Casting device for producing closed deck type cylinder block and sand core used in the device

Abstract: A method and apparatus for providing an "on-the-fly" printing method for applying a material such as a flux, paste, adhesive or other desired material to the bumps of a bump-type chip or carrier (component). A rotating drum is coated with the desired material, the thickness of the material is fixed with a doctor blade, and the component is passed across the top of the drum in synchronicity with the linear speed of the top of the drum so as to imprint the desired material on the bumps of the component while the drum and the component are moving at essentially zero net relative velocity without causing any smearing or buildup of viscous material and without the need to stop the drum or slowly pull the component away from engagement with the drum.

Description: The present invention relates to a casting device for producing a closed deck type cylinder block and a sand core used in the casting device, and more particularly, to a combination of the casting device and the sand core, the combination being capable of performing casting operation while properly holding the sand core in the casting device. A closed deck type cylinder block is known in which bridge portions are provided bridging between a top deck of a cylinder head and outer end portions of cylinders in order to reduce engine vibration and to reinforce the cylinder block. In this type of the cylinder block, an upper open end of a water jacket is partly covered with the bridge portions. In other words, the upper open end of the water jacket constitutes windows each sectioned by the bridge portion. Thus, an undercut is provided in the water jacket below the bridge portions. Therefore, a sand core must be set at a position corresponding to the water jacket and the sand core must be collapsed after casting so as to remove the sand from the water jacket. Further, during casting operation, the sand core must be properly held within a metal mold. JP-A-1-178361, on which the two part form of claim 1 is based, discloses a method for holding a sand core within the metal mold in producing the closed deck type cylinder block. According to the method, a sand core 101 shown in Fig. 12 adapted for forming a water jacket which will surround three cylinders is provided with protruding portions 101a engageble with complementary recesses 102a formed in a slide core 102 shown in Fig. 13 in order to form windows at the engaging portions. A driving means (not shown) for driving holding pins 103 is provided independently of a driving means (not shown) adapted for driving a movable die toward and away from a stationary die (not shown). The holding pins 103 extends through the slide core 102 and projects into and retracts from a mold cavity by the holding pin drive means. The planer end face of the sand core 101 other than the protruding portions 101a is filled with a molten metal so as to produce the bridge portions at the end of the water jacket. With this arrangement, the holding pins 103 project into the mold cavity, and the sand core 101 for forming the water jacket is temporarily mounted on the holding pins 103 as shown in Fig. 12. Then, the protruding portions 101a for forming the windows at the axially end portion of the sand core 101 are engaged with the complementary recesses 102a formed in the slide core 102, and at the same time, projections or core prints 101b projecting from the periphery of the sand core 101 are engaged with recessed portions (not shown) formed in the movable die so as to hold the sand core within the metal mold. Thereafter, the holding pins 103 are retracted from the mold cavity. By the projecting and retracting movement of the holding pins 103 relative to the mold cavity, the sand core 101 is held at a given position within the metal mold. The sand core 101 is ultimately held in the metal mold by the engagement between the protruding portions 101a and the complementary recessed portions 102a and by the engagement between the projections 101b and the recesses. Accordingly, in order to enhance positional accuracy of the sand core 101, clearance between the protruding portions 101a and the complementary recesses 102a for forming windows should be reduced. However, reduction in the clearance incurs accurate dimensional control, which in turn increases production cost. More specifically, the sand core 101 is generally subjected to coating in order to prevent the molten metal from entering into the sand core. However, the coating thickness may not be uniform, which may vary the clearance. Thus, adhesion amount of the coating agent over the protruding portions 101a must be precisely controlled. Further, in producing the sand core, sand filling rate to the protruding portions 101a is inferior to that to the other part, and therefore, the protruding portions 101a provide insufficient mechanical strength and may be easily collapsed. Furthermore, the sand core is heated during casting and a binder contained therein may be burned by the heat, which causes reduction in strength of the sand core. The lowered strength is particularly actualized at the protruding portions 101a which may be easily collapsible. Moreover, if excessive local load is applied during take out of the casted product from the metal mold, the protruding portions lOla are collapsed, and sand remain at the complementary recessed portions 102a. If a subsequent sand core is set in the metal mold and the metal mold is closed while the residual sand remain at the recessed portions 102a, excessive force is applied to the sand core, so that the sand core may be collapsed prior to the casting. Consequently, sand remaining at the recessed portions 102a must be removed. However, it would be rather difficult to acknowledge the residual sand due to the blind space i.e., the recessed portions and cleaning work may be difficult due to the small concaved space of the recessed portions. Accordingly, productivity may be lowered. Furthermore, the casting device having the movable holding pins 103 is only available, otherwise the sand core cannot be set at a position within the metal mold. According to the present invention there is provided a device and a sand core for producing a closed deck type cylinder block having a top deck and being formed with a water jacket surrounding a plurality of juxtaposedly arrayed cylinder liners, the water jacket having an upper end partly open at the top deck for forming windows and partly closed by bridge portions, the device comprising a metal mold defining therein a mold cavity for casting the cylinder block, the sand core being for casting the water jacket in the cylinder block, characterized in that the device further comprises a plurality of holding projections integrally extending from the metal mold toward the mold cavity in an axial direction of the cylinder liner, and the sand core is formed with a plurality of holding bores complementary to respective holding projections and arranged to receive the holding projections extending thereinto for holding the sand core at a predetermined position within the mold cavity during casting. By the combination of the casting device and the sand core, the sand core can be properly held by the engagement between the holding projections provided integrally with the metal mold and the holding bores formed in the sand core. Therefore, it is unnecessary to perform conventional positioning by the engagement between the recesses formed in the metal mold and the protruding portions provided at the sand core. Thus, precise control to the clearance between the metal mold and the sand core, i.e., between the conventional recesses and protrusions, can be eliminated, yet improving positional accuracy of the sand core. Further, because the sand core can be held by the protruding components protruding from the metal mold and the holding bores formed in the sand core, even if the sand is released from the sand core, the residual sand on the protruding components can be easily acknowledged, and cleaning for removing the residual sand can be easily performed, to thus enhance productivity. The hereinafter described embodiments of the present invention can: provide a combination of a casting device and a sand core for producing a closed deck type cylinder block, the combination being capable of accurately holding the sand core within a metal mold for producing the closed deck type cylinder block having high dimensional accuracy; provide such combination capable of eliminating dimensional control with respect to the protruding parts of the sand core for forming the windows; and provide such combination in which residual sand can be easily acknowledged and removed at a sand core holding portion. The invention also provides a corresponding method of casting a closed desk type cylinder block using the device and the sand core above. The invention extends to a cylinder block casting formed by that method. The invention will be further described by way of example, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view showing a sand core according to a first embodiment of this invention for forming a water jacket, the core being used for casting a closed deck type cylinder block; Fig. 2 is a cross-sectional view taken along the corrugated line II-II of Fig. 1, showing the sand core and a metal mold including a slide core in a casting device according to the first embodiment for casting the closed deck type cylinder block; Fig. 3 is a plan view showing a part of the sand core, the part including a holding bore; Fig. 4 is a cross-sectional view taken along the line IV-IV of Fig. 6 and showing the metal mold of the casting device and the sand core held in the casting device according to the first embodiment; Fig. 5 is a cross-sectional view showing an open state of the metal mold in the casting device and the sand core according to the first embodiment; Fig. 6 is a cross-sectional view showing a closed state of the metal mold in the casting device and the sand core according to the first embodiment; Fig. 7 is a perspective view showing a sand core according to a second embodiment of this invention for forming a water jacket, the core being used for casting a closed deck type cylinder block; Fig. 8 is a cross-sectional view showing the sand core of Fig. 7 and a metal mold including a slide core in a casting device according to the second embodiment for casting the closed deck type cylinder block; Fig. 9 is a partial perspective view showing several modifications to the holding bore and a holding protrusion to be inserted thereinto; Fig. 10 is a cross-sectional view taken along the line X-X of Fig. 9; Fig. 11 is a cross-sectional view taken along the line XI-XI of Fig. 9; Fig. 12 is a perspective view showing a conventional sand core to be used for casting a closed deck type cylinder block; and Fig. 13 is a schematic cross-sectional view showing a part of a slide core and the conventional sand core held by the slide core. A casting device for casting a closed deck type cylinder block and a sand core used in the casting device according to a first embodiment of the present invention will be described with reference to Figs. 1 through 6. The first embodiment is applied for casting a closed deck type cylinder block of a V-bank type six cylinder internal combustion engine. The sand core 1 shown in Fig. 1 is adapted for forming a water jacket surrounding three cylinders in the V-bank type six cylinder engine block. Figs. 2 and 4 show a state in which the sand core 1 is set within a mold cavity 6. The mold cavity 6 is defined by a slide core 2, a stationary die 8, a pair of first slide cores 22,22 and a pair of second slide cores 23,23. As shown in Fig. 2, a slide core 2 has a cavity face 2d defining a part of the mold cavity 6. The cavity face 2d is formed with recesses 2a. The sand core 1 has an end face 1d in confrontation with the cavity face 2d. The end face 1d is provided with protruding portion la insertable into the recesses 2a for forming windows at a top end of the water jacket. A space S1 is defined between the cavity face 2d and portions other than the protruding portions la of the end face 1d. During casting, molten metal is filled into the space S1 so that bridge portions are provided at the top end of the water jacket. In other words, in the top end of the water jacket, neighboring windows are sectioned by the bridge portion. The pair of second slide cores 23,23 are formed with engaging holes 23a, 23a. Further, the sand core 1 is provided with a pair of core prints 1b,1b protruding from the periphery of the sand core 1. Each core print 1b is engageable with each engaging hole 23a, so that the sand core 1 is positioned in place in the mold cavity 6. As shown in Figs. 1 and 3, the sand core 1 has a thickened wall portions le at positions adjacent the neighboring cylinders, and holding bores lc are formed from the end face 1d into the thickened wall portions le so as to allow holding projections 2b described later to extend into the holding bores 1c. Because the holding bores 1c are formed in the wall of the sand core 1 in an axial direction of the cylinder, the thickened walls le has a thickness greater than that of the remaining wall potion so as to sustain casing pressure. Incidentally, a reference numeral If designates a rear end surface of the sand core 1. A clearance S2 between the protruding portions 1a of the sand core 1 and the recessed portions 2a of the slide core 2 is relatively large, for example from 0.5 to 1.0 mm. By providing the large clearance, the molten metal can be filled in the clearance S2 as a flash. Therefore, separated or residual sand in the recessed portions 2a can be removed together with the removal of the flash. Because positive flashing is contemplated in the first embodiment at the clearance S2, molten metal pressure is applied to both axial end faces of the sand core 1, i.e., left side and right side of the sand core 1 in Fig. 2. Accordingly, the core prints 1b and complementary engagement holes 23a are required so as to prevent the sand core 1 from being moved in the axial direction of the cylinder within the mold cavity 6. As shown in Figs. 5 and 6, each slide core 2, 2 is disposed at both sides of a movable die 12. The above described first and second slide cores 22,22 and 23,23 are movably disposed beside the slide cores 2,2. A combination of the stationary die 8, the slide cores 2, 2, the first and second slide cores 22,22, and 23,23 and the movable die 12 defines an outer contour of the cylinder block for the V-bank type six cylinder engine. Each slide core 2 includes a cylindrical projection 2c around which a cylinder liner 5 is fittable. Further, sand core holding protrusions 2b protrude from the slide core 2 in the axial direction of the cylinder liner 5 toward the mold cavity 6. The protrusions 2b are provided integrally with the slide core 2, and has a circular cross-section. An outer diameter of each protrusion 2b is gradually reduced toward its tip so as to provide a draft which facilitates removal of the protrusion 2b from the holding bore 1c after casting. Similarly, cross-section of the holding bore 1c has a complementary tapered shape. Incidentally, in Figs. 5 and 6, the cylinder liners 5 are supported by the cylindrical projection 2c such that each axis of the cylinder liner extends in a horizontal direction. Further, a runner 7 is provided for introducing the molten metal into the mold cavity 6. With this arrangement, while maintaining opening state of the metal mold shown in Fig. 5, the holding projections 2b of the slide core 2 are engaged with the holding bores 1c of the sand core 1 so as to hold the sand core 1 to the slide core 2. After the cylinder liners 5 are fitted over the cylindrical projections 2c of the slide core 2, the first and second slide cores 22,22 and 23,23 are moved to move the entire movable die toward the stationary die 8 so as to define the mold cavity 6 shown in Fig. 6. Then, the molten metal is filled into the mold cavity 6 through the runner 7 for casting the cylinder block. During casting, the sand core 1 is held by the holding protrusions 2b, and therefore, the sand core 1 can be positioned precisely within the mold cavity 6. Further, because of the engagement between the core prints 1b and recesses 23a, the sand core 1 can be held stationarily in the metal mold without any displacement in the axial direction of the cylinder liner 5 despite of the molten metal pressure. Further, since relatively large clearance S2 is provided between the protrusions la and the complementary recess 2a for forming the window, the flash can be formed in the clearance S2 during casting. Therefore, even if sand in the protrusion la is separated from the core 1, the separated sand can be removed from the recess 2a together with the flash at the time of removal of the casted product from the metal mold. More specifically, the binder contained in the sand core 1 may be decomposed due to the heat of the molten metal to lower the strength of the sand core 1, and sand constituting the protrusion la may be released therefrom. However, the molten metal can be easily entered into the large space clearance S2 to form the flash. Thus, the outer portion of the protrusion la is surrounded by the flash. After casting, the metal mold is opened and the casted product is removed therefrom. In this case, the released sand can also be removed together with the flash. Accordingly, the sand do not remain in the recess 2a. Further, the casted product containing therein the sand core 1 is removed from the holding projection 2b, and sand may be affixed to the holding projection 2b. However, because the holding projection 2b is of the protruding construction, sand adhesion therearound can be easily acknowledged, and the sand can be easily removed therefrom. Then, the sand core 1 is discharged from the casted product through the formed windows of the water jacket. Further, machining is effected so as to form a female thread at each dimpled portion of the casted product, each dimpled portion being corresponding to each core print 1b. Then, threaded plugs (not shown) are threadably engaged with the female threads so as to plug the dimples. As described above, according to the first embodiment of the present invention, the holding projections 2b which belongs to the metal mold side, are inserted into the holding bores 1c which belongs to the sand core side to hold the sand core 1 in the metal mold, and the engagement between the protruding portions la and the recesses 2a does not serve to hold the sand core 1. Accordingly, large clearance S2 can be provided between the protruding portions la and the recess 2a. Consequently, even if the mechanical strength of the sand core is reduced due to the decomposition of the binders contained therein by the heat of the molten metal so that the part of sand at the protruding portion is released, the released sand can be removed from the recess when removing the flash provided at the large clearance S2. It should be noted that the flash is provided around the protruding portion and the flash can surely be provided because the molten metal can be easily entered into the large space S2. Further, the sand core 1 is held by the engagement between the holding projection 2b protruding from the metal mold and the holding bore 1c formed in the sand core. Therefore, even if sand remains on the holding projection 2b, the remaining sand is easily visible because the holding projection 2b is of the projecting component. Thus, cleaning to the metal mold can be easily performed to enhance productivity. A casting device for casting a closed deck type cylinder block and a sand core used in the casting device according to a second embodiment of the present invention will be described with reference to Figs. 7 and 8. According to the first embodiment, in order to remove the residual sand in the recess 2a of the slide core 2, the clearance S2 is positively provided between the recess 2a and the protruding portion la of the sand core so as to positively introduce the molten metal into the clearance S2 to provide the flash therein. Therefore, after casting operation, flash removing operation is required. Further, because of the positive formation of the flash, the molten metal pressure is applied to the entire end surface 1d of the sand core 1. Because the molten metal pressure is always applied to the rear end surface 1f of the sand core 1, the core prints 1b are required for preventing the sand core from being deviated in the axial direction of the cylinder during casting. Consequently, the above described machining and plugging are required. The second embodiment pertains to an improvement on these aspects. As shown in Figs. 7 and 8, a sand core 51 in the second embodiment is similar to the sand core 1 of the first embodiment except that an end face 51d facing a slide core 52 is of a flat plane without any protruding portions (1a in Fig. 1), and core prints (1b in Fig. 1) are not provided at the periphery of the sand core 51. An end face 52d of the slide core 52 facing the top deck end 51d of the sand core 51 is formed with recesses 52a so as to form bridge portions. The end face 52d other than the recesses 52a will be in intimate contact with the flat end face 51d of the sand core 51 so as to form windows of the water jacket end. In other words, in the second embodiment, it is unnecessary to provide the protruding portions 1a at the end face 51d of the sand core, but the end face 51d is of a simple planer arrangement. Incidentally, the end face 52d other than the recessed portions 52a of the slide core 52 may be referred to as protruding portions. Further, in Fig. 7, the bridge portions will be provided after casting at hatching portions delineated on the end face 51d. Similar to the first embodiment, a pair of slide cores 52,52 are provided besides the movable die 12, and the above described first and second slide cores 22,22 and 23A, 23A are movably disposed around the slide cores 52, 52. The stationary die 8, the slide cores 52, 52, the fist and second slide cores 22,22, 23A, 23A and the movable die 12 will form an outer contour of the V-bank type 6 cylinder engine block. Each of the slide cores 52 is provided with a cylindrical projection for supporting the cylinder liner 5. Each slide core 52 also provides holding projections 52b extending in the axial direction of the cylinder liner 5 and protruding from the end face 52d toward a mold cavity 56. Shape of the holding projections 52b and the holding bores 51c are identical with those of the first embodiment. The second slide cores 23A,23A are not formed with supporting recess (23a in the first embodiment) because core prints are not provided at the sand core 51. Thus, in the closing state of the metal mold, the front end face 51d of the sand core 51 is set in intimate contact with the end face 52d of the slide core 52. With this state, the sand core 51 is stably set in the mold cavity 56 by the engagement between the holding projections 52b and the holding bores 51c. When filling the molten metal into the mold cavity 56, advancing limit position of the sand core 51 in the axial direction of the cylinder liner 5 can be defined by the abutment between the end face 51d of the sand core 51 and the end face 52d of the slide core 52. On the other hand, the rearmost retracting limit position of the sand core in the axial direction is not defined, but large space is provided behind the rear end of the sand core 51 as shown in Fig. 8. However, because of the difference in molten metal pressures between the front end face 51d and the rear end face 51f of the sand core 51, the sand core 51 is urged toward the face 52d of the slide core 52. That is, the molten metal pressure force F1 applied to the front end face 51d of the sand core 51 is F1 = P × (a - b), whereas the molten metal pressure F2 applied to the rear end face 51f of the sand core 51 is F2 = P × a, where "P" is the casting pressure, "a" is an area of the front end face 51d(or rear end face 51f) of the sand core 51, and "b" is the contacting area between the front end face 51d and the end face 52d of the slide core 52. Accordingly, F2 is greater than F1. In this way, the sand core 51 is urged toward the advanced limit position because of the difference between F1 and F2, and consequently, positioning of the sand core 51 in the axial direction of the cylinder liner can be made. As a result, the core prints (1b in Fig. 1) can be eliminated. Upon casting, the molten metal is entered into the recessed portions 52a to form the bridge portions, whereas windows of the water jacket can be formed at the contacting portions between the front end 51d of the sand core 51 and the end face 52d of the slide core 52. After casting, the casted product is removed from the metal mold. In this case, problem of residual sand within the metal mold does not occur because the end face of the sand core does not have protruding portions (2a of Fig. 1) contrary to the first embodiment, but the end face 51d is of a planer arrangement. Similar to the first embodiment, according to the second embodiment, the engagement between the holding projections 52b and the holding bores 51c stably holds the sand core 51 within the mold cavity 56. However, contrary to the first embodiment, the entire flat front face 51d of the sand core 51 can be contacted with the slide core 52 since it is unnecessary to positively provide the flash for the purpose of removing the residual sand, and as a result, contacting areas with the molten metal are different between the front end face 51d and the rear end face 51f of the sand core 51, to thus urgedly position the sand core 51 to the advanced limit position. Consequently, the core prints can be dispensed with, to thereby eliminating the above described machining required in the first embodiment. Further, in the second embodiment, the sand core 51 per se can be easily produced because the end face 51d of the sand core 51 is of a planner arrangement without protruding portions. The flat or planer arrangement is also advantageous in that the problem of release of sand can be reduced or minimized. While the invention has been described in detail and with reference to the specific embodiments thereof, it would be apparent to those skilled in the art that various changes and modifications may be made. For example, in the above described embodiments, four holding projections 2b (52b) and corresponding four holding bores 1c (51c) are provided. However, the number can be not less than 2 as far as the sand core 1 or 51 can be properly held in the metal mold. Further, the die for accommodating the sand core can be any type of die as far as the drop of the sand core due to its own weight is avoidable. Further, the depicted embodiments concern the production of the closed deck type V array six cylinder engine block. However, the invention can be applied to a closed deck type in-line engine block such as four cylinder in line engine block and six cylinder in line engine block. Further, the cross-sectional configuration of the holding projections 2b or 52b and corresponding holding bores 1c or 51c is not limited to the circular shape, but generally triangular shape projections 2b' and bores 1c' shown in Figs. 9 and 10 and rectangular shape projections 2b" and bores 1c" shown in Figs. 9 and 11 are also available. Furthermore, the depth of the holding bores 1c can be varied dependent on the kind and size of the cylinder block and a posture of the sand core during casting as far as the sand core can be properly maintained in the metal mold. Furthermore, position of the holding bores 1c or 51c is not limited to the area le adjacent to the neighboring cylinders, but can be positioned other than the neighboring cylinders such as an area around 1c" in Fig. 9.

Claims: A device and a sand core (1;51) for producing a closed deck type cylinder block having a top deck and being formed with a water jacket surrounding a plurality of juxtaposedly arrayed cylinder liners (5), the water jacket having an upper end partly open at the top deck for forming windows and partly closed by bridge portions, the device comprising a metal mold (2, 8, 22, 23; 52, 8, 22, 23) defining therein a mold cavity (6; 56) for casting the cylinder block, the sand core (1;51) being for casting the water jacket in the cylinder block, characterized in that the device further comprises a plurality of holding projections (2b; 52b) integrally extending from the metal mold (2;52) toward the mold cavity (6; 56) in an axial direction of the cylinder liner (5), and the sand core (1) is formed with a plurality of holding bores (1c, 51c) complementary to respective holding projections and arranged to receive the holding projections extending thereinto (2b; 52b) for holding the sand core (1; 51) at a predetermined position within the mold cavity (6;56) during casting. A device and sand core as claimed in claim 1, wherein the metal mold includes a slide core (2) having an end face (2d) defining a part of the mold cavity (6), the end face (2d) being formed with a plurality of recesses (2a), and the sand core has a top deck end face (1d) formed with protrusions (1a) each engageable with a respective recess (2a) of the slide core (2), a space (S2) being provided between respective recesses (2a) and the protrusions (la) for providing a flash at the space. A device and sand core as claimed in claim 2, wherein the sand core (1) comprises: a wall portion having the top deck end face (1d) and an outer peripheral surface, the wall portion having a shape identical with the water jacket; and core prints (1b) extending from the outer peripheral surface, and the metal mold (23) further comprises a pair of slide cores (23) formed with engaging recesses (23a) for engaging with the core prints (1b) so as to prevent the sand core (1) from being moved in the axial direction of the cylinder lines (5). A device and sand core as claimed in claim 1, wherein the metal mold comprises a slide core (52) having an end face (52d) defining a part of the mold cavity (56), the end face (52d) being formed with a plurality of recesses (52a), and the sand core (51) has a planer top deck end face (51d) in intimate contact with the end face (52d) of the slide core (52) at portions other than the plurality of recesses (52a) during casting, the contacting area between the planer top deck end face (51d) of the sand core (51) and the end face (52d) of the slide core (52) forming the windows. A device and sand core as claimed in any one of the preceding claims, wherein the holding projection (2b) have a tapered shape in which the outer diameter gradually reduces toward its tip, and the holding bore (1c) have a complementary tapered shape for providing a draft. A device and sand core as claimed in any one of the preceding claims, wherein the sand core (1) comprises a wall having a shape identical with the water jacket, the wall of the sand core (1) having an uneven thickness around the cylinders, the thickness of the portions (1e) of the wall between neighbouring cylinders being greater than the thickness of the remaining portions of the wall, the holding bores (1c) being formed in the thicker portions (1e). A method of casting a closed deck type cylinder block using a device and sand core as defined in any one of the preceding claims.

Inventors: MANABE TATSUYA, MIZUKUSA YASUYUKI, USUI HIROTAKE, MANABE, TATSUYA, MIZUKUSA, YASUYUKI, USUI, HIROTAKE
Applicants: RYOBI LTD, RYOBI LTD.
Application year: 1997
Main classification: B22D17
IPC codes: F02F1, B22D17, B22D19