Complex Cast Component and Casting Method Therefor

Patent metadata

Field	Value
Publication number	US-2016208901-A1
Application number	US-201615083439-A
Country	US
Kind code	A1
Filing date	Mar 29, 2016
Priority date	Nov 14, 2013
Publication date	Jul 21, 2016
Grant date	—

Abstract

A complex cast component of an internal combustion engine, in particular a crankshaft or a camshaft, has a longitudinal axis, a plurality of regions, along the longitudinal axis, and a first cavity. Each of the plurality of regions has a certain cool-down rate during a solidification process of a casting process. The first cavity is arranged in a first region of the plurality of regions and has a volume that depends on a first cool-down rate of the first region. In this way, a material thickness in the first region likewise depends on the first cool-down rate.

First claim

What is claimed is:

1 . A complex cast component of an internal combustion engine, comprising:
a component having a longitudinal axis, a multiplicity of regions along the longitudinal axis, wherein each region of the multiplicity of regions has a specific cooling rate during a solidification process during a course of a casting process of the component, and a first cavity which is arranged in a first region of the multiplicity of regions and which has a volume dependent on a first cooling rate of the first region, wherein a material thickness in the first region is dependent on the first cooling rate.

2 . The complex cast component according to claim 1 , further comprising:
a second cavity in a second region of the multiplicity of regions, a second volume of which second cavity is dependent on a second cooling rate of the second region, wherein the first cavity has a smaller volume in relation to the first region than the second cavity has in relation to the second region, wherein a first material thickness in the first region of the complex cast component is greater than a second material thickness in the second region of the complex cast component.

3 . The complex cast component according to claim 2 , wherein the first and/or second region has a large volume in relation to the cast component as a whole.

4 . The complex cast component according to claim 1 , further comprising:
a multiplicity of cavities, wherein each cavity of the multiplicity of cavities is arranged in a region of the cast component, and a respective volume of the cavities is dependent on a specific cooling rate in relation to the respective region, wherein the respective volume increases along the longitudinal axis of the complex cast component, such that, the material thickness in the respective region of the corresponding cavity correspondingly decreases along the longitudinal axis.

5 . The complex cast component according to claim 1 , wherein the complex cast component is a crankshaft and each region of the multiplicity of regions at least partially comprises either a main bearing or a pin bearing.

6 . The complex cast component according to claim 1 , wherein the complex cast component is a crankshaft, and the first region comprises a main bearing at one axial end of the crankshaft and/or a second region comprises another main bearing at an opposite axial end of the crankshaft.

7 . The complex cast component according to claim 1 , wherein the complex cast component is a crankshaft which has a cavity in each pin bearing, wherein a volume of the cavities in relation to the respective region increases along the longitudinal axis of the crankshaft.

8 . The complex cast component according to claim 1 , wherein the complex cast component has eight cavities and/or wherein at least two of the cavities are connected to one another via a duct.

9 . An internal combustion engine comprising a complex cast component according to claim 1 .

10 . A motor vehicle comprising an internal combustion engine according to claim 9 .

11 . A casting method for producing a complex cast component of an internal combustion engine, the method comprising the acts of:
providing a casting mold; providing a first core having a first volume selected on a basis of a first cooling rate in a first region of a multiplicity of regions of the cast component during a solidification process; arranging the first core in the casting mold such that the core is arranged in the first region during a subsequent solidification process of a casting material; introducing the casting material into the casting mold; and removing a finished cast component from the casting mold after the solidification process is complete.

12 . The casting method according to claim 11 , further comprising the act of:
providing a second core having a second volume selected on a basis of a second cooling rate in a second region of the multiplicity of regions of the cast component during a solidification process, wherein the first volume of the first core in relation to the first region is smaller than the second volume of the second core in relation to the second region.

13 . The casting method according to claim 12 , wherein:
a multiplicity of cores is provided, which are arranged in the casting mold such that a volume of the respective core is dependent on a specific cooling rate in relation to the respective region in which the respective core is arranged, the respective volume increases along a longitudinal axis of the cast component to be cast, and p 1 the respective regions take up a large volume in relation to the component as a whole.

14 . The casting method according to claim 13 , wherein the respective regions take up equal volumes in relation to the component as a whole.

15 . The casting method according to claim 13 , wherein, as material of the first, of the second and/or of the multiplicity of cores, a material is selected which has a high heat abstraction rate.

16 . The casting method according to claim 15 , wherein the material is a chromium or sand.

17 . The casting method according to claim 11 , wherein the casting method is a shell mold casting method.

18 . The complex cast component according to claim 1 , wherein the component is a crankshaft or a camshaft of the internal combustion engine.

Assignees

• Bayerische Motoren Werke Ag

Inventors

• Huber Markus

Classifications

• B22C1/00

  Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds · CPC title

• B22D25/02

  by its peculiarity of shape; of works of art {(cylinders, pistons B22D15/02)} · CPC title

• F16H53/025 Primary

  characterised by their construction, e.g. assembling or manufacturing features · CPC title

• F16C3/06

  Crankshafts · CPC title

• B22C9/103

  Multipart cores · CPC title