JPH0636981B2 - Casting method for fiber reinforced cylinder block material - Google Patents

Description

Detailed Description of the Invention A. Object of the Invention (1) Field of Industrial Application The present invention relates to a method for casting a fiber-reinforced cylinder block material in which the circumference of a cylinder bore is reinforced with a fiber molding.

(2) Conventional technology Conventionally, when casting this type of cylinder block material, a cylindrical fiber molded body is mounted on the outer peripheral surface of a cylinder bore molding core whose axis is horizontally arranged, and then the fiber molded body is surrounded. A method of injecting a molten metal into the cavity for forming a cylinder block material from one opening end side of the fiber molded body, thereafter pressurizing the molten metal, and completely solidifying under the pressure is adopted.

(3) Problems to be Solved by the Invention In the above method, the filling of the molten metal into the fiber molding is
This is mainly performed by pressurizing the molten metal, but when the fiber molded body is installed horizontally as described above, there is a problem that gas is easily confined in the fiber molded body, resulting in the formation of cavities.

It is an object of the present invention to provide the casting method that can solve the above problems.

B. Structure of the Invention (1) Means for Solving the Problems The present invention is for molding a cylinder block material in which the cylinder bore is reinforced by a fiber molded body, and the axis line is arranged in the vertical direction during molding. A step of mounting a cylindrical fiber molded body on the outer peripheral surface of the child, and fitting the upper end of the fiber molded body into an annular recess communicating with the minute gas vent hole while opening at the ceiling surface of the cylinder block material molding cavity. And; a step of injecting the molten metal into the cavity, and a step of pressurizing the molten metal and completely solidifying the molten metal under the pressure.

(2) Working The molten metal is filled into the fiber compact by pressurizing it, and the gas in the fiber compact is extruded by the molten metal and discharged from the upper end of the fiber compact through the minute gas vent holes. Therefore, the degassing of the fiber molded body is favorably performed. In this case, since the molten metal that has entered the minute gas vent holes is immediately cooled and solidified, the pressurized state of the molten metal is maintained, and the molten metal is completely solidified under the pressure, so that the metal structure of the matrix is densified and its strength is increased. Is improved.

(3) Examples FIGS. 1 to 3 show a fiber-reinforced aluminum alloy Siamese type cylinder block S made of the material obtained by the present invention. The cylinder blocks S are plural in series, and four in the illustrated example. more configuration and the cylinder barrel 1 ₁ to 1 ₄ Siamese cylinder barrel 1 composed by combining each other, an outer wall portion 2 surrounding the Siamese cylinder barrel 1, a crankcase 3 provided continuously to the lower edge of the outer wall 2 To be done. A cylindrical fiber molded body F is embedded around the cylinder bore ₄ in each of the cylinder barrels 1 ₁ to 14, and the fiber molded body F is reinforced around the cylinder bore 4.

A water jacket 6 facing the outer circumference of the Siamese cylinder barrel 1 is formed between the Siamese cylinder barrel 1 and the outer wall portion 2. At the cylinder head side end of the water jacket 6, the Siamese cylinder barrel 1 and the outer wall 2
The plurality of reinforcing deck parts 8 are partially connected to each other, and the adjacent reinforcing deck parts 8 have a communication port 7 to the cylinder head side.
Function as. As a result, the cylinder block S is constructed as a closed deck type.

5 to 8 show the cylinder block material S shown in FIG.
1 shows a casting apparatus used for practicing the present invention for casting m, which comprises a mold M, which is movable up and down, and is arranged below the upper mold 9, In FIGS. 5 and 6, the left and right halves are divided into the first and second side molds 10 ₁ and 10 ₁ .
₂ and FIG. 7, the left and right parts are divided into third and fourth parts.
It is composed of side molds 10 ₃ and 10 ₄ and a lower mold 11 on which the side molds 10 ₁ to 10 ₄ are slidably mounted.

On the lower surface of the upper mold 9, a mold clamping recess defining a first cavity C ₁ for molding the Siamese cylinder barrel 1 and the outer wall part 2 in cooperation with the upper half of each side mold 10 ₁ to 10 _4. 12 is formed, and a mold clamping protrusion 13 that fits into the recess 12 is provided on the upper surface of each of the side molds 10 ₁ to 10 ₄ .

As shown in FIGS. 7 and 8, the lower mold 11 has a molten metal reservoir portion 14 for receiving a molten aluminum alloy from a melting furnace (not shown).
A hot water supply cylinder 15 that communicates with the hot water reservoir 14, a plunger 16 that slides on the hot water supply cylinder 15, and two branches from the hot water reservoir 14 in the longitudinal direction of the first cavity C ₁ and A pair of runners 17 extending over substantially the same length is provided. Further, the lower die 11 has a forming block 18 projecting upward between the runners 17, and the forming block 18 cooperates with the lower half portions of the side dies 10 ₁ to 10 ₄ to form the crankcase 3. Define a second cavity C ₂ for The upper end of the cavity C ₂ is the first
It communicates with Cavity C _1, and the lower ends of both sides are both runways 17
Through a plurality of weirs 19. These first and second cavities C ₁ and C ₂ constitute a cylinder block material forming cavity.

The molding block 18 includes four tall first semi-cylindrical molding parts 18 ₁ formed at predetermined intervals, and adjacent first molding parts 18 ₁ and outermost first molding parts 18 ₁ . more becomes convex-shaped second molded part 18 ₂ located outside, each of the first mold portion 18 ₁ is used to mold the rotation space 20 for the crank pin and the crank arm (second, third panel),
Second forming unit 18 ₂ bearing holder 2 of the crank journal
1 (FIGS. 2 and 3). Each weir 19 is provided corresponding to each second molding portion 18 ₂ .
The molten metal is quickly injected into the large capacity portion of the second cavity C ₂ .

The cross-sectional area of both runners 17 is the runner tip 17a from the side of the hot water reservoir 14.
The bottom surface of the runner 17 is formed in an upward step shape of several steps from the side of the hot water reservoir portion 14 so as to decrease in a stepwise manner. The rising portions 17c connected to the step portions 17b are provided with molten metal at the weirs 19 respectively.
It is formed diagonally so that it can be smoothly guided to.

When the cross-sectional area of the runner 17 is gradually reduced in this way,
In the part with a large cross-sectional area, a large amount of molten metal is dammed at a slow speed.
The second was injected into cavity C _2, and because the small portion of the cross-sectional area can be injected a small amount of the molten metal in the second cavity C ₂ through weir 19 at a high speed through its from both sides the lower end within the cavity C ₂ The molten metal can be supplied substantially evenly over the entire length. Further, since the molten metal injection work is efficiently performed, the casting efficiency can be improved.

As shown in FIG. 5 and FIG. 6, a positioning projection 22 to which the lower end of the fiber molded body F is fitted is provided on the top surface of each first molding portion 18 ₁ , and a recess 23 is formed at the center of the positioning projection 22. Is formed. Also, the two first molding parts 18 ₁ located on both sides
The first molding portion 18 _{1 on} both sides of the positioning protrusion 22.
Through holes 24 are formed so as to pass through the through holes 24, and a pair of temporary setting pins 25 are slid into the through holes 24, respectively. The temporary setting pins 25 are used for temporary setting of a sand core for a water jacket described later. The lower ends of both temporary installation pins 25 are fixed to a mounting plate 26 installed below the molding block 18. Two support rods 27 are inserted through the mounting plate 26, and a coil spring 28 is contracted between the lower portion of each support rod 27 and the lower surface of the mounting plate 26. When the mold is opened, the mounting plate 26 receives the elastic force of each coil spring 28 and ascends until it comes into contact with the stopper 27a at the tip of each support rod 27, whereby the tip of each temporary installation pin 25 is moved to the first molding portion 18 _1. It protrudes from the top surface. A recess 25a that engages with the lower edge of the sand core is formed on the tip surface of each temporary setting pin 25.

The two first mold portion 18 ₁ positioned at both sides, through-holes 29 penetrating the first mold portion 18 ₁ at the bisecting position between the two through holes 24 are formed, attached to the lower end into the through-holes 29 The operating pin 30 fixed to the plate 26 is slidably engaged. When the mold is opened, the tip of the operating pin 30 projects into the recess 23,
When the mold is closed, it is pushed down by a cylinder bore molding core, which will be described later, so that both temporary setting pins 25 can be pulled in from the top surface of the first molding portion 18 ₁ .

Two core receptacles 31 for permanently installing the sand core are provided in the central portion of the wall defining the first cavity C ₁ in the first and second side molds 10 ₁ and 10 ₂ . Each core receiver 31 has an engagement hole 31a for positioning the sand core, and a sandwiching surface 31b formed on the outer periphery of the opening for sandwiching the sand core.
And consists of.

A plurality of third cavities C _{3 for} communicating with the first cavity C ₁ to overflow the molten metal and a fourth cavity C ₄ for forming the communication port 7 are formed in the mold clamping recess 12 of the upper mold 9, respectively. Further, the upper mold 9 is formed with gas vent holes 32 and 33 communicating with the third cavity C ₃ and the fourth cavity C ₄ , respectively.

Closing pins 34 and 35 are loosely inserted into the gas vent holes 32 and 33, respectively, and upper ends of the closing pins 34 and 35 are fixed to a mounting plate 36 disposed above the upper die 9.

Small-diameter portions 32a and 33a extending upward from the communication ends of the gas vent holes 32 and 33 to the cavities C ₃ and C ₄ for a predetermined length are fitted to the lower end portions of the closing pins 34 and 35, respectively. The third cavity C ₃ and the fourth cavity C ₄ can be closed.

A hydraulic cylinder 39 is interposed between the upper surface of the upper die 9 and the mounting plate 36, and the mounting plate 36 is moved up and down by the operation of the hydraulic cylinder 39 to close the small diameter portions 32a, 33 by the closing pins 34, 35.
It is designed to open and close a. 40 is a guide rod for the mounting plate 36.

The clamping recess 12 top surface of the upper mold 9, on an axis corresponding to each cylinder barrel 1 ₁ to 1 _4, the cylinder bores molding circle Chujo core 41 which is disposed toward the downward projecting At the lower end surface of each core 41, a convex portion 41a that can be fitted into the concave portion 23 of the top surface of the first molding portion 18 ₁ is provided. The outer peripheral surface of the core 41 is formed into a tapered surface that tapers from the upper end toward the lower end, and is provided with a predetermined draft.

Further, an annular recess 42 surrounding the core 41 is formed on the ceiling surface of the mold clamping recess 12, and a gas vent hole 43 penetrating the upper mold 9 and part of the core 41 communicates with the recess 42.
The lower portion of the gas vent hole 43 is formed in the minute diameter portion 43a so as to function as the minute gas vent hole.

9, FIG. 10 shows the water jacket sand core 59, the sand core 59, four cylindrical portion ₆₀ 1 in correspondence with the four cylinder barrels ₁ 1 to 1 ₄ of the cylinder block S 60
_{In order} to form a core main body 61 which is provided with ₄ and lacks peripheral walls where adjacent ones overlap with each other, a communication port 7 for communicating the water jacket with the water jacket of the cylinder head, and a reinforcing deck portion 8, A plurality of projections 62 projecting from the upper end surface of the child body 61 and both outer surfaces of the core body 61 in the cylinder barrel arrangement direction, in the illustrated example, both outsides of the two cylindrical portions 60 ₂ and 60 ₃ located in the middle. It is composed of skirting boards 63 that are respectively provided on the side surfaces. Each skirting board 63 has a large-diameter portion 63a integral with the core body 61, and a small-diameter portion 6 protruding from the end face thereof.
And 3b.

FIG. 11 shows a cylindrical fiber molded body F molded from a mixed fiber of carbon fiber and alumina fiber, the dimensions of which are 89 mm in outer diameter and 78 mm in inner diameter at the upper end, and 89 mm in outer diameter, 74 mm in inner diameter at the lower end. The inner peripheral surface is formed into a taper surface so as to be mounted on the cylinder bore molding core 41 having a length of 152 mm. The bulk density of the fiber molded body F is 0.3 g / cm ³
Is. The fiber molded body F has an average diameter of 18 μm and an average length.
0.8 mm carbon fiber (short fiber) and average diameter 3-4 μm,
Alumina fibers (short fibers) having an average length of 0.5 mm were mixed at a ratio of 1: 3, silica sol was added as a binder to the mixed fibers, and the mixture was molded by a suction adhesion molding method. In this case, an alumina sol simple substance or a mixture of silica sol and alumina sol can be used instead of the silica sol.

The suction adhesion molding method, in a tank containing a mixture of the mixed fiber and silica sol, standing up a breathable cylindrical mold with both end surfaces sealed, and applying a suction action to the inside of the cylindrical mold, It means a method of adsorbing the mixture on the outer peripheral surface of the cylinder.

The fiber molded body molded by the above-mentioned method is used after being subjected to a drying process and a firing process after releasing from the mold.

Next, a casting operation of the cylinder block material Sm by the casting apparatus using the fiber molded body F will be described.

First, as shown in FIG. 5, the upper mold 9 is raised, and the opposite molds 10 ₁ , 10 ₂ ; 10 ₃ , 10 ₄ are moved so as to be separated from each other to open the mold. The hydraulic cylinder 39 on the upper die 9 is operated to raise the respective closing pins 34, 35 via the mounting plate 36, and the lower end portions of the closing pins 34, 35 are separated from the small diameter portions 32a, 33a to make the small diameter portions 32a, 3a.
Open 3a. Further, the plunger 16 in the hot water supply cylinder 15 is lowered.

Each fiber molded body F preheated to about 300 ° C. is mounted on each core 41, and the upper end of the fiber molded body F is fitted into the recess 42 of the upper mold 9.

Fifth, both sides of the cylindrical portion 60 _1, 60 ₄ lower edge of the sand core 59 as shown in FIG. 10, the temporary installation pins projecting into the first top surface of the forming portions 18 ₁ on both sides of the lower mold 11 The sand core 59 is temporarily installed by engaging with the recess 25 a of the sand core 25.

As shown in FIG. 6, the two side molds 10 ₁ and 10 ₂ are moved by a predetermined distance in the direction in which they approach each other, and
The sand core 59 is permanently installed by engaging with the skirting boards 63.
That is, the small diameter portion 63b of each skirting board 63 of the sand core 59 is fitted into the engagement hole 31a of each core receptacle 31 to position the sand core 59, and the cylinder barrel arrangement direction of each large diameter portion 63a. The end face parallel to the abutment surface abuts against the sandwiching surface 31b of each core receiver 31 to sandwich the sand core 59 with the sandwiching surface 31b. Further, the two-sided molds 10 ₃ and 10 ₄ are also moved in the same manner.

Next, the upper mold 9 is lowered, and each fiber molded body F is moved to the sand core 59.
Of each fiber molded body F inserted into each cylindrical portion 60 _{1 to} 60 _{4 of}
The lower end of the core 41 is fitted into the positioning projection 22, and the convex portion 41a of the core 41 is fitted into the concave portion 23 on the top surface of the first molding portion 18 ₁ . Since operating pin 30 by the recess-projection fitting is pressed draw from the first mold portion 18 ₁ a top face each temporarily installed pin 25 is lowered. Further, each protrusion 62 of the sand core 59 is loosely inserted into each fourth cavity C ₄ . Further, the mold clamping concave portion 12 of the upper mold 9 is fitted into the mold clamping convex portion 13 of each of the side molds 10 ₁ to 10 ₄ , and mold clamping is performed.

The molten metal of aluminum alloy (JIS ADC12) at 730 to 740 ° C. is supplied from the melting furnace to the molten metal reservoir 14 of the lower mold 11, and the plunger 16 is raised at a speed of 0.08 to 0.3 m / sec to move the molten metal to both runners 17 It is injected into the cavities C ₂ and the first cavities C ₁ from both lower portions of the second cavities C ₂ through the weirs 19. Gases such as air in the cavities C ₁ and C ₂ are pushed down by the molten metal and mainly communicate with the _third and _fourth cavities C ₃ and C ₄ through the gas vent holes 3
After passing through 2, 33, it escapes above the upper mold 9.

In this case, as described above, the cross-sectional area of both runners 17 is 1
Since the bottom of the runway is formed in a step-like shape with several steps from the side of the hot water reservoir 14 so as to gradually decrease toward 7a,
As the plunger 16 rises, the molten metal is injected from both runways 17 through the weirs 19 into the second cavity C ₂ and from both lower portions thereof substantially evenly over the entire length thereof.

Further, back pressure acts on the molten metal surface due to the small diameters of the gas vent holes 32 and 33, and as a result, as shown in FIG. 12, the injection pressure of the molten metal exceeds the atmospheric pressure, p ₁ Become.
The back pressure suppresses the rippling of the molten metal surface and prevents the gas from being entrained in the molten metal.

When the molten metal is completely poured into the third and fourth cavities C ₃ and C ₄ , the hydraulic cylinder 39 on the upper mold 9 is operated to lower the mounting plate 36, and the closing pins 34 and 35 are used to move both cavities C and C. _3, the small diameter portion 32a which communicates with the _{C 4,} 33a
To close.

Thereafter, the plunger 16 is raised at a rate of 0.14 to 0.18 m / sec to pressurize the molten metal, and the molten metal is kept under a high pressure p ₂ higher than the pressure p ₁ mentioned above, that is, a pressure of 400 kg / cm ² to completely solidify. Then, the structure of the aluminum alloy as the matrix is densified to improve its strength. When the pressure of the molten metal reaches 5 to ²⁰ kg / cm ² in the process of increasing the pressure of the molten metal, the fiber molded body F is filled with the molten metal. Since the filling pressure of the molten metal is low as described above, the fiber molded body F is not destroyed by the molten metal during filling. Further, the gas in the fiber molded body F is extruded by the molten metal and discharged from the upper end portion of the fiber molded body F through the minute gas vent holes, and hence the minute diameter portions 43a, so that the gas discharge of the fiber molded body F is favorably performed. Done. In this case, the molten metal that has entered the small diameter portion 43a is immediately cooled and solidified, so that the pressurized state of the molten metal can be maintained.

The sand core 59 is a double-sided mold 1 through each skirting board 63 thereof.
Since it is clamped by 0 ₁ , 10 _{2 in the} correct position,
The sand core 59 does not float up when the molten metal is poured into the first cavity C ₁ and when the molten metal in the cavity C ₁ is pressurized. The large diameter portion 63 of each skirting board 63
Since the end face of a abuts against the sandwiching surface 31b of the core receiver 31 in the double-sided molds 10 ₁ and 10 ₂ , when the sand core 59 tends to expand, its deforming force is supported by each sandwiching surface 31b. As a result, the sand core 59 is prevented from being deformed, and the Siamese cylinder barrel 1 having a uniform thickness around each cylinder bore 4 is obtained.

When the mold is opened after the solidification of the molten metal is completed, the cylinder block material Sm shown in FIG. 4 is obtained.

The cylinder block material Sm each fourth is subjected to grinding into cavity C ₄ and sand the protrusions 62 in concert Removal of each protrusion 64 which is formed by cooperation each communicating port 7 of the core 59 and the reinforcing deck section 8 Is formed, and the sand jacket is removed to obtain the water jacket 6.
When the annular protrusions 65 formed by the cooperation of the upper end portion and the annular recesses 42 are removed, and the inner peripheral surface of each cylinder bore 4 is subjected to other predetermined processing such as perfect circle processing, the first ~ The cylinder block S shown in Fig. 3 is obtained.

The fiber molded body F may be molded from one type of reinforcing fiber. In addition to the aluminum alloy, cast iron, copper, magnesium alloy or the like is used as the matrix.

C. EFFECTS OF THE INVENTION According to the present invention, the gas in the fiber molded body can be efficiently extruded by the molten metal filled therein, and the gas can be satisfactorily degassed. Further, the molten metal is completely solidified under pressure and the metallic structure of the matrix is obtained. Can be densified.

Therefore, by adopting the above-mentioned method, it is possible to efficiently cast a high-strength fiber-reinforced cylinder block material which is surely fiber-reinforced around the cylinder bore and does not have cavities.

[Brief description of drawings]

1 to 3 show a Siamese type cylinder block made of the material obtained by the present invention, FIG. 1 is a perspective view seen from above, FIG. 2 is a sectional view taken along line II-II of FIG. 1, and 2A.
Fig. 2 is a sectional view taken along line IIa-IIa in Fig. 2, Fig. 3 is a perspective view seen from below, Fig. 4 is a perspective view seen from above of a Siamese type cylinder block material obtained by the present invention, and Fig. 5 is FIG. 6 is a vertical sectional front view when the mold of the casting apparatus is opened, FIG. 6 is a vertical sectional front view when the mold of the casting apparatus is closed, FIG. 7 is a sectional view taken along line VII-VII of FIG. 6, and FIG. 8 is VIII-VIII of FIG. FIG. 9 is a perspective view of the sand core seen from above, FIG. 10 is a sectional view taken along line XX of FIG. 9, FIG. 11 is a perspective view of a fiber molding, and FIG. It is a graph which shows the relationship between pressure and time. C ₁ , C ₂ ... First and second cavities constituting a cylinder block material forming cavity, F ... Fiber molded body,
Sm …… Siamese type cylinder block material, 4 ……
Cylinder bore, 41 ... Core, 42 ... Annular recess, 43
a: Micro gas vent

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Claims (1)

[Claims] 1. When casting a cylinder block material in which the periphery of a cylinder bore is reinforced with a fiber molded body, a cylindrical fiber molded body is mounted on the outer peripheral surface of a cylinder bore molding core arranged with its axis oriented vertically. A step of fitting an upper end portion of the fiber molded body into an annular recess which is open to a ceiling surface of a cylinder block material molding cavity and communicates with a minute gas vent hole; a step of injecting a molten metal into the cavity; A method for casting a fiber-reinforced cylinder block material, comprising the step of pressurizing the molten metal and completely solidifying it under pressure.