JP2007277607A - Pretreatment method before thermal spraying of inner surface of cylinder, and pretreated shape of inner surface of cylinder before thermal spraying - Google Patents

Pretreatment method before thermal spraying of inner surface of cylinder, and pretreated shape of inner surface of cylinder before thermal spraying Download PDF

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JP2007277607A
JP2007277607A JP2006102977A JP2006102977A JP2007277607A JP 2007277607 A JP2007277607 A JP 2007277607A JP 2006102977 A JP2006102977 A JP 2006102977A JP 2006102977 A JP2006102977 A JP 2006102977A JP 2007277607 A JP2007277607 A JP 2007277607A
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cylindrical inner
spraying
axial
axial direction
cylinder
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JP5087854B2 (en
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Kimio Nishimura
公男 西村
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Nissan Motor Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To suppress the stress caused when a molten material deposited on an end in the axial direction of an inner surface of a cylinder after the thermal spraying is solidified and condensed. <P>SOLUTION: A roughened surface 9 consisting of screw-shaped uneven parts is formed as the pretreatment before depositing a spray deposit film 30 on an inner surface 5 of a cylinder bore. The roughened surface 9 roughens the surface roughness of a crank case side end 13 and a cylinder head side end 15 which are ends in the axial direction of the cylinder bore 3 more than the surface roughness of a center portion 17 in the axial direction. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は、円筒内面に対して溶射皮膜を形成する前に、前記円筒内面を粗面に形成する円筒内面の溶射前下地加工方法および円筒内面の溶射前下地処理形状に関する。   The present invention relates to a pre-spraying substrate processing method for a cylindrical inner surface, in which the cylindrical inner surface is formed into a rough surface before forming a sprayed coating on the cylindrical inner surface, and a pre-sprayed base treatment shape for the cylindrical inner surface.

内燃機関の出力・燃費・排気性能向上あるいは小型・軽量化といった観点から、アルミシリンダブロックのシリンダボア部に適用しているシリンダライナを廃止することへの設計要求は極めて高く、その代替技術の一つとして、シリンダボア内面に溶射皮膜を形成する溶射技術の適用が進められている。   From the standpoint of improving the output, fuel consumption, exhaust performance of an internal combustion engine, and reducing the size and weight, the design requirements for eliminating the cylinder liner applied to the cylinder bore of the aluminum cylinder block are extremely high. Application of thermal spraying technology for forming a thermal spray coating on the inner surface of a cylinder bore is being promoted.

上記した溶射技術をシリンダボア部に適用する場合には、溶射用材料を噴出する溶射ガンをシリンダボア内に軸方向に移動させつつ回転させて行い、溶射皮膜形成後は、例えばホーニング加工によって皮膜表面を研削加工して仕上げを行う。   When applying the above-mentioned spraying technology to the cylinder bore part, the spraying gun for spraying the spraying material is rotated while moving in the axial direction in the cylinder bore. Finish by grinding.

そして、上記した溶射皮膜を形成する前には、例えば本出願人が提案している下記特許文献１に記載されているように、シリンダボア内面を粗面に形成する下地処理を実施することで、溶射皮膜の密着度を高めている。
特開２００２−１５５３５０号公報（段落０００２，００１９） And, before forming the above-mentioned sprayed coating, for example, as described in the following Patent Document 1 proposed by the present applicant, by performing a base treatment to form the cylinder bore inner surface into a rough surface, The adhesion of the thermal spray coating is increased.
JP 2002-155350 A (paragraphs 0002, 0019)

しかしながら、シリンダボア内面に対し、上記したような下地処理を行っているにも拘わらず、シリンダボア内面の軸方向端部においては、軸方向中央部に比較して溶射皮膜が剥離しやすいものとなっている。これは、溶射後のシリンダボア内面の軸方向端部に付着した溶融用材料が固化し凝縮する際に、この凝縮部位が軸方向中央部側に引っ張られるような応力が発生するからである。   However, in spite of the above-described surface treatment being performed on the inner surface of the cylinder bore, the thermal spray coating is more easily peeled off at the axial end portion of the inner surface of the cylinder bore than at the central portion in the axial direction. Yes. This is because when the melting material adhering to the axial end of the inner surface of the cylinder bore after thermal spraying is solidified and condensed, a stress is generated such that this condensing part is pulled toward the axial center.

そこで、本発明は、溶射後の円筒内面の軸方向端部に付着した溶融用材料が固化し凝縮する際に発生する応力を抑えることを目的としている。   Therefore, an object of the present invention is to suppress the stress generated when the melting material adhering to the axial end of the inner surface of the cylinder after spraying is solidified and condensed.

本発明は、円筒内面に対して溶射皮膜を形成する前に、前記円筒内面を粗面に形成する円筒内面の溶射前下地加工方法において、前記円筒内面の軸方向端部の面粗度を、軸方向中央部の面粗度より粗くすることを最も主要な特徴とする。   The present invention provides a surface roughness of the axial end of the cylindrical inner surface in the pre-spraying base surface processing method of the cylindrical inner surface, in which the cylindrical inner surface is formed into a rough surface before the thermal spray coating is formed on the cylindrical inner surface. The main feature is that the surface roughness is greater than the surface roughness of the central portion in the axial direction.

本発明によれば、円筒内面の軸方向端部において、軸方向中央部より面粗度を粗くしているので、軸方向端部にて付着した溶融用材料が固化し凝縮する際に、この凝縮部位が軸方向中央部側に引っ張られるような応力が発生しても、凝縮部位が面粗度の粗い部位に引っ掛かることで応力に対抗し、この応力を抑えることができる。   According to the present invention, since the surface roughness is rougher than the axial central portion at the axial end of the cylindrical inner surface, when the melting material adhering at the axial end solidifies and condenses, Even if a stress is generated such that the condensing site is pulled toward the center in the axial direction, the condensing site is caught by the site having a rough surface roughness, so that the stress can be countered and suppressed.

以下、本発明の実施の形態を図面に基づき説明する。   Hereinafter, embodiments of the present invention will be described with reference to the drawings.

図１は、本発明の第１の実施形態に係わる自動車用エンジンにおける円筒部材としてのアルミシリンダブロック１の断面図であり、シリンダブロック１のシリンダボア３の円筒内面となるシリンダボア内面５に、後述する方法で溶射皮膜３０（図６参照）を形成する。溶射皮膜３０の形成後は、後述する方法により仕上げ加工（ここではホーニング加工）を行う。なお、図１は、溶射皮膜３０の形成前で、シリンダボア内面５を下地処理として粗面９に形成した状態を示す。粗面９を形成することで、その後に形成する溶射皮膜３０の密着度が高まる。符号１１はクランクケースである。   FIG. 1 is a cross-sectional view of an aluminum cylinder block 1 as a cylindrical member in the automobile engine according to the first embodiment of the present invention. A cylinder bore inner surface 5 serving as a cylinder inner surface of the cylinder bore 3 of the cylinder block 1 will be described later. The sprayed coating 30 (see FIG. 6) is formed by the method. After the thermal spray coating 30 is formed, finishing (here honing) is performed by a method described later. FIG. 1 shows a state in which the cylinder bore inner surface 5 is formed on the rough surface 9 as a base treatment before the thermal spray coating 30 is formed. By forming the rough surface 9, the adhesion degree of the thermal spray coating 30 to be formed thereafter increases. Reference numeral 11 denotes a crankcase.

図２は、図１に示すシリンダブロック１のシリンダボア３周辺の拡大した断面図である。シリンダボア３のシリンダボア内面５は、前述したように粗面９に形成しているが、この粗面９は、シリンダボア３の軸方向端部であるクランクケース側端部１３およびシリンダヘッド側端部１５の面粗度を、軸方向中央部１７の面粗度より粗くしている。   FIG. 2 is an enlarged cross-sectional view around the cylinder bore 3 of the cylinder block 1 shown in FIG. The cylinder bore inner surface 5 of the cylinder bore 3 is formed on the rough surface 9 as described above, and this rough surface 9 is the crankcase side end portion 13 and the cylinder head side end portion 15 which are axial ends of the cylinder bore 3. Is made rougher than the surface roughness of the central portion 17 in the axial direction.

上記した粗面９は、図３に示すように、縦型のマシニングセンタの主軸１９に取り付けたボーリング加工用バー２１の先端に、切削工具２３を取り付け、主軸１９を偏心回転さるコンタリング加工によって、図中上部から下部に向かう送り方向Ａに向けて移動させながら、ねじ切り加工を行ってねじ状の凹凸部を形成する。   As shown in FIG. 3, the rough surface 9 is formed by a contouring process in which a cutting tool 23 is attached to the tip of a boring bar 21 attached to a main shaft 19 of a vertical machining center, and the main shaft 19 is eccentrically rotated. While moving in the feed direction A from the upper part to the lower part in the figure, threading is performed to form a screw-like uneven part.

上記したねじ状の凹凸部は、切削工具２３によって直接切削されるねじ状の凹部２５（１３ａ，１５ａ，１７ａ）と、これら凹部２５（１３ａ，１５ａ，１７ａ）相互間に形成され、凹部２５（１３ａ，１５ａ，１７ａ）の切削時に発生する切削片によって、ねじ切り時の凸部（山部）２６（１３ｂ，１５ｂ，１７ｂ）先端の一部（頂部）を破断して形成する破断部としての微細凹凸部２７（１３ｃ，１５ｃ，１７ｃ）とを備えている。   The above-described screw-shaped uneven portion is formed between the thread-shaped recess 25 (13a, 15a, 17a) that is directly cut by the cutting tool 23 and the recess 25 (13a, 15a, 17a). 13a, 15a, 17a) As a fractured part formed by breaking a part (top) of the tip (ridge) 26 (13b, 15b, 17b) at the time of threading by a cutting piece generated at the time of cutting Concave and convex portions 27 (13c, 15c, 17c) are provided.

図４（ａ）は、切削工具２３により上記した凹部２５と微細凹凸部２７とからなる粗面９を形成する様子を示している。図４（ｂ）は、参考例として工具２０１により通常のねじ切り加工を行う様子を示す。   FIG. 4A shows a state in which the rough surface 9 composed of the concave portion 25 and the fine uneven portion 27 is formed by the cutting tool 23. FIG. 4B shows a state in which normal threading is performed with the tool 201 as a reference example.

図４（ｂ）では、切削工具２０１が、回転しながら図中で下方に向けて移動し、この際切りくず２０３が矢印Ｂで示す方向に排出され、これにより谷部２０５と山部２０７とからなる通常のねじ切り加工がなされる。   In FIG. 4 (b), the cutting tool 201 moves downward in the figure while rotating, and at this time, the chips 203 are discharged in the direction indicated by the arrow B. A normal threading process consisting of

一方、図４（ａ）では、切削工具２３により、図４（ｂ）の谷部２０５に相当する凹部２５を形成する際に排出される切りくずＫにより、現在形成している凹２５に隣接する凸部（山部）２６の頂部２６ａを破断し、これにより微細凹凸部２７を形成する。   On the other hand, in FIG. 4A, the cutting tool 23 is adjacent to the currently formed recess 25 by the chip K discharged when the recess 25 corresponding to the valley 205 in FIG. 4B is formed. The top part 26a of the convex part (mountain part) 26 to be broken is broken, and thereby the fine uneven part 27 is formed.

ここで、図４（ａ）の工具２３は、工具送り方向後方側の面２３ａの水平面Ｌに対する角度α1を、図４（ｂ）の同角度α2に比較して大きくして約３０度とするとともに、工具送り方向前方側の面２３ｂの水平面Ｌに対する角度β１を、図４（ｂ）の同角度β2に比較して小さくして約１０度としている。これにより、図４（ａ）では、凹２５を形成する際に排出される切りくずＫが、工具送り方向後方側に傾けた面２３ａによって凸部２６側に押し付けられ、凹２５に隣接する凸部２６の頂部２６ａを破断し、微細凹凸部２７を形成する。   Here, in the tool 23 in FIG. 4A, the angle α1 with respect to the horizontal plane L of the surface 23a on the rear side in the tool feed direction is set to about 30 degrees as compared with the same angle α2 in FIG. At the same time, the angle β1 with respect to the horizontal plane L of the surface 23b on the front side in the tool feed direction is set to about 10 degrees, which is smaller than the same angle β2 in FIG. Accordingly, in FIG. 4A, the chip K discharged when forming the recess 25 is pressed against the convex portion 26 by the surface 23 a inclined to the rear side in the tool feeding direction, and the convex adjacent to the recess 25. The top portion 26 a of the portion 26 is broken to form a fine uneven portion 27.

そして、本実施形態では、前述したように、シリンダボア３の軸方向端部であるクランクケース側端部１３およびシリンダヘッド側端部１５の面粗度を、軸方向中央部１７の面粗度より粗くしているが、このような面粗度の相違を、前記図３に示した切削工具２３の送り方向Ａの送り速度を、クランクケース側端部１３およびシリンダヘッド側端部１５で、軸方向中央部１７に比べて速くすることで達成している。   In the present embodiment, as described above, the surface roughness of the crankcase side end portion 13 and the cylinder head side end portion 15, which are axial ends of the cylinder bore 3, is determined from the surface roughness of the axial center portion 17. Although the surface roughness is rough, the difference in surface roughness is obtained by changing the feed speed in the feed direction A of the cutting tool 23 shown in FIG. 3 between the crankcase side end 13 and the cylinder head side end 15. This is achieved by making it faster than the direction center portion 17.

具体的には、加工時の回転数，工具送り速度について、軸方向中央部１７では、それぞれ２０００ｒｐｍ，０．１５ｍｍ／ｒｅｖとし、軸方向端部（クランクケース側端部１３およびシリンダヘッド側端部１５）では、それぞれ２０００ｒｐｍ，０．２５ｍｍ／ｒｅｖとしている。   Specifically, the rotational speed and the tool feed speed at the time of machining are set to 2000 rpm and 0.15 mm / rev at the axial direction central portion 17, respectively, and axial end portions (the crankcase side end portion 13 and the cylinder head side end portion). In 15), they are 2000 rpm and 0.25 mm / rev, respectively.

クランクケース側端部１３およびシリンダヘッド側端部１５での切削工具２３の送り速度を速くすることによって、これら軸方向端部における凹部１３ａおよび１５ａのそれぞれのピッチＰ１を、軸方向中央部１７における凹部１７ａのピッチＰ２より大きくしている。   By increasing the feed speed of the cutting tool 23 at the crankcase side end portion 13 and the cylinder head side end portion 15, the pitches P <b> 1 of the recesses 13 a and 15 a at these axial end portions are set at the axial center portion 17. It is larger than the pitch P2 of the recesses 17a.

また、凹部１７ａのピッチＰ２が大きくなるように切削工具２３の送り速度を速くすることで、１周分のねじ切り加工に続く次周のねじ切り加工相互間での軸方向の切削工具２３の重なり量が少なくなり、加工後の凹部２５に隣接する凸部２６の頂部２６ａを破断する量が少なくなる。その結果、図２に示すように、クランクケース側端部１３およびシリンダヘッド側端部１５のねじ状の凹凸部における凸部２６（１３ｂ，１５ｂ）の高さＨ１が、軸方向中央部１７における同凸部２６（１７ｂ）の高さＨ２に比べて高くなる。   Further, by increasing the feed speed of the cutting tool 23 so that the pitch P2 of the recesses 17a is increased, the overlapping amount of the cutting tool 23 in the axial direction between the threading processes of the next circumference following the threading process of one round. And the amount of breaking the top portion 26a of the convex portion 26 adjacent to the concave portion 25 after processing is reduced. As a result, as shown in FIG. 2, the height H1 of the convex portions 26 (13b, 15b) in the thread-like uneven portions of the crankcase side end portion 13 and the cylinder head side end portion 15 is It becomes higher than the height H2 of the convex portion 26 (17b).

なお、上記した各高さＨ1およびＨ２の基準となる凹部２５（１３ａ，１５ａ）および凹部２５（１７ａ）における最深部（底部）のシリンダボア中心からの距離（半径）は同等である。   It should be noted that the distance (radius) from the center of the cylinder bore of the deepest part (bottom part) in the recesses 25 (13a, 15a) and the recesses 25 (17a) serving as the reference for the respective heights H1 and H2 is the same.

このようにして、シリンダボア内面５に対し粗面９を形成した後は、図５に示すような溶射装置を用い、図６に示すように粗面９上に溶射皮膜３０を形成する。この溶射皮膜３０は、シリンダボア内面５に対してほぼ均一となるよう形成する。   After the rough surface 9 is formed on the cylinder bore inner surface 5 in this way, a thermal spray coating 30 is formed on the rough surface 9 as shown in FIG. The thermal spray coating 30 is formed to be substantially uniform with respect to the cylinder bore inner surface 5.

図５に示す溶射装置は、シリンダボア３内の中心に、ガス溶線式の溶射ガン３１を挿入し、その溶射口３１ａから溶射用材料として溶融した鉄系金属材料を溶滴３３として溶射してシリンダボア内面５に溶射皮膜３０を形成する。   The thermal spraying apparatus shown in FIG. 5 inserts a gas spray type thermal spray gun 31 into the center of the cylinder bore 3 and sprays a molten iron-based metal material as a thermal spray material from the thermal spray port 31a as a thermal spray 33 to form a cylinder bore. A thermal spray coating 30 is formed on the inner surface 5.

溶射ガン３１は、溶線送給機３５から溶射用材料として鉄系金属材料の溶線３７の送給を受けるとともに、アセチレンまたはプロパンあるいはエチレンなどの燃料を貯蔵した燃料ガスボンベ３９および酸素を貯蔵した酸素ボンベ４１から、配管４３および４５を介して燃料ガスおよび酸素の供給をそれぞれ受ける。   The thermal spray gun 31 is supplied with a molten metal 37 of an iron-based metal material as a thermal spray material from a thermal feeder 35, and also has a fuel gas cylinder 39 storing fuel such as acetylene, propane or ethylene, and an oxygen cylinder storing oxygen. The fuel gas and oxygen are supplied from the pipe 41 through the pipes 43 and 45, respectively.

上記した溶線３７は、溶射ガン３１に対し、中央部の上下に貫通する溶線送給孔４７の上端から下方に向けて送給する。また、燃料および酸素は、溶線送給孔４７の外側の円筒部４９に、上下方向に貫通して形成してあるガス案内流路５１に供給する。この供給した燃料および酸素の混合ガスは、ガス案内流路５１の図５中で下端開口部５１ａから流出し、点火されることで燃焼炎５３が形成される。   The above-mentioned molten wire 37 is fed to the thermal spray gun 31 downward from the upper end of the molten wire feed hole 47 penetrating vertically in the central portion. Further, the fuel and oxygen are supplied to the gas guide channel 51 formed in the cylindrical portion 49 outside the melt feed hole 47 so as to penetrate in the vertical direction. The supplied mixed gas of fuel and oxygen flows out from the lower end opening 51a in FIG. 5 of the gas guide channel 51 and is ignited to form a combustion flame 53.

前記円筒部４９の外周側には、アトマイズエア流路５５を設けてあり、さらにその外周側には、いずれも円筒形状の隔壁５７と外壁５９との間に形成したアクセラレータエア流路６１を設けてある。   An atomizing air flow channel 55 is provided on the outer peripheral side of the cylindrical portion 49, and an accelerator air flow channel 61 formed between the cylindrical partition wall 57 and the outer wall 59 is provided on the outer peripheral side thereof. It is.

アトマイズエア流路５５を流れるアトマイズエアは、燃焼炎５３の熱を前方（図５中で下方）へ送って周辺部に対する冷却を行うとともに、溶融した溶線３７を同前方へ送る。一方、アクセラレータエア流路６１を流れるアクセラレータエアは、上記前方へ送られ溶融した溶線３７を、この送り方向と交差するように前記シリンダボア内面５に向けて溶滴３３として送り、シリンダボア内面５に溶射皮膜３０を形成する。   The atomizing air flowing through the atomizing air flow channel 55 sends the heat of the combustion flame 53 forward (downward in FIG. 5) to cool the peripheral portion, and sends the molten wire 37 forward. On the other hand, the accelerator air flowing through the accelerator air flow path 61 sends the molten wire 37 sent forward and melted as the droplet 33 toward the cylinder bore inner surface 5 so as to intersect the feed direction, and sprayed onto the cylinder bore inner surface 5. A film 30 is formed.

アトマイズエア流路５５には、アトマイズエア供給源６７から、減圧弁６９を備えたエア供給管７１を通してアトマイズエアを供給する。一方、アクセラレータエア流路６１には、アクセラレータエア供給源７３から、減圧弁７５およびマイクロミストフィルタ７７をそれぞれ備えたエア供給管７９を通してアクセラレータエアを供給する。   Atomized air is supplied to the atomized air flow channel 55 from an atomized air supply source 67 through an air supply pipe 71 provided with a pressure reducing valve 69. On the other hand, accelerator air is supplied from the accelerator air supply source 73 to the accelerator air flow channel 61 through an air supply pipe 79 provided with a pressure reducing valve 75 and a micro mist filter 77.

アトマイズエア流路５５とアクセラレータエア流路６１との間の隔壁５７は、図５中で下部側の先端部に、外壁５９に対しベアリング８１を介して回転可能となる回転筒部８３を備えている。この回転筒部８３の上部外周に、アクセラレータエア流路６１に位置する回転翼８５を設けてある。回転翼８５に、アクセラレータエア流路６１を流れるアクセラレータエアが作用することで、回転筒部８３が回転する。   The partition wall 57 between the atomizing air flow channel 55 and the accelerator air flow channel 61 is provided with a rotating cylinder portion 83 that can rotate with respect to the outer wall 59 via a bearing 81 at the lower end portion in FIG. Yes. A rotating blade 85 located in the accelerator air flow path 61 is provided on the outer periphery of the upper portion of the rotating cylinder portion 83. When the accelerator air flowing through the accelerator air flow path 61 acts on the rotary blade 85, the rotary cylinder portion 83 rotates.

回転筒部８３の先端（下端）面８３ａには、回転筒部８３と一体となって回転する先端部材８７を固定してある。先端部材８７の周縁の一部には、前記したアクセラレータエア流路６１にベアリング８１を通して連通する噴出流路８９を備えた突出部９１を設けてあり、噴出流路８９の先端に、溶滴３３を噴出させる前記した溶射口３１ａを設けている。   A tip member 87 that rotates integrally with the rotary cylinder 83 is fixed to the tip (lower end) surface 83 a of the rotary cylinder 83. A protrusion 91 having an ejection flow path 89 communicating with the accelerator air flow path 61 through the bearing 81 is provided at a part of the peripheral edge of the distal end member 87, and the droplet 33 is formed at the distal end of the ejection flow path 89. The above-described thermal spraying port 31a is provided for jetting.

溶射口３１ａを備える先端部材８７が回転筒部８３と一体となって回転しつつ溶射ガン３１をシリンダボア３の軸方向に往復移動させることで、シリンダボア内面５のほぼ全域に溶射皮膜３０を形成する。   The thermal spray coating 30 is formed on almost the entire area of the cylinder bore inner surface 5 by reciprocating the thermal spray gun 31 in the axial direction of the cylinder bore 3 while the tip member 87 having the thermal spray port 31a rotates integrally with the rotary cylinder portion 83. .

このようにして形成した溶射皮膜３０は、その溶射前の下地処理として加工した粗面９が、シリンダボア５の軸方向端部すなわちクランクケース側端部１３およびシリンダヘッド側端部１５において、軸方向中央部１７より面粗度を粗くしているので、軸方向端部にて付着した溶融用材料が固化し凝縮する際に、この凝縮部位が軸方向中央部１７側に引っ張られるような応力が発生しても、凝縮部位が面粗度の粗い部位に引っ掛かることで応力に対抗し、この応力を抑えることができ、その結果軸方向端部での溶射皮膜３０の剥離を防止することができる。   The sprayed coating 30 formed in this way has a rough surface 9 processed as a base treatment before spraying at the axial end of the cylinder bore 5, that is, the crankcase side end 13 and the cylinder head side end 15 in the axial direction. Since the surface roughness is made rougher than the central portion 17, when the melting material adhering to the axial end portion is solidified and condensed, there is a stress that pulls the condensed portion toward the axial central portion 17 side. Even if it occurs, the condensing part is caught by the part having a rough surface to counter the stress, and this stress can be suppressed. As a result, the thermal spray coating 30 can be prevented from peeling off at the axial end. .

また、シリンダボア内面５の粗面９は、切削工具２３を用いてねじ状の凹凸部を形成するもので、このねじ状の凹凸部における凸部２６の高さを、シリンダボア内面５の軸方向中央部１７よりも軸方向端部（クランクケース側端部１３およびシリンダヘッド側端部１５）で高くしているので、軸方向端部における凹部２５（１３ａ，１５ａ）の容積が軸方向中央部１７の凹部２５（１７ａ）に比較して大きくなり、これに対応して凹部２５（１３ａ，１５ａ）に入り込む溶射用材料の量も多くなって、上記した応力をより確実に抑えることができる。   The rough surface 9 of the cylinder bore inner surface 5 forms a screw-like uneven portion using the cutting tool 23, and the height of the convex portion 26 in the screw-like uneven portion is set to the center in the axial direction of the cylinder bore inner surface 5. Since the axial end portion (crankcase side end portion 13 and cylinder head side end portion 15) is higher than the portion 17, the volume of the recess 25 (13a, 15a) at the axial end portion is set to the axial central portion 17. Accordingly, the amount of the thermal spray material that enters the recesses 25 (13a, 15a) increases correspondingly, and the above-described stress can be more reliably suppressed.

さらに、上記したねじ状の凹凸部における凸部２６の先端に微細凹凸部２７を形成しているので、溶射被膜３０の密着度が高まり、溶射被膜３０の剥離を確実に防止することができる。   Furthermore, since the fine uneven part 27 is formed at the tip of the convex part 26 in the above-described screw-like uneven part, the adhesion degree of the thermal spray coating 30 is increased, and the thermal spray coating 30 can be reliably prevented from peeling off.

図６のように溶射皮膜３０を形成した後は、図７に示すように、シリンダボア３におけるクランクケース側端部１３およびシリンダヘッド側端部１５付近の不要な部位（図示しないピストンが摺動しない部位）を研削加工して溶射皮膜３０とともに除去する。この際、軸方向端部側ほど大径となるようなテーパ面９３，９５を形成して面取り加工を実施する。   After the thermal spray coating 30 is formed as shown in FIG. 6, as shown in FIG. 7, unnecessary portions of the cylinder bore 3 near the crankcase side end 13 and the cylinder head side end 15 (the piston (not shown) does not slide). The part) is ground and removed together with the thermal spray coating 30. At this time, chamfering is performed by forming tapered surfaces 93 and 95 having a larger diameter toward the end in the axial direction.

上記した面取り加工を実施する際には、クランクケース側端部１３およびシリンダヘッド側端部１５付近における溶射皮膜３０の前記した応力を抑えているので、面取り加工時での溶射皮膜３０の剥離も発生しにくく、このため面取り加工時での加工速度を従来よりも高めて加工時間を短縮でき、加工コスト低下に寄与することができる。   When carrying out the above chamfering process, the above-described stress of the thermal spray coating 30 in the vicinity of the crankcase side end portion 13 and the cylinder head side end portion 15 is suppressed, so that the thermal spray coating 30 is also peeled off during the chamfering processing. Therefore, it is possible to reduce the processing time by increasing the processing speed at the time of chamfering processing as compared with the conventional method, thereby contributing to a reduction in processing cost.

そして、最後に図８に示すように、溶射皮膜３０の表面を仕上げ加工としてホーニング加工を行う。図８は、シリンダブロック１に対し、ホーニングツール１０５によりホーニング加工をしている状態を示す断面図である。ホーニングツール１０５におけるホーニングヘッド１０７の外周には、例えばダイヤモンドなどの砥粒で構成した砥石１０９が円周方向等間隔に４つ取り付けている。   Finally, as shown in FIG. 8, honing is performed with the surface of the thermal spray coating 30 as a finishing process. FIG. 8 is a cross-sectional view showing a state where the honing process is performed on the cylinder block 1 by the honing tool 105. On the outer periphery of the honing head 107 in the honing tool 105, four grindstones 109 made of abrasive grains such as diamond are attached at equal intervals in the circumferential direction.

ホーニングヘッド１０７内には、砥石１０９を直径方向外側に向けて拡張させる拡張手段を備えており、加工時には、この砥石１０９を拡張させてシリンダボア内面５に所定の圧力で押し付ける。   The honing head 107 is provided with expansion means for expanding the grindstone 109 outward in the diametrical direction. At the time of processing, the grindstone 109 is expanded and pressed against the cylinder bore inner surface 5 with a predetermined pressure.

そして、上記したホーニングツール１０５を回転させつつ軸方向に往復移動させることで、溶射皮膜３０の表面を研削してホーニング加工を行う。これにより、シリンダボア内面５に対する加工が完了する。なお、ホーニング加工では、使用する砥石の粒度を変更することで、荒工程や仕上げ工程を順次実施する。   The honing tool 105 is rotated and reciprocated in the axial direction to grind the surface of the thermal spray coating 30 and perform honing. Thereby, the process with respect to the cylinder bore inner surface 5 is completed. In the honing process, the roughing process and the finishing process are sequentially performed by changing the grain size of the grindstone to be used.

図９は、本発明の第２の実施形態を示す、前記図２に相当するシリンダブロック１Ａの断面図であり、粗面９を形成した後で、溶射皮膜３０Ａ（図１０参照）の形成前の状態を示す。第２の実施形態では、シリンダボア３Ａの軸方向端部であるクランクケース側端部１３およびシリンダヘッド側端部１５よりさらに軸方向外側の端部に、前記した凹部１３ａ，１５ａより大きい溝９７および９９をそれぞれ形成している。その他については、前記した図２と同様の構造である。   FIG. 9 is a cross-sectional view of the cylinder block 1A corresponding to FIG. 2 showing a second embodiment of the present invention, and after forming the rough surface 9 and before forming the thermal spray coating 30A (see FIG. 10). Shows the state. In the second embodiment, a groove 97 larger than the recesses 13a and 15a described above is provided at the axially outer end of the crankcase side end 13 and the cylinder head side end 15 which are axial ends of the cylinder bore 3A. 99 are formed. The other structure is the same as that shown in FIG.

溝９７，９９は、シリンダボア内面５Ａにおける軸方向幅が広く、底部には同軸方向に延びる平面形状の底面部９７ａ，９９ａを備えており、少なくとも１周分形成する。なお、溝９７，９９の加工には、前記図３に示した切削工具２３とは別の工具を用いて行い、その際の加工条件としては、回転数が２０００ｒｐｍ，工具送り速度が０．１ｍｍ／ｒｅｖである。   The grooves 97 and 99 have a wide axial width on the cylinder bore inner surface 5A, and are provided with flat bottom surface portions 97a and 99a extending in the coaxial direction at the bottom, and are formed at least for one round. The grooves 97 and 99 are processed using a tool different from the cutting tool 23 shown in FIG. 3, and the processing conditions at that time are a rotational speed of 2000 rpm and a tool feed speed of 0.1 mm. / Rev.

図１０は、溶射皮膜３０Ａの形成後で、面取り加工前の状態を示す。面取り加工部分については二点鎖線で示している。第２の実施形態では、溶射皮膜３０Ａは、溶射用材料が溝９７，９９内に入り込むことで、この溝９７，９９が堰のような役目を果たし、溝９７，９９を形成した部位の溶射皮膜３０に窪み３０ａが形成される。   FIG. 10 shows a state after forming the thermal spray coating 30A and before chamfering. The chamfered portion is indicated by a two-dot chain line. In the second embodiment, the thermal spray coating 30A is formed by spraying the thermal spray material into the grooves 97 and 99, so that the grooves 97 and 99 serve as weirs and spray the portions where the grooves 97 and 99 are formed. A depression 30 a is formed in the film 30.

この窪み３０ａが形成されることで、窪み３０ａを境として溶射皮膜３０Ａが、軸方向中央部１７側の溶射皮膜３０ｂと、軸方向端部側の溶射皮膜３０ｃ，３０ｄとが互い分断されたような形となる。この結果、溶射後の溶射用材料の固化凝縮によって軸方向端部の溶射皮膜３０ｃ，３０ｄが軸方向中央部１７側へ引っ張られるように発生する応力が小さく抑えられ、溝９７，９９より軸方向中央部１７側における溶射皮膜３０ｂの剥離を抑えることができる。   By forming the depression 30a, the thermal spray coating 30A is separated from the thermal spray coating 30b on the axial central portion 17 side and the thermal spray coatings 30c and 30d on the axial end portion side with the depression 30a as a boundary. It becomes a shape. As a result, the stress generated so that the thermal spray coatings 30c and 30d at the axial end portions are pulled toward the axial central portion 17 side due to solidification condensation of the thermal spray material after thermal spraying is suppressed, and the axial direction from the grooves 97 and 99 is reduced. Separation of the thermal spray coating 30b on the center portion 17 side can be suppressed.

なお、上記した窪み３０ａは、さらに大きく窪んで最終的に溝９７，９９を境として、軸方向中央部１７の溶射皮膜３０ｂと軸方向端部の溶射皮膜３０ｃ，３０ｄとを完全に分断する場合もあり、そのような場合には、溝９７，９９より軸方向中央部１７側における溶射皮膜３０ｂの剥離をより確実に抑えることができる。   In addition, the above-mentioned hollow 30a is further greatly depressed, and finally the thermal spray coating 30b at the axial center portion 17 and the thermal spray coating 30c, 30d at the axial end portion are completely divided by the grooves 97, 99 as a boundary. In such a case, peeling of the thermal spray coating 30b on the axial center portion 17 side from the grooves 97 and 99 can be more reliably suppressed.

このように、軸方向中央部１７の溶射皮膜３０ｂと軸方向端部の溶射皮膜３０ｃ，３０ｄとを完全に分断するには、シリンダボア内面５における軸方向の幅が、面粗度が粗い部位の凹部１３ａ，１５ａの同幅よりも広く、また溝９７，９９の底部に、シリンダボア内面５の軸方向に延びる底面部７ａ，９９ａを形成して、溝９７，９９への溶射用材料の流入量を多くするとよい。   Thus, in order to completely divide the thermal spray coating 30b at the axial center portion 17 and the thermal spray coatings 30c, 30d at the axial end portion, the axial width of the cylinder bore inner surface 5 is set at a portion having a rough surface roughness. The bottom portions 7a and 99a that are wider than the recesses 13a and 15a and extend in the axial direction of the cylinder bore inner surface 5 are formed at the bottoms of the grooves 97 and 99, so that the inflow amount of the thermal spray material into the grooves 97 and 99 It is good to increase.

溶射皮膜３０Ａの形成後は、前記図７に示したものと同様に、シリンダボア３におけるクランクケース側端部１３およびシリンダヘッド側端部１５付近の不要な部位（図示しないピストンが摺動しない部位）を研削加工して溶射皮膜３０Ａとともに除去する。この際、軸方向端部ほど大径となるようなテーパ面９３Ａ，９５Ａを形成して面取り加工を実施する。   After the formation of the thermal spray coating 30A, as in the case shown in FIG. 7, unnecessary portions near the crankcase side end 13 and the cylinder head side end 15 in the cylinder bore 3 (portions where a piston (not shown) does not slide). Is removed together with the sprayed coating 30A. At this time, chamfering is performed by forming tapered surfaces 93A and 95A having a larger diameter at the end in the axial direction.

上記した面取り加工を実施する際には、クランクケース側端部１３およびシリンダヘッド側端部１５付近における溶射皮膜３０Ａの前記した応力を抑えているので、面取り加工時での溶射皮膜３０Ａの剥離も発生しにくく、このため面取り加工時での加工速度を従来よりも高めて加工時間を短縮でき、加工コスト低下に寄与することができる。   When carrying out the above chamfering process, the above-described stress of the thermal spray coating 30A in the vicinity of the crankcase side end 13 and the cylinder head side end 15 is suppressed, so that the thermal spray coating 30A is also peeled off during the chamfering process. Therefore, it is possible to reduce the processing time by increasing the processing speed at the time of chamfering processing as compared with the conventional method, thereby contributing to a reduction in processing cost.

なお、上記した各実施形態では、シリンダボア内面５に対し、溶射皮膜３０，３０Ａを形成する前の下地処理加工として、ねじ状の凹凸部を形成して粗面９としているが、この粗面９は、ねじ状の凹凸部に限るものではなく、シリンダボア３の軸方向端部であるクランクケース側端部１３およびシリンダヘッド側端部１５の面粗度が、軸方向中央部１７の面粗度より粗くなっていれば、例えばショットピーニング加工によるものでも構わない。   In each of the above-described embodiments, the rough surface 9 is formed by forming a screw-shaped uneven portion on the cylinder bore inner surface 5 as a surface treatment before forming the thermal spray coatings 30 and 30A. The surface roughness of the crankcase side end portion 13 and the cylinder head side end portion 15, which are the axial end portions of the cylinder bore 3, is not limited to the screw-shaped uneven portion, but the surface roughness of the axial center portion 17. As long as it is rougher, for example, shot peening may be used.

ショットピーニング加工によって面粗度に相違を持たせるには、軸方向端部１３，１５を加工する際には軸方向中央部１７にショット玉が当たらないように、マスキングを行い、逆に軸方向中央部１７を加工する際には軸方向端部１３，１５にショット玉が当たらないように、マスキングを行う必要がある。   In order to make the surface roughness different by shot peening, masking is performed so that the shot ball does not hit the axial central portion 17 when the axial end portions 13 and 15 are processed. When processing the central portion 17, it is necessary to perform masking so that the shot balls do not hit the axial end portions 13 and 15.

本発明の第１の実施形態に係わるシリンダブロックの断面図である。It is sectional drawing of the cylinder block concerning the 1st Embodiment of this invention. 図１に示すシリンダブロックのシリンダボア周辺の拡大した断面図である。FIG. 2 is an enlarged cross-sectional view around a cylinder bore of the cylinder block shown in FIG. 1. 図１のシリンダブロックに対する下地処理加工を行っている状態を示す断面図である。It is sectional drawing which shows the state which is performing the surface treatment process with respect to the cylinder block of FIG. （ａ）は図３の下地処理加工を工具および切りくずにより行っている状態を示す説明図、（ｂ）は工具による通常のねじ切り加工を示す説明図である。(A) is explanatory drawing which shows the state which is performing the ground treatment of FIG. 3 with a tool and a chip, (b) is explanatory drawing which shows the normal thread cutting process by a tool. 図１のシリンダブロックのシリンダボア内面を粗面化した後に溶射皮膜を形成するための溶射装置の概略を示す全体構成図である。It is a whole block diagram which shows the outline of the thermal spraying apparatus for forming a thermal spray coating, after roughening the cylinder bore inner surface of the cylinder block of FIG. 図２の下地処理加工後に、溶射皮膜を形成した状態を示すシリンダブロックの断面図である。It is sectional drawing of the cylinder block which shows the state in which the sprayed coating was formed after the base-treatment process of FIG. 図６の溶射皮膜形成後に、シリンダボアの軸方向端部に対して面取り加工を行った状態を示すシリンダブロックの断面図である。It is sectional drawing of the cylinder block which shows the state which performed the chamfering process with respect to the axial direction edge part of a cylinder bore after spraying coating formation of FIG. 図７の面取り加工後に、ホーニング加工を行っている状態を示すシリンダブロックの断面図である。It is sectional drawing of the cylinder block which shows the state which is performing the honing process after the chamfering process of FIG. 本発明の第２の実施形態を示す、図２に相当するシリンダブロックの断面図である。It is sectional drawing of the cylinder block equivalent to FIG. 2 which shows the 2nd Embodiment of this invention. 図９の下地処理加工後に、溶射皮膜を形成した状態を示すシリンダブロックの断面図である。It is sectional drawing of the cylinder block which shows the state which formed the sprayed coating after the base-treatment process of FIG.

符号の説明Explanation of symbols

３，３Ａ シリンダボア
５，５Ａ シリンダボア内面（円筒内面）
９ 粗面
１３ シリンダボアのクランクケース側端部（軸方向端部）
１５ シリンダボアのシリンダヘッド側端部（軸方向端部）
１７ シリンダボアの軸方向中央部
２６（１３ｂ，１５ｂ，１７ｂ） ねじ状の凹凸部の凸部
２７（１３ｃ，１５ｃ，１７ｃ） 凸部先端の微細凹凸部（破断部）
３０，３Ａ 溶射皮膜
９７，９９ 溝
９７ａ，９９ａ 溝の底面部 3,3A Cylinder bore 5,5A Cylinder bore inner surface (cylindrical inner surface)
9 Rough surface 13 Crankcase side end of cylinder bore (end in axial direction)
15 Cylinder bore end of cylinder bore (end in axial direction)
17 Cylinder bore axial center portion 26 (13b, 15b, 17b) Threaded uneven portion convex portion 27 (13c, 15c, 17c) Fine uneven portion at the tip of the convex portion (rupture portion)
30, 3A Thermal sprayed coating 97, 99 groove 97a, 99a groove bottom surface

Claims (12)

円筒内面に対して溶射皮膜を形成する前に、前記円筒内面を粗面に形成する円筒内面の溶射前下地加工方法において、前記円筒内面の軸方向端部の面粗度を、軸方向中央部の面粗度より粗くすることを特徴とする円筒内面の溶射前下地加工方法。   Before forming the sprayed coating on the cylindrical inner surface, in the pre-spraying base surface processing method of the cylindrical inner surface, the surface roughness of the axial end of the cylindrical inner surface is determined by the axial central portion. A surface treatment method before spraying of an inner surface of a cylinder, characterized in that the surface roughness is roughened. 前記円筒内面の粗面は、切削工具を用いてねじ状の凹凸部を形成するもので、このねじ状の凹凸部における凸部の高さを、前記円筒内面の軸方向中央部よりも軸方向端部で高くすることを特徴とする請求項１に記載の円筒内面の溶射前下地加工方法。   The rough surface of the cylindrical inner surface forms a screw-shaped uneven portion using a cutting tool, and the height of the convex portion in the screw-shaped uneven portion is more axial than the axial central portion of the cylindrical inner surface. 2. The pre-spraying substrate processing method for a cylindrical inner surface according to claim 1, wherein the height is increased at the end. 前記ねじ状の凹凸部における凸部の先端に破断部を形成することを特徴とする請求項２に記載の円筒内面の溶射前下地加工方法。   The pre-spraying pre-spraying method for a cylindrical inner surface according to claim 2, wherein a fracture portion is formed at the tip of the convex portion in the screw-like concave and convex portion. 前記円筒内面における軸方向端部の面粗度が粗い部位よりさらに軸方向外側の端部に、前記面粗度が粗い部位の凹部よりも大きい溝を形成することを特徴とする請求項１ないし３のいずれか１項に記載の円筒内面の溶射前下地加工方法。   The groove | channel larger than the recessed part of the site | part with said rough surface roughness is formed in the edge part of the axial direction outer side further from the site | part where the surface roughness of the axial direction edge part in the said cylindrical inner surface is rough. 4. The pre-spraying substrate processing method for a cylindrical inner surface according to any one of 3. 前記凹部よりも大きい溝は、前記円筒内面における軸方向の幅が、前記面粗度が粗い部位の凹部よりも広いことを特徴とする請求項４に記載の円筒内面の溶射前下地加工方法。   5. The pre-spraying pre-spraying method for a cylindrical inner surface according to claim 4, wherein the groove larger than the concave portion has a wider width in the axial direction on the inner surface of the cylindrical portion than a concave portion at a portion where the surface roughness is rough. 前記凹部よりも大きい溝の底部に、前記円筒内面の軸方向に延びる底面部を形成することを特徴とする請求項４または５に記載の円筒内面の溶射前下地加工方法。   6. The pre-spraying substrate processing method for a cylindrical inner surface according to claim 4 or 5, wherein a bottom surface portion extending in the axial direction of the cylindrical inner surface is formed at a bottom portion of a groove larger than the concave portion. 円筒内面に対して溶射皮膜を形成する前に、溶射前下地加工として前記円筒内面を粗面に形成する円筒内面の溶射前下地処理形状において、前記円筒内面の軸方向端部の面粗度を、軸方向中央部の面粗度より粗くしていることを特徴とする円筒内面の溶射前下地処理形状。   Before forming the thermal spray coating on the inner surface of the cylinder, the surface roughness of the axial end of the cylindrical inner surface in the pre-sprayed surface treatment shape of the cylindrical inner surface that forms the cylindrical inner surface as a rough surface as a pre-spraying base processing The surface treatment before spraying of the cylindrical inner surface, characterized by being rougher than the surface roughness of the central portion in the axial direction. 前記円筒内面の粗面は、切削工具を用いてねじ状の凹凸部を形成するもので、このねじ状の凹凸部の凸部高さが、前記円筒内面の軸方向中央部よりも軸方向端部で高いことを特徴とする請求項７に記載の円筒内面の溶射前下地処理形状。   The rough surface of the cylindrical inner surface forms a screw-shaped uneven portion using a cutting tool, and the height of the convex portion of the screw-shaped uneven portion is more axial than the central portion of the cylindrical inner surface in the axial direction. The surface treatment shape before spraying of the cylindrical inner surface according to claim 7, wherein the shape is high at a portion. 前記ねじ状の凹凸部における凸部の先端に破断部が形成されていることを特徴とする請求項８に記載の円筒内面の溶射前下地処理形状。   The shape of the surface treatment before spraying of the cylindrical inner surface according to claim 8, wherein a fracture portion is formed at the tip of the convex portion of the screw-shaped concave and convex portion. 前記円筒内面における軸方向端部の面粗度が粗い部位よりさらに軸方向外側の端部に、前記面粗度が粗い部位の凹部よりも大きい溝が形成されていることを特徴とする請求項７ないし９のいずれか１項に記載の円筒内面の溶射前下地処理形状。   The groove which is larger than the concave portion of the portion having the rough surface roughness is formed at the end portion on the outer side in the axial direction from the portion where the surface roughness of the axial end portion on the cylindrical inner surface is rough. The surface treatment shape before spraying of the cylindrical inner surface according to any one of 7 to 9. 前記凹部よりも大きい溝は、前記円筒内面における軸方向の幅が、前記面粗度が粗い部位の凹部よりも広いことを特徴とする請求項１０に記載の円筒内面の溶射前下地処理形状。   11. The pre-sprayed surface treatment shape of a cylindrical inner surface according to claim 10, wherein the groove larger than the concave portion has a wider axial width on the inner surface of the cylindrical portion than a concave portion at a portion where the surface roughness is rough. 前記凹部よりも大きい溝の底部に、前記円筒内面の軸方向に延びる底面部が形成されていることを特徴とする請求項１０または１１に記載の円筒内面の溶射前下地処理形状。   The bottom surface shape of the inner surface of the cylindrical inner surface according to claim 10 or 11, wherein a bottom surface portion extending in the axial direction of the inner surface of the cylindrical surface is formed at a bottom portion of the groove larger than the concave portion.
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