CN100431777C - 采用液态模锻工艺生产汽车空调器摇盘的方法 - Google Patents
采用液态模锻工艺生产汽车空调器摇盘的方法 Download PDFInfo
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- CN100431777C CN100431777C CNB200510010475XA CN200510010475A CN100431777C CN 100431777 C CN100431777 C CN 100431777C CN B200510010475X A CNB200510010475X A CN B200510010475XA CN 200510010475 A CN200510010475 A CN 200510010475A CN 100431777 C CN100431777 C CN 100431777C
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- liquid
- die
- air conditioner
- forging
- shaking tray
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- 238000005242 forging Methods 0.000 title claims abstract description 83
- 239000007788 liquid Substances 0.000 title claims abstract description 63
- 238000000034 method Methods 0.000 title claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 title abstract description 12
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 51
- 238000003723 Smelting Methods 0.000 claims abstract description 4
- 230000032683 aging Effects 0.000 claims abstract description 4
- 239000006104 solid solution Substances 0.000 claims abstract description 4
- 229910052573 porcelain Inorganic materials 0.000 claims description 12
- 238000005496 tempering Methods 0.000 claims description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Chemical compound data:image/svg+xml;base64,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 data:image/svg+xml;base64,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 [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound 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- 229910052742 iron Inorganic materials 0.000 claims description 3
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials 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- 229910000831 Steel Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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Abstract
采用液态模锻工艺生产汽车空调器摇盘的方法，涉及汽车空调器摇盘的加工方法。解决了现有的汽车空调器摇盘力学性能差、满足不了工作环境的要求和加工工序复杂、模具结构复杂、产品的生产周期长的问题。本发明的方法采用下列步骤：一、模具的设计与成形；二、铝合金熔炼；三、液态模锻过程；四、固溶时效处理。本发明采用液态模锻工艺生产汽车空调器摇盘的方法，可实现无切削加工、简化模具结构、缩短生产周期，且具有减少或消除缩孔、缩松、冷隔、气孔和裂纹等缺陷，减轻偏析，细化和改善组织和力学性能等优点。
Description
采用液态模锻工艺生产汽车空调器摇盘的方法
技术领域
本发明涉及汽车空调器摇盘的加工方法。 背景技术
目前，汽车空调器摇盘的生产是采用金属型重力铸造或金属压力铸造的，
该方法致使汽车空调器摇盘的力学性能差，满足不了工作环境的要求；而用普 通热模锻生产汽车空调器摇盘，其切削加工工序复杂，无法简化模具结构，产 品的生产周期长。 发明内容
本发明为了解决现有汽车空调器摇盘力学性能差、满足不了工作环境的要 求和加工工序复杂、模具结构复杂、产品的生产周期长的问题，提出了一种采 用液态模锻工艺生产汽车空调器摇盘的方法，解决该问题的具体技术方案如 下：
本发明采用液态模锻工艺生产汽车空调器摇盘的方法步骤如下： 步骤一、模具的设计：
根据汽车空调器摇盘结构、形状、尺寸和性能要求，进行汽车空调器摇盘
的凸模3、凹模6、凸模套板2、凹模套板5、上模板1和下模板8组成的液态 模锻模具的设计；
步骤二、铝合金熔炼：
(1) 坩埚使用前，要除去粘附在表面的铁锈、氧化渣、旧涂料层等脏物，
然后涂上新涂料；
(2) 将铝合金表面清理干净，放入坩埚里加热；坩埚被加热至500~800 °C时添加铝合金坯料进行熔化；
(3) 铝合金熔化后，除去液面上的浮渣； 步骤三、液态模锻过程：
(1)将空调器摇盘液态模锻模具安装在液压机上，对液态模锻模具进行
调试；(2) 液态模锻模具加热到100〜15(TC时，向液态模锻模具型腔内喷涂润
滑剂；
(3) 液态模锻模具加热到220〜28(TC时，按液态模锻模具的型腔的容积 将经步骤二熔化的铝合金液体浇入液态模锻模具的型腔内；铝合金液体浇注时 的温度为740〜7卯-C;
(4) 铝合金液体浇入液态模锻模具后,凸模以18〜20mm/s的速度加压 2~7s，当压力达到120〜160MPa，压力维持时间为30~80s;
(5) 取出经液态模锻的汽车空调器摇盘并把模锻件迅速放入砂堆里降温; 步骤四、固溶时效处理：
将经步骤三的液态模锻的汽车空调器摇盘进行淬火和回火，即制得铝合金 汽车空调器摇盘。
本发明采用液态模锻工艺生产汽车空调器摇盘的方法，可实现无切削加 工、简化模具结构、縮短生产周期，且具有减少或消除縮孔、縮松、冷隔、气 孔和裂纹等缺陷，减轻偏析，细化和改善组织和力学性能等优点。
附图说明
图1是液态模锻工艺生产汽车空调器摇盘成型装置的整体结构剖示图，图 2电阻丝加热器15的结构示意图。
图中l是上模板，2是凸模套板，3是凸模，4是保温板，5是凹模套板， 6是凹模,7是顶杆,8是下模板，9是螺栓，10是定位销，11是汽车空调器摇盘， 12是电阻丝，13是内层高频瓷管，14是外层高频瓷管，15是电阻丝加热器。
具体实施方式
具体实施方式一:本实施方式采用液态模锻生产汽车空调器摇盘的工艺方 法步骤如下：
步骤一、模具的设计与成型：
根据汽车空调器摇盘结构、形状、尺寸和性能要求，进行汽车空调器摇盘 凸模和凹模液态模锻模具的设计。汽车空调器摇盘的凸模3和凹模6液态模锻 模具的设计要充分考虑模具材料、间隙、脱模斜度、排气影响，汽车空调器摇
盘的五个凹孔为传动动力表面，加工余量放大l.Omm，脱模斜度放大3°;中心孔因装配固定的需要，放大加工余量l.Omm，摇盘按铝合金热收縮量1.5% 进行设计；凸模3和凹模6选用3Cr2W8V，在1130-1150 °C油淬后，再经 550〜600。C回火1~2小时；凸模套板2、凹模套板5、上模板1和下模板8选 用45号钢，在820~840 。C油淬后，再经500~540 °C回火1~2小时； 步骤二、铝合金熔炼：
(1) 坩埚使用前，要除去粘附在表面的铁锈、氧化渣、旧涂料层等脏物， 然后涂上新涂料；
(2) 将铝合金型号为4A11 (LD11)表面清理干净，放入坩埚里加热； 坩埚放在电阻炉内加热至500〜80(TC时添加铝合金坯料进行熔化；
(3) 铝合金熔化后，将2号精炼熔剂均匀地撒在铝合金液体表面上，搅 拌均匀，使精炼熔剂溶入到铝合金液体中去，静置5〜15分钟后，除去液面上 的浮渣；
步骤三、液态模锻过程：
(1) 将汽车空调器摇盘液态模锻模具安装在液压机或经改造的压铸机上； 随着液态模锻模具温度的升高，螺栓9可能产生松动，导致液态模锻模具位置 的偏移，容易损坏液态模锻模具型腔，所以要对液态模锻模具进行调试；
(2) 液态模锻模具的加热采用电阻丝加热器15，考虑电阻丝12和液态 模锻模具之间的绝缘，采用4根①40mm的外层高频瓷管14和4根①32mm的 内层高频瓷管13每两根组成一对(见图2)，电阻丝12成螺旋状缠绕在①32mm 的内层高频瓷管13上，①32mm的内层高频瓷管13固定在①40mm外层高频 瓷管14的中间，电阻丝12选用Cr20Ni80材料，直径为1.5mm，螺旋螺距为 4mm，节径为36mm组成电阻丝加热器15，每对之间串联接在220V的电压上， 功率控制在3〜4kW，采取此加热器预热速度快，易于控制；液态模锻模具预 热至100〜15(TC时，采用润滑剂喷涂液态模锻模具型腔（润滑剂由5%的 200~300目的石墨粉，添加95%的机油，搅拌均匀，制成机油石墨润滑剂）， 喷涂涂料时保持喷凃均匀；
(3) 液态模锻模具喷凃后继续加热到220〜280'C时，按液态模锻模具型 腔的容积将经步骤二熔化的铝合金液体浇入液态模锻模具型腔内；浇注时应尽 量接近液态模锻模具口，降低铝合金液流体高度，避免铝合金液体飞溅，盛铝合金液体容器的温度应与铝合金液体的温度相近，铝合金液体浇注时的温度为
740~790°C;
(4) 铝合金液体浇入液态模锻模具后,凸模3以18~20mm/s的速度加压 2〜7s，当压力达到120~160MPa，压力维持时间为30~80s;
(5) 取出经液态模锻的汽车空调器摇盘11并迅速放入砂堆里降温； 步骤四、固溶时效处理：
对经步骤三得到的液态模锻汽车空调器摇盘11在535土5'C下保温2.5〜3.5 小时淬火，在175士5-C下保温5~7小时回火，即制得铝合金汽车空调器摇盘 11。
采用本实施方式生产的汽车空调器摇盘，其力学性能指标达到：ob》 280Mpa; S》10%; HVai为100~120。该摇盘在IO(TC的条件下进行台架试 验1500小时无形状尺寸变化，摇盘表面及内部无冷隔、气孔、縮孔、裂纹等 缺陷。
具体实施方式二:本实施方式与具体实施方式一的不同点在于步骤三中铝 合金液体浇注时的温度为740°C，向液态模锻模具型腔内浇注铝合金液体时液 态模锻模具的温度为280°C，凸模向浇入液态模锻模具型腔内的铝合金液体施 加的压力为120Mpa，压力维持时间为80s。其它步骤与具体实施方式一相同。
具体实施方式三:本实施方式与具体实施方式一和具体实施方式二的不同 点在于步骤三中铝合金液体浇注时的温度为760°C，向液态模锻模具型腔内浇 注铝合金液体时液态模锻模具的温度为250°C，凸模向浇入液态模锻模具型腔 内的铝合金液体施加的压力为140MPa，加压维持时间为60s。其它步骤与具 体实施方式一相同。
具体实施方式四：本实施方式与具体实施方式一、二、三的不同点在于步 骤三中铝合金液体浇注时的温度为790°C，向液态模锻模具型腔内浇注铝合金 液体时液态模锻模具的温度为220'C，凸模向浇入液态模锻模具型腔内的铝合 金液体施加的压力为160Mpa ，压力维持时间为30s。其它步骤与具体实施方
式一相同。
Claims (8)
1、采用液态模锻工艺生产汽车空调器摇盘的方法，其特征在于该方法的步骤如下： 步骤一、模具的设计： 根据汽车空调器摇盘结构、形状、尺寸和性能要求，进行汽车空调器摇盘的由凸模(3)、凹模(6)、凸模套板(2)、凹模套板(5)、上模板(1)和下模板(8)组成的液态模锻模具的设计； 步骤二、铝合金熔炼： (1)坩埚使用前，要除去粘附在表面的铁锈、氧化渣、旧涂料层等脏物，然后涂上新涂料； (2)将铝合金表面清理干净，放入坩埚里加热；坩埚被加热至500～800℃时添加铝合金坯料进行熔化； (3)铝合金熔化后，除去液面上的浮渣； 步骤三、液态模锻过程： (1)将空调器摇盘液态模锻模具安装在液压机上，对液态模锻模具进行调试； (2)液态模锻模具加热到100～150℃时，向液态模锻模具型腔内喷涂润滑剂； (3)液态模锻模具加热到220～280℃时，按液态模锻模具型腔的容积将经步骤二熔化的铝合金液体浇入液态模锻模具的型腔内；铝合金液浇注时的温度为740～790℃； (4)铝合金液体浇入液态模锻模具后，凸模以18～20mm/s的速度加压2～7s，当压力达到120～160MPa，压力维持时间为30～80s； (5)取出经液态模锻的汽车空调器摇盘并把模锻件迅速放入砂堆里降温； 步骤四、固溶时效处理： 将经步骤三的液态模锻的汽车空调器摇盘进行淬火和回火，即制得铝合金汽车空调器摇盘。
2、根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于汽车空调器摇盘的液态模锻模具的凸模（3)和凹模（6)设计时加工余量放大l.Omm，脱模斜度放大3。；中心孔放大加工余量l.Omm，摇盘按 铝合金热收縮量的1.5%进行设计。
3、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于凸模（3)和凹模（6)经1130〜1150 。C油淬后，再经550-600 。C 回火1〜2小时；凸模套板（2)、凹模套板（5)、上模板（1)和下模板（8)经 820~840 。C油淬后，再经500〜540 。C回火1〜2小时。
4、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于步骤二中的坩埚加热采用电阻炉加热。
5、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于步骤三中的模具加热采用电阻丝加热器（15)，电阻丝加热器（15) 由内层高频瓷管（13)、外层高频瓷管（14)和电阻丝（12)组成，电阻丝（12) 成螺旋状缠绕在内层高频瓷管（13)的外圆表面上，内层高频瓷管（13)固定 在外层高频瓷管（14)的中间。
6、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于步骤三中铝合金液体浇注时的温度为740°C，向液态模锻模具型腔 内浇注铝合金液体时液态模锻模具的温度为2S(TC，凸模向浇入液态模锻模具 型腔内的铝合金液体施加的压力为120Mpa，压力维持时间为80s。
7、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于步骤三中铝合金液体浇注时的温度为760°C，向液态模锻模具型腔 内浇注铝合金液体时液态模锻模具的温度为250°C，凸模向浇入液态模锻模具 型腔内的铝合金液体施加的压力为140MPa，加压维持时间为60s。
8、 根据权利要求1所述的采用液态模锻工艺生产汽车空调器摇盘的方法， 其特征在于步骤三中铝合金液体浇注时的温度为790°C，向液态模锻模具型腔 内浇注铝合金液体时液态模锻模具的温度为220°C，凸模向浇入液态模锻模具 型腔内的铝合金液体施加的压力为160Mpa ，压力维持时间为30s。
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| CN102251158A (zh) * | 2011-07-09 | 2011-11-23 | 浙江巨科铝业有限公司 | 一种汽车轮毂用铝合金及其制作方法 |
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