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    • 专利摘要:
    An insert (11), whose largest effective cross-sectional area with molten metal improves the weight reduction of a molded body in a casting insert, has a cross-shaped convex portion (3) on a surface of a molded body. insertion (11S), the convex portion of cross-linked shape (3) including a linear portion (1) and a convergence portion (2) in which at least two linear portions meet. A method for making an insert (11) includes: applying a mold coating agent to a surface of a mold to which molten metal is to be poured; forming a crack-like mold coating layer on its surface by drying the applied mold coating agent; and pouring the molten metal from above the mold coating layer and performing casting during mold rotation.
    公开号:FR3051380A1
    申请号:FR1754231
    申请日:2017-05-15
    公开日:2017-11-24
    发明作者:Nobuaki Suzuki；Mirai Hisaoka；Ryo Nagasawa；Akito Yamamoto；Yuichi Mizumura
    申请人:Suzuki Motor Co Ltd；
    IPC主号:
    专利说明:

    INSERT AND METHOD FOR MANUFACTURING THE SAME
    The present invention relates to an insert and its method of manufacture.
    With the development of a die-casting technique and the like, a method called casting insertion has been used, in which a previously cast element is placed in a mold, a molten metal, such as aluminum, is poured between the element and the mold, and the metal is fixed or bound to the element. The element to be cast by this process is called insert.
    Examples of the insert include a cylinder liner (also referred to as a cylinder liner or sleeve) for casting in a cylinder block for an internal combustion engine, a boss and a drum of a die cast hub. , a bearing portion of a cylinder block, a crankcase, or the like, a bearing member for casting in a bearing portion in a transmission housing, and the like. Particularly, when the insert is used in such applications, a thermal load or a large external force often acts on the insert. Thus, it is necessary to improve heat dissipation, heat transfer, and stiffness by improving the adhesion between the insert and the cast metal on the insert.
    Patent documents 1 and 2 relate to an insertion cylinder sleeve, and disclose that adhesion and joining force with a cylinder block material are improved by providing a plurality of protuberances having a constricted shape on an outer periphery. insertion.
    Patent documents 3 and 4 relate to an insert, and disclose that, by providing a plurality of protuberances, each having an approximately conical, outwardly extending undercut portion, on an insertion surface that contacts with another molten metal during casting, the adhesion to the other metal is improved and a desired clamping positioning accuracy can be maintained.
    A technique for providing a plurality of needle-shaped protuberances on the insertion surface is also known. In this case, a mold coating agent is applied to a surface of the mold to which a molten metal is to be poured, for example, and holes produced when steam exits the coating film when the coating agent is coated. mold is dried form many tiny concavities. The protuberances are formed by allowing the molten metal to enter the concavities.
    Patent Document 5 discloses a sleeve structure of a cylinder block for inserting a sleeve into which a piston is slidably inserted. In the sleeve structure, a portion of the sleeve, from the motor sump surface to approximately the center of the cylinder block, is formed to have a thickness greater than that of the other portion, and a sleeve of water extending approximately from the center of the cylinder block and having a U-shaped cross-section with an opening in a surface on the cylinder head side is formed to surround the sleeve. Patent Document 5 discloses that this structure can suppress deformation of the sleeve while maintaining cooling performance of the cylinder block. Patent Document 1: JP 2005-194983 A Patent Document 2: JP 2007-015005 A Patent Document 3: JP 2003-326353 A Patent Document 4: JP 2003-326346 A Patent Document 5: JP 2001-221098 A
    A high productivity die casting process is used to form an aluminum cylinder block which is a central part of the engine. According to this method, a sleeve in which a piston slides is also cast with aluminum. In recent years, requirements for reducing the weight of motors, and reducing the size of motors by reducing a pitch between bores have appeared. Thus, an attempt has been made to reduce the thickness of the sleeve, namely to reduce the useful thickness (thickness obtained by subtracting the protuberance height from the total thickness) of the insert.
    However, reducing the thickness of the sleeve can reduce the stiffness of the sleeve. In die casting, a stress remains in the sleeve by exposure to a high injection pressure of molten aluminum. Also, a high compression load is applied to the sleeve by axial bolt force during attachment to a cylinder head after the sleeve is inserted into the cylinder block, as well. In addition, a high combustion pressure inside the cylinder acts intermittently in a radial direction also during operation. Thus, in a sleeve of low rigidity, distortion will likely occur in the radial direction or the axial direction. This can substantially reduce the bore roundness of the sleeve. For this reason, mechanical loss and more gas leakage can result in reduced fuel efficiency. In addition, reduced rigidity of the cylinder block itself can also reduce NV characteristics (noise and vibration).
    In the structure described in patent document 5, a shape difference appears in a circumferential direction due to the influence of a mold-splitting portion during casting, resulting in an asymmetric shape and thus an irregular rigidity in the direction radial or axial direction. In addition, the outer diameter of the sleeve is asymmetric in the axial direction, for example the thickness of the cylinder block increases approximately below its center. Thus, to try to adopt the structure on a multi-cylinder engine, the pitch between the bores is naturally restricted, which can make it difficult to reduce the size and weight of the engine. Furthermore, as there is no undercutting shape provided in a convex portion, a large gap will likely be caused between the sleeve and the aluminum by the starting or stopping of the motor, due to a linear expansion difference between the cast aluminum and a cast iron sleeve. Therefore, since the gap serves as an insulator, efficient cooling performance can not be achieved. As described above, further improvement is required to improve the engine cooling performance while ensuring a stable stiffness of the cylinder liner.
    As a result of careful study, the inventors of the present invention solved the problems described above by forming a continuous linear protrusion, rather than needle-like protrusions of the conventional technique, on the insertion surface, increasing thus a useful surface used for the adhesion between the insert and the casting metal and thus allowing a weight reduction.
    According to one aspect of the present invention, an insert having a cross-shaped convex portion on an insertion surface is provided, wherein the cross-shaped convex portion includes a linear portion and a convergence portion in which at least two linear portions. join.
    It is preferable that the convex portion includes a constricted shape and / or a shape in which a vertical wall of the convex portion is inclined with respect to a line perpendicular to a flat surface.
    It is preferable that the convex shaped portion of the cross-section includes at least two of the convergence portions.
    It is preferable that the number of the joining linear portions differs between the at least two convergence portions, and that the linear portions join in random directions.
    It is preferable that when the convexly shaped convex portion is projected onto the flat surface, a projected area of the convex portion is from 5% to 70%, inclusive, of a total projected area.
    It is preferable that, in a flat portion surrounded by the linear portions, a diameter of an inscribed circle tangential to the contour of the flat portion is 0.5 mm to 30 mm, inclusive.
    It is preferable that in the convex portion of a cross-section, a height of a surface smaller than an upper surface of an upper portion is 0.1 mm to 5.0 mm inclusive.
    It is preferable that a length, in a transverse direction, of the linear portion is 0.1 mm to 8.0 mm, inclusive.
    It is preferred that the insert be a cylinder sleeve for insertion into an engine cylinder block.
    According to another aspect of the present invention, a method for making an insert may be provided, including the steps of: applying a mold coating agent to a surface of a mold on which molten metal is to be paid; forming a crack-like mold coating layer on its surface by drying the applied mold coating agent; and pouring the molten metal from above the mold coating layer and performing casting during mold rotation.
    It is preferred that the cracks include a plurality of voids reaching the mold surface from the surface of the mold coating layer, a width of each of the voids is reduced to the mold surface from the surface of the layer mold coating, and / or the voids extend along the surface of the mold.
    It is preferable that the cracks have a crosslinked form.
    It is preferred that the mold coating agent contain at least one fire resistant material, a binder, and a solvent.
    It is preferred that the step of forming a mold coating layer includes evaporating the solvent by heating the mold coating agent to a temperature not lower than a solvent evaporation temperature and not greater than a temperature of 110 ° C higher than the evaporation temperature, thus forming the mold-forming layer having a cracks shape.
    According to the present invention, the insertion surface of the insert has a predetermined shape, and the protuberance has an undercut shape. Therefore, the adhesion force between the insert and the casting aluminum is improved, making it difficult to create a gap in an interface with the aluminum, of different linear expansion, during engine operation or immediately after stopping the engine. In addition, in the predetermined form, protuberances have a continuous linear configuration, rather than a needle-like structure. Thus, a contact area with the casting aluminum can be increased, and the thermal conductivity associated with the heat transfer or heat diffusion of the insert to the aluminum can be improved. In addition, a reinforcing rib effect is obtained, for producing a reticulated shape structure having a convergence portion in which the linear portions according to the present invention meet. Thus, with respect to the conventional insert having the same useful thickness, the specific rigidity or specific modulus (here, booster / specific weight) and the like can be improved. Thus, weight reduction and stiffness improvement can be achieved even when the insert is cast with aluminum to obtain an insert element.
    Fig. 1 (A) is a perspective view illustrating a cylinder sleeve, and Fig. 1 (B) is a schematic enlarged view of a region d1 surrounded by a square in Fig. 1 (A).
    Figure 2 is a cross-sectional view of a cylinder block.
    Figure 3 is a plan view of Figure 1 (B).
    Figure 4 is a schematic enlarged view of a cross-section of a linear portion.
    Figs. 5 (A) through 5 (C) are schematic enlarged views of cross-sections of linear portions, Fig. 5 (A) illustrating an example of a linear portion having an approximately T-shaped cross-section, Fig. 5 (B) illustrating another example, and Fig. 5 (C) illustrating yet another example.
    Figures 6 (A) and 6 (B) are schematic enlarged views of cross-sections of linear portions, Figure 6 (A) illustrating an example of a host portion having a cross-section in approximate L-shape upside down. and Figure 6 (B) illustrating another example.
    Figs. 7 (A) and 7 (B) are schematic enlarged views of cross sections of linear portions, Fig. 7 (A) illustrating an example of a linear portion having an irregularity on the side of a vertical wall and the FIG. 7 (B) illustrating an example of a linear portion having a vertical wall extending in an oblique direction.
    Figs. 8 (A) to 8 (D) are schematic views illustrating a mechanism for forming a mold coating layer.
    Figs. 9 (A) to 9 (H) are schematic views illustrating a method for making an insert according to one aspect of the present invention.
    Figure 10 illustrates a photograph of a mold coating layer formed on a mold of Example 18.
    Figs. 11 (A) and 11 (B) illustrate photographs of an insert of Example 1, Fig. 11 (A) showing an external form of the insert, and Fig. 11 (B) showing an enlarged view of a region d2 surrounded by a square in Fig. 11 (A).
    Figs. 12 (A) and 12 (B) illustrate photographs of an insert of Example 21, Fig. 12 (A) showing an external form of the insert and Fig. 12 (B) showing an enlarged view of an insert. a region d3 surrounded by a square in Fig. 12 (A).
    Figs. 13 (A) and 13 (B) illustrate photographs of an insert of Example 16, Fig. 13 (A) showing an external form of the insert, and Fig. 13 (B) showing an enlarged view of an insert. a region d4 surrounded by a square in Fig. 13 (A).
    Figure 14 illustrates a photograph (magnification: 17X) of an insertion surface of the insert of Example 1, observed with a scanning electron microscope.
    Figure 15 illustrates a photograph (magnification: 16X) of an insertion surface of the insert of Example 21, observed with the scanning electron microscope.
    Figure 16 illustrates a photograph (enlargement: 14X) of an insertion surface of an insert of Example 5, observed with the scanning electron microscope.
    Fig. 17 is a schematic view illustrating an insert insertion surface of an insert of Comparative Example 1, at an enlargement of about 25X, according to an observation with the scanning electron microscope.
    Fig. 18 illustrates a photograph of the mold coating layer formed on a mold of Example 25, which is taken by macrophotography.
    FIG. 19 illustrates an image obtained by binarizing an image of the insertion surface of the insert of example 2.
    Fig. 20 illustrates a photograph when inscribed circles are measured on the insertion surface of the insert of Example 1.
    Fig. 21 illustrates a photograph when the height of the convex portion is measured on the insertion surface of the insert of Example 1.
    Fig. 22 (A) illustrates an external form of a test piece of Example 5 and Fig. 22 (B) illustrates a photograph of the insert illustrated in Fig. 22 (A) just before a compression test in one direction radial.
    FIG. 23 illustrates a relation between the mass and the restoring constant for the insert elements of Examples 5, 7, 9, 11, 13, 21, 22, and 23 and Comparative Example 1.
    Fig. 24 illustrates a cross-section of a specimen of Example 33.
    Fig. 25 (A) illustrates an outer shape of a test piece of Example 28 and Fig. 25 (B) illustrates a photograph of the test piece shown in Fig. 25 (A) just before a compression test in one direction axial.
    Hereinafter, a mode for carrying out the present invention is described in detail, but the scope of the present invention is not limited thereto.
    In one aspect, the present invention relates to an insert having a convex portion of cross-linked shape on an insertion surface. As the material of the insert, a metal having a high specific gravity and a self-sliding property can be used, such as cast iron, a copper alloy, a tin or zinc alloy.
    The melt is a ternary alloy generally containing iron, carbon, and silicon, and may contain other elements depending on the intended use. For example, the melt may contain from 3.1 to 3.8% by weight of TC (total carbon), from 1.9 to 2.5% by weight of Si, from 0.5 to 1.0% by weight Mn, from 0.01 to 0.5% by weight of P, from 0.02 to 0.1% by weight of S, in addition to Fe, relative to the total mass of the melt. When a raw material of the insert has a large thickness or a large amount of molten metal is to be poured, the cast iron may contain, according to circumstances, at least one of: from 0.01 to 1, 0% by weight of Cu, from 0.01 to 0.10% by weight of Sn, from 0.01 to 0.4% by weight of Cr, 0.15% by mass or less of Mo, and 0.5 % by weight or less Ni, or may further contain other unavoidable impurities, in order to obtain optimum hardness and metal composition.
    The shape of the insert main body is not particularly limited, but may be appropriately selected according to the intended use. Examples of the shape of the insert include, for example, a cylindrical shape, a semi-cylindrical shape, a U-shaped or T-shape upside down in cross-section, a curved or approximately flat plate shape, and like. Examples of the insert include those intended to be cast into a certain type of die casting, such as a cylinder sleeve to be cast into an engine cylinder block, a sliding member, which contacts a brake shoe intended to be cast in an aluminum drum brake, in a regenerative brake of an electric vehicle or the like, or a rear plate of the brake shoe, a boss of a die cast wheel hub for motorcycle and special machine, a crankshaft trunnion portion in a cylinder block or a lower crankcase, and a bearing portion in a housing, such as a transmission crankcase. Hereinafter, the present invention is described using a cylindrical cylinder sleeve as an example. However, the present invention is not limited to an insert having a specific shape or a specific product.
    Figure 1 (A) is a perspective view illustrating a cylinder sleeve 11 as an example of an insert. As a form of the cylinder sleeve, a cylindrical shape is used. The cylinder sleeve 11 has an outer surface 11 as an insertion surface. Fig. 1 (B) is a schematic enlarged view illustrating a region indicated by d1 in Fig. 1 (A). The cylinder sleeve has a convex portion of cross-linked shape 3 on the insertion surface 11c. The convex shaped portion 3 is a portion protruding from an approximately flat surface F included in the cylinder sleeve, and is present on the entire insertion surface. The convex shaped portion 3 includes a linear portion 1 and a convergence portion 2 formed by causing more than one linear portion to meet. The cylinder sleeve is briefly described below. Fig. 2 is a conceptual diagram illustrating an example of a cylinder block including the cylinder sleeve as a constituent component. A cylinder block 10 is cast by pouring aluminum 12 on an outer periphery of the cylinder sleeve 11.
    Figure 3 is a plan view of Figure 1 (B). The linear portion 1 is a portion where the convex portion can be identified as a linear or banded shape with a width when the insertion surface of the insert is viewed in plan from a direction perpendicular to the surface. The linear portion may be linear or curved, and may not be uniform in width, length, or height, and may have an indefinite shape. A long side length of the linear portion is not particularly limited. A short side length of the linear portion, i.e., a length in the transverse direction Lb of an upper portion of the linear portion, is preferably 0.1 mm to 8.0 mm, more preferably 0, 1 mm to 5.0 mm, most preferably 0.2 mm to 3.0 mm. The short side length of the linear portion corresponds to a width when projected on a plane. The short side length of less than 0.1 mm can result in insufficient anchoring effect on the casting aluminum. When the short side length exceeds 8.0 mm, on the other hand, a weight reduction may be insufficient. When the length in the transverse direction of the upper part of the linear portion is set within the above range, more center portions, intended to be convergence portions in which the linear portions meet, can be guaranteed. It should be noted that the cross-sectional length of an upper surface of the upper portion of the linear portion can be measured using a digital microscope, for example. For example, values can be measured in 1 to 50 locations, and a range, including values measured as a function of their average value, or the minimum and maximum values, preferably a range including all the measured values, can be obtained.
    A convergence portion 2a is formed by making three linear portions 1a, 1b, and 1 join. The number of linear portions that meet in the convergence portion is not particularly limited, but is at least 2, preferably from 2 to 6, inclusive. The convex shaped portion preferably includes at least two of the convergence portions. When there are two or more convergence portions in the convex portion of cross-linked shape, the numbers of linear portions that have joined in the respective convergence portions may be the same or different among them. The convex shaped portion formed on the outer periphery exerts a reinforcing rib effect which improves the rigidity of the insert. In addition, in the convergence portion, the linear portions are preferably joined in random directions from the point of view of the dispersion of the stress generated by an external force during the insertion. The fact that linear portions meet in random directions means, for example, that two linear portions meet in a convergence portion in different directions rather than parallel to each other.
    In one embodiment, the convex portion 3 may have a constricted shape and / or a shape in which a vertical wall of the convex portion 3 is inclined with respect to a line perpendicular to the flat surface. Such a form is described below. Figure 4 is a schematic enlarged view of a cross-section of the linear portion. This cross section is that of a linear portion, and is in a direction perpendicular to the surface of the insert. In one example, the convex portion 3 includes an upper portion 4 and a vertical wall 7 extending vertically, approximately perpendicularly, from a flat surface 6 to the upper portion 4. The convex portion 3 has a height h3 which is the sum of a height h4 of the upper part 4 and of a height h7 of the vertical wall 7. The height h3 of the convex part is preferably from 0.1 mm to 5.0 mm, including, more preferred from 0.1 mm to 3 mm, most preferably from 0.5 mm to 1.5 mm. Height h3 less than 0.1 mm can result in insufficient anchoring effect on casting aluminum, and can also reduce the reinforcing rib effect which improves rigidity. In addition, there is a case where a contact area with aluminum, required to diffuse heat, also becomes insufficient. On the other hand, when the height h3 exceeds 5.0 mm, centrifugal casting can become difficult. By adjusting the height of the convex portion within the above range, a useful contact area with the casting metal can be increased to improve heat dissipation. It should be noted that the height, from the bottom of the convex portion to the upper surface of the upper part, can be obtained by calculating a mean value by linear analysis of a freely selected surface of the insert with a Digital microscope measurement function and image analysis software WinROOF2013, for example. Alternatively, a cross section can be observed with the digital microscope to obtain a range including values measured as a function of the minimum height and the maximum height of each convex portion from the flat surface 6 in a freely selected measuring area. preferably a range including all the measured values.
    As shown in FIG. 4, a shape in which a width L4 of the upper portion of the convex portion is greater than a width L7 of the vertical wall portion can be called a constricted shape. The width L4 of the upper part corresponds to the width Lb of the linear portion described with reference to FIG. 3. With the structure having the form described above on the surface of the insert, molten metal is displaced around the constricted shape, for example, during the casting of the insert. Thus, the anchoring effect can be improved.
    Examples of the cross-sectional shape, when the linear portion is cut in a direction perpendicular to the long side thereof, include an approximate shape of T and an approximate shape of L in reverse. Such cross-sectional shapes are preferable with respect to improving adhesion strength and thermal conductivity with a casting metal when the insert is inserted, for example. The approximate shape of T is a T-like shape. FIGS. 5 (A) through 5 (C) illustrate examples of a linear portion having a roughly T-shaped cross section. In FIG. 5 (A) the vertical wall is connected to a position in which the upper part of the convex part is divided equally. On the other hand, in Figs. 5 (B) and 5 (C), the vertical wall is connected to a position in which the upper portion is not divided equally. The approximate shape of L upside down is a shape that looks like an upside down L. Figures 6 (A) and 6 (B) illustrate examples of a linear portion having an approximately L-shaped cross section upside down. The upper portion of the convex portion tapers toward the end in Fig. 6 (A), while the upper portion of the convex portion has some thickness up to the end in Fig. 6 (B).
    Figures 7 (A) and 7 (B) are schematic enlarged views of cross sections of linear portions. As shown in Fig. 7 (A), the vertical wall may have an irregularity on one side 22 thereof. Alternatively, as shown in Fig. 7 (B), the vertical wall may extend with an inclination 21 of an angle θ relative to a line perpendicular to the flat surface. The shapes illustrated in Figs. 7 (A) and 7 (B) may be considered as a shape having the vertical wall of the convex portion 3 inclined with respect to the line perpendicular to the flat surface.
    An insert may include at least one of the approximate shapes of T shown in Figs. 5 (A) through 5 (C), the approximate upside-down L shapes shown in Figs. 6 (A) and 6 (B). , and the shapes illustrated in Figures 7 (A) and 7 (B). For example, the vertical wall of the convex portion having, or having no, approximately T-shaped or L-shaped cross-sectional shape upside down may be inclined with respect to the line perpendicular to the flat surface, or may have an irregularity on his side. It should be noted that, in the vertical wall of the convex portion having no approximate T-shaped or L-shaped cross-section, the width L4 of the upper portion of the convex portion is equal to or less than the width L7 of the vertical wall portion.
    As illustrated in FIG. 3, an inscribed circle 1c can be drawn on the flat surface F, surrounded by the linear portions 1a, 1b, 1d, and 1c and the convergence portions 2a, 2b, 2c, and 2d. The diameter of the inscribed circle is preferably from 0.5 mm to 30 mm inclusive, more preferably from 1.0 mm to 15 mm, most preferably from 1.5 mm to 5.0 mm. The diameter of less than 0.5 mm can result in insufficient surface area of contact with aluminum during insertion. Therefore, it can become difficult to maintain the effective anchoring effect for casting aluminum. Also, the thermal conductivity may become insufficient. On the other hand, the diameter exceeding 30 mm may result in insufficient surface area of contact with the aluminum after insertion. This may result in a case in which an effective cross-linked structure can not be obtained, which contributes to the dispersion of the stress generated by an external force. By adjusting the diameter of the circle inscribed within the above range, the useful area of contact with aluminum during insertion becomes sufficient, resulting in good thermal conductivity in the case of use as an element. insertion. Also, the crosslinked form structure can disperse the stress. It should be noted that when the insert has a cylindrical shape, for example, the diameter of the inscribed circle can be obtained by calculating an average value of 1 to 50 registered circles created on a flat surface according to an image obtained by correcting an image taken from a convex part, on a curved surface, on the flat surface, with a digital microscope, for example. Alternatively, a range including the measured value as a function of the minimum diameter and the maximum diameter, preferably a range including all the measured values can be obtained. It should be noted that the present invention is not limited to the embodiment in which the entire flat portion is surrounded by the linear portions. In this case, an inscribed circle may be drawn along some of the linear portions, and its diameter may be treated in the same manner as above.
    Further, when the insertion surface of the insert is projected onto a flat surface, a projected area of the cross-shaped convex portion projected on the flat surface is preferably from 5% to 70%, inclusive, more preferably preferred from 10% to 60%, inclusive, most preferably from 16% to 43%, inclusive, of the total projected area. When the projected area is less than 5%, the effective area of contact with aluminum during insertion may become insufficient. Also, a reinforcing rib effect, which reduces the stress generated by external force, can be reduced. On the other hand, when the projected area exceeds 70%, a weight reduction effect can not be obtained. The projected area of the cross-shaped convex portion is an area of the convex portion projected from above the upper portion of the convex portion. By adjusting the projected area of the crosslinked convex portion within the above range relative to the total projected area, adhesion strength, heat transfer, heat dissipation, and rigidity, relative to to the casting metal during insertion, can be improved. In addition, the thermal conductivity and a specific module of the insertion element after insertion can also be improved. It should be noted that the projected area can be calculated by binarization processing as a function of an image taken with a microscope, for example, and subjected to a plane correction. The projected area can be obtained as an average ratio of convex portion area projected from one or more results of a measurement made at 1 to 50 locations, for example. Alternatively, the projected area can be obtained as a range, including measured values of the area ratio as a function of its minimum value and its maximum value, preferably a range including all the measured values.
    The convex portion of cross-linked shape may be continuously formed on the surface of the insert. The word "continuous" is not limited to a configuration in which all linear portions are connected, but also includes a configuration in which only certain linear portions are connected.
    As illustrated in Figs. 11 (A) through 13 (B), the overall external shape of the insert has a shape, which is similar to a net, such as a surface pattern of a musk melon . The insert preferably has a thickness 11b of 2 to 20 mm. In FIG. 4, for example, the thickness of the insert is the sum of a thickness h9 of the inner periphery of the insert at the flat surface on the outer periphery and the height h3 of the convex shaped portion. crosslinked. The height h 3 of the convex portion may preferably be from 1 to 10%, more preferably from 10 to 50% of the thickness of the insert.
    As described above, the insert has the convex portion, including the linear portions and the convergence portions on the insertion surface. Thus, the contact area with the casting metal can be increased compared to the conventional case, and heat transfer and heat dissipation can be effectively improved. In addition, the insert has a constricted shape between the bottom and the top of the convex portion and / or a shape in which the vertical wall of the convex portion is inclined relative to the line perpendicular to the flat surface. Thus, the casting metal flows in such portions to improve the adhesion strength, making it difficult to create a gap between the insert and the casting metal. Thus, the thermal conductivity to the casting metal can be improved. Further, when the convex portion has an isotropic crosslinked shape structure, for example, the convex portion exerts a reinforcing rib effect, making it possible to contribute to the dispersion and reduction of the stress caused by an external force from various directions. When the insert is a cylinder liner, for example, a specific module in a bore diameter direction or an axial direction can be improved. Thus, the deformation of the insertion element can be prevented. As a result, the thickness and weight of the cylinder liner can be reduced while maintaining the same rigidity. The insert can be cast with aluminum, an aluminum alloy, or other non-ferrous alloy. Here, an insert element obtained by casting the insert with such a metal or alloy has good adhesion between the insert and the metal or casting alloy, such as aluminum, and also has good conductivity. thermal as an insert element. It should be noted that the thermal conductivity can be measured using a flash laser method.
    For example, when the insert is a cylinder sleeve for insertion into an engine cylinder block, the cylinder sleeve must uniformly release heat to an aluminum cylinder barrel around it, and must exhibit a high rigidity because a combustion pressure or a compressive load during the fixing of a cylinder head will probably be applied to it. An engine cylinder block with excellent thermal conductivity and thermal diffusivity can be obtained by applying the present invention to a cylinder liner and casting the cylinder liner with aluminum, for example. In addition, even with an increased compression ratio of the engine, heat can be efficiently released from the cylinder sleeve to the aluminum cylinder barrel. Thus, an increase in combustion temperature associated with a higher compression ratio can be suppressed. In addition, since the specific module of the cylinder sleeve can be improved, the bore deformation, namely a roundness change of the inserted cylinder sleeve, can be prevented during the operation or attachment described above with the same weight. . Thus, the mechanical loss of the engine or the leakage of the gases can be reduced. If the cylinder sleeve has the same rigidity, the thickness and weight of the sleeve itself can be reduced. As a result, the weight of the engine can be reduced.
    In addition, according to another aspect, the present invention relates to a method for making an insert. The method of the present invention includes the steps of: applying a mold coating agent to a surface of a mold to which molten metal is to be poured; forming a crack-like mold coating layer on its surface by drying the applied mold coating agent; and pouring the molten metal from above the mold coating layer and performing casting during mold rotation.
    The material and shape of the mold for molding the insert is not particularly limited, but may be selected according to a raw material and a intended use of a target insert. For example, in the case of molding a cylinder sleeve for insertion into an engine cylinder block, as an insert, the mold is preferably a metal mold and preferably has a cylindrical shape. In this case, the insert is preferably molded with a centrifugal casting process using centrifugal force. It should be noted that the mold for molding the insert may have an approximately smooth surface that is machined, for example.
    Figs. 9 (A) to 9 (H) are schematic diagrams illustrating a method for making an insert according to one aspect of the present invention. Figure 9 (A) illustrates a mold coating agent 321 prepared in a container 36. The mold coating agent may contain at least one fire-resistant material, a binder, and a solvent. Depending on circumstances, the mold coating agent may also contain an aggregate. As a fire-resistant material, diatomite powder is preferable particularly for the purpose of preventing molten metal bleaching and ensuring sufficient mold release capability, in addition to protecting the mold surface. A lower limit of an amount of the fire-resistant material to be blended is preferably at least 2% by weight, and more preferably at least 8% by weight of the total weight of the blending agent. mold. An upper limit thereof is preferably at most 40% by weight, more preferably at most 27% by weight, and most preferably at most 15% by weight of the total weight of the coating agent. of mold.
    Examples of the binder include bentonite, montmorillonite, kaolinite, sepiolite, attapulgite, refractory clay, and the like. Particularly, bentonite which absorbs the solvent and swells in a gel is preferable with respect to separation suppression, when mixed in the solvent together with the fire-resistant material and the aggregate, and obtaining the viscosity to allow the mold coating agent to be attached to the surface of the mold. A lower limit of an amount of the binder, to be mixed, is preferably at least 2% by weight, more preferably at least 5% by weight, and most preferably at least 8% by weight of the total mass of the mold coating agent. An upper limit thereof is preferably at most 20% by weight, more preferably at most 12% by weight, and most preferably at most 10% by weight of the total weight of the coating agent. of mold. When the amount of the binder is less than 2% by weight, the binder readily separates from the fire resistant material, resulting in a possibility of insufficient strength of the mold coating layer. On the other hand, when the amount of the binder exceeds 20% by weight, the slip viscosity of the mold coating agent is too high, making the coating difficult. As a solvent, water can be used. A lower limit of an amount of the solvent to be mixed is preferably at least 60% by weight of the total weight of the mold coating agent. An upper limit thereof is preferably at most 85% by weight of the total weight of the mold coating agent. The mold coating agent may also contain an organic solvent having a boiling point higher than that of water, such as butanol, in addition to the materials described above. In this case, such an organic solvent can be mixed with water and used. The mold coating agent may also contain an aggregate, in addition to the materials described above. As an aggregate, inorganic powder composed of aluminum oxide and silicon dioxide, such as mullite and Thera Beads, artificial ceramic sand or casting sand, such as zircon, chromite sand, silica sand, olivine sand, and spinel sand may be used. Particularly, mullite and Thera Beads are preferable because of a low specific mass, to prevent separation, from the fire-resistant material and the binder, and also with regard to the facilitation of contraction of the layer. mold coating when dried and solidified, without absorbing the solvent, and increasing cracks in the mold coating layer. A lower limit of an amount of the aggregate, to be mixed, is preferably at least 1.0% by weight, more preferably at least 1.5% by weight, and most preferably at least 3.0% by weight of the total mass of the mold coating agent. An upper limit thereof is not particularly limited, but is preferably at most 25% by weight, and more preferably at most 10% by weight. The mold coating agent may be prepared as a slip, by mixing at least the fire-resistant material, the binder, and the solvent, and further mixing the aggregate therein according to circumstances.
    Fig. 9 (B) is a conceptual diagram illustrating a step of applying the mold coating agent 321 to a surface 31s of a mold 31 to which molten metal is to be poured. In this embodiment, the surface on which molten metal is to be poured (hereinafter also referred to as the molten metal contact surface) is the inner periphery of the mold, and the surface before the formation of the coating layer of mold is preferably approximately flat. In this step, the mold coating agent 321 is applied to the inner periphery 31s of the mold using a nozzle 41, during rotation of the cylindrical mold 31 in a fixed direction 40. It is preferred that the coating agent The mold is uniformly applied to the entire inner periphery of the cylinder by moving the nozzle 41 in a longitudinal direction 42 of the cylinder at a constant speed, while maintaining a certain distance, from the inner periphery 31s of the mold. In the case of using a cylindrical mold, it is preferable that the mold is rotated in a state in which the roll is rolled horizontally, for example. Centrifugal acceleration of the mold during rotation is preferably set at a range of 4 G to 40 G, inclusive. It is preferred that the inner periphery 31s of the mold, during the application of the mold coating agent to the mold, be heated to a temperature which does not cause a sudden increase in the temperature of the coating agent. of mold. The heating temperature is preferably 110 to 210 ° C, and more preferably 120 to 180 ° C.
    Fig. 9 (C) is a conceptual diagram illustrating a step of forming a crust-like mold coating layer 32s by drying the applied mold coating agent. It is preferred that the mold 31 be rotated in the fixed direction 40 until the mold coating agent is dried. The mold coating agent can be dried during rotation of the mold after application. The mold coating agent can be dried and solidified by heating or heat from the heated mold. The rotational holding time is preferably from 0.25 to 3 minutes. Alternatively, the time required to dry and solidify the mold coating agent can be reduced by heating the mold from the inside or end of the mold, if necessary, after the rotation of the mold is stopped.
    When the mold coating agent is dried by further heating after the application, the heating is preferably carried out at a temperature not lower than a solvent evaporation temperature and not higher than a higher temperature of 110 ° C. at the evaporation temperature. Thus, the crack-like mold coating layer can be formed in a suppressed state of a sudden increase in solvent temperature from within the mold coating agent and also generation suppressing. excessive air bubbles (water vapor). A lower limit of the heating temperature is preferably the solvent evaporation temperature, or more, more preferably a higher temperature of 10 ° C, at the evaporation temperature of the solvent, or more preferably between all of them a higher temperature, of 20 ° C, at the evaporation temperature of the solvent. An upper limit of the heating temperature is preferably a higher temperature, 110 ° C, at the solvent evaporation temperature, or lower, more preferably a higher temperature, 80 ° C, at the temperature of 80 ° C. solvent evaporation, or less, most preferably a higher temperature of 40 ° C at the solvent evaporation temperature. When the mold coating agent is dried by further heating after application, the heating time is preferably from 0.25 to 3 minutes. The thickness of the mold coating layer, after it is dried, is not particularly limited, but its average thickness is preferably from 0.1 mm to 5.0 mm, and more preferably from , 5 mm to 2.0 mm.
    Figs. 8 (A) to 8 (D) are conceptual diagrams illustrating a formation mechanism of the mold coating layer. As shown in Fig. 8 (A), some volatile components 33 evaporate from the mold coating agent 321 applied to the heated mold 31. Fig. 8 (B) illustrates an initial state of the coating layer 32s mold during drying and solidification. At this point, a large amount of volatile components 33 evaporate from the mold coating layer 32s, and a contraction 34 begins to appear at random intervals in the surface of the mold coating layer 32s, thereby causing cracks 35i. Figure 8 (C) illustrates an intermediate state during drying and solidification. The contraction 34 of the mold coating layer 32s progresses further, and cracks 35m, extended to the mold surface 31, are generated from the surface of the mold coating layer 32s. As a result, voids in the thickness direction of the mold coating layer each have a wedge-shaped cross section. Depending on circumstances, the mold coating layer may be completely dried and solidified in such a cracked state. Figure 8 (D) illustrates a final state during drying and solidification. Cracks 35f penetrating into the mold coating layer are generated, and thus the mold coating layer 32s, divided into certain blocks, is obtained. In addition, the cracks are further extended along the mold surface in a direction approximately perpendicular to the cracks 35f by contraction of the mold coating layer. The resulting mold coating layer may include crosslinked form cracks on its surface.
    Fig. 9 (D) is a conceptual diagram illustrating a pouring step of molten cast iron 43 into the mold 31 from above the mold coating layer 32s and centrifugal casting execution during the rotation of the mold 31 in the fixed direction 40. As in the case of Figure 9 (B), the molten metal can be poured into the cylinder using molten metal feed means, such as a nozzle, during the rotation of the mold. For the rotation of the mold, the centrifugal acceleration of the mold is preferably set to a range of 100 G to 120 G, inclusive. By rotating the mold, the centrifugal force causes the molten metal to also flow into the cracks in the mold coating layer. Thus, desired linear protuberances may be formed on the surface of the insert. The temperature of the molten metal is not particularly limited so long as its temperature is a melting temperature of cast iron, metal, alloy or the like, to be used. In the case of reuse of cast iron, the temperature of the molten metal is preferably from 1380 to 1450 ° C. Also, the temperature of the mold, when the molten metal is poured into the mold, is preferably from 100 to 300 ° C.
    Fig. 9 (E) is a conceptual diagram illustrating a step of solidification of the molten cast iron. An insert molded body 44 is obtained by cooling the molten cast iron 43 from the outside of the mold 31 and thereby solidifying the molten cast iron. After casting by pouring the molten metal into the mold, the molten metal can be left for a period of 0.25 to 1 minute, for example, to be naturally cooled and solidified. Alternatively, the molten metal can be solidified by naturally cooling the molded body of a final eutectic solidification temperature to a lower temperature of 100 ° C at the final eutectic solidification temperature. It is preferable that the rotation of the mold is stopped after the molten metal is solidified. In order to prevent the precipitation of ferrite in the metal composition of the molded body 44, the outside of the mold may be water-cooled, for example, during mold rotation, at a final eutectoid transformation temperature (Ar1 conversion), for example, a temperature of up to about 730 ° C, depending on the mass or thickness of the insert. The molded body, in the form of an insert, is obtained by solidifying and cooling the molten metal, as described above.
    FIG. 9 (F) is a conceptual diagram illustrating a step of extracting the molded body 44, in the form of an insert, out of the mold 31. A method for extracting the molded body from the mold is not particularly limited, and is selected according to the shape of the mold. In the case of a cylindrical mold, for example, the molded body 44 can be extracted from the mold 31 by fixing a guide having a claw opening outwardly at the inner diameter end of the molded body and pulling the mold. other end side of the guide in an arrow direction 45 in Fig. 9 (E) with a hydraulic cylinder or the like.
    Fig. 9 (G) is a conceptual diagram illustrating a step of removing the mold coating layer 32s from the molded body 44 extracted from the mold 31. The molded body extracted from the mold may have the mold coating layer attached to its area. A method for removing the mold coating layer from the molded body is not particularly limited, but shot blast cleaning, water jet cleaning, dry ice cleaning or the like may be adopted. For example, the mold coating layer 32s can be removed from the molded body 44 by moving the molded body 44 in an arrow direction 46 and by projecting a shot jet 47 onto the mold coating layer 32s on the body surface 44. In the case of shot blast cleaning, ceramic powder having a grain size of 240 to 8000 and an average grain diameter of 0.5 to 60 μm may be used as a material for to be projected, and a projection pressure is preferably 0.1 to 0.4 MPa. In the case of water jet cleaning, the projection pressure is preferably 0.1 to 0.4 MPa.
    Fig. 9 (H) illustrates an insert 48 after the mold coating layer is removed from the molded body. The insert 48, having a convex portion of cross-sectional shape on a surface 48s thereof, is obtained by removing the mold coating layer from the molded body.
    According to the present invention, a convex portion having a predetermined shape with a height that can not be achieved by a conventional manufacturing method can be formed on the insertion surface of the insert. Thus, the insert can have a high adhesive force to the casting aluminum. The inseit according to the present invention is also applicable to an element other than a sliding part having a high rigidity and excellent heat transfer, heat dissipation, and thermal conductivity, for example, an insertion element in a room wherein a rotational torque acts, such as an aluminum brake drum, a die cast aluminum wheel hub for a motorcycle, and a bearing journal portion in a power train system.
    The method of manufacture described above is preferable to form a disengaged structure on the insertion surface of the insert. When a portion having no disengaged structure is required in a portion of the insert insertion surface, the portion may be molded or cut. Alternatively, an insert having a portion without the disengaged structure may also be formed by masking the insertion surface, other than the above-described portion, for example, and thermally spraying a metal on the surface during rotation of the insert.
    Injection conditions are not particularly limited, but ADC12, ADC10, or ADC3, for example, can be used and poured at 620 to 670 ° C, and the injection can be performed with an injection pressure of 50 to 100 MPa at an injection rate of 1.5 to 4.0 m / sec. Thus, the insertion element can be obtained.
    Preparation of the insert.
    Example 1
    A mold coating agent was prepared by mixing diatomite, mullite, bentonite, and water, and stirring the mixture with an electric mixer (manufactured by Ryobi Co., Ltd.). With respect to a mixing ratio of the respective components, diatomite accounted for 9% by mass, mullite accounted for 6% by mass, bentonite for 10% by weight, and water for 75% by mass of the total mass of the mold coating agent.
    A cylindrical mold having an inside diameter of about 79 mm was used as a mold for an insert, and a temperature of the cylinder inner periphery was set at 160 ° C. This temperature could be measured with a contact thermometer or a radiation thermometer. A mold coating layer was formed by applying the mold coating agent to the inner periphery of the mold with a nozzle during rotation of the mold at a centrifugal acceleration of 4 to 10 G with the cylindrical portion (longitudinal direction of the cylinder ) placed laterally. The mold coating layer was formed on the inner periphery of the mold by maintaining the rotation of the mold for about 1 minute after application. Figure 10 illustrates a photograph of the inner periphery of the mold after the mold coating layer has been formed. The mold coating layer thus obtained had the form of cracks, formed on its surface, and had an average thickness of about 1 mm. The thickness of the layer was obtained by measuring the surface of the 10-slot mold coating layer with a measuring probe (Le-2.5 LwA) connected to an electromagnetic film thickness meter (Model No. SWT-8000II manufactured by Sanko Electronic Laboratory Co., Ltd.), and then averaging from the measured values.
    Then, the insert was cast by pouring a molten metal into the mold having the mold coating layer formed on its inner periphery. As the molten metal, molten pig iron at 1420 ° C was used. The pouring of the molten metal into the mold was effected by adjusting the temperature of the inner periphery of the mold to 160 ° C during rotation of the mold at a centrifugal rate of 120 G. After the molten metal was poured into the mold, mold, the rotation of the mold was maintained for 0.5 minutes. Then, the mold was cooled to 730 ° C or less with cooling water from the outer periphery of the mold during mold rotation. Thus, the molten metal has been solidified and cooled to obtain a molded body of the insert.
    After the molten metal was solidified and cooled, the rotation of the mold was stopped. Then, an outwardly opening claw guide was attached to the inside diameter end of the molded body, and the molded body was removed from the mold by moving the guide in a direction opposite to the mold, with the other end of the guide connected to a hydraulic cylinder. After that, the mold coating layer was removed from the molded body by projecting a shot jet onto the outer periphery of the molded body thus extracted. The shot shot jet was ceramic powder having a mean grain diameter of 23 μm, and a projection pressure was 0.3 MPa. Thus, the mold coating layer was removed to obtain an elongated cylindrical raw material of an insert, having an inside diameter of 64 mm and a thickness of 7.5 mm. In addition, the raw material of the insert was cut to a required length, and also the inner periphery was machined by turning depending on the outside diameter. Thus, an insert having a length of 124 mm and a thickness of 4.5 mm was obtained. Table 1 illustrates a mixing ratio of the mold coating agent to obtain the insert, a mold temperature, a thickness of the mold coating layer, a thickness of the insert, and a type of mold structure. protuberance on the outer periphery of the insert. The thicknesses of the insert and insert material described above mean a roll thickness, which was obtained by measuring the thickness between the two 5-slot end faces with a micrometer and calculating its thickness. average value.
    Table 1
    Examples 2 to 24 and 26.
    Inserts were obtained in the same manner as Example 1 except that the mixing ratio of the mold coating agent, the mold temperature, the thickness of the mold coating layer, and the The thickness of the insert was adjusted as shown in Table 1.
    Example 25
    Thera beads were used instead of mullite as an aggregate, and the mixing ratio of the mold coating agent, the mold temperature, and the thickness of the mold coating layer were adjusted as this is shown in Table 1. A mold coating agent was poured onto the surface of a preheated mold. Then, the mold coating agent was dried and solidified to form a mold coating layer. Figure 18 illustrates a photograph of a surface of the mold coating layer of Example 25. From this photograph, the fact that the crack shape could be formed on the surface even when Thera Beads were used as an aggregate and the flat-plate mold was used was confirmed. Therefore, the fact that even when the conditions of this example were adopted with a cylindrical mold on which a centrifugal force acts, protuberances could be formed to have a cross-linked shape, as in the case of Examples 1 to 24 and 26, a been confirmed.
    Comparative Example 1
    A cylindrical main body, which had heretofore been used as a die casting insert, was used as an insert of Comparative Example 1.
    Observation of outer periphery of insertion of the insert.
    Fig. 11 (A) illustrates a photograph of the insert of Example 1. Fig. 11 (B) is an enlarged view of a region d2 surrounded by a square in Fig. 11 (A). Fig. 12 (A) illustrates a photograph of the insert of Example 21. Fig. 12 (B) is an enlarged view of a region d3 surrounded by a square in Fig. 12 (A). Fig. 13 (A) illustrates a photograph of the insert of Example 16. Fig. 13 (B) is an enlarged view of a region d4 surrounded by a square in Fig. 13 (A). The enlarged views represent images of the outer peripheries of the inserts, taken by macro photography with a close-up camera. From Figs. 11 (A), 12 (A), and 13 (A), the fact that a cross-shaped convex portion was present on the outer periphery of each of the inserts of Examples 1, 21, and 16 was confirmed. In Figs. 12 (B) and 13 (B), a convex portion brighter than that in Fig. 11 (B) has been observed, this is considered to be due to the height of the convex portion. Furthermore, the linear portion in Fig. 13 (B) tended to be wider than that in Fig. 12 (B), this is believed to be due to the fact that cracks generated in the mold coating layer have large openings. As a function of such a difference in structure, the type of Example 1 was classified as a type of crosslinked form I, the type of Example 21 was classified as a type of crosslinked form II, and the type of Example 16 has been classified as a type of crosslinked form III. Also, Table 1 presents a ranking result of the inserts of the other examples by controlling the surface structures on their outer peripheries.
    Figures 14 to 16 illustrate photographs of the outer peripheries of insertion of the inserts of Examples 1, 21, and 5, observed with a scanning electron microscope (SEM). Fig. 17 is a schematic view illustrating the outer insertion periphery of the insert of Comparative Example 1 at an enlargement of about 25X. In FIGS. 14 to 16, portions surrounded by discontinuous circles represent convergence portions in which linear portions have joined. The number in each of the circles represents the number of linear portions joined in each of the convergence portions. FIGS. 14 to 16 illustrate that the convex portion of cross-linked shape includes a plurality of linear portions and a plurality of convergence portions, each having, in it, some of the linear portions that have met, the number of linear portions The meeting point was different between the convergence portions, and the linear portions were joined in random directions. On the other hand, in Fig. 17, no continuous linear protrusion structure has been observed, although more than one constricted needle-shaped protuberance has been observed. Evaluation of projected area of convex section of cross-linked form.
    A projected area ratio of the convex portion relative to the total area of the observed region was calculated by observing the outer insertion periphery of the insert of Example 2 with a VHX-5000 digital microscope (manufactured by Keyence Corporation) and performing binarization processing with QuickGrainPro image processing software (produced by Inotech Co., Ltd.). Then, an average value was calculated by performing the same evaluation at 3 locations. Table 2 presents the results. Also, the inserts of Examples 6, 8, 15 to 20, and 24 were similarly evaluated, and Table 2 presents their results.
    Table 2
    Figure 19 illustrates an image obtained by binarizing an image of the outer insertion periphery of the insert of Example 2, taken at 2.5X magnification with the VHX-5000 digital microscope. In Fig. 19, the insertion surface is divided into a portion U in which the convex portion has been projected from above the upper portion of the convex portion and a flat portion L surrounded by the convex portion. Next, a ratio of the projected portion U of the convex portion to the total area, which is the sum of the two portions, has been set as the projected area ratio of the convex portion. As shown in Table 2, the projected area ratio tended to vary among the types of crosslinked form structures described above. The projected area ratio was 11% to 33% for crosslinked form structure type I, 18% to 42% for crosslinked form structure type II, and 42% to 60% for structure type crosslinked form III.
    Measurement and evaluation of circle inscribed in the convex part of reticulated form.
    The outer periphery of the insert of Example 1 was observed with the VHX-5000 digital microscope (manufactured by Keyence Corporation) and an inscribed circle tangent to the contour of a portion surrounded by linear portions was created in the region. observed. Then, the diameter of the inscribed circle was measured. The diameters of the inscribed circles, which could be identified in the observed region, were randomly measured at 10 locations, and their mean values were calculated. Table 3 presents the results. Also, the inserts of Examples 5, 7, 9, 11, 21, and 22 have been similarly evaluated, and Table 3 presents their results.
    Table 3
    Figure 20 illustrates a photograph of the outer insertion periphery of the insert of Example 1 taken at 7X magnification with the VHX-5000 digital microscope. In Fig. 20, discontinuous circles represent circles inscribed in portions surrounded by the convex portion of cross-linked shape.
    As shown in Table 3, the diameter of the inscribed circle tended to vary among the types of cross-linked structure described above. The diameter of the inscribed circle was 1.8 to 4.1 mm for the type of reticulated form structure I, 1.2 to 5.0 mm for the type of reticulated form structure II, and 1.7 to 5.0 mm for the type of reticulated form structure III. Length evaluation in transverse direction of upper surface of linear portion in a convex portion of cross-linked shape.
    The outer insertion periphery of the insert of Example 1 was observed with the VHX-5000 digital microscope (manufactured by Keyence Corporation) and the length in the transverse direction of the upper surface of the linear portion in the upper portion of the convex portion of crosslinked form has been measured. An average value was calculated by performing a 10-location evaluation in the observed region, and Table 3 presents the results. Also, the inserts of Examples 5, 7, 9, 11, 21, and 22 have been similarly evaluated, and Table 3 presents their results. As shown in Table 3, the cross-sectional length of the linear portion tended to vary among the types of crosslinked form structures described above. The length in the transverse direction was 0.1 to 1.2 mm for the type of crosslinked structure I, 0.2 to 2.7 mm for the type of crosslinked structure II, and 0.2 to 2.9 mm for the type of reticulated form structure III. Evaluation of height, from the bottom of the convex part of reticulated form to the upper surface of the upper part.
    The outer periphery of insertion of the insert of Example 1 was observed with the VHX-5000 digital microscope (manufactured by Keyence Corporation) and the height, from the bottom (flat surface) of the convex part to the upper surface of the upper part of the convex part has been measured. In three views, the height was measured in 6 to 10 locations per view, and Table 4 shows the results of calculating its mean value. Also, the inserts of Examples 5, 7, 9, 11, 13, 14, 21, 22, 23, and 24 and Comparative Example 1 were similarly evaluated, and Table 4 shows their results.
    Table 4
    Figure 21 illustrates a photograph of the Tinsert outer insertion periphery of Example 1 taken at 6X magnification with the VHX-5000 digital microscope. In Fig. 21, a line 49 represents a position of a surface (bottom of the convex portion) without a convex portion c1 intended to be measured. As shown in Table 4, the range of height, from the convex-free surface to the upper surface of the upper portion of the convex portion, tended to vary among the types of cross-linked structure described above . The height range was 0.6 to 0.8 mm for the type of crosslinked structure I, 0.8 to 1.1 mm for the type of crosslinked structure II, and 0.9 to 1 , 5 mm for the type of reticulated form structure III. Insertion stiffness evaluation (radial direction).
    The raw Tinsert material of Example 5 was cut to a required length, and also the inner periphery was machined by turning as a function of the outside diameter to obtain the insert. The insert thus obtained was used as a test piece for rigidity evaluation. Fig. 22 (A) is a photograph illustrating the external shape of the test piece. As illustrated in FIG. 22 (A), the test specimen had an internal diameter β of 73 mm, a length γ of 30 mm, and a thickness of 3 mm. Next, a modulus of elasticity of the specimen was evaluated using a precision universal tester (AG-100kN Xplus manufactured by Shimadzu Co., Ltd.). Fig. 22 (B) is a photograph showing a state of the test apparatus and the test piece just prior to the test run. The test apparatus compressed a specimen 51 in a radial direction by moving a compression end (compression punch) 52 in a downward direction 53. Next, a load displacement curve was created by measuring a displacement with respect to a load in the compressive deformation of the specimen 51. After that, a compression load progression with respect to the displacement within the proportional limit, namely a restoring constant, was calculated and used for the stiffness comparison of the insert. The test piece 51 has been arranged to cause its outer periphery to contact the compression end. In addition, a V-shaped block 50 was used to attach the specimen 51 to prevent the specimen from moving during the test. A falling speed of the compression end was 1 mm / min. Table 5 and Figure 23 illustrate the results. Also, the inserts of Examples 7, 9, 11, 13, 21, 22, and 23, and Comparative Example 1 were similarly evaluated, and Table 5 and Figure 23 illustrate their results.
    Table 5
    A relational expression y = was derived as a result of the creation of a graph of a recall constant with respect to the weight of the insert, in Figure 23, as a function of the result shown in Table 5, and the creating an approximate line with the results of Examples 5, 7, 9, 11, 13, 21, 22, and 23. Depending on the expression, a weight of about 102 g, for the same recall constant as that of Comparative Example 1 was confirmed. This showed that the weight could be reduced by 4% compared to the insert of Comparative Example 1.
    Insertion element preparation.
    Example 27.
    An approximately cylindrical insertion member was prepared by casting the outer periphery of the insert of Example 2 with aluminum using a die casting process. ADC12 was used as aluminum and poured at 650 ° C, and casting was performed with an injection pressure of 65 MPa at an injection rate of 2.0 m / sec. The insertion element thus obtained was machined by turning until the outer diameter of the aluminum on the outer periphery reached 81 mm, depending on the inner periphery, and then machined by turning until the inside diameter of the inner periphery of the insertion element reaches 73 mm, depending on the outer circumference. Thus, the thickness of the insertion element was set to 4 mm. In addition, the insertion element has been cut so that the long side length of the insert member cylinder is 30 mm. Thus, specimens were prepared for rigidity evaluation in a bore diameter direction and in an axial direction of the insertion element, respectively.
    Examples 28 to 30 and Comparative Example 2
    Specimens to evaluate the rigidity of the insertion element were prepared in the same manner as Example 27, except that the insertion elements of Examples 3,4, and 7 and Comparative Example 1 were prepared. were used, respectively. It should be noted, however, that the test specimen of Example 30 was used only for rigidity evaluation in the axial direction.
    Example 31.
    An approximately cylindrical insertion member was prepared by casting the outer periphery of the insert of Example 2 with aluminum using a die casting process. ADC12 was used as aluminum and poured at 650 ° C, and casting was performed with an injection pressure of 65 MPa at an injection rate of 2.0 m / sec. Thus, an approximately cylindrical insertion member having an outer diameter of 89 mm, an internal diameter of 70 mm and a length of about 128 mm was prepared. As described below, a test piece for measuring the thermal conductivity and a test piece for measuring the adhesion strength between the aluminum and the insert were prepared from the insertion element thus obtained.
    Examples 32 to 34 and Comparative Examples 3 and 4
    Inserts were prepared in the same manner as Example 31, except that the insert elements of Examples 10, 12, and 14 and Comparative Example 1 were used. In addition, Comparative Examples 3 and 4 were insertion elements obtained by separately casting under that of Comparative Example 1, whereas Comparative Example 4 was used to control the reproductive capacity of the invention. Comparative Example 3
    Cross section observation of the insertion element.
    Figure 24 illustrates a result of observing the cross-section of the insert member of Example 33 with an optical microscope (Model No. GX51 manufactured by Olympus Corporation). On an interface between an insert71 and an aluminum 72, convex portions having an approximate shape of T Tl and an approximate shape of L upside T2 in cross section have been observed. Insertion element stiffness evaluation (bore diameter direction).
    A constant in a radial direction of the specimen of Example 27 was evaluated using the Universal Precision Test Apparatus (AG-100kN Xplus manufactured by Shimadzu Co., Ltd.). A measurement method was the same as that used for the rigidity evaluation of the insert described above. Table 6 presents the results. Also, the test pieces of Examples 28 and 29 and Comparative Example 2 were evaluated similarly, and Table 6 shows their results. The restoring constant was calculated from a load displacement curve when the load was 400 to 1000 N. The calculation was performed assuming a ratio of the constant to the specific weight, to be an indication of rigidity assessment, was a "specific module". An apparent density of the test specimen was used as the specific gravity. The apparent density of the specimen was measured by dividing the measured weight of the specimen by the volume calculated from the dimensions of the specimen. The result confirmed that the specific modulus in the radial direction of the specimen was higher in Examples 27-29 than in Comparative Example 2.
    Table 6
    Insertion element stiffness evaluation (axial direction).
    An elastic modulus in the axial direction of the specimen of Example 27 was evaluated using the Universal Precision Test Apparatus (AG-100kN Xplus manufactured by Shimadzu Co., Ltd.). Fig. 25 (A) illustrates the external shape of the test piece. Fig. 25 (B) illustrates a state just before the test run. As described above, the specimen had an outside diameter α of 81 mm, the internal diameter β of 73 mm, and the length γ of 30 mm. The test apparatus compressed a specimen 61 by moving a compression end in a downward direction 63. Next, a load displacement curve before specimen 61 exceeds the proportional compressive load limit was obtained to measure a modulus of elasticity in the axial direction. In order to evaluate the rigidity in the axial direction of the test piece, the test piece was arranged so that the two end faces, rather than the outer periphery of the test piece, come into contact with the end of the test piece. compression and a test bench. A falling speed of the compression end was 1 mm / min. Table 7 presents the results. Also, the test pieces of Examples 28 to 30, and Comparative Example 2 were evaluated similarly, and Table 7 presents their results. The modulus of elasticity was calculated from a load displacement curve when the load was 30 to 70 kN. The specific modulus was calculated using the bulk density of the specimen as the specific gravity. The apparent density of the specimen was measured by dividing the measured weight of the specimen by the volume calculated from the dimensions of the specimen. The result confirmed that the specific modulus in the axial direction of the specimen was higher in Examples 27-30 than in Comparative Example 2.
    Table 7
    Thermal conductivity evaluation of insertion element.
    A circular plate having a diameter compatible with a test apparatus was cut from the insertion member of Example 31 to obtain a test piece. The test piece was placed in such a way that the insert and casting aluminum had the same thickness on the interface between them. It should be noted that the circular test piece was cut from a portion near an injection attack (attack side) in the casting with aluminum and a portion farthest from the attack (opposite side attack ). After that, as a thermal conductivity test, specific heat and thermal diffusivity were measured by laser irradiating the test piece melt surface in the atmosphere at room temperature (25 ° C) using a flash laser method with a thermal constant measurement system (TC-7000 manufactured by ULVAC-RIKO, Inc.). Thus, a thermal conductivity was calculated by the following equation (1).
    ... (1)
    In the expression, λ is the thermal conductivity, Cp is the specific heat, a is the thermal diffusivity, and p is the density at room temperature. Density at room temperature was calculated using the dimensions and weight of the specimen measured in the atmosphere at room temperature (25 ° C). Also, samples were cut in a similar manner for Examples 32 to 34 and Comparative Examples 3 and 4, and the thermal conductivity was evaluated. Table 8 presents their results. The results confirmed that the thermal conductivity was higher in Examples 31-34 than in Comparative Examples 3 and 4, and that the specimen collection position was on the attack or opposite side.
    Table 8
    Insertion element adhesion force evaluation.
    Seven square test pieces, each having a V 2 adhesion area of 300 to 500 mm, were cut from the insertion member of Example 31. Next, tension gauges were attached to the aluminum side surface and the cast iron side of the test piece, respectively, with a thermosetting epoxy adhesive, and then a vertical adhesion test was carried out using the universal precision test apparatus (AG-100kN Xplus manufactured by Shimadzu Co., Ltd.). A value obtained by dividing the maximum load when the insert and the aluminum separated from each other by the adhesion area of the specimen before the test was used as the adhesion strength. Also, specimens were cut and evaluated similarly for Examples 31-34 and Comparative Examples 3 and 4. Table 9 illustrates the measured values and the average values of the specimens. Specimens of No. 7 in Example 33 and No. 2 and 7 in Example 34 were separated (broken) in the adhesive portion attached to the tension gauges, but were included in the average value of the force. adhesion. The result confirmed that the adhesion strength between the insert and aluminum was higher in Examples 31-34 than in Comparative Examples 3 and 4.
    Table 9
    List of reference signs. 1 linear portion 1a, 1b, 1c, 1d, the linear portion 2 convergent portion 2a, 2b, 2c, 2d convergence portion 3 convex cross-shaped portion 4 convex upper portion 5 convex portion upper surface 6 bottom (flat surface) of convex part 7 portion (vertical wall) of bottom to upper part of convex part 8 height of convex part
    The long side length of linear portion Lb short side length (width) of linear portion L4 width of convex part top part L7 vertical wall width h3 convex part height h4 height (thickness) of convex part top h7 height vertical wall h9 thickness up to the flat surface of the insertion element F flat surface the circle inscribed.
    权利要求:
    Claims (14)
    [1" id="c-fr-0001]
    CLAIMS l.Insert (11) having a convex portion of cross-linked shape (3) on an insertion surface (IIS), in which the cross-shaped convex portion (3) includes a linear portion (1) and a convergence portion (2) wherein at least two linear portions meet.
    [2" id="c-fr-0002]
    An insert (11) according to claim 1, wherein the convex portion (3) includes at least one of a constricted form and a shape in which a vertical wall of the convex portion (3) is inclined with respect to a line perpendicular to a flat surface (F).
    [3" id="c-fr-0003]
    An insert (11) according to claim 1 or 2, wherein the convex shaped portion (3) includes at least two of the convergence portions (2).
    [4" id="c-fr-0004]
    4. Insert (11) according to claim 3, wherein the number of the joining linear portions (1) differs between the at least two convergence portions (2), and the linear portions (1) meet in random directions.
    [5" id="c-fr-0005]
    An insert (11) according to any one of claims 1 to 4, wherein when the convex shaped portion (3) is projected onto the flat surface (F), a projected area of the convex portion is 5% to 70%, inclusive, of a total projected area.
    [6" id="c-fr-0006]
    6. Insert (11) according to any one of claims 1 to 5, wherein in a flat portion surrounded by the linear portions, a diameter of an inscribed circle (the) tangent to the contour of the flat portion is 0, 5 mm to 30 mm, included.
    [7" id="c-fr-0007]
    An insert (11) according to any one of claims 1 to 6, wherein a height, from a lower surface to an upper surface of an upper portion in the convexly shaped portion (3), is 0. , 1 mm to 5.0 mm, included.
    [8" id="c-fr-0008]
    8. Inseit (11) according to any one of claims 1 to 7, wherein a length in the transverse direction of the linear portion (1) is 0.1 mm to 8.0 mm, inclusive.
    [9" id="c-fr-0009]
    9. Insert (11) according to any one of claims 1 to 8, wherein the insert (11) is a cylinder sleeve for insertion into a cylinder engine block.
    [10" id="c-fr-0010]
    A method of making an insert (11), comprising: applying a mold coating agent to a surface of a mold to which molten metal is to be poured; forming a crack-like mold coating layer on its surface by drying the applied mold coating agent; and pouring the molten metal from above the mold coating layer and performing casting during mold rotation.
    [11" id="c-fr-0011]
    A method of making an insert (11) according to claim 10, wherein the cracks include a plurality of voids reaching the mold surface, from the surface of the mold coating layer, a width of each of the voids is reduced to the surface of the mold, from the surface of the mold coating layer, and / or the voids extend along the surface of the mold.
    [12" id="c-fr-0012]
    A method of making an insert (11) according to claim 10 or 11, wherein the cracks have a crosslinked form.
    [13" id="c-fr-0013]
    A method for making an insert (11) according to any one of claims 10 to 12, wherein the mold coating agent contains at least one fire-resistant material, a binder, and a solvent.
    [14" id="c-fr-0014]
    The method for making an insert (11) according to claim 13, wherein forming a mold coating layer includes evaporating the solvent by heating the mold coating agent to a temperature of not less than a temperature. of evaporation of the solvent and not higher than 110 ° C higher than the evaporation temperature, thus forming the mold-forming layer having a cracks shape.
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    同族专利:
    公开号 | 公开日
    CN107377943A|2017-11-24|
    FR3051380B1|2022-02-25|
    DE102017106458B4|2020-07-16|
    JP2017205780A|2017-11-24|
    JP6256524B2|2018-01-10|
    DE102017106458A1|2017-11-23|
    CN107377943B|2019-09-10|
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    法律状态:
    2018-03-27| PLFP| Fee payment|Year of fee payment: 2 |
    2019-03-27| PLFP| Fee payment|Year of fee payment: 3 |
    2020-03-30| PLFP| Fee payment|Year of fee payment: 4 |
    2021-03-30| PLFP| Fee payment|Year of fee payment: 5 |
    2021-07-23| PLSC| Publication of the preliminary search report|Effective date: 20210723 |
    优先权:
    申请号 | 申请日 | 专利标题
    JP2016098883A|JP6256524B2|2016-05-17|2016-05-17|Cast-in member and manufacturing method thereof|
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