, assemblies, components, and methods thereof

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Also Published As

Publication number Publication date
US20050173091A1 (en) 2005-08-11
CA2550033A1 (fr) 2005-07-07
WO2005060343A3 (fr) 2006-03-23
JP2007514550A (ja) 2007-06-07
WO2005060343A8 (fr) 2007-02-15
WO2005060343A2 (fr) 2005-07-07

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