The present invention relates to cylindrical surfaces of cylindrical engine bores.
Automotive engine blocks include a number of cylindrical engine bores. The inner surface of each engine bore is machined so that the surface is suitable for use in automotive applications, e.g., exhibits suitable wear resistance and strength. The machining process may include roughening the inner surface and subsequently applying a metallic coating to the roughened surface and subsequently honing the metallic coating to obtain a finished inner surface. Various surface roughening techniques are known in the art, but have suffered from one or more drawbacks or disadvantages.
In a first embodiment, a cylinder bore is disclosed. The cylinder bore includes an inner surface including an axial travel area and an axial non-travel area including two discontinuous axial widths of the cylindrical bore and the axial travel area extending therebetween. A nominal diameter of the axial travel area is greater than that of the axial non-travel area. A plurality of annular grooves is formed in the two discontinuous axial widths of the cylindrical bore.
In a second embodiment, a cylinder bore is disclosed. The cylinder bore includes first and second axial non-travel inner surface portions and an axial travel inner surface portion extending therebetween. A nominal diameter of the axial travel inner surface portion is greater than that of the first and second axial non-travel inner surface portions. A plurality of the annular grooves is formed in each of the first and second axial non-travel inner surface portions. A plurality of peaks extends between the plurality of annular grooves.
In a third embodiment, a cylinder bore is disclosed. The cylinder bore includes first and second axial non-travel inner surface portions and an axial travel inner surface portion extending therebetween. A nominal diameter of the axial travel inner surface portion is greater than that of the first and second axial non-travel inner surface portions. A plurality of annular grooves is formed in each of the first and second axial non-travel areas and has a square wave shape of a uniform dimension.
Reference will now be made in detail to embodiments known to the inventors. However, it should be understood that disclosed embodiments are merely exemplary of the present invention which may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, rather merely as representative bases for teaching one skilled in the art to variously employ the present invention.
Except where expressly indicated, all numerical quantities in this description indicating amounts of material are to be understood as modified by the word “about” in describing the broadest scope of the present invention.
Automotive engine blocks include a number of cylindrical engine bores. The inner surface of each engine bore is machined so that the surface is suitable for use in automotive applications, e.g., exhibits suitable wear resistance and strength. The machining process may include roughening the inner surface and subsequently applying a metallic coating to the roughened surface and subsequently honing the metallic coating to obtain a finished inner surface with requisite strength and wear resistance. Alternatively, a liner material having requisite strength and wear resistance characteristics may be applied to the unfinished inner surface of the engine bore.
Embodiments disclosed herein provide cutting tools and processes for roughening the inner surface of cylindrical bores, e.g., engine bores, to enhance the adhesion and bonding of a subsequently applied metallic coating, e.g., thermal spray coating, onto the inner surface. Accordingly, the finished inner surface may have enhanced strength and wear resistance.
The length of the travel area corresponds to the distance in which a piston travels within the engine bore. In some variations, the length of travel area 202 is 90 to 150 millimeters. In one variation, the length of travel area 202 is 117 millimeters. The travel area surface is manufactured to resist wear caused by piston travel. The cutting tool forms annular grooves 204 (as shown in magnified area 208 of
The pre-bored inner surface 200 also includes non-travel portions 214 and 216. These areas are outside the axial travel distance of the piston. Dimensions 218 and 220 show the length of non-travel portions 214 and 216. In some variations, the length of non-travel area 214 is 2 to 7 millimeters. In one variation, the length of non-travel area 214 is 3.5 millimeters. In some variations, the length of non-travel area 216 is 5 to 25 millimeters. In one variation, the length of non-travel area 216 is 17 millimeters. The cutting tool and the interpolating step are described in greater detail below.
In the embodiment shown, the arrangement of teeth on the G1 and G2 cutting elements are dimensioned differently. Regarding G1 shown in
In some variations, there is at least one of G1 and G2 and at least one of P. As shown in
Referring to
In the embodiment shown, the arrangement of teeth on the G1 and G2 cutting elements are dimensioned differently. Regarding G1 shown in
Referring to
Having described the structure of cutting tool 300 according to one embodiment, the following describes the use of cutting tool 300 to machine a profile into an inner surface of a cylinder bore.
In one embodiment, the aspect ratio of the diameter of the cutting tool DT to the inner diameter of the bore DB is considered. In certain variations, the inner diameter is substantially greater than the cutting tool diameter. In certain variations, the cutting tool diameter is 40 to 60 millimeters. In certain variations, the inner diameter of the cylinder bore is 70 to 150 millimeters. Given this dimensional difference, this cutting tool may be utilized with a significant variation in bore diameter. In other words, use of the cutting tools of one or more embodiments does not require separate tooling for each bore diameter.
Regarding the pre-boring step of
Regarding the interpolating step of
As described above, cutting tool 300 includes cylindrical body 302 that includes four rows of cutting elements. According to this embodiment, the axial length of the cut is 35 mm. Therefore, if the length of the travel area is 105 mm, three axial steps are used to complete the interpolating of the travel area. In other words, the axial position of the spindle is set at an upper, middle and lower position before rotating the cutting tool at each of the positions. While 4 cutting element rows are shown in one embodiment, it is understood that additional rows may be utilized. For example, 6 rows may be used to cut a similar travel area in 2 axial steps instead of 3. Further, 12 rows may be used to cut a similar travel area in 1 axial step.
Moving to
The groove cutting elements G1 and G2 remove material 504 to create peaks 506. The height of these peaks is h and the width is wp. In the non-limiting, specific example shown, wp is 150 microns. The h value is determined by the radial offset between the top of groove cutting elements G1 and G2 and the pocket cutting element P. In the non-limiting, specific example set forth above, this offset is 120 microns. Therefore, h is 120 microns. The wv value corresponds to the length of the flat valleys between groove-cutting teeth top surfaces. In the non-limiting, specific example set forth above, the valley length is 250 microns. Accordingly, wv is 250 microns. Given the rotational speed of cutting tool 300, the cutting of the pocket and annular grooves described above occurs simultaneously or essentially simultaneously, e.g., for a period of time equal to a ⅙ revolution of the cutting tool 300, if the cutting tool includes six cutting elements and adjacent elements are groove and pocket cutting elements.
Regarding the deforming step of
The swiping tool 602 is dull enough that it does not cut into the inner surface of the cylinder bore. Instead, the swiping tool 602 mechanically deforms grooves formed in the inner surface of the cylinder bore. Moving back to
The machined surface after the pocket grooving step and the swiping step has one or more advantages over other roughening processes. First, adhesion strength of the metal spray may be improved by using the swiping step instead of other secondary processes, such as diamond knurling, roller burnishing. The adhesion strength was tested using a pull test. The adhesion strength may be in the range of 40 to 70 MPa. In other variations, the adhesion strength may be 50 to 60 MPa. Compared to the adhesion strength of a diamond knurling process, the adhesion strength of swiping is at least 20% higher. Further, the Applicants have recognized that adhesion is independent of profile depth of the grooves after the first processing step. This may be advantageous for at least two reasons. The swiping tool cuts relatively lower profile depths compared to conventional processes, such as diamond knurling, roller burnishing. In certain variations, the reduction in profile depth is 30 to 40%. Accordingly, less metal spray material is necessary to fill the profile while not compromising adhesion strength. Also, any variation in the depth of the grooves does not affect the adhesion strength, which makes the swiping step more robust than conventional processes. As another benefit of one or more embodiments, the swiping tool can be operated at much higher operational speeds than other processes, such as roller burnishing.
Regarding the interpolating step of
These non-travel areas do not require a subsequent metal spray. However, a torch for metal spraying typically stays on throughout the spray process. If these non-ring travel areas are not roughened, then spray metal that is inadvertently sprayed on these areas do not adhere, causing delamination. This delamination may fall into the bore during honing and become entrapped between the honing stones and bore walls, causing unacceptable scratching. The delamination may also fall into the crank case, which would then require removal. As such, by applying the annual grooves identified herein to the non-ring travel areas, thermal spray material adheres during the spray process and mitigates contamination of the intended spray surface and the crank case. The lightly sprayed non-ring travel areas may be easily removed during subsequent honing operation.
While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.
This application is a division of Ser. No. 13/913,865, filed Jun. 10, 2013, issued as U.S. Pat. No. 9,511,467 on Dec. 6, 2016. This application is also related to the application having Ser. No. 13/461,160, filed May 1, 2012, issued as U.S. Pat. No. 8,726,874 on May 20, 2014. This application is also related to the application having Ser. No. 13/913,871, filed Jun. 10, 2013, the disclosures of which are hereby incorporated in their entirety by reference herein.
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Number | Date | Country | |
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Parent | 13913865 | Jun 2013 | US |
Child | 15334603 | US |