Cylinder block cast core casting geometry for saw cut inlet enhancement

Abstract

The present invention relates to a cylinder block casting plate core casting geometry for saw cut access enhancement. An automotive vehicle engine includes a plurality of water jackets individually formed proximate to successive ones of a plurality of bores in a cast engine block. A plurality of in situ cast transition regions are individually formed at inlets of individual ones of the plurality of water jackets during a casting operation of the cast engine block. Individual ones of a plurality of saw cuts open into individual ones of the plurality of in situ cast transition regions.

Description

[0001] Government License Rights

[0002] This invention was made with government support under United States Department of Energy (USDOE) contract DE-EE0008877 awarded by the USDOE. The government has certain rights in the invention. TECHNICAL FIELD

[0003] The present disclosure relates to an automotive vehicle engine cylinder block with water jacket cooling passages. BACKGROUND

[0004] In automotive vehicle engine blocks, a saw cut is machined into the cylinder head region proximate to the coolant inlet ramp to enhance coolant flow to the cylinder wall. Current processes for the saw cut geometry require machining of the saw cut in a separate cylinder bore bridge and a ramp between the saw cut and the coolant inlet port. The production block will then contain a sharp corner between the water jacket casting surface and the saw cut, which creates a high stress concentration and reduces the safety factor. In addition to the difficulty of machining the saw cut, the existing inlet ramp shape is difficult to measure and the location tolerance of the inlet ramp is difficult to control.

[0005] Accordingly, while the current engine coolant saw cut designs for use in automotive vehicle engine blocks achieve their intended purpose, there is a need for new and improved engine block designs having improved coolant flow designs. SUMMARY

[0006] According to aspects, an automotive vehicle engine includes a plurality of water jackets individually formed proximate to successive ones of a plurality of cylinder bores in a cast engine block. A plurality of as-cast transition regions are individually formed at an inlet of each of the plurality of water jackets during a casting operation of the cast engine block. Each of a plurality of saw cuts opens into each of the plurality of as-cast transition regions.

[0007] In another aspect of the present disclosure, a curved region of the as-cast transition region opens into one of the plurality of water jackets, the curved region formed during casting at a junction of each of the plurality of water jackets and each of the as-cast transition regions.

[0008] In another aspect of the present disclosure, each of the plurality of saw cuts extends into the curved region.

[0009] In another aspect of the present disclosure, the plurality of as-cast transition regions define a semicircular slot extending through the curved region.

[0010] In another aspect of the disclosure, the plurality of cast-in-place transition regions includes: a first downwardly tapering channel transitioning at a first interface into a second downwardly tapering channel; a surface channel interface between an open end of one of the plurality of kerf sections and the second downwardly tapering channel; and the second downwardly tapering channel transitioning via a second interface into a curved region leading to a water jacket.

[0011] In another aspect of the disclosure, the plurality of cast-in-place transition regions each include a tapered portion leading to a continuous width portion.

[0012] In another aspect of the disclosure, the plurality of kerf sections have a first continuous width over a length of the plurality of kerf sections.

[0013] In another aspect of the disclosure, the continuous width portion defines a semi-circular or concave shape over an entire length of the continuous width portion and has a second continuous width that is greater than the first continuous width.

[0014] In another aspect of the disclosure, the cast-in-place transition region and the corner radius are collectively formed by a sand board core during casting.

[0015] In another aspect of the disclosure, the cast-in-place transition region, the corner radius, and the semi-circular channel are collectively shaped by a sand board core during casting.

[0016] According to aspects, an automotive vehicle engine block includes a plurality of water jackets individually formed proximate to respective bores in a cast engine block. A plurality of cast-in-place transition regions are individually formed during a casting operation to form the cast engine block positioned proximate to respective ones of the plurality of water jackets. A curved region of each of the cast-in-place transition regions leads to one of the plurality of water jackets. The cast-in-place transition regions including the curved regions are collectively formed as a sand board core during casting.

[0017] In another aspect of the disclosure, the plurality of kerf sections are formed in respective bore bridges positioned between consecutive bores in the bores.

[0018] In another aspect of the disclosure, each of the plurality of kerf sections leads into a respective one of the plurality of cast-in-place transition regions.

[0019] In another aspect of the disclosure, the plurality of cast-in-place transition regions have a first end proximate to the curved region and a second end leading to one of the plurality of kerf sections, the second end being narrower than the first end.

[0020] In another aspect of the disclosure, each of the plurality of cast-in-place transition regions includes a first semicircular portion having a first transition to a second semicircular portion, and a surface slot interface positioned between an open end of each of the plurality of saw cuts and the second semicircular portion.

[0021] In another aspect of the disclosure, the curved region has a concave shape.

[0022] In another aspect of the disclosure, the second transition transitions from the second semicircular portion to a third semicircular portion that slopes downwardly leading to a water jacket.

[0023] According to several aspects, a method for making an automotive vehicle engine block includes forming a plurality of water jackets proximate to each of a plurality of cylinder bores, individually positioning a plurality of cast-in-place transition regions at an inlet of each of the plurality of water jackets, and forming a curved region of each of the cast-in-place transition regions leading to one of the plurality of water jackets.

[0024] In another aspect of the disclosure, the method further includes, during casting, collectively forming the cast-in-place transition regions including the curved region as a sand plate core, and forming a core insert for insertion into the sand plate core.

[0025] In another aspect of the disclosure, the method further includes forming a core insert having an inorganic sand core insert.

[0026] 1. An automotive vehicle engine comprising:

[0027] a plurality of water jackets individually formed proximate to successive ones of a plurality of cylinder bores in a cast engine block;

[0028] a plurality of cast-in-place transition regions individually formed at an inlet of each of the plurality of water jackets during a casting operation of the cast engine block; and

[0029] a plurality of saw cuts, each of the plurality of saw cuts leading to each of the plurality of cast-in-place transition regions.

[0030] 2. The automotive vehicle engine of aspect 1, further comprising a curved region of the cast-in-place transition region leading to one of the plurality of water jackets, the curved region formed during casting at a junction of each of the plurality of water jackets and each of the cast-in-place transition regions.

[0031] 3. The automotive vehicle engine of aspect 2, wherein each of the plurality of saw cuts extends into the curved region.

[0032] 4. The automotive vehicle engine of aspect 2, wherein the plurality of cast-in-place transition regions define a semi-circular slot extending through the curved region.

[0033] 5. The automotive vehicle engine of aspect 4, wherein the plurality of cast-in-place transition regions comprise:

[0034] a first downwardly tapering slot transitioning at a first interface to a second downwardly tapering slot;

[0035] a surface slot interface between an open end of one of the plurality of saw cuts and the second downwardly tapering slot; and

[0036] the second downwardly tapering slot transitioning via a second interface to a curved region leading to one of the plurality of water jackets.

[0037] 6. The automotive vehicle engine of aspect 1, wherein the plurality of cast-in-place transition regions each comprise a tapered portion leading to a continuous width portion.

[0038] 7. The automotive vehicle engine of aspect 6, wherein the plurality of saw cuts have a first continuous width over a length of the plurality of saw cuts.

[0039] 8. The automotive vehicle engine block of aspect 7, wherein the continuous width portion defines a semi-circular or concave shape over the entire continuous width portion and has a second continuous width that is greater than the first continuous width.

[0040] 9. The automotive vehicle engine of aspect 2, wherein the cast-in-place transition region and the curved region are collectively formed by a sand plate core during casting.

[0041] 10. The automotive vehicle engine of aspect 1, comprising:

[0042] a sand plate core, wherein the cast-in-place transition region is collectively shaped by the sand plate core during casting; and

[0043] a core insert for insertion into the sand plate core; and

[0044] wherein the core insert comprises an inorganic sand core insert.

[0045] 11. An automotive vehicle engine block, comprising:

[0046] a plurality of water jackets formed separately proximate to each of a plurality of cylinder bores in a cast engine block;

[0047] a plurality of in-situ cast transition regions formed separately and positioned proximate to each of the plurality of water jackets during a casting operation forming the cast engine block; and

[0048] a curved region of each of the in-situ cast transition regions, the curved region leading to one of the plurality of water jackets, the in-situ cast transition region including the curved region formed collectively as a sand panel core during casting.

[0049] 12. The automotive vehicle engine block of Solution 11, further comprising a plurality of saw cuts formed in each of a plurality of cylinder bridge positioned between successive cylinder bores of a plurality of cylinder bores.

[0050] 13. The automotive vehicle engine block of Solution 12, further comprising each of a plurality of saw cuts, the saw cut leading to each of the plurality of in-situ cast transition regions.

[0051] 14. The automotive vehicle engine block of Solution 13, wherein a first end of the plurality of in-situ cast transition regions is positioned proximate to the curved region and a second end of the plurality of in-situ cast transition regions leads to one of the plurality of saw cuts, the second end being narrower than the first end.

[0052] 15. The automotive vehicle engine block of Solution 12, wherein each of the plurality of in-situ cast transition regions comprises:

[0053] a first semicircular portion having a first transition zone to a second semicircular portion; and

[0054] a surface groove interface between an open end of each of the plurality of saw cuts and the second semicircular portion.

[0055] 16. The automotive vehicle engine block of Solution 15, wherein the curved region has a concave shape.

[0056] 17. The automotive vehicle engine block of Solution 16, further comprising a second transition zone transitioning from the second semicircular portion to a third semicircular portion that is downwardly sloped, the third semicircular portion leading to one of the plurality of water jackets.

[0057] 18. A method for casting an automotive vehicle engine block, comprising:

[0058] a plurality of water jackets are formed proximate each bore;

[0059] one of the plurality of in-situ cast transition regions is individually positioned at each inlet of the plurality of water jackets; and

[0060] a curved region of each of the plurality of in-situ cast transition regions leading to one of the plurality of water jackets is formed.

[0061] 19. The method of aspect 18, further comprising:

[0062] the plurality of in-situ cast transition regions, including the curved regions, are collectively formed into a sand plate core during casting; and

[0063] a core insert for insertion into the sand plate core is formed.

[0064] 20. The method of aspect 19, further comprising forming the core insert with an inorganic sand core insert.

[0065] Further areas of application will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0066] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.

[0067] Figure 1 is a top plan view of a cylinder block cast plate core casting geometry with surface groove inlets according to an exemplary aspect;

[0068] Figure 2 is a modified top perspective view from Figure 1

[0069] Figure 3 is a modified top perspective view from Figure 1

[0070] Figure 4 is a top perspective view of region 4 of Figure 1

[0071] Figure 5 is a top perspective view of region 5 of Figure 1

[0072] Figure 6 is a top perspective view of region 6 of Figure 1

[0073] Figure 7 is a top perspective view of region 7 of Figure 1 ​​​​​a cross-sectional side elevation view of a water jacket formed at the interface of the as-cast plate core of the exemplary aspects of the processing table and the

[0074] Figure 8 is a cross-sectional side elevation view of a water jacket formed at the interface of the as-cast plate core of the exemplary aspects of the processing table and the Figure 1 is a cross-sectional side elevation view of a water jacket formed at the interface of the as-cast plate core of the exemplary aspects of the processing table and the DETAILED DESCRIPTION

[0075] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application or uses.

[0076] Referring to Figure 1 , having a surface pocket inlet 10, the cylinder block cast plate core cast geometry includes an engine cylinder block casting 12 for an engine of an automotive vehicle having an exemplary plurality of bores, including a first bore 14, a second bore 15, a third bore 16, and a fourth bore 18. Successive pairs of bores are separated by a bore bridge, such as the exemplary first bore bridge 19. The number of bores is not deterministic and can vary from two to twelve bores within the scope of the present disclosure. Between successive ones of the bores, coolant is fed into respective ones of a plurality of water jackets formed in the bore bridges during casting, including a first water jacket 20 formed between the first bore 14 and the second bore 15, a second water jacket 22 formed between the second bore 15 and the third bore 16, and a third water jacket 24 formed between the third bore 16 and the fourth bore 18.

[0077] To facilitate effective cooling flow from the water jackets, after the casting operation is complete, a saw cut is machined in respective ones of the bore bridges, such as, for example, a first saw cut 26 is machined in the first bore bridge 19. The known saw cut creates a coolant passage that includes a sharp corner and edge at an inlet ramp between the saw cut and the water jacket. The known saw cut geometry inhibits coolant flow, therefore, according to aspects, a transition area is formed between the location in the bore bridge where the saw cut will be machined and the respective ones of the water jackets during the casting operation. The transition area provides a streamlined flow path, where the respective ones of the saw cuts lead to the respective ones of the water jackets. According to aspects, the transition area can vary in geometry, providing a plurality of alternative transition area designs to enhance coolant flow.

[0078] According to aspects, when the first saw cut 26 is subsequently machined, a first transition area 28 is created during casting at the first water jacket 20 and at the inlet location of the first saw cut 26. The first transition area 28 is referenced with respect to Figure 4are shown and described in greater detail. After casting, a second saw cut 30 is machined in a second cylinder bore bridge 31 that separates the second cylinder bore 15 from the third cylinder bore 16. When the second saw cut 30 is subsequently machined, a second transition region 32 is formed during casting at the inlet location of the second water jacket 22 and the second saw cut 30. The second transition region 32 is referenced by the numeral 32 in FIG. 1. Figure 5 are shown and described in greater detail. Similarly, after casting, a third saw cut 34 is machined in a third cylinder bore bridge 35 that separates the third cylinder bore 16 from the fourth cylinder bore 18. When the third saw cut 34 is subsequently machined, a third transition region 36 is formed during casting at the inlet location of the third water jacket 24 and the third saw cut 34. The third transition region 36 is referenced by the numeral 36 in FIG. 1. Figure 6 are shown and described in greater detail.

[0079] According to aspects, a minimum gap 38 of 4.5 mm is maintained between the cylinder bore wall 40 of any cylinder bore and the closest point of the transition region wall 42 of the transition region to the cylinder bore wall 40 of any transition region. The minimum gap 38 is maintained to preserve the operational strength and stiffness of the engine cylinder block casting 12 where casting material is omitted to create the transition region.

[0080] Referring to Figure 2 and referring again to Figure 1 According to aspects, the cylinder block cast core casting geometry with surface groove inlet 44 differs from the cylinder block cast core casting geometry with surface groove inlet 10 as follows. A saw cut 46 having a first continuous width 47 over its length is machined into a machining land 48 of a fourth cylinder bore bridge 50 that separates an exemplary cylinder bore 52 and the next consecutive cylinder bore 54. The saw cut 46 opens into a transition region 58 having a tapered portion 60 at an interface 56 that opens into a continuous width portion 62. The continuous width portion 62 defines a semi-circular or concave shape over its entire length and has a second continuous width 64 that is greater than the first continuous width 47 of the saw cut 46. The saw cut 46 transitions from the continuous width portion 62 via a curved transition region 66 to a curved portion 68 to open into a water jacket 70. The interface junction 72 between the continuous width portion 62 and the curved portion 68 is radiused to further reduce coolant flow resistance and flow drag.

[0081] Referring to Figure 3 and referring again to Figure 1 and Figure 2According to several aspects, the cylinder block cast core geometry with surface slot inlet 74 differs from the cylinder block cast core geometry with surface slot inlet 10 and the cylinder block cast core geometry with surface slot inlet 44 as follows. A saw cut 76 having a first continuous width 77 over its length is machined into a machined land 78 of a fifth bore bridge 79 that separates consecutive bores. The saw cut 76 at a fillet interface 80 leads to a transition area 82 that defines a continuously tapered portion 84 that continuously increases in width between the fillet interface 80 and a curved transition area 86. The curved transition area 86 transitions to a curved portion 88 that leads to a water jacket 90. The continuously tapered portion 84 defines a semi-circular or concave shape over its entire length. An interface joint 92 between the transition area 82 and the curved transition area 86 is radiused to further reduce coolant flow resistance and flow drag.

[0082] Referring to Figure 4 and again to Figure 1 , the first transition area 28 can include a downwardly sloped portion 94 that transitions to a curved area 96 leading to the first water jacket 20. A surface slot interface 98 between the open end of the first saw cut 26 and the curved area 96 reduces turbulence of coolant flowing into the first saw cut 26.

[0083] Referring to Figure 5 and again to Figure 1 , the second transition area 32 can include a first downwardly tapered slot 100 that transitions at a first interface 102 into a second downwardly tapered slot 104. A surface slot interface 106 between the open end of the second saw cut 30 and the second downwardly tapered slot 104 reduces turbulence of coolant flowing into the second saw cut 30. The second downwardly tapered slot 104 transitions via a second interface 108 to a curved area 110 leading to the second water jacket 22.

[0084] Referring to Figure 6 and again to Figure 1 , the third transition area 36 differs from the first transition area 28 in that a semi-circular flow channel is used. The third transition area 36 can include a first semi-circular portion 112 that changes at a first transition 114 to a second semi-circular portion 116. A surface slot interface 118 between the open end of the third saw cut 34 and the second semi-circular portion 116 reduces turbulence of coolant flowing into the third saw cut 34. From the second semi-circular portion 116, a second transition 120 transitions to a downwardly sloped third semi-circular portion 122 that leads to the third water jacket 24.

[0085] Referring to Figure 7 and again to Figure 1The as-cast geometry of the plate core 124 provides approximately 10 mm of water jacket 126 below the parting line 128 at approximately 4.75 mm below the machining land 130 eliminates the need to machine a V-saw cut.

[0086] Referring to Figure 8 and again referring to Figure 7 The water jacket 132 formed at the interface with the machining land 130 and the plate core 134 provides approximately 10 mm of water jacket geometry 136 at multiple locations within the plate core 134. The parting line is provided at approximately 4.75 mm below the machining land 130 only at the locations of the water jacket geometry 136 to provide for the formation of a transition region 138 that can be formed into any of the transition regions discussed herein.

[0087] The cylinder block cast plate core castings geometry of the present disclosure having a surface slot inlet provides several advantages. These advantages include eliminating sharp corners between the casting water jacket and the known saw cut to produce a more streamlined shape cast into the cylinder block. This geometry provides a transition region that eliminates the machined entry ramp of the saw cut for machining. The slot sand core can be formed using an inorganic sand core insert molded with the sand plate core.

[0088] The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.

Claims

1. An automotive vehicle engine, comprising: a plurality of water jackets individually formed proximate to successive ones of a plurality of bores in a cast engine block; a plurality of in-situ cast transition areas individually formed at an inlet of each of the plurality of water jackets during a casting operation of the cast engine block; a plurality of saw cuts, each of the plurality of saw cuts leading to a respective one of the plurality of in-situ cast transition areas; and a curved area of the plurality of in-situ cast transition areas leading to one of the plurality of water jackets, the curved area formed during casting at a junction of each of the plurality of water jackets and a respective one of the in-situ cast transition areas, wherein the plurality of in-situ cast transition areas define a semi-circular slot extending through the curved area. Each of the plurality of saw cuts extends into the curved area.

2. The automotive vehicle engine of claim 1 wherein, The plurality of in-situ cast transition areas includes:

3. The automotive vehicle engine of claim 1 wherein, a first downwardly tapering slot transitioning at a first interface to a second downwardly tapering slot; a surface slot interface between an open end of one of the plurality of saw cuts and the second downwardly tapering slot; and the second downwardly tapering slot transitioning via a second interface to the curved area leading to one of the plurality of water jackets. Each of the plurality of in-situ cast transition areas includes a tapered portion leading to a continuous width portion.

4. The automotive vehicle engine of claim 1, wherein, The plurality of saw cuts has a first continuous width over a length of the plurality of saw cuts.

5. The automotive vehicle engine of claim 4 wherein, The continuous width portion defines a semi-circular or concave shape over the entire continuous width portion and has a second continuous width that is greater than the first continuous width.

6. The automotive vehicle engine block of claim 5 wherein, The in-situ cast transition area and the curved area are collectively formed during casting by a sand plate core.

7. The automotive vehicle engine of claim 1, wherein, 8. The automotive vehicle engine of claim 1, comprising: a sand plate core, wherein the in-situ cast transition area is collectively shaped during casting by the sand plate core; and a core insert for insertion into a sand plate core; and wherein the core insert comprises an inorganic sand core insert.

9. An automotive vehicle engine block, comprising: a plurality of water jackets individually formed proximate to each of a plurality of bores in a cast engine block; a plurality of in-situ cast transition areas individually formed during a casting operation forming the cast engine block and positioned proximate to each of the plurality of water jackets; a curved area of each of the in-situ cast transition areas leading to one of the plurality of water jackets, the in-situ cast transition area including the curved area collectively formed during casting as a sand plate core; and a plurality of saw cuts formed in each of a plurality of bore bridges positioned between successive ones of a plurality of bores, wherein each of the plurality of in-situ cast transition areas includes: a first semi-circular portion having a first transition zone to a second semi-circular portion; and a surface slot interface between an open end of each of the plurality of saw cuts and the second semi-circular portion. ​ 10. The automotive vehicle engine block of claim 9, further comprising a respective one of a plurality of saw cuts leading to a respective one of the plurality of cast-in-place transition regions.

11. The automotive vehicle engine block of claim 10 wherein, A first end of the plurality of cast-in-place transition regions is positioned closest to the curved region, and a second end of the plurality of cast-in-place transition regions leads to one of the plurality of saw cuts, the second end being narrower than the first end.

12. The automotive vehicle engine block of claim 9 wherein, The curved region has a concave shape.

13. The automotive vehicle engine block of claim 12, further comprising a second transition region transitioning from the second semi-circular portion to a third semi-circular portion that is sloped downwardly leading to one of the plurality of water jackets.

14. A method for casting an automotive vehicle engine block, comprising: forming a plurality of water jackets individually formed proximate to successive ones of a plurality of bores in a cast engine block; forming a plurality of cast-in-place transition regions individually formed at an inlet of a respective one of the plurality of water jackets during a casting operation of the cast engine block; forming a plurality of saw cuts, a respective one of the plurality of saw cuts leading to a respective one of the plurality of cast-in-place transition regions; and forming a curved region of the plurality of cast-in-place transition regions leading to one of the plurality of water jackets; the curved region formed during casting at a junction of a respective one of the plurality of water jackets and a respective one of the cast-in-place transition regions, wherein the plurality of cast-in-place transition regions define a semi-circular slot extending through the curved region.

15. The method of claim 14, further comprising: collectively forming the plurality of cast-in-place transition regions including the curved region as a sand board core during casting; and forming a core insert for insertion into the sand board core.

16. The method of claim 15, further comprising forming the core insert with an inorganic sand core insert. ​

Images