Process and tool for forming a vehicle component

Patent metadata

Field	Value
Publication number	US-2016256921-A1
Application number	US-201514635418-A
Country	US
Kind code	A1
Filing date	Mar 2, 2015
Priority date	Mar 2, 2015
Publication date	Sep 8, 2016
Grant date	—

Abstract

A tool and a process for forming a vehicle component is provided. An insert has a lost core generally encapsulated by a cast metal shell. The insert has an anchor surface and a first locating member spaced apart therefrom, and is shaped to form a fluid passage in the vehicle component. A first die is configured to mate with the anchor surface and constrain the insert. A second die defines a first locator recess sized to receive the first locating member and constrain the insert. The first and second dies mate with one another to form the tool. The first and second dies constrain the insert in multiple degrees of freedom.

First claim

What is claimed is:

1 . A tool for forming a component comprising:
an insert having a lost core generally encapsulated by a cast metal shell, the insert having an anchor surface and a first locating member spaced apart therefrom, the insert shaped to form a fluid passage in the component; a first die configured to mate with the anchor surface; and a second die defining a first locator recess sized to receive the first locating member; and wherein the first and second dies are configured to mate together and constrain movement of the insert in at least five degrees of freedom.

2 . The tool of claim 1 wherein the insert further comprises a second locating member spaced apart from the anchor surface and from the first locating member; the tool further comprising:
a third die defining a second locator recess sized to receive the second locating member and constrain movement of the insert.

3 . The tool of claim 2 wherein the first and second locating members are generally opposed to one another.

4 . The tool of claim 2 wherein the first, second and third dies are configured to mate together and constrain movement of the insert in six degrees of freedom.

5 . The tool of claim 1 , wherein the insert further comprises a metal wall directly adjacent to the lost core, the metal wall configured to conduct heat from the component to the fluid passage.

6 . The tool of claim 5 wherein the insert further comprises a cylinder liner, the metal wall positioned between the cylinder liner and the lost core.

7 . A process of forming a vehicle component comprising:
positioning an insert into at least two dies of a tool, the insert having a lost core within a metal shell; closing the dies around the insert to constrain movement of the insert relative to the tool in at least four degrees of freedom; injecting material into the tool to form the component; and removing the lost core to form a fluid passage in the component.

8 . The process of claim 7 further comprising closing the dies around the insert such that movement of the insert is constrained relative to the tool in six degrees of freedom.

9 . The process of claim 7 further comprising forming an insert having a first locating feature sized to be received by one of the dies, and a second locating feature sized to be received by another of the dies, the first and second locating features constraining movement of the insert in three degrees of freedom, the first and second locating features each containing a portion of the lost core.

10 . The process of claim 9 further comprising forming an insert having an anchor surface sized to be received by a third die of the tool, the anchor surface constraining movement of the insert in three degrees of freedom.

11 . The process of claim 7 further comprising forming the insert by casting the metal shell around the lost core;
wherein the insert is formed prior to being positioned in the tool.

12 . The process of claim 11 wherein casting the metal shell comprises die casting by injecting molten metal at a pressure of less than 10 psi, wherein the molten metal comprises aluminum.

13 . The process of claim 7 further comprising removing the lost core to provide a fluid passage in the vehicle component after forming the component.

14 . The process of claim 7 wherein injecting material into the tool comprises injecting molten metal at a pressure of at least 20,000 psi, wherein the molten metal comprises aluminum.

15 . The process of claim 7 wherein injecting material into the tool comprises injecting a polymer material in an injection molding process.

16 . The process of claim 7 further comprising forming an insert having a first locating feature sized to be received by one of the dies, and a second locating feature sized to be received by another of the dies, the first and second locating features each containing a portion of the lost core, the first and second locating features positioned to constrain movement of the insert in the tool and positioned to oppose a reactive force on the insert caused by flow of injected material.

17 . The process according to claim 7 further comprising forming the insert with a metal wall directly adjacent to the lost core, a thickness of the metal wall greater than a thickness of the metal shell, the metal wall configured to conduct heat from the vehicle component to the fluid passage.

18 . A tool for forming an engine component, comprising:
an insert having a longitudinal axis, a first transverse axis, and a second transverse axis, the insert including:
a metal wall,
a lost core having an outer surface, a portion of the outer surface in contact with a surface of the metal wall, the lost core shaped to provide a fluid passage in the component, the core forming a locating edge, a first locating member extending outwardly from an intermediate region of the core along the first transverse axis, and a second locating member extending outwardly from the intermediate region of the core along the second transverse axis, the second locating member spaced apart from the first locating member, and
a metal shell in contact with and covering another portion of the outer surface of the lost core; and
a first die configured to move in translation along the longitudinal axis and having a locating surface configured to mate with the locating edge of the insert to constrain movement of the insert; a second die having a first locating recess sized to receive the first locating member to constrain movement of the insert, the second die configured to move in translation along the first transverse axis; and a third die having a second locating recess sized to receive the second locating member to constrain movement of the insert, the third die configured to move in translation along the second transverse axis.

19 . The tool according to claim 18 wherein the metal wall has a first thickness, and the shell has a second thickness, the first thickness greater than the second thickness.

20 . The tool according to claim 18 wherein the insert further comprises a cylinder liner, the metal wall surrounding an outer circumference of the cylinder liner and adjacent to an end of the cylinder liner;
wherein the locating edge of the insert is adjacent to the end of the cylinder liner; and
wherein the first die includes a mandrel sized to be received in the cylinder liner.

Assignees

• Ford Global Tech Llc

Inventors

• Maki Clifford E
• Schepak Antony George

Classifications

• B22D17/24 Primary

  Accessories for locating and holding cores or inserts · CPC title

• B29C33/52 Primary

  soluble or fusible {(in particular used in injection moulding B29C45/4457)} · CPC title

• B29C41/36

  Feeding the material on to the mould, core or other substrate · CPC title

• B22D19/009

  for casting objects the members of which can be separated afterwards · CPC title

• B22D15/00

  Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor · CPC title