Abstract:
A mold design is disclosed for precision sand casting of engine cylinder blocks, such as engine cylinder V-blocks, having chills disposed therein, wherein an expansion and contraction caused by changes in temperature during the casting operation are accommodated by the chills.

Description:
FIELD OF THE INVENTION 
     The invention relates to a mold design and more particularly to the mold design for precision sand casting of engine cylinder blocks, such as engine cylinder V-blocks, having chills disposed therein. 
     BACKGROUND OF THE INVENTION 
     In a sand casting process of an internal combustion engine cylinder block, an expendable mold package is assembled from a plurality of resin-bonded sand cores (also known as mold segments) that define the internal and external surfaces of the engine block. Typically, each of the sand cores is formed by blowing resin-coated foundry sand into a core box and curing it therein. 
     Traditionally, the mold assembly method involves positioning a base core on a suitable surface and building up or stacking separate mold elements to shape such casting features as the sides, ends, valley, water jacket, cam openings, and crankcase. Additional cores may be present as well depending on the engine design. 
     Removal of thermal energy from the liquid metal in the mold package is an important consideration in the foundry process. Rapid solidification and cooling of the casting promotes a fine grain structure in the metal leading to desirable material properties such as high tensile and fatigue strength, and good machinability. For engine designs with highly stressed bulkhead features, the use of a thermal chill may be necessary. The chill is much more thermally conductive than foundry sand and readily conducts heat from those casting features it contacts. The chill typically consists of one or more steel or cast iron bodies assembled in the mold in a manner to shape some portion of the features of the casting. The chills may be placed into the base core tooling and a core formed about them, or they may be assembled into the base core or between the crankcase cores during mold assembly. 
     In some casting processes, metals and metal alloys are being used which differ from the metals used to form the chills. Thus, thermal expansion characteristics differ between the chills and the metal being used in the casting process. Further, the chills become larger following pouring of the metal, while the casting contracts as it cools. This results in relative movement between the metal chills and the casting. 
     It would be desirable to produce a mold for sand casting of engine cylinder blocks having chills wherein an expansion of a chill and a contraction of a casting caused by changes in temperature following a mold filling operation are accommodated by the chills without damage to the chill or the casting. 
     SUMMARY OF THE INVENTION 
     Consistent and consonant with the present invention, a mold for sand casting of engine cylinder blocks having chills wherein an expansion of a chill and a contraction of a casting caused by changes in temperature following a mold filling operation are accommodated by the chills without damage to the chill or the casting, has surprisingly been discovered. 
     In one embodiment, the mold for sand casting of engine cylinder blocks comprises a chill plate adapted to be assembled into a mold package; and at least one chill supported by the chill plate to allow relative movement therebetween to facilitate variable positioning of the chill to accommodate expansion and contraction between the chill, the chill plate, and a casting due to temperature fluctuations during a casting process, the chill selectively cooling a portion of the casting. 
     In another embodiment, the mold comprises a chill plate adapted to be assembled into a mold package; a chill supported by the chill plate for selectively cooling a portion of a casting; and a spring disposed between the chill plate and the chill to support the chill to permit relative movement between the chill and the chill plate to facilitate variable positioning of the chill to accommodate expansion and contraction between the chill, the chill plate, and the casting due to temperature fluctuations during a casting process. 
     In another embodiment, the mold comprises a chill plate; a mold carrier plate disposed on the chill plate, the mold carrier plate having an aperture formed therein; a base core supported by the mold carrier plate and adapted to support a core package therein; a cover core supported by the base core and cooperating with the base core to enclose the core package therein; a chill supported by the chill plate for selectively cooling a portion of a casting, the chill extending through the aperture to contact the casting, a spring disposed between the chill plate and the chill to support the chill to allow relative movement between the chill and the chill plate to facilitate variable positioning of the chill to accommodate expansion and contraction between the chill, the chill plate, and the casting due to temperature fluctuations during a casting process. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which: 
         FIG. 1  is a flow diagram showing an assembly process for an engine V-block mold package with the front end core omitted for clarity; 
         FIG. 2  is a partial sectional view of a mold package according to an embodiment of the invention; 
         FIG. 3  is a perspective view of the crankcase chill and two pan rail chills shown in  FIG. 2 ; and 
         FIG. 4  is a perspective view of a crankcase chill and two rail chills according to another embodiment of the invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  depicts a flow diagram showing a sequence for assembling an engine cylinder block mold package  10 . The invention is not limited to the sequence of assembly steps shown as other sequences can be employed to assemble the mold package. For purposes of illustration, and not limitation, a core for an eight-cylinder V-type engine is shown. It is understood that more or fewer cylinders can be used and that other engine cylinder configurations can be used according to the invention without departing from the scope and spirit thereof. It is also understood that the features of the invention could be used with other core types. In the embodiment shown, a resin bonded sand core is used. 
     The mold package  10  is assembled from resin-bonded sand cores including a base core  12  mated with a crankcase chill  28   a , a chill plate  28   b , and a mold carrier plate  28   c , an integral barrel crankcase core (IBCC)  14  having a metal cylinder bore liner  15  thereon such as cast iron, aluminum, or aluminum alloy, for example, two end cores  16 , two side cores  18 , two water jacket slab core assemblies  22 , a tappet valley core  24 , and a cover core  26 . The water jacket slab core assembly  22  includes a water jacket core  22   a , a jacket slab core  22   b , and a lifter core  22   c . The cores  12 ,  14 ,  16 ,  18 ,  22 ,  24 ,  26  described above are offered for purposes of illustration and not limitation as other types of cores and core configurations may be used in assembly of the engine cylinder block mold package  10  depending upon the particular engine block design to be cast. For illustrative purposes, only a crankcase chill  28   a  has been shown in  FIG. 1 , however, it is understood that other chill types can, and typically are, used as desired. The use of chills in a casting process such as that described herein facilitates forming of a desired grain structure in cast metal parts. 
     The resin-bonded sand cores can be made using conventional core-making processes such as a phenolic urethane cold box or Furan hot box where a mixture of foundry sand and resin binder is blown into a core box and the binder cured with either a catalyst gas and/or heat. The foundry sand can comprise silica, zircon, fused silica, and others. 
     The cores  14 ,  16 ,  18 ,  22 ,  24  initially are assembled apart from the base core  12  and cover core  26  to form a subassembly or core package  30  of multiple cores. The cores  14 ,  16 ,  18 ,  22 ,  24  are assembled on a temporary base or member TB that does not form a part of the final engine block mold package  10 . 
     The subassembly  30  and the temporary base TB are separated by lifting the subassembly  30  off of the temporary base TB at a separate station. The temporary base TB is returned to the starting location of the subassembly sequence where a new integral barrel crankcase core  14  is placed thereon for use in assembly of another subassembly  30 . 
     The subassembly  30  is taken to a cleaning station or blow-off station BS, where the subassembly  30  is cleaned to remove loose sand from the exterior surfaces of the subassembly  30  and from interior spaces between the cores  12 ,  16 ,  18 ,  22 ,  24 ,  26  thereof. The loose sand typically is present as a result of the cores rubbing against one another at the joints therebetween during the subassembly sequence. A small amount of sand can be abraded off of the mating joint surfaces and lodge on the exterior surfaces and in narrow spaces between adjacent cores where its presence can contaminate the engine block casting made in the mold package  10 . 
     The blow-off station BS typically includes a plurality of high velocity air nozzles N which direct high velocity air on exterior surfaces of the subassembly  30  and into the narrow spaces between adjacent cores  12 ,  16 ,  18 ,  22 ,  24 ,  26  to dislodge any loose sand particles and cause the sand to be blown out of the subassembly  30 . In lieu of, or in addition to, moving the subassembly  30 , the nozzles N may be movable relative to the subassembly  30  to direct high velocity air at the exterior surfaces of the subassembly  30  and into the narrow spaces between adjacent cores  12 ,  16 ,  18 ,  22 ,  24 ,  26 . It is understood that other cleaning methods can be used as desired such as the use of a vacuum cleaning station, for example. 
     The cleaned subassembly  30  is positioned on base core  12  residing on the chill plate  28   b . Chill plate  28   b  includes the mold stripper plate  28   c  disposed on the chill plate  28   b  to support the base core  12 . The base core  12  is placed on the mold carrier plate  28   c  with the crankcase chill  28   a  disposed on the chill plate  28   b . The crankcase chill  28   a  can be produced from an assembly or formed as a unitary structure. The crankcase chill  28   a  extends through an opening formed in mold carrier plate  28   c  and an opening formed in the base core  12  into a cavity formed in the core  14 . The chill plate  28   b  includes apertures through which lifting rods R extend which facilitate separating the crankcase chill  28   a  from the mold carrier plate  28   c  and mold package  10 . The crankcase chill  28   a  can be made of cast iron or other suitable thermally conductive material to rapidly remove heat from the bulkhead features of the casting, the bulkhead features being those casting features that support the engine crankshaft via the main bearings and main bearing caps. The chill plate  28   b  and the mold carrier plate  28   c  can be constructed of steel, thermal insulating ceramic plate material, combinations thereof, or other durable material. The function of the chill plate  28   b  is to facilitate the handling of the crankcase chill  28   a  and other chills, and the function of the mold carrier plate  28   c  is to facilitate the handling of the mold package  10 . The chill plate  28   b  and the mold carrier plate  28   c  typically are not intended to play a significant role in extraction of heat from the casting, however. 
     The cover core  26  is placed on the base core  12  and subassembly  30  to complete assembly of the engine block mold package  10 . Additional cores (not shown) which are not part of the subassembly  30  can be placed on or fastened to the base core  12  and the cover core  26  as desired before being moved to the assembly location where the base core  12  and the cover core  26  are united with the subassembly  30 . For example, the subassembly  30  can be assembled without side cores  16 , which instead are assembled on the base core  12 . The subassembly  30  without side cores  16  is subsequently placed in the base core  12  having side cores  16  thereon. 
     The completed engine block mold package  10  is moved to a mold filling station MF, where the mold package  10  is filled with molten metal such as molten aluminum, for example. Any suitable mold filling technique may be used to fill the mold package  10  such as gravity pouring or electromagnetic pump, for example. 
     After a predetermined time following casting of the molten metal into the mold package  10 , the mold package  10  is moved to a station where the lift rods R are inserted through the holes of chill plate  28   b  to raise and separate the mold carrier plate  28   c  with the cast mold package  10  thereon from the chill plate  28   b . The chill plate  28   b  can be returned to the beginning of the assembly process for reuse in assembling another mold package  10 . The cast mold package  10  can be further cooled on the mold carrier plate  28   c.    
       FIG. 2  shows a sectional view of a mold package  100  according to an embodiment of the invention, after a casting  102  has been formed. Duplicative elements from  FIG. 1  have the same reference numerals. A pan rail chill  104  is disposed on each side of the crankcase chill  28   a . In the embodiment shown, two pan rail chills  104  are shown. However, it is understood that more or fewer pan rail chills  104  can be used. Additionally, the pan rail chills  104  are shown to illustrate an embodiment of the invention. It is understood that other chill types can be used without departing from the scope and spirit of the invention. As illustrated in  FIG. 3 , each of the pan rail chills  104  is an elongate structure. From a top surface  105  to a bottom surface, the pan rail chills are tapered such that a width thereof increases from the top surface  105  to the bottom surface. The top surface  105  of the pan rail chill  104  shapes an oil pan mounting face (not shown) of the casting  102 . The pan rail chills  104  are spaced from the crankcase chill  28   a.    
     A leaf spring  106  extends from one pan rail chill  104 , under the crankcase chill  28   a , to the other pan rail chill  104 . Although two leaf springs  106  are shown in  FIG. 3 , more or fewer leaf springs can be used as desired. A pair of leaf springs, one extending outwardly from each side of the crankcase chill  28   a  to respective pan rail chills  104  can also be used. A threaded fastener  108  secures the leaf spring  106  to each of the pan rail chills  104  and the chill plate  28   b . It is understood that other conventional fastening methods may be used without departing from the scope and spirit of the invention. A removal aid  109  is attached to the chill plate  28   b . The removal aid  109  extends upwardly from the chill plate  28   b  to engage the leaf spring  106 . When removing the chill plate  28   b  from the mold package  100 , the removal aid  109  cooperates with the bolts  108  to cause the leaf spring  106  to urge the pan rail chill  104  for removal. 
       FIG. 4  shows another embodiment of the invention using coil springs  110  instead of the leaf springs  106 . One end of the coil springs  110  are disposed in apertures  112  formed in the pan rail chill  104 . The other end of the coil springs  110  is secured to the chill plate  28   b.    
     During the casting process, temperature variations occur which cause an expansion and contraction of the materials used to form the casting  102 , the chills  28   a ,  104 , and the chill plate  28   b . The chills  28   a ,  104  are caused to expand due to being heated and the casting  102  is caused to contract due to being cooled, resulting in a relative movement therebetween. 
     The leaf springs  106  secured to the pan rail chills  104  allow for play or movement of the pan rail chills  104 . The movement allowed for the pan rail chills  104  combined with the taper of the pan rail chills  104  from top to bottom, facilitates an insertion of the pan rail chills  104  into the core package or subassembly  30 . Misalignment of the pan rail chills  104  due to expansion and contraction is also accommodated. The leaf springs  106  allow the pan rail chills  104  to move generally in any coordinate direction as indicated by the arrows X, Y, Z in  FIG. 3 , although the movement in the Z-direction may be somewhat limited. The pan rail chills  104  are free to rotate about the Z axis as indicated by the rotational arrow R. As the temperature is caused to fluctuate, the pan rail chills  104  are permitted to move as needed by the flexing of the leaf springs  106 . The movement permitted by the leaf springs  106  militates against the buildup of undesirable stresses in the casting  102 . The coil springs  110  illustrated in  FIG. 4  facilitate the same freedom of movement during the temperature fluctuations as indicated by the arrows X, Y, R while increasing the flexibility of the pan rail chills  104  in the Z direction in comparison to the leak spring configuration. 
     Direct contact of the pan rail chills  104  with the chill plate  28   b  affect the heat transfer characteristics of the pan rail chills  104 . The leaf springs  106  provide a thermal buffer or isolation between the pan rail chills  104  and the chill place  28   b  to temper the affect on the heat transfer characteristics of the pan rail chills  104 . 
     From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.