Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
  • B22D15/02—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of cylinders, pistons, bearing shells or like thin-walled objects
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22C—FOUNDRY MOULDING
  • B22C21/00—Flasks; Accessories therefor
  • B22C21/12—Accessories
  • B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22C—FOUNDRY MOULDING
  • B22C9/00—Moulds or cores; Moulding processes
  • B22C9/02—Sand moulds or like moulds for shaped castings

Definitions

• the invention relates to a method for assembling a mold assembly composed of mold parts for casting a cylinder block of an internal combustion engine from a molten metal, wherein at least one cooling mold, which forms at least a portion of the inner surfaces of a cylinder chamber of the cylinder block is positioned and held on a wall of one of the mold parts ,
• cooling molds are used in particular when pouring light metal melts into the mold, from a high consist of thermally conductive material and as such constitute a heat sink over which the melt coming into contact with the metal inserts are removed in a short time comparably large amounts of heat. Accordingly, cooling molds are, for example, arranged during the casting of cylinder blocks of cast aluminum material in such a way that they depict the cylinder liners on the block to be cast.
• the casting material which contacts the cooling molds arranged in this way then cools much faster than the melt which is present further away from the molds in the casting mold, so that the desired directed solidification with the expression of a fine-grained microstructure is established in the region of the raceways.
• Patent publication is a method for casting an engine block made of aluminum, in which the engine block is cast in a sand mold and its cylinder cavities are formed by inserted into the sand mold cooling molds, which consist of a brass material, wherein the brass material adapted to the thermal expansion coefficients of each cast aluminum melt
• German Patent 719 454 a method and an apparatus for producing cores or moldings for casting molds from a core or molding material are known from German Patent 719 454, it allow to keep in the respective mold or core box a chill so that it sits securely at its intended position of each manufactured core or molding.
• the respective cooling iron is first positioned in the empty mold or core box, wherein it rests in this position in each case on an outer wall of the mold or core box.
• an electromagnet which sits in a molded-in from the outside in the relevant wall of the molding box recess and acts through the present between him and the cooling iron wall portion therethrough, the cooling iron is then held in this position. After completion of the filling of form or core mass of the excitation circuit of the electromagnet is turned off, so that the respective molded part or the respective core can be removed with the incorporated in it cooling iron from the box.
• the invention had the object of specifying a method of the type mentioned, with which can be mounted in a simple yet reliable way casting molds for the casting of cylinder blocks with provided in the mold cavity metal inserts. This object has been achieved by the method specified in claim 1.
• Advantageous embodiment of the method according to the invention are specified in the dependent claims on claim 1.
• the inventive method is particularly suitable for casting of light metal melts, especially aluminum-based melts.
• the respective cooling mold which may also be referred to below as "metal insert" is held in the mold in the mold intended for installation in a simple manner by magnetic forces exerted by at least one suitably arranged magnet.
• the cooling molds themselves are magnetically sensitive. Accordingly, in particular ferromagnetic materials, such as iron and its alloys, are suitable as the material for the chill molds.
• cooling molds used in accordance with the invention can be produced from cost-effective and wear-resistant materials, such as cast iron.
• the magnetic body exerting the holding forces on the respective cooling mold during the assembly process is arranged such that it does not disturb the pouring of the molten metal or other assembly operations.
• the magnet is so behind the wall on which the metal insert is positioned, arranged that its magnetic forces penetrate the wall and hold the insert without direct contact between the insert and magnet.
• cooling molds no longer have to be firmly bound in a casting mold part or in the respective casting in the procedure according to the invention, there is no longer the problem of damage to the cooling molds or the casting during demoulding when removing a mold according to the invention.
• the coating of the cooling molds can be omitted and the preparation effort can be reduced.
• cooling molds can be easily removed after casting from the casting and the moldings of the mold. This advantage is particularly evident in the casting of cylinder blocks of internal combustion engines, in technical language also referred to as "engine blocks" in which the cooling molds depict the running surfaces of the cylinders.
• Another advantage of the invention is that it can be easily integrated into existing systems.
• the inventive method thus enables a simpler and more cost-effective production of castings compared to the prior art.
• the invention is particularly suitable for casting castings from light metal melts, in particular aluminum melts.
• the mold parts from which a casting mold according to the invention is composed are preferably made from a molding material which is mixed from a molding base material and a binder.
• a molding material which is mixed from a molding base material and a binder.
• quartz-containing or quartz-free sands may be used as mold bases, while both inorganic and organic binders may be used as binders.
• the invention proves to be particularly advantageous when the casting mold is designed in a manner known per se as a core package.
• the positioning and holding a chill mold in the mold can be carried out in the inventive procedure, regardless of a specific preparation of the respective place where the metal part is to be arranged. Accordingly, the positioning of the metal part can be made at a time that is determined solely by the each optimal workflow during assembly of the respective mold.
• the decisive factor is merely that the magnet required for holding can be arranged in the region of the cooling mold to be held in such a way that the forces exerted by it reliably grasp the cooling mold.
• an opening can be formed in the mold part, on the wall of which the cooling mold is positioned, into which the magnet is inserted.
• the magnet used to hold the mold may be moved into close proximity to the mold to facilitate the assembly process.
• a plurality of cooling molds can be arranged side by side on the outer surface of the mold part, so that together they image the inner shape of the respective cylinder and are held together by a magnet arranged in the central blind opening.
• cooling mold is held in its position by means of the magnet until a further casting mold part is arranged which subsequently holds the cooling mold in its position in a positive and / or nonpositive manner.
• the cooling mold is by mounted after positioning mold parts in held their position without this magnetic forces are required.
• Another advantage of this approach when holding the cooling mold is that the position of the cooling mold in the mold can be accurately defined by the other, with him form and / or kraft gleichig coming in contact mold parts.
• Holding the cooling mold according to the invention by means of magnetic forces thus serves in this embodiment of the invention for bridging an undefined state with regard to the hold of the cooling mold in the mold until the respective mold is held in place by another mold part, without being affected by any Separate holding device exercised holding forces are needed.
• all magnets which can generate a sufficiently strong magnetic field are suitable for applying the magnetic forces used to hold the cooling mold according to the invention.
• permanent magnets are provided to apply the holding forces in the inventive manner to the respective cooling mold.
• Electromagnets not only allow an exact adjustment of the strength of the respective magnetic field generated by them, but it is also possible with them in a simple manner to set by turning on and off the electrical power exactly the period within which the magnetic forces in the inventive manner to the respective Kuhlkokille be applied. In question come for this purpose, for example, based on coils produced electromagnets. The magnetic field of such electromagnets can be proportionally controlled by the current conducted through the coils.
• the invention is particularly suitable for the production of a cylinder block
• Internal combustion engine made of a light metal melt, such as an aluminum or a magnesium melt, with at least one partial section of the inner surfaces of the respective cylinder chamber of the cylinder block can be imaged with one or more cooling molds.
• a light metal melt such as an aluminum or a magnesium melt
• the invention is particularly suitable for use in a fully automatic device for assembling a casting mold, in which devices, such as robots, are provided for handling the mold parts. These devices can also easily position the chill mold when using the invention, since the hold of this metal insert is secured in its respective position by the magnet and no cohesive connection of the chill mold to one of the mold parts is required.
• FIG. 1 shows a first mold part in a section along the section line A - A shown in FIG. 3, FIG.
• Fig. 2 shows the mold part shown in Figure 1 in a side view
• Fig. 3 that shown in Figures 1 and 2
• the einstuckig trained mold part 1 is part of a casting mold, not further shown here for casting a cylinder block for an internal combustion engine from a melt, which is formed from a cast aluminum alloy. It is produced in a manner known per se from a molding material which is mixed from a molding sand as a molding material and a binder, and has a base portion 2, which carries an upwardly projecting, substantially cylindrically shaped mandrel portion 3.
• the mandrel portion 3 has a lateral surface 4, which is divided by four radially projecting ribs 5 into four sections.
• a circumferential groove 6 is formed in the substantially perpendicular to the peripheral surface 4 of the mandrel portion 3 aligned around the mandrel portion 3 encircling upper end surface 7 of the base portion.
• the mandrel section may also have a lateral surface which is divided by radially projecting ribs into two, three or more sections.
• the ribs in contrast to the here shown, having parallel side walls having shape in cross section conically tapered or widening.
• the mandrel portion and a lateral surface not by additional ribs is divided. In this case, the lateral surface is completely enclosed by the respectively accommodating cooling molds.
• a blind hole 9 is formed, extending from the end face 8 of the base portion 2 to the end face of the mandrel portion 3 forming end wall 10th of the mandrel portion 3 extends.
• the diameter of the blind hole 9 is adapted to the outer diameter of the mandrel portion 3, that between the inner surfaces of the blind hole 9 and the lateral surface 4, only a wall 11 is provided with a small wall thickness, which is sufficient to ensure the required dimensional stability of the mandrel portion 3.
• an electromagnet 12 is inserted, which is attached to the free end of a rod 13.
• the rod 13 with the electromagnet 12 is part of a further not shown device for holding metal parts 14,15,16,17, which have been recognized as cooling molds from a device, not shown here for positioning on the lateral surface 4 of the mandrel portion 3.
• the rod 13 with the electromagnet 12 can be moved by means of a likewise not shown adjusting device from a rest position in which the electromagnet 12 is outside the blind hole 9 in the operating position shown in Fig. 1, in which the electromagnet 12 completely into the blind hole 9 is introduced.
• the supply of the electromagnet 12 with electrical Energy is supplied via a control device, also not shown, which energizes the electromagnet 12 when the cooling molds 14 - 17 are positioned to hold them in position.
• the height of the cooling molds 14-17 is adapted to the height of the mandrel portion 3.
• the cooling molds on their upper and lower narrow side in each case an upwardly or downwardly projecting web 18,19, of which the lower web 18 engages in the groove 6, so that the cooling molds 14 - 17 are held there form-fitting.
• the cooling molds 14 - 17 are curved in such a way that they lie flush against the respectively assigned section of the lateral surface 4 of the mandrel section 3.
• the width of the cooling molds 14 - 17 is matched to the width of the sections of the lateral surface 4 such that the sections of the lateral surface 4 are completely filled by the cooling molds 14 - 17 lying flush against them.
• the cooling molds 14-17 are cast as cast iron from a cast iron alloy, which is known under the name GG20 (according to DIN 1691).
• the electromagnet 12 is subjected to electrical energy.
• the magnetic field subsequently generated by the electromagnet 12 detects the cooling molds 14-17 and holds them in their position on the lateral surface 4 of the mandrel portion 3.
• the other, not shown here parts of the mold are mounted.
• One of the mold parts, not shown, in this case has a groove-shaped receptacle, in the after the positioning of the respective mold part at the upper end of the cooling molds 14 - 17 formed rib 19 engages, so that the cooling molds 14 - 17 are then held positively at its upper end.
• the power supply of the electromagnet 12 can be switched off and the rod 13 with the electromagnet 12 can be pulled out of the blind opening 9.
• the cooling molds 14 - 17 form the raceways of one of the cylinders of the cylinder block.
• the cooling molds 14 - 17 form a heat sink, by which it is ensured that the cooling molds 14 - 17 coming into contact
• Aluminum melt solidifies quickly and forms a fine-grained microstructure.

Priority Applications (7)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Citations (5)

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• 2006
  • 2006-02-10 DE DE102006006132A patent/DE102006006132A1/de not_active Withdrawn
• 2007
  • 2007-02-09 CA CA002640308A patent/CA2640308A1/en not_active Abandoned
  • 2007-02-09 PL PL07704507T patent/PL1981667T3/pl unknown
  • 2007-02-09 JP JP2008553780A patent/JP2009525875A/ja active Pending
  • 2007-02-09 WO PCT/EP2007/051294 patent/WO2007090895A1/de active Application Filing
  • 2007-02-09 DE DE502007002040T patent/DE502007002040D1/de active Active
  • 2007-02-09 US US12/278,856 patent/US20090165983A1/en not_active Abandoned
  • 2007-02-09 EP EP07704507A patent/EP1981667B1/de active Active
  • 2007-02-09 BR BRPI0707647-9A patent/BRPI0707647A2/pt not_active IP Right Cessation

Patent Citations (5)

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