Cylinder Liner Projection Layout for Void-Free Insert Casting
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Solution Overview
Problem
In the production of cylinder blocks, the casting material often fails to sufficiently spread between projections on the cylinder liner's outer peripheral surface, leading to voids and insufficient bonding strength between the cylinder liner and the cylinder block, particularly in gravitational casting methods.
Innovation Solution
The cylinder liner features a controlled number and arrangement of projections on its outer peripheral surface, with specific gap settings and projection characteristics that allow the casting material to spread evenly, inhibiting void formation and enhancing bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If projections are formed on the cylinder liner outer peripheral surface to improve bonding strength, then bonding strength between cylinder liner and cylinder block is improved, but voids are generated in the cylinder block due to insufficient spreading of casting material
Solution Approach 1:
The invention changes the geometric parameters of the projections, specifically setting the gap between adjacent projections to 0.5mm or more. This parameter modification allows casting material to sufficiently spread into the regions between projections during gravitational casting, preventing void formation while maintaining bonding strength through the controlled projection geometry
2Productivity
If casting material is poured into the mold to insert-cast the cylinder liner, then the cylinder block is produced, but the casting material does not sufficiently spread between projections leading to voids
Solution Approach 1:
The invention modifies the geometric parameters of the projection arrangement, specifically controlling the gap between adjacent projections to be 0.5mm or more. This parameter change ensures that casting material can sufficiently spread into the regions between projections during gravitational casting, eliminating void formation while maintaining production efficiency
Solution Approach 2:
The invention applies local quality by creating specific gap regions between adjacent projections on the cylinder liner outer peripheral surface. These localized gap regions with controlled dimensions (0.5mm or more) provide pathways for casting material to penetrate and bond properly, while other regions maintain the projection structure for bonding strength
Data Source
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AI summary
The present invention addresses the problem of providing a cylinder liner for insert casting, with which the bonding strength between a cylinder liner and a cylinder block can be improved by reducing voids generated on the cylinder block. The problem is solved by a cylinder liner for insert casting which includes plural projections on its outer peripheral surface and satisfies the following (i) and (ii): (i) the number of the projections is 5 to 50 per 1 cm2 on the outer peripheral surface, and (ii) when two 15.2 mm × 0.03 mm lines are set in parallel with a gap of 3.8 mm therebetween at an arbitrary position on the outer peripheral surface of the cylinder liner, the total number of projections that are in contact with the two lines is 8 or less.