Cylinder Liner Projection Spacing for Stronger Void-Free Cast Bonding
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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.
Innovation Solution
A cylinder liner with 5 to 50 projections per square centimeter and moderate gaps between them, allowing the casting material to spread and reducing void formation, is used. The projections have a specific arrangement and geometry, including a projection area ratio of 5% to 20% and a constriction ratio of 50% or higher, ensuring adequate bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plural projections are formed on the cylinder liner outer peripheral surface to improve bonding strength, then bonding strength is improved, but voids are generated due to insufficient casting material spread
Solution Approach 1:
The invention changes the geometric parameters of projections by specifying the number of projections (5-50 per 1 cm²) and the gap between adjacent projections (maximum 3.8 mm based on line contact method). These parameter adjustments optimize the balance between bonding surface area and casting material flowability, resolving the contradiction between improving bonding strength and preventing void formation.
2Strength
If the number of projections is increased to improve bonding strength, then bonding strength is improved, but casting material spread is hindered
Solution Approach 1:
The invention optimizes the density parameter by limiting projections to 5-50 per 1 cm² and controlling the spatial distribution through the gap specification. This parameter optimization ensures sufficient bonding surface area while maintaining adequate pathways for casting material to flow between projections, preventing material starvation and void formation.
3Strength
If projections are made closer together to increase bonding area, then bonding strength is improved, but casting material cannot sufficiently spread between them
Solution Approach 1:
The invention establishes optimal parameter ranges for projection density (5-50 per 1 cm²) and inter-projection spacing (gap ≤ 3.8 mm). These parameter specifications create an optimal balance where bonding area is maximized while ensuring sufficient material flow paths, thereby achieving both high bonding strength and high casting quality without void defects.
Data Source
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.