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EP3697554B1 - Die casting mold for casting cylinder crankcases or crankcase subparts - Google Patents

Die casting mold for casting cylinder crankcases or crankcase subparts Download PDF

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Publication number
EP3697554B1
EP3697554B1 EP18778378.2A EP18778378A EP3697554B1 EP 3697554 B1 EP3697554 B1 EP 3697554B1 EP 18778378 A EP18778378 A EP 18778378A EP 3697554 B1 EP3697554 B1 EP 3697554B1
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EP
European Patent Office
Prior art keywords
crankcase
cylinder
die casting
casting
casting mold
Prior art date
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EP18778378.2A
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German (de)
French (fr)
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EP3697554A1 (en
Inventor
Christian Klimesch
Steffen Ziegler
Horst Denndörfer
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KS Huayu Alutech GmbH
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KS Huayu Alutech GmbH
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Publication of EP3697554A1 publication Critical patent/EP3697554A1/en
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2272—Sprue channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/24—Accessories for locating and holding cores or inserts

Definitions

  • the invention relates to a die casting mold for casting cylinder crankcases or crankcase lower parts, comprising a fixed mold part in which a sprue system for distributing the melt is at least partially formed, and movable mold parts in which a cavity for forming a cylinder crankcase or a crankcase lower part is at least partially formed.
  • Die casting molds for the production of cylinder crankcases or crankcase lower sections are well known, with the die casting process being used primarily in the field of light metal casting, especially aluminum alloys or magnesium alloys.
  • the molds used usually have a one- or two-sided gate onto the oil pan flanges or the parting surfaces between the cylinder crankcase and the crankcase lower section.
  • this has the consequence that a sufficiently low-porosity structure is often not achieved in the thick-walled areas during casting, as the required pressure often cannot be applied via the gate because the thinner areas in between solidify earlier. For this reason, additional squeezers are used below the bearing blocks in order to generate a sufficiently high holding pressure in the thick-walled areas.
  • a die casting mold with fixed and movable mold parts in which a sprue system is formed in a movable mold part, the gates of which extend through an intermediate mold part into a cavity of a cylinder crankcase to be cast on the cylinder walls.
  • the challenge therefore, is to provide a die-casting mold for casting cylinder crankcases or crankcase lower sections that can achieve a good microstructure in thick-walled areas of the castings without the need for additional squeezers.
  • the possible holding pressure should be increased compared to existing designs and handling during post-processing should be simplified.
  • an intermediate mold part between the stationary mold part and the movable mold parts, which at least partially defines the cavity for forming the cylinder crankcase or the crankcase lower section and in which the sprue system and several gates are at least partially formed, which open at the thick-walled areas of the cylinder crankcase or the crankcase lower section, wherein the gates are designed in a funnel shape and narrow towards the cavity, it is achieved that the thick-walled areas can be supplied directly with melt and the holding pressure can be introduced via the thick-walled areas so that the areas that solidify last can be supplied with melt throughout the entire solidification time. This connection compensates for shrinkage deficits during the solidification process and thus achieves a low-porosity structure even in these areas.
  • the funnel shape of the gates simplifies demolding and creates predetermined breaking points at the transition between the cavity or the casting and the runner system, ensuring a clean separation of the casting from the runner system when the mold is opened. This also improves the conditions for subsequent aging, quenching, and heat treatment, as the runner system is no longer present and therefore no energy can be drawn from it.
  • a first parting plane is formed between the fixed mold part and the intermediate mold part and a second parting plane is formed between the intermediate mold part and the movable side mold parts, which second parting plane is formed substantially parallel to a
  • the gates are arranged on the base surface of the cylinder block or crankcase lower section to be cast. This allows for easy demolding with a clean separation of the casting from the sprue. This allows for multiple gates to be created for a single cavity, especially in difficult-to-access positions within the cavity.
  • the sprue can be ejected between the stationary mold part and the intermediate mold part when the mold is opened, and the cylinder crankcase or the crankcase lower section can be ejected between the intermediate mold part and the movable mold parts when the mold is opened.
  • the tool used thus ensures easy separation when the plates are moved apart.
  • the die-casting mold can be filled from the crankcase side, and the gates open at the bearing block of the cylinder crankcase or the crankcase lower section. This allows the filling to be carried out directly onto the loaded and thick-walled bearing block, thereby achieving a low-porosity structure.
  • the die-casting mold can be filled from the cylinder deck side, and the gates open in the area of the tie rod cores of the cylinder crankcase, allowing filling below the water jacket core toward the bearing blocks or the tie rod cores. This allows these thick-walled areas to be produced with a low-porosity structure through the internal filling. This achieves a good structure in the area of the loaded tie rods.
  • the die casting mould can preferably be filled from the cylinder top side and the gates open in the area of the Cylinder walls of the cylinder crankcase, so that improved structures are achieved through the increased pressure to be applied.
  • two gates are formed on each bearing block, which are arranged on both sides of each bearing shell receptacle of the cylinder crankcase or the crankcase lower part, so that a filling on both sides of the bearing block is produced, which leads to a uniform structure of the bearing block area regardless of the casting layer.
  • a main pouring runner is formed between the stationary mold part and the intermediate mold part.
  • This main pouring runner extends along the length of the mold parts. From this runner, several individual pouring runners extend perpendicular to the main pouring runner on both sides through the intermediate mold part to the cavity.
  • This design achieves uniform and low-turbulence filling with constant holding pressure. This results in a uniform distribution of the melt and a uniform feeding into the bearing seats.
  • a projected area of the sprue system arranged in the intermediate mold part onto the second parting plane between the movable mold part and the intermediate mold part is arranged within a projected area of the cavity onto this parting plane.
  • the individual casting runners have a diameter that essentially corresponds to the width of the bearing block. This large diameter allows the holding pressure from the piston system to act for a significantly longer period during the solidification phase.
  • the die casting mold according to the invention is therefore particularly suitable for producing cylinder crankcases and crankcase lower sections with high strength by achieving low-porosity structures in highly stressed, thick-walled areas without the need for additional squeezers. Higher final pressures are possible due to the reduced blast area, and the amount of recycle material is reduced during demolding due to the small sprue system.
  • the Figure 1 shows schematically a side view of a die casting mold according to the invention with a crank chamber-side sprue system in the closed state in a sectional view.
  • the Figure 2 schematically a side view of the die casting mold according to the invention Figure 1 in the opened state in a sectional view.
  • the Figure 3 shows schematically the cast cylinder crankcase with the crankcase side gating system in perspective view.
  • the Figure 4 shows schematically a side view of an alternative die casting mold according to the invention with a cylinder cover-side sprue system in the closed state in a sectional view.
  • the die casting mold according to the invention shown in the figures has a fixed mold part 10, via which the melt is introduced into the die casting mold.
  • This fixed mold part 10 is attached to a machine plate (not shown), which is provided with a casting chamber and the casting piston for generating the pressure, whereby the casting piston presses the melt through the fixed machine plate and into the fixed mold part 10.
  • a main casting runner 12 is formed between the stationary mold part 10 and an intermediate mold part 14.
  • a first parting plane 16 is formed between the intermediate mold part 14 and the stationary mold part 10, at which the two mold parts 10, 14 rest on one another and are pressed together during casting, and at which the two mold parts 10, 14 are separated from one another after casting.
  • the cavity 20 has the shape of a cylinder crankcase 34 with three cylinders 36, whose inner cylinder walls 38 are formed by the molds 30 used, and whose cylinder deck 39 and the outside of the cylinder crankcase 34 are formed by the movable mold parts 28, 29.
  • a crank chamber 40 is delimited by the intermediate mold part 14, with the gates 22 each opening into thick-walled regions 42 of the cylinder crankcase 34, which in the present embodiment are formed by bearing blocks 44 of the cylinder crankcase 34.
  • Tie rod cores 46 extend from the cylinder deck 39 into the cylinder crankcase.
  • Each of the four bearing blocks 44 is fed with melt via a pair of individual pouring runners 18, with the gates 22 being arranged on either side of bearing shell receptacles 48.
  • the pressure generated during the die-casting process acts exclusively on a projected surface of the cylinder crankcase 34 or the cavity 20 on the second parting plane 32 between the intermediate mold part 14 and the movable side mold parts 29, since the entire casting run on the intermediate mold part 14 or the projected area of the sprue system 26 within this projected area acts on the base area or the second parting plane 32. Accordingly, a very high holding pressure can be introduced or, compared to known embodiments, the closing force on the die casting mold can be reduced.
  • the die casting mold is opened at both parting lines. Due to their smallest cross-section, the individual runners 18 break off in the area of the gates 22, so that an entire solidified sprue 50 is ejected between the stationary mold part 10 and the intermediate mold part 14.
  • the cylinder crankcase 34 is ejected via ejector 52 after the molds 30 have been withdrawn from the movable mold part 10 and between the movable mold part 10 and the intermediate mold part 14, ensuring a clean separation between the casting and the sprue 50.
  • FIG. 4 An alternative possibility for casting a cylinder crankcase 34 is shown. In this case, filling does not take place on the crankcase side, but on the cylinder cover side.
  • a part of the sprue system 26 is again formed, which continues in the intermediate mold part 14.
  • This likewise has eight individual runners 18, which extend in a plane between the cylinders 36 to an area in which the tie rod cores 46 are arranged and from there fill the thick-walled area 42.
  • the individual runners could also extend through the parts of the intermediate mold part 14 forming the cylinders 36 and there, from the inside, via the crankcase-side end of the cylinder walls 38, in turn fill the thick-walled areas of the bearing blocks 44.
  • the cavity 20 is also formed in this embodiment between the intermediate mold part 14, the movable side mold parts 29 and the movable mold part 28, wherein the mold part 28
  • the side mold parts 29 form the cylinder outer surfaces and the outer surface of the crankcase 40.
  • the cylinder deck is formed by the intermediate mold part 14.
  • the pressing and feeding also take place directly on the thick-walled areas 42 of the cylinder crankcase, which are most subject to shrinkage, so that a low-pore structure can be achieved here as well.
  • the sprue 50 is also separated from the casting by simply opening the die-casting mold.
  • Such a die casting mold opens up various possibilities for filling and feeding the relevant thick-walled areas of a casting, and in particular of a cylinder crankcase, so that a low-porosity structure can be achieved.
  • this filling and feeding can take place at high pressures, since the small sprue system keeps the mold's burst area very small.
  • the cross-sections of the individual runners or the entire sprue system can be made relatively large, allowing the applied holding pressure to act for a long time. This also leads to improved structures in the relevant areas of the bearing block or the tie rods. Since the sprue is also very small, the amount of recycled material is reduced, which can save energy. In addition, the necessary post-processing is reduced, since the sprue automatically detaches from the casting at the correct position when the mold is opened.

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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)
  • Moulds For Moulding Plastics Or The Like (AREA)

Description

Die Erfindung betrifft eine Druckgussform zum Gießen von Zylinderkurbelgehäusen oder Kurbelgehäuseunterteilen mit einem feststehenden Formteil, in welchem zumindest teilweise ein Angusssystem zur Verteilung der Schmelze ausgebildet ist und beweglichen Formteilen, in welchen zumindest teilweise eine Kavität zur Bildung eines Zylinderkurbelgehäuses oder eines Kurbelgehäuseunterteils ausgebildet ist.The invention relates to a die casting mold for casting cylinder crankcases or crankcase lower parts, comprising a fixed mold part in which a sprue system for distributing the melt is at least partially formed, and movable mold parts in which a cavity for forming a cylinder crankcase or a crankcase lower part is at least partially formed.

Druckgussformen zur Herstellung von Zylinderkurbelgehäusen oder Kurbelgehäuseunterteilen, auch bedplates genannt, sind allgemein bekannt, wobei das Druckgussverfahren vor allem im Bereich des Leichtmetallgusses, insbesondere von Aluminiumlegierungen oder Magnesiumlegierungen verwendet wird. Die verwendeten Formen weisen üblicherweise einen ein- oder zweiseitigen Anschnitt auf die Ölwannenflansche beziehungsweise die Trennflächen vom Zylinderkurbelgehäuse und dem Kurbelgehäuseunterteil auf. Dies hat jedoch zur Folge, dass in den dickwandigen Bereichen häufig kein ausreichend porenarmes Gefüge beim Gießen erzielt wird, da der aufzubringende Druck über den Anschnitt oft nicht eingebracht werden kann, da die zwischenliegenden dünneren Bereiche früher erstarren, weswegen zusätzliche Squeezer unterhalb der Lagerstühle verwendet werden, um in den dickwandigen Bereichen einen ausreichend hohen Nachdruck erzeugen zu können.Die casting molds for the production of cylinder crankcases or crankcase lower sections, also called bedplates, are well known, with the die casting process being used primarily in the field of light metal casting, especially aluminum alloys or magnesium alloys. The molds used usually have a one- or two-sided gate onto the oil pan flanges or the parting surfaces between the cylinder crankcase and the crankcase lower section. However, this has the consequence that a sufficiently low-porosity structure is often not achieved in the thick-walled areas during casting, as the required pressure often cannot be applied via the gate because the thinner areas in between solidify earlier. For this reason, additional squeezers are used below the bearing blocks in order to generate a sufficiently high holding pressure in the thick-walled areas.

Um die bei diesen Gießverfahren erzielbaren Gefügestrukturen zu verbessern, wird in der DE 10 2006 030 129 B4 ein Niederdruckgießverfahren vorgeschlagen, bei dem in liegender Lage gegossen wird und die Speisung direkt über den Lagerstuhl erfolgt, so dass an diesem Anschnitt auch ein Nachdruck erzeugt werden kann.In order to improve the microstructures achievable with these casting processes, DE 10 2006 030 129 B4 A low-pressure casting process is proposed in which casting is carried out in a horizontal position and the feeding takes place directly via the bearing block, so that a holding pressure can also be generated at this gate.

Nachteilig an dieser Ausführung ist es jedoch, dass der Lagerstuhlbereich lediglich einseitig befüllt werden kann, so dass Gefügeunterschiede innerhalb des Lagerstuhlbereiches nicht ausgeschlossen werden können. Zusätzlich kann aufgrund der relativ großen Sprengfläche nicht mit erhöhten Drücken nachgepresst werden.The disadvantage of this design, however, is that the bearing block area can only be filled from one side, so structural differences within the bearing block area cannot be ruled out. Furthermore, due to the relatively large blast area, additional pressing at higher pressures is not possible.

Des Weiteren ist aus der DE 10 2013 105 769 A1 eine Druckgussform mit feststehenden und beweglichen Formteilen bekannt, bei der in einem beweglichen Formteil ein Angusssystem ausgebildet ist, dessen Anschnitte sich durch ein Zwischenformteil in eine Kavität eines zu gießenden Zylinderkurbelgehäuses an den Zylinderwänden erstrecken.Furthermore, the DE 10 2013 105 769 A1 a die casting mold with fixed and movable mold parts is known, in which a sprue system is formed in a movable mold part, the gates of which extend through an intermediate mold part into a cavity of a cylinder crankcase to be cast on the cylinder walls.

Des Weiteren ist aus der DE 10 2012 107 363 A1 ein Dreiplattenwerkzeug zum Gießen eines Motorlagers bekannt, bei dem in einem der Formteile das Angussssystem ausgebildet ist, in einem zweiten Formteil mehrere kegelförmige Anschnitte sowie die Kavität ausgebildet ist und das dritte Formteil die Kavität in der entgegengesetzten Richtung begrenzt.Furthermore, the DE 10 2012 107 363 A1 a three-plate tool for casting an engine mount is known, in which the sprue system is formed in one of the mold parts, several conical gates and the cavity are formed in a second mold part and the third mold part limits the cavity in the opposite direction.

Es stellt sich daher die Aufgabe, eine Druckgussform zum Gießen von Zylinderkurbelgehäusen oder Kurbelgehäuseunterteilen zur Verfügung zu stellen, mit der eine gute Gefügestruktur in dickwandigen Bereichen der Gussteile erzielt werden kann, ohne zusätzliche Squeezer nutzen zu müssen. Zusätzlich soll der mögliche Nachdruck im Vergleich zu bekannten Ausführungen erhöht werden können und die Handhabung bei der Nachbehandlung vereinfacht werden.The challenge, therefore, is to provide a die-casting mold for casting cylinder crankcases or crankcase lower sections that can achieve a good microstructure in thick-walled areas of the castings without the need for additional squeezers. In addition, the possible holding pressure should be increased compared to existing designs and handling during post-processing should be simplified.

Diese Aufgabe wird durch eine Druckgussform zum Gießen von Zylinderkurbelgehäusen oder Kurbelgehäuseunterteilen mit den Merkmalen des Anspruchs 1 gelöst.This object is achieved by a die-casting mold for casting cylinder crankcases or crankcase lower parts having the features of claim 1.

Dadurch, dass zwischen dem feststehenden Formteil und den beweglichen Formteilen ein Zwischenformteil angeordnet ist, welches zumindest teilweise die Kavität zur Bildung des Zylinderkurbelgehäuses oder des Kurbelgehäuseunterteils begrenzt und in dem zumindest teilweise das Angusssystem und mehrere Anschnitte ausgebildet sind, die an den dickwandigen Bereichen des Zylinderkurbelgehäuses oder des Kurbelgehäuseunterteils münden, wobei die Anschnitte sich trichterförmig zur Kavität verengend ausgebildet sind, wird erreicht, dass die dickwandigen Bereiche direkt mit Schmelze versorgt werden können und der Nachdruck über die dickwandigen Bereiche eingebracht werden kann, so dass während der gesamten Erstarrungszeit die zuletzt erstarrenden Bereiche mit Schmelze versorgt werden können. Durch diese Anbindung werden Schwindungsdefizite während des Erstarrungsvorgangs ausgeglichen und so ein porenarmes Gefüge auch in diesen Bereichen erzielt. Durch die Trichterform der Anschnitte ist einerseits die Entformung vereinfacht und es werden Sollbruchstellen am Übergang zwischen der Kavität beziehungsweise des Gussteils und des Angusssystems erzeugt, so dass eine saubere Trennung des Gussteils vom Angusssystem beim Öffnen der Form erreicht wird. Hierdurch werden auch die Voraussetzungen bei der anschließenden Auslagerung beziehungsweise beim anschließenden Abschrecken und Wärmebehandlung verbessert, da das Angusssystem nicht mehr vorhanden ist und somit aus diesem keine Energie nachgezogen werden kann.By arranging an intermediate mold part between the stationary mold part and the movable mold parts, which at least partially defines the cavity for forming the cylinder crankcase or the crankcase lower section and in which the sprue system and several gates are at least partially formed, which open at the thick-walled areas of the cylinder crankcase or the crankcase lower section, wherein the gates are designed in a funnel shape and narrow towards the cavity, it is achieved that the thick-walled areas can be supplied directly with melt and the holding pressure can be introduced via the thick-walled areas so that the areas that solidify last can be supplied with melt throughout the entire solidification time. This connection compensates for shrinkage deficits during the solidification process and thus achieves a low-porosity structure even in these areas. The funnel shape of the gates simplifies demolding and creates predetermined breaking points at the transition between the cavity or the casting and the runner system, ensuring a clean separation of the casting from the runner system when the mold is opened. This also improves the conditions for subsequent aging, quenching, and heat treatment, as the runner system is no longer present and therefore no energy can be drawn from it.

Vorzugsweise ist zwischen dem feststehenden Formteil und dem Zwischenformteil eine erste Trennebene und zwischen dem Zwischenformteil und dem beweglichen Seitenformteilen eine zweite Trennebene ausgebildet, welche im Wesentlichen parallel zu einer Grundfläche des zu gießenden Zylinderkurbelgehäuses oder des zu gießenden Kurbelgehäuseunterteils angeordnet sind. Dies ermöglicht eine leichte Entformbarkeit mit einer sauberen Trennung des Gussteils vom Anguss. So können mehrere Anschnitte für eine einzige Kavität insbesondere an schlecht zugänglichen Positionen der Kavität realisiert werden.Preferably, a first parting plane is formed between the fixed mold part and the intermediate mold part and a second parting plane is formed between the intermediate mold part and the movable side mold parts, which second parting plane is formed substantially parallel to a The gates are arranged on the base surface of the cylinder block or crankcase lower section to be cast. This allows for easy demolding with a clean separation of the casting from the sprue. This allows for multiple gates to be created for a single cavity, especially in difficult-to-access positions within the cavity.

Insbesondere ist zwischen dem feststehenden Formteil und dem Zwischenformteil beim Öffnen der Gussform der Anguss auswerfbar und zwischen dem Zwischenformteil und den beweglichen Formteilen beim Öffnen der Gussform das Zylinderkurbelgehäuse oder das Kurbelgehäuseunterteil auswerfbar. So wird durch das verwendete Werkzeug eine einfache Trennung beim Auseinanderfahren der Platten hergestellt.In particular, the sprue can be ejected between the stationary mold part and the intermediate mold part when the mold is opened, and the cylinder crankcase or the crankcase lower section can be ejected between the intermediate mold part and the movable mold parts when the mold is opened. The tool used thus ensures easy separation when the plates are moved apart.

In einer vorteilhaften Ausführungsform ist die Druckgussform kurbelraumseitig befüllbar und die Anschnitte münden am Lagerstuhl des Zylinderkurbelgehäuses oder des Kurbelgehäuseunterteils. So kann die Füllung direkt auf den belasteten und dickwandigen Lagerstuhl erfolgen, in dem so ein porenarmes Gefüge erzielt werden kann.In an advantageous embodiment, the die-casting mold can be filled from the crankcase side, and the gates open at the bearing block of the cylinder crankcase or the crankcase lower section. This allows the filling to be carried out directly onto the loaded and thick-walled bearing block, thereby achieving a low-porosity structure.

In einer vorteilhaften alternativen Ausführungsform ist die Druckgussform zylinderdeckseitig befüllbar und die Anschnitte münden im Bereich der Zugankerkerne des Zylinderkurbelgehäuses, wodurch unterhalb des Wassermantelkernes in Richtung der Lagerstühle oder der Zugankerkerne befüllt werden kann, so dass auch hier diese dickwandigen Bereiche durch die innere Füllung mit einem porenarmen Gefüge hergestellt werden können. So wird ein gutes Gefüge im Bereich der belasteten Zuganker erzielt.In an advantageous alternative embodiment, the die-casting mold can be filled from the cylinder deck side, and the gates open in the area of the tie rod cores of the cylinder crankcase, allowing filling below the water jacket core toward the bearing blocks or the tie rod cores. This allows these thick-walled areas to be produced with a low-porosity structure through the internal filling. This achieves a good structure in the area of the loaded tie rods.

Wiederum alternativ ist die Druckgussform vorzugsweise zylinderdeckseitig befüllbar und die Anschnitte münden im Bereich der Zylinderwände des Zylinderkurbelgehäuses, so dass durch den erhöhten einzubringenden Druck verbesserte Gefüge erzielt werden.Alternatively, the die casting mould can preferably be filled from the cylinder top side and the gates open in the area of the Cylinder walls of the cylinder crankcase, so that improved structures are achieved through the increased pressure to be applied.

Vorteilhafterweise sind an jedem Lagerstuhl zwei Anschnitte ausgebildet, die beidseits jeder Lagerschalenaufnahme des Zylinderkurbelgehäuses oder des Kurbelgehäuseunterteils angeordnet sind, so dass eine beidseitige Füllung am Lagerstuhl hergestellt wird, welche unabhängig von der Gießlage zu einer gleichmäßigen Struktur des Lagerstuhlbereiches führt.Advantageously, two gates are formed on each bearing block, which are arranged on both sides of each bearing shell receptacle of the cylinder crankcase or the crankcase lower part, so that a filling on both sides of the bearing block is produced, which leads to a uniform structure of the bearing block area regardless of the casting layer.

Vorzugsweise ist zwischen dem feststehenden Formteil und dem Zwischenformteil ein Hauptgießlauf ausgebildet, der sich entlang der Länge der Formteile erstreckt und von dem aus sich beidseits mehrere senkrecht zum Hauptgießlauf erstreckende Einzelgießläufe durch das Zwischenformteil zur Kavität erstrecken. Durch diese Ausbildung wird eine gleichmäßige und turbulenzarme Füllung mit konstantem Nachdruck erreicht. Es entsteht eine gleichmäßige Verteilung der Schmelze und ein gleichmäßiges Nachspeisen in die Lagerstühle.Preferably, a main pouring runner is formed between the stationary mold part and the intermediate mold part. This main pouring runner extends along the length of the mold parts. From this runner, several individual pouring runners extend perpendicular to the main pouring runner on both sides through the intermediate mold part to the cavity. This design achieves uniform and low-turbulence filling with constant holding pressure. This results in a uniform distribution of the melt and a uniform feeding into the bearing seats.

Vorzugsweise ist eine projizierte Fläche des im Zwischenformteil angeordneten Angusssystems auf die zweite Trennebene zwischen dem beweglichen Formteil und dem Zwischenformteil innerhalb einer projizierten Fläche der Kavität auf diese Trennebene angeordnet. Durch diese Ausbildung verringert sich die Sprengfläche der Druckgussform, da das Angusssystem keine zusätzliche Sprengfläche für die Druckgussform aufweist. So kann entweder der Nachdruck erhöht werden oder die Schließkräfte der Form reduziert werden.Preferably, a projected area of the sprue system arranged in the intermediate mold part onto the second parting plane between the movable mold part and the intermediate mold part is arranged within a projected area of the cavity onto this parting plane. This design reduces the blasting area of the die casting mold, since the sprue system does not have an additional blasting area for the die casting mold. This allows either the holding pressure to be increased or the mold clamping forces to be reduced.

In einer bevorzugten Ausbildung der Erfindung weisen die Einzelgießläufe einen Durchmesser auf, der im Wesentlichen der Breite des Lagerstuhls entspricht. Durch diesen großen Durchmesser kann der Nachdruck aus dem Kolbensystem deutlich länger während der Erstarrungsphase wirken.In a preferred embodiment of the invention, the individual casting runners have a diameter that essentially corresponds to the width of the bearing block. This large diameter allows the holding pressure from the piston system to act for a significantly longer period during the solidification phase.

Die erfindungsgemäße Druckgussform eignet sich somit in besonderer Weise um Zylinderkurbelgehäuse und Kurbelgehäuseunterteile mit einer hohen Festigkeit herzustellen, indem porenarme Gefüge in hochbelasteten dickwandigen Bereichen erzielt werden, ohne zusätzliche Squeezer verwenden zu müssen. Dabei sind höhere Enddrücke aufgrund der verringerten Sprengfläche möglich und die Menge an Kreislaufmaterial wird durch die Entformung aufgrund des kleinen Angusssystems verringert.The die casting mold according to the invention is therefore particularly suitable for producing cylinder crankcases and crankcase lower sections with high strength by achieving low-porosity structures in highly stressed, thick-walled areas without the need for additional squeezers. Higher final pressures are possible due to the reduced blast area, and the amount of recycle material is reduced during demolding due to the small sprue system.

Im Folgenden wird eine erfindungsgemäße Druckgussform sowie deren Verwendung zur Herstellung eines Zylinderkurbelgehäuses beispielhaft anhand der Figuren erklärt.In the following, a die-casting mold according to the invention and its use for producing a cylinder crankcase are explained by way of example with reference to the figures.

Die Figur 1 zeigt schematisch eine Seitenansicht einer erfindungsgemäßen Druckgussform mit kurbelraumseitigen Angusssystem im geschlossenen Zustand in geschnittener Darstellung.The Figure 1 shows schematically a side view of a die casting mold according to the invention with a crank chamber-side sprue system in the closed state in a sectional view.

Die Figur 2 schematisch eine Seitenansicht der erfindungsgemäßen Druckgussform aus Figur 1 im geöffneten Zustand in geschnittener Darstellung.The Figure 2 schematically a side view of the die casting mold according to the invention Figure 1 in the opened state in a sectional view.

Die Figur 3 zeigt schematisch das gegossene Zylinderkurbelgehäuse mit dem kurbelraumseitigen Angusssystem in perspektivischer Darstellung.The Figure 3 shows schematically the cast cylinder crankcase with the crankcase side gating system in perspective view.

Die Figur 4 zeigt schematisch eine Seitenansicht einer alternativen erfindungsgemäßen Druckgussform mit zylinderdeckseitigem Angusssystem im geschlossenen Zustand in geschnittener Darstellung.The Figure 4 shows schematically a side view of an alternative die casting mold according to the invention with a cylinder cover-side sprue system in the closed state in a sectional view.

Die in den Figuren dargestellte, erfindungsgemäße Druckgussform weist ein feststehendes Formteil 10 auf, über welches die Schmelze in die Druckgussform eingebracht wird. Dieses feststehende Formteil 10 ist an einer nicht dargestellten Maschinenplatte befestigt, welche mit einer Gießkammer und dem Gießkolben zur Erzeugung des Druckes verbunden ist, wobei der Gießkolben die Schmelze durch die feststehende Maschinenplatte und in das feststehende Formteil 10 drückt.The die casting mold according to the invention shown in the figures has a fixed mold part 10, via which the melt is introduced into the die casting mold. This fixed mold part 10 is attached to a machine plate (not shown), which is provided with a casting chamber and the casting piston for generating the pressure, whereby the casting piston presses the melt through the fixed machine plate and into the fixed mold part 10.

Ein Hauptgießlauf 12 ist zwischen dem feststehenden Formteil 10 und einem Zwischenformteil 14 ausgebildet. So wird zwischen dem Zwischenformteil 14 und dem feststehenden Formteil 10 eine erste Trennebene 16 ausgebildet, an der die beiden Formteile 10, 14 aufeinander aufliegen und beim Gießen aufeinandergedrückt werden und an der die beiden Formteile 10, 14 nach dem Gießen voneinander getrennt werden.A main casting runner 12 is formed between the stationary mold part 10 and an intermediate mold part 14. Thus, a first parting plane 16 is formed between the intermediate mold part 14 and the stationary mold part 10, at which the two mold parts 10, 14 rest on one another and are pressed together during casting, and at which the two mold parts 10, 14 are separated from one another after casting.

Durch das Zwischenformteil 14 erstrecken sich senkrecht zur Trennebene 16 und senkrecht zum Hauptgießlauf 12 vom Hauptgießlauf 12 aus acht Einzelgießläufe 18, die in vier Reihen zu je zwei Paaren angeordnet sind. Diese Einzelgießläufe 18 sind leicht kegelstumpfförmig in Richtung einer Kavität 20 zulaufend ausgebildet und weisen an ihren Enden, mit denen sie an der Kavität 20 münden und die als Anschnitte 22 zum Gussteil dienen, eine zusätzliche trichterförmige Querschnittsverengung 24 auf. Die Einzelgießläufe 18 bilden mit dem Hauptgießlauf 12 ein Angusssystem 26 der Druckgussform, welches durch die Anordnung der Einzelgießläufe 18 zum Hauptgießlauf 12 turbulenzarm die Kavität 20 mit Schmelze versorgen kann.Extending through the intermediate mold part 14 from the main runner 12, perpendicular to the parting plane 16 and perpendicular to the main runner 12, are eight individual runners 18 arranged in four rows of two pairs each. These individual runners 18 are slightly truncated conical in shape, tapering towards a cavity 20 and having an additional funnel-shaped cross-sectional constriction 24 at their ends, with which they open at the cavity 20 and serve as gates 22 to the casting. The individual runners 18, together with the main runner 12, form a sprue system 26 of the die casting mold, which, thanks to the arrangement of the individual runners 18 relative to the main runner 12, can supply the cavity 20 with melt with low turbulence.

Die Kavität 20 ist zwischen dem Zwischenformteil 14 und Seitenformteilen 29 ausgebildet, an die sich ein bewegliches Formteil 28 anschließt. Am beweglichen Formteil 28 sind einschiebbare Kokillen 30 angeordnet, die ebenso wie das bewegliche Formteil 28 an einer nicht dargestellten beweglichen Maschinenplatte befestigt sind. Zwischen dem Zwischenformteil 14 und den Seitenformteilen 29 wird entsprechend eine zweite Trennebene 32 der Druckgussform gebildet, die gleichzeitig eine Grundfläche des zu gießenden Gussteils bildet.The cavity 20 is formed between the intermediate mold part 14 and side mold parts 29, which are adjoined by a movable mold part 28. Insertable molds 30 are arranged on the movable mold part 28, which, like the movable mold part 28, are attached to a movable machine plate (not shown). Accordingly, a second parting plane 32 of the die casting mold is formed between the intermediate mold part 14 and the side mold parts 29, which simultaneously forms a base surface of the casting to be cast.

Im vorliegenden Ausführungsbeispiel weist die Kavität 20 die Form eines Zylinderkurbelgehäuses 34 mit drei Zylindern 36 auf, deren innere Zylinderwände 38 durch die verwendeten Kokillen 30 ausgeformt werden und dessen Zylinderdeck 39 sowie die Außenseite des Zylinderkurbelgehäuses 34 durch die beweglichen Formteile 28, 29 ausgeformt werden. Ein Kurbelraum 40 wird durch das Zwischenformteil 14 begrenzt, wobei die Anschnitte 22 jeweils an dickwandigen Bereichen 42 des Zylinderkurbelgehäuses 34 münden, welche in vorliegendem Ausführungsbeispiel durch Lagerstühle 44 des Zylinderkurbelgehäuses 34 gebildet sind. Vom Zylinderdeck 39 aus erstrecken sich Zugankerkerne 46 in das Zylinderkurbelgehäuse. Jeder der vier Lagerstühle 44 wird über je ein Paar der Einzelgießläufe 18 mit Schmelze gespeist, wobei die Anschnitte 22 jeweils beidseits von Lagerschalenaufnahmen 48 angeordnet sind.In the present embodiment, the cavity 20 has the shape of a cylinder crankcase 34 with three cylinders 36, whose inner cylinder walls 38 are formed by the molds 30 used, and whose cylinder deck 39 and the outside of the cylinder crankcase 34 are formed by the movable mold parts 28, 29. A crank chamber 40 is delimited by the intermediate mold part 14, with the gates 22 each opening into thick-walled regions 42 of the cylinder crankcase 34, which in the present embodiment are formed by bearing blocks 44 of the cylinder crankcase 34. Tie rod cores 46 extend from the cylinder deck 39 into the cylinder crankcase. Each of the four bearing blocks 44 is fed with melt via a pair of individual pouring runners 18, with the gates 22 being arranged on either side of bearing shell receptacles 48.

Wird nun die Druckgussform mit Schmelze gefüllt, gelangt diese über den Hauptgießlauf 12 und die Einzelgießläufe 18 in die Kavität 20. Die Schmelze beginnt daraufhin in der Kavität 20 zu erstarren, wobei dünnwandige und gekühlte Bereiche, wie beispielsweise die Zylinder 36, welche über die Kokillen 30 gekühlt werden können, schneller erstarren als die dickwandigen Bereiche 42. Beim Erstarren setzt eine Schrumpfung des Gussteils ein, welche mit wachsendem Volumen größer ist und normalerweise zu porenreichen Gefügen oder sogar Lunkern führen könnte. Durch die erfindungsgemäße Druckgussform kann über die Anschnitte 22 direkt in die dickwandigen Bereiche 42 mit über den Gießkolben erzeugten Druck nachgespeist werden, so dass ein sehr porenarmes Gefüge auch in den dickwandigen Bereichen 42 erzielt werden kann.If the die casting mold is now filled with melt, it flows into the cavity 20 via the main pouring runner 12 and the individual pouring runners 18. The melt then begins to solidify in the cavity 20, with thin-walled and cooled areas, such as the cylinders 36, which can be cooled via the molds 30, solidifying faster than the thick-walled areas 42. During solidification, shrinkage of the casting begins, which increases with increasing volume and could normally lead to porous structures or even shrinkage cavities. The die casting mold according to the invention allows the pressure generated by the casting piston to be used to feed melt directly into the thick-walled areas 42 via the gates 22, so that a very low-porosity structure can be achieved even in the thick-walled areas 42.

Der beim Druckgussvorgang erzeugte Druck wirkt bei dieser Ausführung ausschließlich auf eine projizierte Fläche des Zylinderkurbelgehäuses 34 beziehungsweise der Kavität 20 auf die zweite Trennebene 32 zwischen dem Zwischenformteil 14 und den beweglichen Seitenformteilen 29, da der gesamte Gießlauf am Zwischenformteil 14 beziehungsweise die projizierte Fläche des Angusssystems 26 innerhalb dieser projizierten Fläche auf die Grundfläche beziehungsweise die zweite Trennebene 32 wirkt. Entsprechend kann ein sehr hoher Nachdruck eingebracht werden oder im Vergleich zu bekannten Ausführungsformen die Schließkraft auf die Druckgussform verringert werden.In this embodiment, the pressure generated during the die-casting process acts exclusively on a projected surface of the cylinder crankcase 34 or the cavity 20 on the second parting plane 32 between the intermediate mold part 14 and the movable side mold parts 29, since the entire casting run on the intermediate mold part 14 or the projected area of the sprue system 26 within this projected area acts on the base area or the second parting plane 32. Accordingly, a very high holding pressure can be introduced or, compared to known embodiments, the closing force on the die casting mold can be reduced.

Nach dem Erstarren wird die Druckgussform an beiden Trennebenen geöffnet. Dabei reißen die Einzelgießläufe 18 aufgrund des geringsten Querschnitts im Bereich der Anschnitte 22 ab, so dass ein gesamter erstarrter Anguss 50 zwischen dem feststehenden Formteil 10 und dem Zwischenformteil 14 ausgeworfen wird. Das Zylinderkurbelgehäuse 34 wird über Auswerfer 52 nach dem Ausziehen der Kokillen 30 aus dem beweglichen Formteil 10 und zwischen dem beweglichen Formteil 10 und dem Zwischenformteil 14 ausgeworfen, so dass eine saubere Trennung zwischen Gussteil und Anguss 50 erfolgt.After solidification, the die casting mold is opened at both parting lines. Due to their smallest cross-section, the individual runners 18 break off in the area of the gates 22, so that an entire solidified sprue 50 is ejected between the stationary mold part 10 and the intermediate mold part 14. The cylinder crankcase 34 is ejected via ejector 52 after the molds 30 have been withdrawn from the movable mold part 10 and between the movable mold part 10 and the intermediate mold part 14, ensuring a clean separation between the casting and the sprue 50.

In der Figur 4 ist eine alternative Möglichkeit zum Gießen eines Zylinderkurbelgehäuses 34 dargestellt. Die Füllung erfolgt hierbei nicht kurbelraumseitig, sondern zylinderdeckseitig. Im feststehenden Formteil 10 ist erneut ein Teil des Angusssystems 26 ausgebildet, der sich im Zwischenformteil 14 fortsetzt. Dieses weist ebenfalls acht Einzelgießläufe 18 auf, die sich in einer Ebene zwischen den Zylindern 36 zu einem Bereich erstrecken, in dem die Zugankerkerne 46 angeordnet sind und von dort den dickwandigen Bereich 42 füllen. Alternativ könnten die Einzelgießläufe sich auch durch die die Zylinder 36 bildenden Teile des Zwischenformteils 14 erstrecken und dort von innen über das kurbelraumseitige Ende der Zylinderwände 38 wiederum die dickwandigen Bereiche der Lagerstühle 44 befüllen. Die Kavität 20 wird auch bei dieser Ausführungsform zwischen dem Zwischenformteil 14, den beweglichen Seitenformteilen 29 und dem beweglichen Formteil 28 ausgebildet, wobei das Formteil 28 den Kurbelraum 40 ausbildet und die Seitenformteile 29 die Zylinderaußenflächen und die Außenfläche des Kurbelraums 40. Das Zylinderdeck wird durch das Zwischenformteil 14 gebildet. Das Nachdrücken und Speisen erfolgt auch bei diesen Ausführungen direkt auf die am stärksten durch Schrumpfen belasteten dickwandigen Bereiche 42 des Zylinderkurbelgehäuses, so dass auch hier porenarme Gefüge erreicht werden können. Auch die Trennung des Angusses 50 vom Gussteil erfolgt durch einfaches Öffnen der Druckgussform.In the Figure 4 An alternative possibility for casting a cylinder crankcase 34 is shown. In this case, filling does not take place on the crankcase side, but on the cylinder cover side. In the fixed mold part 10, a part of the sprue system 26 is again formed, which continues in the intermediate mold part 14. This likewise has eight individual runners 18, which extend in a plane between the cylinders 36 to an area in which the tie rod cores 46 are arranged and from there fill the thick-walled area 42. Alternatively, the individual runners could also extend through the parts of the intermediate mold part 14 forming the cylinders 36 and there, from the inside, via the crankcase-side end of the cylinder walls 38, in turn fill the thick-walled areas of the bearing blocks 44. The cavity 20 is also formed in this embodiment between the intermediate mold part 14, the movable side mold parts 29 and the movable mold part 28, wherein the mold part 28 The side mold parts 29 form the cylinder outer surfaces and the outer surface of the crankcase 40. The cylinder deck is formed by the intermediate mold part 14. In these designs, the pressing and feeding also take place directly on the thick-walled areas 42 of the cylinder crankcase, which are most subject to shrinkage, so that a low-pore structure can be achieved here as well. The sprue 50 is also separated from the casting by simply opening the die-casting mold.

Eine derartige Druckgussform eröffnet entsprechend verschiedene Möglichkeiten zur Füllung und Speisung der relevanten dickwandigen Bereiche eines Gussteils und insbesondere eines Zylinderkurbelgehäuses, so dass porenarme Gefüge erreicht werden können. Gleichzeitig kann diese Füllung und Nachspeisung mit hohen Drücken erfolgen, da durch das kleine Angusssystem die Sprengfläche der Form sehr klein gehalten wird. Dabei können jedoch die Querschnitte der Einzelgießläufe beziehungsweise des gesamten Angusssystems relativ groß ausgeführt werden, wodurch der eingebrachte Nachdruck lange wirken kann. Auch dies führt zu verbesserten Gefügen in den relevanten Bereichen des Lagerstuhls oder der Zuganker. Da der Anguss ebenfalls sehr klein ist, wird auch das Kreislaufmaterial reduziert, wodurch Energie eingespart werden kann. Zusätzlich wird die notwendige Nachbearbeitung verringert, da sich der Anguss beim Öffnen der Form an der korrekten Position automatisch vom Gussteil löst.Such a die casting mold opens up various possibilities for filling and feeding the relevant thick-walled areas of a casting, and in particular of a cylinder crankcase, so that a low-porosity structure can be achieved. At the same time, this filling and feeding can take place at high pressures, since the small sprue system keeps the mold's burst area very small. However, the cross-sections of the individual runners or the entire sprue system can be made relatively large, allowing the applied holding pressure to act for a long time. This also leads to improved structures in the relevant areas of the bearing block or the tie rods. Since the sprue is also very small, the amount of recycled material is reduced, which can save energy. In addition, the necessary post-processing is reduced, since the sprue automatically detaches from the casting at the correct position when the mold is opened.

Es sollte deutlich sein, dass der Schutzbereich der Anmeldung nicht auf das beschriebene Ausführungsbeispiel beschränkt ist. Insbesondere können auch andere Gussteile insbesondere Unterteile (bedplates) von Zylinderkurbelgehäusen auf diese Weise hergestellt werden.It should be clear that the scope of protection of the application is not limited to the described embodiment. In particular, other castings, especially bedplates for cylinder crankcases, can also be produced in this way.

Claims (10)

  1. A die casting mold for casting cylinder crankcases or crankcase sub parts, comprising
    a stationary molded part (10) in which a sprue system (26) for distributing the melt is at least partially provided,
    movable molded parts (28, 29) in which a cavity (20) for forming a cylinder crankcase (34) or a crankcase sub part is at least partially provided,
    characterized in that
    an intermediate molded part (14) which is arranged between the stationary molded part (10) and the movable molded parts (28, 29) and which at least partially delimits the cavity (20) for forming the cylinder crankcase (34) or the crankcase sub part and in which the sprue system (26) and a plurality of gates (22) which open at thick-walled regions (42) of the cylinder crankcase (34) or the crankcase sub part are at least partially provided, wherein the gates (22) are formed so as to narrow in a funnel-shaped manner with respect to the cavity (20).
  2. The die casting mold for casting cylinder crankcases or crankcase sub parts according to claim 1,
    characterized in that
    a first parting plane (16) is provided between the stationary molded part (10) and the intermediate molded part (14) and a second parting plane (32) is provided between the intermediate molded part (14) and the movable side molded parts (29), which parting planes are arranged substantially parallel to a base surface (17) of the cylinder crankcase (34) to be cast or of the crankcase sub part to be cast.
  3. The die casting mold for casting cylinder crankcases or crankcase sub parts according to claim 1 or 2,
    characterized in that
    the sprue (50) can be ejected between the stationary molded part (10) and the intermediate molded part (14) when the die casting mold is opened, and the cylinder crankcase (34) or the crankcase sub part can be ejected between the intermediate molded part (14) and the movable molded parts (28, 29) when the die casting mold is opened.
  4. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of claims 1 to 3,
    characterized in that
    the die casting mold can be filled on the crankcase space side, and the gates (22) open at the bearing block (44) of the cylinder crankcase (34) or of the crankcase sub part.
  5. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of claims 1 to 3,
    characterized in that
    the die casting mold can be filled on the cylinder cover side, and the gates (22) open in the region of the tie rod cores (46) of the cylinder crankcase (34).
  6. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of claims 1 to 3,
    characterized in that
    the die casting mold can be filled on the cylinder cover side, and the gates (22) open in the region of cylinder walls (38) of the cylinder crankcase (34).
  7. The die casting mold for casting cylinder crankcases or crankcase sub parts according to claim 4,
    characterized in that
    two gates (2) are provided at each bearing block (44), which gates are arranged on both sides of each bearing shell receptacle (48) of the cylinder crankcase (34) or of the crankcase sub part.
  8. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of the preceding claims,
    characterized in that
    a main casting run (12) is provided between the stationary molded part (10) and the intermediate molded part (14), which main casting run extends along the length of the molded parts (10, 14, 28) and from which a plurality of individual casting runs (18) extending perpendicularly to the main casting run (12) extend on both sides through the intermediate molded part (14) to the cavity (20).
  9. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of the preceding claims,
    characterized in that
    a projected area of the sprue system (26) arranged in the intermediate molded part (13) onto the second parting plane (32) is arranged within a projected area of the cavity (20) onto the second parting plane (32).
  10. The die casting mold for casting cylinder crankcases or crankcase sub parts according to any one of the preceding claims,
    characterized in that
    the individual casting runs (18) have a diameter which substantially corresponds to the width of the bearing block (44).
EP18778378.2A 2017-10-17 2018-09-10 Die casting mold for casting cylinder crankcases or crankcase subparts Active EP3697554B1 (en)

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DE102017124150.7A DE102017124150B4 (en) 2017-10-17 2017-10-17 Die casting mold for casting cylinder crankcases or crankcase lower parts
PCT/EP2018/074310 WO2019076536A1 (en) 2017-10-17 2018-09-10 DIE CASTING FOR CASTING CYLINDER CRANKCASE OR CRANKSHAFT UNITS

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DE102020108022A1 (en) 2020-03-24 2021-09-30 Bayerische Motoren Werke Aktiengesellschaft Three-platen die-casting tool with a sprue system and improved sprue separation and method for die-casting
DE102020125343B3 (en) 2020-09-29 2021-09-16 Bayerische Motoren Werke Aktiengesellschaft Three-platen die-casting tool with improved sprue separation and method for die-casting (I)
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MX2020003352A (en) 2020-07-29
RU2747340C1 (en) 2021-05-04

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