EP2636468B1 - Device for manufacturing a cylinder crankcase - Google Patents

Device for manufacturing a cylinder crankcase Download PDF

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Publication number
EP2636468B1
EP2636468B1 EP13152983.6A EP13152983A EP2636468B1 EP 2636468 B1 EP2636468 B1 EP 2636468B1 EP 13152983 A EP13152983 A EP 13152983A EP 2636468 B1 EP2636468 B1 EP 2636468B1
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EP
European Patent Office
Prior art keywords
cylinder
cylinder crankcase
web
manufacturing
casting mold
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EP13152983.6A
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German (de)
French (fr)
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EP2636468A3 (en
EP2636468A2 (en
Inventor
Stephan Beer
Steffen Ziegler
Christian Klimesch
Ludger Urhahn
Helge Woelbing
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KS Huayu Alutech GmbH
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KS Huayu Alutech GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/103—Multipart cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F1/00—Cylinders; Cylinder heads 
    • F02F1/02—Cylinders; Cylinder heads  having cooling means
    • F02F1/10—Cylinders; Cylinder heads  having cooling means for liquid cooling
    • F02F1/108—Siamese-type cylinders, i.e. cylinders cast together

Definitions

  • the invention relates to a device for producing a cylinder crankcase with a casting mold with several molded parts, at least one water jacket core, which is arranged on both longitudinal sides of one or more molded parts forming a cylinder row, and at least one web core, which is arranged between the molded parts forming the individual cylinders of a cylinder row .
  • the cylinder crankcase In modern internal combustion engines, the cylinder crankcase is manufactured with very small gaps between the cylinders of a cylinder bank, regardless of the selection of the cylinder arrangement in order to reduce weight and installation space. Nevertheless, both sufficient strength of the side walls delimiting the cylinders and adequate cooling of these web areas between the cylinders must be ensured, since otherwise there is a risk of thermal overloading in the case of highly loaded engines.
  • connection openings between the opposing coolant jackets are in the DE 10 2009 033 402 A1 through the use of a fibrous material or in the DE 38 28 093 A1 by using ceramic, which is held in position between the cooling jacket cores and connecting the two cooling jacket cores to one another. These parts forming the bar cooling channels are then removed from the casting. In the DE 38 28 093 A1 the cores are removed through openings on the cylinder cover surface by subsequent core cleaning.
  • a cylinder crankcase with a cooling channel which is generated by a sand core.
  • the two halves of the sand core are connected by a wire that is fixed in the sand of the water jacket core that is inserted into the casting mold.
  • a casting mold is known in which the water jacket core is interrupted between two cylinders. A plate is inserted into this area, which forms the coolant jacket in the area of the web. It is attached in a form-fitting manner in the water jacket core. One end of the plate protrudes into the casting mold and is received there in order to be able to pull the plate out of the casting after casting.
  • the DE 100 33 271 A1 discloses a water jacket core in which a web core is introduced in a form-fitting manner between the two water jacket core halves.
  • the object is therefore to create a device for producing cylinder crankcases, in particular from a light metal alloy, with which it can be ensured that even filigree web cooling systems with a connection to the cylinder head are optimally arranged in the casting.
  • the at least one web core is inserted into the casting mold and aligned with the casting mold, the at least one web core being arranged in relation to the water jacket core in such a way that, after casting, a connection between the cooling channel formed by the web core and the cooling channel formed by the Water jacket core formed cooling channel can be produced or two separate cooling water circuits are available, the subsequent cooling channel is in exact alignment with the walls of the cylinder crankcase. A summation of positional tolerances is excluded.
  • the attachment can be made by simply plugging in, whereby the cycle times are shortened compared to a non-positive connection.
  • both the bar cooling and the rest of the cylinder cooling can be supplied with cooling water via common inlets and outlets, for example via the cylinder head, so that additional connections can be omitted.
  • the at least one web core is preferably attached to a molded part of the casting mold in a form-fitting manner. Fastening can be carried out by simply plugging in, whereby the cycle times are shortened compared to a non-positive connection.
  • the at least one web core protrudes from at least one surface, which forms a cylinder deck, of a cavity of the casting mold which forms the cylinder crankcase. Accordingly, there is the possibility of supplying the web cooling via the cylinder head in the finished cylinder crankcase, whereby connections to the water jacket of the cylinder can be dispensed with.
  • the at least one web core protrudes on two opposite sides with respect to the molded part forming the cylinder from the surface of the casting mold cavity forming the cylinder crankcase.
  • the bar core can be attached to the casting mold on both sides.
  • both passages on the finished cylinder crankcase can be used for the cooling water supply.
  • the at least one web core preferably has two legs which extend parallel to the cylinder axis and which extend into the cavity forming the web between the molded parts forming the cylinder. Correspondingly, thin boundary surfaces, as would arise with an inclined arrangement, are avoided, which increases the strength of the finished cylinder crankcase.
  • the part of the web core arranged in the cavity of the casting mold is essentially U-shaped, with the two legs protruding over the cavity of the casting mold that forms the cylinder crankcase. There is a connection between the two legs, which means that the two passages of the web core from the cavity can be used as coolant inlets and outlets, which simplifies the flow guidance and reliably prevents dead water areas.
  • arms extend from the legs above the cavity of the casting mold on both sides in directions opposite to the mold parts forming the cylinders, which arms rest on a mold part of the casting mold.
  • the arms can be fixed to the mold outside the areas in which the cores are to be arranged.
  • At least one of the arms has a projection via which the web core engages in a form-fitting manner in a correspondingly shaped recess in the casting mold.
  • the position of the web core is determined by simply inserting it into the casting mold.
  • the web core preferably has an opening at the connection between the legs, via which an upper connection between the legs is separated from a lower connection between the legs is. In this way, an upper and a lower bar cooling system is produced with a bar core. However, the strength of the web is sufficiently retained by the connection arranged between the later channels.
  • the at least one web core is made of sand, artificial sand, salt, glass, graphite or ceramic. Depending on the desired filigree shape and application, different materials are suitable, all of which are compatible with the corresponding arrangement
  • bar cores are arranged one behind the other and connected to one another by a frame, whereby the bar cores can be inserted together, which shortens the set-up time for casting.
  • the frame consists of two struts which run parallel to the longitudinal sides of the cavity forming the cylinder crankcase. This results in only little effort in the production of the frame, which can also be made from different materials.
  • a device for producing a cylinder crankcase is thus created, with which a reliable positioning of the web cooling relative to the cylinders is ensured, the outlay for producing the corresponding channels being reduced by optimizing the assembly and installation of the cores.
  • the device according to the invention for producing a cylinder crankcase 10 consists of a casting mold 12, which has, for example, a lower part 14, two side parts 15 and an upper part 16 as molded parts forming the outer contours of the cylinder crankcase 10, as well as molded parts 20 forming the cylinder 18 of the cylinder crankcase 10.
  • this casting mold 12 there are one or more water jacket cores 22 which surround a row, which consists of several mold parts 20 forming the cylinders 18, with a small spacing on their opposite longitudinal sides 24 as well as on the head and foot area.
  • These water jacket cores 22 are removed from the cast part after the cylinder crankcase 10 has been cast, so that the resulting cavity forms a cooling channel for the cylinders 18.
  • these water jacket cores 22 are not suitable for forming a cavity in webs 26 between the cylinders 18, which is urgently required to ensure sufficient cooling to prevent thermal overloading in these areas.
  • web cores 28 are therefore proposed for forming cooling water channels in the web area, which are arranged in the casting mold 12 and aligned on the casting mold 12 or on one of the mold parts 14, 16 of the casting mold 12.
  • Such a web core 28 can be made of mineral sands, synthetic sand, salt, glass, ceramic or graphite.
  • the web core 28 shown in the figures has in the area which is arranged in the cavity 30 of the casting mold 12 forming the cylinder crankcase 10, a U-shape with two legs 32, 34 running parallel to the cylinder axis and a connection 36 between these legs 32, 34 on.
  • the legs 32, 34 protrude from the surface which, after casting, forms a cylinder deck 38, that is to say the surface of the cylinder crankcase 10, from the cavity 30.
  • the completely cast cylinder crankcase 10 has openings at these positions which make it possible to establish a connection to the cooling water channel of a cylinder head (not shown).
  • the web core 28 can have an opening 35 at the connection 36 between the legs 32, 34. This opening is filled with material during casting, so that an upper connection 37 extends between the legs 32, 34 and a lower connection 39 extends between the legs 32, 34. Correspondingly, different areas of the web 26 can be cooled without the strength of the webs 26 being reduced too much.
  • arms 40, 42 of the web core 28 extend from the legs 32, 34 in opposite directions to one another and rest on the casting mold 12 and, in the present exemplary embodiment, on the side parts 15 of the casting mold 12. Both arms 40, 42 have in their end regions 48, 50 a section which extends essentially obliquely from the Surface of the cylinder deck 38 and thus removed from the side parts 15.
  • the upper part 16 has a recess 44 into which a projection 46 engages, which is formed on the end region 48 of the arm 40 of the web core 28.
  • the surrounding casting mold 12 has a section 52 shaped correspondingly thereto.
  • the result is an essentially form-fitting position of the web core 28 in the casting mold 12, which is finally fixed by closing the casting mold 12 by lowering the upper part 16 or an overlying cover molding, not shown, in which the molding for forming the cylinder is also formed . Shifting within the casting mold 12 is excluded, so that the position relative to the cylinders in the web 26 is fixed with very small tolerances, so that filigree cooling channels can be produced in the web area.
  • the web cores 28, as in Figure 2 are connected to one another via a frame 54.
  • This frame 54 has two struts 56, 58 running parallel to the longitudinal sides 24 of the cylinder crankcase 10, which are connected to the arms 40, 42 of a plurality of web cores 28 arranged one behind the other in the longitudinal direction or are made in one piece with them and together with the web cores 28 in the casting mold 12 can be inserted positively. In this way, several web cores 28 can be inserted together, whereby the set-up time of the casting mold 12 is shortened.
  • the web cores are removed from the cylinder crankcase in a known manner, depending on the material selected.
  • the cooling water channels of the cylinders 18 can then be connected to the web cooling water channels by means of simple bores. However, two separate cooling water circuits can also be used.

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

Description

Die Erfindung betrifft eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses mit einer Gießform mit mehreren Formteilen, zumindest einem Wassermantelkern, welcher an beiden Längsseiten eines oder mehrerer eine Zylinderreihe bildender Formteile angeordnet ist und zumindest einem Stegkern, welcher zwischen den die einzelnen Zylinder einer Zylinderreihe bildenden Formteilen angeordnet ist.The invention relates to a device for producing a cylinder crankcase with a casting mold with several molded parts, at least one water jacket core, which is arranged on both longitudinal sides of one or more molded parts forming a cylinder row, and at least one web core, which is arranged between the molded parts forming the individual cylinders of a cylinder row .

Bei modernen Verbrennungsmotoren wird das Zylinderkurbelgehäuse unabhängig von der Wahl der Zylinderanordnung zur Reduzierung von Gewicht und Bauraum mit sehr kleinen Abständen zwischen den Zylindern einer Zylinderreihe hergestellt. Dennoch muss sowohl eine ausreichende Festigkeit der die Zylinder begrenzenden Seitenwände sichergestellt werden als auch eine ausreichende Kühlung dieser Stegbereiche zwischen den Zylindern, da andernfalls bei hochbelasteten Motoren eine thermische Überbeanspruchung zu befürchten ist.In modern internal combustion engines, the cylinder crankcase is manufactured with very small gaps between the cylinders of a cylinder bank, regardless of the selection of the cylinder arrangement in order to reduce weight and installation space. Nevertheless, both sufficient strength of the side walls delimiting the cylinders and adequate cooling of these web areas between the cylinders must be ensured, since otherwise there is a risk of thermal overloading in the case of highly loaded engines.

Aus diesem Grund ist es bekannt, in die Gießformen neben den einen Kühlkanal an den Längsseiten der Zylinder bildenden Wassermantelkernen zusätzliche Bohrungen in den Stegbereich einzubringen, über die die gegenüberliegenden Kühlkanäle miteinander verbunden werden. Eine Brennkraftmaschine mit einer derartig ausgebildeten Stegkühlung ist beispielsweise aus der DE 10 2005 037 384 A1 bekannt.For this reason, it is known to make additional holes in the web area in the casting molds in addition to the water jacket cores forming a cooling channel on the longitudinal sides of the cylinder, via which the opposing cooling channels are connected to one another. An internal combustion engine with a web cooling designed in this way is, for example, from DE 10 2005 037 384 A1 known.

Häufig ist es jedoch wünschenswert auf eine Nachbearbeitung an den dünnen Stegen verzichten zu können. Entsprechend wird in der DE 198 32 718 A1 bzw. der EP 0 974 414 A1 vorgeschlagen, zwischen die den Wassermantel bildenden Kerne eine Graphitplatte einzusetzen, welche in die beiden Kerne eingeformt ist. Die Graphitplatte bildet nach ihrem Abbrennen am fertigen Zylinderkurbelgehäuse eine Querbohrung zwischen den beiden Wassermänteln an den Längsseiten.However, it is often desirable to be able to dispense with post-processing on the thin webs. Accordingly, in the DE 198 32 718 A1 or the EP 0 974 414 A1 suggested between the the The cores forming the water jacket use a graphite plate, which is molded into the two cores. After it burns off, the graphite plate forms a transverse bore on the finished cylinder crankcase between the two water jackets on the long sides.

Ähnliche Verbindungsöffnungen zwischen den gegenüberliegenden Kühlmittelmänteln werden in der DE 10 2009 033 402 A1 durch die Verwendung eines faserhaltigen Materials oder in der DE 38 28 093 A1 durch die Verwendung von Keramik, welches zwischen den Kühlmantelkernen durch diese in Position gehalten wird und die beiden Kühlmantelkerne miteinander verbinden, geschaffen. Diese die Stegkühlungskanäle bildenden Teile werden anschließend aus dem Gussstück entfernt. Bei der DE 38 28 093 A1 werden die Kerne über Öffnungen an der Zylinderdeckfläche durch anschließendes Kernputzen entfernt.Similar connection openings between the opposing coolant jackets are in the DE 10 2009 033 402 A1 through the use of a fibrous material or in the DE 38 28 093 A1 by using ceramic, which is held in position between the cooling jacket cores and connecting the two cooling jacket cores to one another. These parts forming the bar cooling channels are then removed from the casting. In the DE 38 28 093 A1 the cores are removed through openings on the cylinder cover surface by subsequent core cleaning.

Des Weiteren ist aus der EP 0 197 365 A2 eine Vorrichtung zur gießtechnischen Herstellung eines Kühlkanals im Stegbereich zwischen zwei Zylindern bekannt, bei der separate Kerne zur Bildung dieser Kühlwasserkanäle verwendet werden, die nicht gezwungenermaßen mit den Kühlwasserkanälen der üblichen Wassermäntel in Kontakt stehen. Diese werden im Sohlenkern fixiert und sind wie der Sohlenkern aus Sand hergestellt. Entsprechend befinden sich an der zum Zylinderkopf weisenden Oberfläche des fertigen Zylinderkurbelgehäuses Öffnungen, über die die Stegkühlkanäle mit Kühlmittel versorgt werden können.Furthermore, from the EP 0 197 365 A2 a device for the casting production of a cooling channel in the web area between two cylinders is known, in which separate cores are used to form these cooling water channels, which are not necessarily in contact with the cooling water channels of the usual water jackets. These are fixed in the sole core and, like the sole core, are made of sand. Correspondingly, there are openings on the surface of the finished cylinder crankcase facing the cylinder head, via which the web cooling channels can be supplied with coolant.

Des Weiteren ist aus der DE 103 30 520 A1 ein Zylinderkurbelgehäuse mit einem Kühlkanal bekannt, der durch einen Sandkern erzeugt wird. Die beiden Hälften des Sandkerns sind durch einen Draht verbunden, der im Sand des Wassermantelkerns fixiert ist, der in die Gießform eingelegt ist. Aus der US 5,217,059 ist eine Gießform bekannt, bei der der Wassermantelkern zwischen zwei Zylindern unterbrochen ist. In diesen Bereich wird eine Platte eingeschoben, die den Kühlmittelmantel im Bereich des Steges bildet. Die Befestigung erfolgt formschlüssig im Wassermantelkern. Ein Ende der Platte ragt in die Gießform und wird dort aufgenommen, um die Platte nach dem Gießen aus dem Gussteil ziehen zu können.Furthermore, from the DE 103 30 520 A1 a cylinder crankcase with a cooling channel is known, which is generated by a sand core. The two halves of the sand core are connected by a wire that is fixed in the sand of the water jacket core that is inserted into the casting mold. From the U.S. 5,217,059 a casting mold is known in which the water jacket core is interrupted between two cylinders. A plate is inserted into this area, which forms the coolant jacket in the area of the web. It is attached in a form-fitting manner in the water jacket core. One end of the plate protrudes into the casting mold and is received there in order to be able to pull the plate out of the casting after casting.

Die DE 100 33 271 A1 offenbart einen Wassermantelkern, bei dem zwischen die beiden Wassermatelkernhälften ein Stegkern formschlüssig eingebracht wird.The DE 100 33 271 A1 discloses a water jacket core in which a web core is introduced in a form-fitting manner between the two water jacket core halves.

Nachteilig an den bekannten Ausführungen ist, dass diese eine Stegkühlung schaffenden Kerne lediglich zu anderen Kernteilen ausgerichtet werden, wodurch insbesondere dann Fehler entstehen können, wenn diese Kanäle aus dem Zylinderkopf mit Kühlwasser versorgt werden.The disadvantage of the known designs is that these cores, which create web cooling, are only aligned with other core parts, which can lead to errors in particular when these channels are supplied with cooling water from the cylinder head.

Es stellt sich daher die Aufgabe, eine Vorrichtung zur Herstellung von Zylinderkurbelgehäusen insbesondere aus einer Leichtmetalllegierung zu schaffen, mit der sichergestellt werden kann, dass auch filigrane Stegkühlungen mit Anschluss zum Zylinderkopf optimal im Gussstück angeordnet sind.The object is therefore to create a device for producing cylinder crankcases, in particular from a light metal alloy, with which it can be ensured that even filigree web cooling systems with a connection to the cylinder head are optimally arranged in the casting.

Diese Aufgabe wird durch eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses mit den Merkmalen des Hauptanspruchs gelöst.This object is achieved by a device for producing a cylinder crankcase with the features of the main claim.

Dadurch, dass der zumindest eine Stegkern in die Gießform eingelegt und an der Gießform ausgerichtet ist, wobei der zumindest eine Stegkern derart zum Wassermantelkern angeordnet ist, dass nach dem Gießen entweder mittels einer Bohrung eine Verbindung zwischen dem durch den Stegkern gebildeten Kühlkanal und dem durch den Wassermantelkern gebildeten Kühlkanal herstellbar ist oder zwei getrennte Kühlwasserkreisläufe vorhanden sind, befindet sich der spätere Kühlkanal in exakter Ausrichtung zu den Wänden des Zylinderkurbelgehäuses. Eine Summation von Lagetoleranzen wird ausgeschlossen. Die Befestigung kann durch einfaches Einstecken vorgenommen werden, wodurch die Taktzeiten im Vergleich zu einer kraftschlüssigen Verbindung verkürzt werden. Bei einer Anordnung mit einem Kühlkreislauf kann sowohl die Stegkühlung als auch die übrige Zylinderkühlung über gemeinsame Einlässe und Auslässe beispielsweise über den Zylinderkopf mit Kühlwasser versorgt werden, so dass zusätzliche Anschlüsse entfallen können.In that the at least one web core is inserted into the casting mold and aligned with the casting mold, the at least one web core being arranged in relation to the water jacket core in such a way that, after casting, a connection between the cooling channel formed by the web core and the cooling channel formed by the Water jacket core formed cooling channel can be produced or two separate cooling water circuits are available, the subsequent cooling channel is in exact alignment with the walls of the cylinder crankcase. A summation of positional tolerances is excluded. The attachment can be made by simply plugging in, whereby the cycle times are shortened compared to a non-positive connection. In an arrangement with a cooling circuit, both the bar cooling and the rest of the cylinder cooling can be supplied with cooling water via common inlets and outlets, for example via the cylinder head, so that additional connections can be omitted.

Vorzugsweise ist der zumindest eine Stegkern formschlüssig an einem Formteil der Gießform befestigt. So kann die Befestigung durch einfaches Einstecken vorgenommen werden, wodurch die Taktzeiten im Vergleich zu einer kraftschlüssigen Verbindung verkürzt werden.The at least one web core is preferably attached to a molded part of the casting mold in a form-fitting manner. Fastening can be carried out by simply plugging in, whereby the cycle times are shortened compared to a non-positive connection.

In einer vorteilhaften Ausführung ragt der zumindest eine Stegkern aus zumindest einer ein Zylinderdeck bildenden Oberfläche eines das Zylinderkurbelgehäuse bildenden Hohlraums der Gießform hinaus. Entsprechend besteht die Möglichkeit einer Versorgung der Stegkühlung über den Zylinderkopf im fertigen Zylinderkurbelgehäuse, wobei auf Verbindungen zum Wassermantel der Zylinder verzichtet werden kann.In an advantageous embodiment, the at least one web core protrudes from at least one surface, which forms a cylinder deck, of a cavity of the casting mold which forms the cylinder crankcase. Accordingly, there is the possibility of supplying the web cooling via the cylinder head in the finished cylinder crankcase, whereby connections to the water jacket of the cylinder can be dispensed with.

In einer weiterführenden Ausbildung der erfindungsgemäßen Vorrichtung ragt der zumindest eine Stegkern an zwei bezüglich des den Zylinder bildenden Formteils gegenüberliegenden Seiten aus der das Zylinderdeck bildenden Oberfläche des das Zylinderkurbelgehäuse bildenden Hohlraums der Gießform hinaus. Hierdurch kann der Stegkern beidseitig an der Gießform befestigt werden. Des Weiteren können am fertigen Zylinderkurbelgehäuse beide Durchgänge zur Kühlwasserversorgung genutzt werden.In a further embodiment of the device according to the invention, the at least one web core protrudes on two opposite sides with respect to the molded part forming the cylinder from the surface of the casting mold cavity forming the cylinder crankcase. As a result, the bar core can be attached to the casting mold on both sides. Furthermore, both passages on the finished cylinder crankcase can be used for the cooling water supply.

Bevorzugt weist der zumindest eine Stegkern zwei sich parallel zur Zylinderachse erstreckende Schenkel auf, die sich in den Steg bildenden Hohlraum zwischen den die Zylinder bildenden Formteile erstrecken. Entsprechend werden dünne Grenzflächen, wie sie bei schräger Anordnung entstünden, vermieden, was die Festigkeit des fertigen Zylinderkurbelgehäuses erhöht.The at least one web core preferably has two legs which extend parallel to the cylinder axis and which extend into the cavity forming the web between the molded parts forming the cylinder. Correspondingly, thin boundary surfaces, as would arise with an inclined arrangement, are avoided, which increases the strength of the finished cylinder crankcase.

In einer weiterführenden vorteilhaften Ausgestaltung der Erfindung ist der im Hohlraum der Gießform angeordnete Teil des Stegkerns im Wesentlichen U-förmig ausgebildet, wobei die beiden Schenkel über den das Zylinderkurbelgehäuse bildenden Hohlraum der Gießform ragen. So besteht eine Verbindung zwischen den beiden Schenkeln, die dazu führt, dass die beiden Durchtritte des Stegkerns aus dem Hohlraum als Kühlmittelein- und -auslässe genutzt werden können, was die Strömungsführung vereinfacht und Totwassergebiete zuverlässig verhindert.In a further advantageous embodiment of the invention, the part of the web core arranged in the cavity of the casting mold is essentially U-shaped, with the two legs protruding over the cavity of the casting mold that forms the cylinder crankcase. There is a connection between the two legs, which means that the two passages of the web core from the cavity can be used as coolant inlets and outlets, which simplifies the flow guidance and reliably prevents dead water areas.

Vorzugsweise erstrecken sich von den Schenkeln aus oberhalb des Hohlraums der Gießform zu beiden Seiten Arme in zu den die Zylinder bildenden Formteilen entgegengesetzten Richtungen, welche auf einem Formteil der Gießform aufliegen. Entsprechend können die Arme außerhalb der Bereiche, in denen die Kerne anzuordnen sind, an der Form fixiert werden.Preferably, arms extend from the legs above the cavity of the casting mold on both sides in directions opposite to the mold parts forming the cylinders, which arms rest on a mold part of the casting mold. Correspondingly, the arms can be fixed to the mold outside the areas in which the cores are to be arranged.

In einer besonderen Ausbildung weist zumindest einer der Arme einen Vorsprung auf, über den der Stegkern formschlüssig in eine entsprechend geformte Ausnehmung der Gießform greift. So wird durch einfaches Einlegen des Stegkerns in die Gießform dessen Lage festgelegt.In a special embodiment, at least one of the arms has a projection via which the web core engages in a form-fitting manner in a correspondingly shaped recess in the casting mold. The position of the web core is determined by simply inserting it into the casting mold.

Vorzugsweise weist der Stegkern an der Verbindung zwischen den Schenkeln eine Öffnung auf, über die eine obere Verbindung zwischen den Schenkeln von einer unteren Verbindung zwischen den Schenkeln getrennt ist. So wird eine obere und eine untere Stegkühlung mit einem Stegkern hergestellt. Die Festigkeit des Steges bleibt jedoch durch die zwischen den späteren Kanälen angeordnete Verbindung ausreichend erhalten.The web core preferably has an opening at the connection between the legs, via which an upper connection between the legs is separated from a lower connection between the legs is. In this way, an upper and a lower bar cooling system is produced with a bar core. However, the strength of the web is sufficiently retained by the connection arranged between the later channels.

Weiterhin ist der zumindest eine Stegkern aus Sand, Kunstsand, Salz, Glas, Graphit oder Keramik hergestellt. Je nach gewünschter filigraner Form und Anwendung eignen sich unterschiedliche Materialien, welche alle mit der entsprechenden Anordnung vereinbar sindFurthermore, the at least one web core is made of sand, artificial sand, salt, glass, graphite or ceramic. Depending on the desired filigree shape and application, different materials are suitable, all of which are compatible with the corresponding arrangement

In einer besonders bevorzugten Ausführung sind mehrere Stegkerne hintereinander angeordnet und durch einen Rahmen miteinander verbunden, wodurch die Stegkerne gemeinsam eingelegt werden können, was die Rüstzeit zum Gießen verkürzt.In a particularly preferred embodiment, several bar cores are arranged one behind the other and connected to one another by a frame, whereby the bar cores can be inserted together, which shortens the set-up time for casting.

In einer hierzu weiterführenden Ausbildung besteht der Rahmen aus zwei Streben, die sich parallel zu den Längsseiten des das Zylinderkurbelgehäuse bildenden Hohlraums verlaufen. Hierdurch entsteht lediglich ein geringer Aufwand bei der Herstellung des Rahmens, der ebenfalls aus verschiedenen Materialien hergestellt werden kann.In a further development, the frame consists of two struts which run parallel to the longitudinal sides of the cavity forming the cylinder crankcase. This results in only little effort in the production of the frame, which can also be made from different materials.

Auch besteht die Möglichkeit, den Rahmen und die Stegkerne einstückig auszubilden, so dass jeglicher Zusammenbau entfällt, wodurch die Montagezeiten verkürzt werden.There is also the possibility of designing the frame and the web cores in one piece, so that there is no need for any assembly, whereby the assembly times are shortened.

Es wird somit eine Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses geschaffen, mit dem eine zuverlässige Positionierung der Stegkühlung zu den Zylindern sichergestellt wird, wobei der Aufwand zur Herstellung der entsprechenden Kanäle reduziert wird, indem der Zusammenbau und die Montage der Kerne optimiert wird.A device for producing a cylinder crankcase is thus created, with which a reliable positioning of the web cooling relative to the cylinders is ensured, the outlay for producing the corresponding channels being reduced by optimizing the assembly and installation of the cores.

Ein Ausführungsbeispiel einer erfindungsgemäßen Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses ist in den Zeichnungen dargestellt und wird nachfolgend beschrieben.

  • Figur 1 zeigt eine Seitenansicht einer erfindungsgemäßen Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses in geschnittener Darstellung.
  • Figur 2 zeigt eine perspektivische Darstellung einer bevorzugten Ausführungsform eines Rahmens mit Stegkernen.
An embodiment of a device according to the invention for producing a cylinder crankcase is shown in the drawings and is described below.
  • Figure 1 shows a side view of a device according to the invention for producing a cylinder crankcase in a sectional illustration.
  • Figure 2 shows a perspective view of a preferred embodiment of a frame with web cores.

Die erfindungsgemäße Vorrichtung zur Herstellung eines Zylinderkurbelgehäuses 10 besteht aus einer Gießform 12, die beispielsweise ein Unterteil 14, zwei Seitenteile 15 und ein Oberteil 16 als die Außenkonturen des Zylinderkurbelgehäuses 10 bildende Formteile sowie mehrere Zylinder 18 des Zylinderkurbelgehäuses 10 bildende Formteile 20 aufweist.The device according to the invention for producing a cylinder crankcase 10 consists of a casting mold 12, which has, for example, a lower part 14, two side parts 15 and an upper part 16 as molded parts forming the outer contours of the cylinder crankcase 10, as well as molded parts 20 forming the cylinder 18 of the cylinder crankcase 10.

In dieser Gießform 12 befinden sich ein oder mehrere Wassermantelkerne 22, welche eine Reihe, die aus mehreren die Zylinder 18 bildenden Formteilen 20 besteht, mit geringem Abstand an ihren gegenüberliegenden Längsseiten 24 sowie am Kopf- und Fußbereich umgeben. Diese Wassermantelkerne 22 werden nach dem Gießen des Zylinderkurbelgehäuses 10 aus dem Gussteil entfernt, so dass der entstehende Hohlraum einen Kühlkanal der Zylinder 18 bildet.In this casting mold 12 there are one or more water jacket cores 22 which surround a row, which consists of several mold parts 20 forming the cylinders 18, with a small spacing on their opposite longitudinal sides 24 as well as on the head and foot area. These water jacket cores 22 are removed from the cast part after the cylinder crankcase 10 has been cast, so that the resulting cavity forms a cooling channel for the cylinders 18.

Diese Wassermantelkerne 22 sind jedoch aufgrund der extrem kleinen Abmessungen der Stege 26 nicht geeignet, auch einen Hohlraum in Stegen 26 zwischen den Zylindern 18 zu bilden, der dringend erforderlich ist, um eine ausreichende Kühlung zur Verhinderung thermischer Überlastung in diesen Bereichen sicherzustellen.However, due to the extremely small dimensions of the webs 26, these water jacket cores 22 are not suitable for forming a cavity in webs 26 between the cylinders 18, which is urgently required to ensure sufficient cooling to prevent thermal overloading in these areas.

Erfindungsgemäß werden daher zur Bildung von Kühlwasserkanälen im Stegbereich Stegkerne 28 vorgeschlagen, welche in der Gießform 12 angeordnet und an der Gießform 12 beziehungsweise an einem der Formteile 14, 16 der Gießform 12 ausgerichtet werden.According to the invention, web cores 28 are therefore proposed for forming cooling water channels in the web area, which are arranged in the casting mold 12 and aligned on the casting mold 12 or on one of the mold parts 14, 16 of the casting mold 12.

Ein derartiger Stegkern 28 kann aus mineralischen Sanden, aus Kunstsand, Salz, Glas, Keramik oder Graphit hergestellt werden. Der in den Figuren dargestellte Stegkern 28 weist in dem Bereich, welcher Im das Zylinderkurbelgehäuse 10 bildenden Hohlraum 30 der Gießform 12 angeordnet ist, eine U-Form mit zwei parallel zur Zylinderachse verlaufenden Schenkeln 32, 34 und einer Verbindung 36 zwischen diesen Schenkeln 32, 34 auf. Die Schenkel 32, 34 ragen dabei aus der Fläche, welche nach dem Gießen ein Zylinderdeck 38, also die Oberfläche des Zylinderkurbelgehäuses 10 bildet, aus dem Hohlraum 30 heraus. Entsprechend weist das fertig gegossene Zylinderkurbelgehäuse 10 an diesen Positionen Öffnungen auf, die es ermöglichen, eine Verbindung zum Kühlwasserkanal eines nicht dargestellten Zylinderkopfes herzustellen.Such a web core 28 can be made of mineral sands, synthetic sand, salt, glass, ceramic or graphite. The web core 28 shown in the figures has in the area which is arranged in the cavity 30 of the casting mold 12 forming the cylinder crankcase 10, a U-shape with two legs 32, 34 running parallel to the cylinder axis and a connection 36 between these legs 32, 34 on. The legs 32, 34 protrude from the surface which, after casting, forms a cylinder deck 38, that is to say the surface of the cylinder crankcase 10, from the cavity 30. Correspondingly, the completely cast cylinder crankcase 10 has openings at these positions which make it possible to establish a connection to the cooling water channel of a cylinder head (not shown).

Des Weiteren ist in Figur 2 dargestellt, dass der Stegkern 28 an der Verbindung 36 zwischen den Schenkeln 32, 34 eine Öffnung 35 aufweisen kann. Diese Öffnung wird beim Gießen mit Material gefüllt, so dass sich eine obere Verbindung 37 zwischen den Schenkeln 32, 34 und eine untere Verbindung 39 zwischen den Schenkeln 32, 34 erstreckt. Entsprechend können unterschiedliche Bereiche des Steges 26 gekühlt werden, ohne dass die Festigkeit der Stege 26 zu sehr herabgesetzt wird.Furthermore, in Figure 2 shown that the web core 28 can have an opening 35 at the connection 36 between the legs 32, 34. This opening is filled with material during casting, so that an upper connection 37 extends between the legs 32, 34 and a lower connection 39 extends between the legs 32, 34. Correspondingly, different areas of the web 26 can be cooled without the strength of the webs 26 being reduced too much.

Entlang der das Zylinderdeck 38 bildenden Oberfläche des Hohlraums 30 erstrecken sich von den Schenkeln 32, 34 in entgegengesetzter Richtung zueinander Arme 40, 42 des Stegkerns 28, welche auf der Gießform 12 und im vorliegenden Ausführungsbeispiel auf den Seitenteilen 15 der Gießform 12 aufliegen. Beide Arme 40, 42 weisen in ihren Endbereichen 48, 50 einen Abschnitt auf, der sich im Wesentlichen schräg von der Oberfläche des Zylinderdecks 38 und somit von den Seitenteilen 15 entfernt. Das Oberteil 16 weist eine Ausnehmung 44 auf, in welche ein Vorsprung 46 greift, der am Endbereich 48 des Arms 40 des Stegkerns 28 ausgebildet ist. Die umgebende Gießform 12 weist einen hierzu korrespondierend geformten Abschnitt 52 auf. Insgesamt ergibt sich eine im Wesentlichen formschlüssige Lage des Stegkerns 28 in der Gießform 12, welche durch das Schließen der Gießform 12 durch Absenken des Oberteils 16 beziehungsweise eines nicht dargestellten aufliegenden Deckelformteils, in dem auch das Formteil zur Bildung der Zylinder ausgebildet ist, abschließend fixiert wird. Ein Verschieben innerhalb der Gießform 12 ist ausgeschlossen, so dass die Lage zu den Zylindern im Steg 26 mit sehr geringen Toleranzen festliegt, so dass filigrane Kühlkanäle im Stegbereich hergestellt werden können.Along the surface of the cavity 30 that forms the cylinder deck 38, arms 40, 42 of the web core 28 extend from the legs 32, 34 in opposite directions to one another and rest on the casting mold 12 and, in the present exemplary embodiment, on the side parts 15 of the casting mold 12. Both arms 40, 42 have in their end regions 48, 50 a section which extends essentially obliquely from the Surface of the cylinder deck 38 and thus removed from the side parts 15. The upper part 16 has a recess 44 into which a projection 46 engages, which is formed on the end region 48 of the arm 40 of the web core 28. The surrounding casting mold 12 has a section 52 shaped correspondingly thereto. Overall, the result is an essentially form-fitting position of the web core 28 in the casting mold 12, which is finally fixed by closing the casting mold 12 by lowering the upper part 16 or an overlying cover molding, not shown, in which the molding for forming the cylinder is also formed . Shifting within the casting mold 12 is excluded, so that the position relative to the cylinders in the web 26 is fixed with very small tolerances, so that filigree cooling channels can be produced in the web area.

Zur weiteren Vereinfachung können die Stegkerne 28, wie in Figur 2 dargestellt ist, über einen Rahmen 54 miteinander verbunden werden. Dieser Rahmen 54 weist zwei parallel zu den Längsseiten 24 des Zylinderkurbelgehäuses 10 verlaufende Streben 56, 58 auf, die mit den Armen 40, 42 mehrerer in Längsrichtung hintereinander angeordneter Stegkerne 28 verbunden oder einstückig mit diesen hergestellt sind und gemeinsam mit den Stegkernen 28 in die Gießform 12 formschlüssig eingelegt werden. Auf diese Weise können mehrere Stegkerne 28 gemeinsam eingelegt werden, wodurch die Rüstzeit der Gießform 12 verkürzt wird.For further simplification, the web cores 28, as in Figure 2 is shown, are connected to one another via a frame 54. This frame 54 has two struts 56, 58 running parallel to the longitudinal sides 24 of the cylinder crankcase 10, which are connected to the arms 40, 42 of a plurality of web cores 28 arranged one behind the other in the longitudinal direction or are made in one piece with them and together with the web cores 28 in the casting mold 12 can be inserted positively. In this way, several web cores 28 can be inserted together, whereby the set-up time of the casting mold 12 is shortened.

Nach dem Gießen werden die Stegkerne je nach gewähltem Material in bekannter Weise aus dem Zylinderkurbelgehäuse entfernt. Anschließend können die Kühlwasserkanäle der Zylinder 18 durch einfache Bohrungen mit den Stegkühlwasserkanälen verbunden werden. Es können jedoch auch zwei getrennte Kühlwasserkreisläufe benutzt werden.After casting, the web cores are removed from the cylinder crankcase in a known manner, depending on the material selected. The cooling water channels of the cylinders 18 can then be connected to the web cooling water channels by means of simple bores. However, two separate cooling water circuits can also be used.

Die Ausbildung der beschriebenen Stegkerne und deren Anordnung in der Gießform ermöglicht eine filigrane Ausbildung von Stegkühlungen auch bei Zylinderkurbelgehäusen mit sehr dicht beieinander angeordneten Zylindern.The design of the web cores described and their arrangement in the casting mold enables a filigree design of web cooling even in the case of cylinder crankcases with cylinders arranged very close to one another.

Es sollte deutlich sein, dass der Schutzbereich nicht auf das beschriebene Ausführungsbeispiel begrenzt ist. Insbesondere die genaue Ausbildung der Stegkerne sowie deren Befestigung in der Gießform sind veränderbar. Die Vorrichtung eignet sich für unterschiedliche Zylinderkurbelgehäuse und verschiedene Gießverfahren und Gießformen.It should be clear that the scope of protection is not limited to the exemplary embodiment described. In particular, the exact design of the web cores and their attachment in the casting mold can be changed. The device is suitable for different cylinder crankcases and different casting processes and molds.

Claims (13)

  1. Device for manufacturing a cylinder crankcase (10) with a casting mold (12) comprising several mold parts (14, 15, 16),
    at least one water jacket core (22) arranged on both longitudinal sides (24) of one or more mold parts (20) forming a cylinder bank and
    at least one web core (28) arranged between the mold parts (20) forming the individual cylinders (18) of a cylinder bank,
    characterized in that
    the at least one web core (28) is inserted into the casting mold (12) and is aligned with the casting mold (12), wherein the at least one web core (28) is arranged with respect to the water jacket core (22) such that, after casting, either a connection between the cooling channel formed by the web core (28) and the cooling channel formed by the water jacket core (22) can be formed by a bore or two separate cooling water circuits are present.
  2. Device for manufacturing a cylinder crankcase of claim 1, characterized in that the at least one web core (28) is fastened in a form-fitting manner to a mold part (14, 16) of the casting mold (12).
  3. Device for manufacturing a cylinder crankcase of one of claims 1 or 2, characterized in that the at least one web core (28) protrudes from at least one surface, which forms a cylinder deck (38), of a cavity (30) of the casting mold (12) which forms the cylinder crankcase (10).
  4. Device for manufacturing a cylinder crankcase of one of the preceding claims, characterized in that on two opposite sides with respect to the mold part (20) forming the cylinder (18), the at least one web core (28) protrudes from the surface forming the cylinder deck (38) of the cavity (30) of the casting mold (12) forming the cylinder crankcase (10).
  5. Device for manufacturing a cylinder crankcase of claim 4, characterized in that the at least one web core (28) comprises two legs (32, 34) extending substantially parallel to a cylinder axis, said legs extending into the cavity (30) forming the web (26) between the mold parts (20) forming the cylinders (18).
  6. Device for manufacturing a cylinder crankcase of claim 5, characterized in that the part of the web core (28) arranged in the cavity (30) of the casting mold (12) is substantially U-shaped, the two legs (32, 34) protruding over the cavity (30) of the casting mold (12) forming the cylinder crankcase (10).
  7. Device for manufacturing a cylinder crankcase of one of claims 5 or 6, characterized in that arms (40, 42) extend in opposite directions from the legs (32, 34) above the cavity (30) of the casting mold (12) on both sides into the mold parts (20) forming the cylinders (18), which arms rest on a mold part (14, 16) of the casting mold (12).
  8. Device for manufacturing a cylinder crankcase of claim 7, characterized in that at least one of the arms (40, 42) comprises a projection (46) via which the web core (28) engages in a form-fitting manner into a correspondingly shaped recess (44) in the casting mold (12).
  9. Device for manufacturing a cylinder crankcase of one of claims 6 to 8, characterized in that the web core (28) has an opening (35) at the connection (36) between the legs (32, 34) via which opening an upper connection (37) between the legs (32, 34) is separated from a lower connection (39) between the legs (32, 34).
  10. Device for manufacturing a cylinder crankcase of one of the preceding claims, characterized in that the at least one web core (28) is made from sand, synthetic sand, salt, glass, graphite or ceramics.
  11. Device for manufacturing a cylinder crankcase of one of the preceding claims, characterized in that a plurality of web cores (28) is arranged one behind the other and is connected to one another by a frame (54).
  12. Device for manufacturing a cylinder crankcase of claim 11, characterized in that the frame (54) consists of two struts (56, 58) extending parallel to the longitudinal sides (24) of the cavity (30) forming the cylinder crankcase (10).
  13. Device for manufacturing a cylinder crankcase of one of claims 11 or 12, characterized in that the frame (54) and the web cores (28) are formed integrally.
EP13152983.6A 2012-03-06 2013-01-29 Device for manufacturing a cylinder crankcase Active EP2636468B1 (en)

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DE102012101893.6A DE102012101893C5 (en) 2012-03-06 2012-03-06 Device for manufacturing a cylinder crankcase

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DE102013101942B3 (en) * 2013-02-27 2014-07-31 Ks Aluminium-Technologie Gmbh Coolant jacket core and method for producing a coolant jacket core
CN104325068A (en) * 2014-10-30 2015-02-04 沈阳工业大学 Method for preparing triangular hole by adopting casting mode
DE102017213542A1 (en) * 2017-08-04 2019-02-07 Bayerische Motoren Werke Aktiengesellschaft Casting mold and method for producing a crankcase
AT520849B1 (en) * 2018-01-16 2023-04-15 Avl List Gmbh PROCESS FOR MANUFACTURING A CYLINDER BLOCK OF AN INTERNAL ENGINE
AT525313B1 (en) * 2018-01-16 2023-06-15 Avl List Gmbh CYLINDER BLOCK OF AN INTERNAL ENGINE

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DE102012101893C5 (en) 2022-06-23
EP2636468A2 (en) 2013-09-11
DE102012101893A1 (en) 2013-09-12
DE102012101893B4 (en) 2016-03-31

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