CN101905305B - Die-casting forming method for aluminum alloy casing die castings - Google Patents
Die-casting forming method for aluminum alloy casing die castings Download PDFInfo
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Abstract
The invention discloses a high-density die-casting forming method for aluminum alloy casing die castings, which can effectively solve the problems of the large-scale aluminum alloy die castings that the gas holes are easily formed, the leakage occurs and the like. The method has comprises the following steps of: (1) adding a technological bridge structure in a mould design, thereby quickly filling to quickly fill the far ends of the die castings; (2) adopting the specific low-temperature casing and high-pressure charging die-casting process to realize high densifying of, and then highly densifying the die castings; (3) adding the vacuum die-casting step on the die-casting mould to assist the die-casting filling process; (4) controlling low gas content of aluminum liquor, and then realizing the casting process of low-gas melt. The composite die casting has the advantages that the porosity rate is smaller less than 5%; the gas content is 1-3cm<3>/(100g Al); and the appearance quality and dimension precision are high.
Description
Technical field
The invention belongs to the shaping processing technique field of metallic element, relate to a kind of high-compactness method of squeeze forming of Al-alloy casing die casting, it is particularly useful for large aluminum alloy housing die casting.
Technical background
The die cast of aluminum alloy part is that the liquid aluminium alloy with fusion pours in the pressure chamber of die casting machine, motion by injection punch head, under the high pressure effect, be packed in the compression mod die cavity with higher speed, and to make aluminium alloy coagulation forming under pressure be the method for aluminum alloy die casting.The pressur casting size precision height, any surface finish, the clear-cut that make.The market of aluminium alloy compression casting product maximum is auto industry, in order to make the automobile lightweight, realize the production of high speed, safety, energy-saving and environmental protection, many auto parts have all replaced ironcasting by aluminium alloy, make vehicle weight alleviate 30%-40%, obviously improve the acceleration and the decelerability of automobile, significantly reduced oil consumption and toxic emission.
The diecast parts of using in industrial production has some accessory sizes bigger, and weight is greater than 5kg, or during die casting the weight of cast aluminum liquid greater than 8kg.In industries such as auto parts and components, electronic shell part, electric tools, this class large aluminum alloy die casting has many application at present.The general shape of this type of large-scale die casting part is more complicated all, and mostly is housing class die casting greatly.The gear box casing on the automobile for example, about long 420mm, about wide 400mm, about high 420mm, cast aluminum liquid weight reaches about 18kg.And for example automobile engine cylinder-body according to the difference of model, approximately is of a size of long 480mm, wide 380mm, and high 270mm, casting weight reaches about 30kg.Cylinder cover of engine for another example, long 490mm, wide 90mm, high 200mm, casting weight are about 6kg.For this type of large-scale, complicated die casting, stroke is bigger because molten metal flows in mould, and flowing in these housing components is not steady, molten metal has serious volume gas phenomenon in the cavity filling process, especially in the end fill the position of type and final set, formed more pore, the porosity has reached more than 5%.Because defectives such as these are loose, pores, the seepage phenomenon will take place in foundry goods when bearing air pressure, hydraulic pressure, causes part not reach instructions for use and scraps.The waste of consequent man-hour, material, the energy is very big, and casting dimension is big more, and manufacturing procedure is complicated more, and the waste that causes is just big more.
A kind of process that reduces being involved in property of aluminum alloy die casting pore is disclosed among the patent documentation CN101758197A, exhaust facility by the design die casting, before die casting, carry out pump-down process, reduce die casting speed, thereby reduce the pore in the aluminum alloy die casting.But at the large aluminum alloy housing part, because it is complex-shaped, size is bigger, only not can solve the gas hole defect problem by the design exhaust facility, and is very violent because molten metal flows in die cavity, inevitably is involved in gas.Patent documentation CN201313168Y discloses a kind of gear box casing aluminum alloy die-casting die, and this method is by improving the running gate system of mould, makes molten metal flowing in die cavity more even, has reduced the gas, the shrinkage cavity that form in the die casting.Patent documentation CN201061825 discloses the hermetically-sealed construction that a kind of high vacuum die casting is used, and by extract the gas in the die cavity in press casting procedure, reduces original gas flow in the die cavity.But,, on extrusion process, also do not have concrete optimization method at the large aluminum alloy housing part.
The part that gas hole defect is arranged that goes out for die casting, the general impregnation technology processing foundry goods that adopts makes it to meet instructions for use in the factory, liquid adhesive is immersed in the micropore of foundry goods,, thereby reach the purpose of filling space, sealing and plugging and pressure-bearing by the curing polymerisation.(Zhang Tao such as Zhang Tao, Gao Yongjun, Feng Zaixin. the application [J] of impregnation technology on the large thin-wall aluminium casting. Northcentral University's journal (natural science edition), 2006,27 (4)) describe the application of impregnation technology on the large thin-wall aluminium casting in detail, by the seepage technology, defectives such as loose, the pore that can remedy in the die casting effectively to be produced, retrieve the certain economic loss, but so not only increased by a procedure, also increased the production cost of part.
The method that more than solves the die casting defective still has weak point, though can remedy partial loss by impregnation technology, but can't fundamentally solve the defect problem that large aluminum alloy housing die casting itself occurs, new improvement method to extrusion process still need be proposed, so that improve the part performance, reduce part defect, increase economic efficiency.
Summary of the invention
The purpose of this invention is to provide a kind of high-compactness method of squeeze forming of Al-alloy casing die casting, this method can improve the density of foundry goods, does not need to make foundry goods reach instructions for use to the foundry goods processing of further infiltrating again.
The high-compactness method of squeeze forming of a kind of Al-alloy casing die casting provided by the invention, its step is as follows:
(1) increases the manufacturability bridge structure, the flow direction of guide wire liquid at mold cavity near the position of ingate and between away from the position of ingate; The width of described manufacturability bridge structure is 20～40mm, and thickness is 2～4mm, with foundry goods junction width be 1～3mm;
(2) adopt aluminium liquid to carry out cast cold, the air content≤0.12cm of aluminium liquid
3/ 100g, cast cold be meant and pour into die casting machine by aluminium liquid to press the temperature of chamber be above 30～50 ℃ of aluminium alloy liquidus temperature, the degree of filling that has just watered fashionable pressure chamber requires 〉=and 50%;
(3) carry out casting forming according to following process:
(3.1) at first carry out slow shot, its speed is 0.3～0.7m/s;
(3.2) when the stroke of injection punch head is 100～300mm, begins to carry out fast shot and fill type, injection filling velocity 〉=5m/s;
(3.3) carry out the supercharging feeding then, make the pressure 〉=80MPa that acts on aluminium liquid, obtain the Al-alloy casing die casting at last.
Can separate defect problems such as pore that large aluminum alloy housing die casting often easily occurs, seepage by the foregoing invention content, thereby improve the density of foundry goods, and not need again to make foundry goods reach instructions for use the foundry goods processing of further infiltrating.The inventive method is by being optimized casting structure, improve extrusion process, and the auxiliary process of in addition evacuated die-casting process system, to an automobile gearbox housing part pressure testing casting, the long 420mm of part, wide 400mm, high 420mm, minimum thickness 4mm, die-cast aluminum alloy material is selected YL112 for use, pouring temperature is elected 660 ℃ as, and the vacuum suction valve is installed at die tip overflow launder place.The part that die casting goes out is analyzed, and the result shows, the die casting porosity＜5% that obtains, and air content is 1～3cm
3/ 100g, presentation quality is outstanding, and dimensional accuracy is also very high, meets the instructions for use of part fully.
Description of drawings
Fig. 1 has the schematic diagram of running gate system and bridge structure for large-size cylinder body class die casting.
Fig. 2 was the schematic diagram of bridge shape and structure.
Fig. 3 has running gate system for the disc-like part and has added the schematic diagram of bridge structure.
Fig. 4 is for having added the schematic diagram of bridge structure to framework class formation part.
Fig. 5 is the example flow chart of evacuated die-casting process manufacturing process.
The specific embodiment
Below in conjunction with accompanying drawing and example the inventive method is described in further detail.
1. realize method and process structure away from the quick filling in position of ingate.
Because large aluminum alloy housing die casting volume size is bigger, the liquid metal filling time can reach 0.5-0.8 second, and liquid flow is comparatively violent, in cavity filling process, very easily produce comparatively serious volume gas phenomenon, particularly the distal site air content away from ingate is very high, produces defectives such as serious pore and shrinkage cavity.Method of the present invention is for by increasing express passway between mold cavity is near the proximal location of ingate and far-end, the established technology bridge structure, the flow direction of guide wire liquid makes the quick filling distal site of aluminium liquid, and carry out pressure and transmit rapidly, reach the effect that reduces pore and shrinkage cavity generation.The width of general bridge structure is 20～40mm, and thickness is 2～4mm, is removed by cleaning easily so that pass a bridge when removing running gate system after the foundry goods moulding.
(1) large-size cylinder body class die casting as shown in Figure 1, when molten metal flows to A position, opposite bank during die casting, the core in the middle of need walking around, distance is very long, easily generates pore and shrinkage cavity in the A of far-end portion.According to the present invention, in the mould process design, on the die joint of mould, increasing express passway---gap bridge B makes the quick filling far-end of molten metal.The method for designing of gap bridge B is: width 20～40mm, and thickness is 1/2～2/3 of casting section thickness, it is thick to be generally 2～4mm.Be reduced to 1～3mm at the thickness of passing a bridge with the foundry goods junction.Shape of passing a bridge and structure are as shown in Figure 2.
(2) the disc-like structure in the heavy parts as shown in Figure 3, there is a cored hole centre, has hindered flowing of molten metal, on the opposite bank intersection C position after streaming core, pore and shrinkage cavity defect are a lot, or produce cold shut.According to the present invention, in the mould process design, increase express passway---gap bridge D, make the quick filling far-end of molten metal.Shape of passing a bridge and structure are also as shown in Figure 2.
(3) the framework class formation in the large-scale die casting spare as shown in Figure 4, if no express passway---gap bridge F, molten metal will be walked around very long distance could arrive far-end E portion, the defective of this moment even generation misrun.According to the present invention, in the mould process design, increase express passway---gap bridge F, make the quick filling far-end of molten metal, obtain imperforate high-compactness foundry goods.Shape of passing a bridge and structure are also as shown in Figure 2.
2. specific cast cold, high pressure fill type technology, realize the high densification of die casting
(1) the present invention adopts aluminium liquid cast cold, and promptly aluminium liquid pours into die casting machine to press the temperature of chamber is above 30～50 ℃ of aluminium alloy liquidus temperature, than low 20～40 ℃ of traditional die casting pouring temperature.Simultaneously, the degree of filling that has just watered fashionable pressure chamber require 〉=50%.Because aluminium liquid pouring temperature descends, the liquid contraction reduced, and casting compactness improves.
(2) three grades of injection technologies that adopt high pressure to fill type: according to pressure chamber degree of filling situation, slow shot rate request 0.3～0.7m/s, the injection punch head stroke of high speed switching point is 100～300mm; Fast shot speed 〉=5m/s, boost pressure 〉=80MPa is than the high 20～40MPa of boost pressure of conventional liquid die casting.The principle that the type that fills high pressure improves casting compactness is the feeding of having strengthened heavy parts, has also solved pouring temperature simultaneously and has reduced the problem that the flowability that may cause reduces.
3. evacuated die-casting process system supplymentary filling process and control
(1) to the large-scale housing die casting of leak test requirement is arranged, adopt the high vacuum extrusion process (be the vacuum 〉=91kPa in the die cavity, or absolute pressure≤10kPa).
(2) evacuated die-casting process forming technology flow process as shown in Figure 5.Evacuated die-casting process and the difference of common die casting on flow process be, evacuated die-casting process has increased to the pressurization in injection at a slow speed mold cavity is vacuumized, and reduces the air pressure in the die cavity, the volume tolerance when reducing liquid metal and filling type.Vacuum process is to start to vacuum from vacuum to finish, and whole process duration is about 1 second.Vacuum process is accompanied by injection process and finishes, so evacuated die-casting process has the high efficiency the same with common die casting.
(3) the vacuum die casting process parameter is: the injection punch head stroke was 50～120mm when vacuum started, and in 0.8～1.5 second pumpdown time, punch stroke was 300～800mm when vacuum stopped, more than the die cavity vacuum 91kPa.
4. control the low tolerance melt cast technology of aluminium liquid air content
For large aluminum alloy housing die casting, because part is big, the die casting die cavity is big, and the aluminium liquid distance that flows is air-breathing easily in the aluminum liquid filling type process, has increased the possibility of foundry goods generation pore.Therefore, the air content that reduces the preceding original aluminum liquid of cast will help to reduce bleb, improve casting compactness.
To the large-scale housing die casting of leak test requirement being arranged, control aluminium liquid air content≤0.12cm
3/ 100g.Adopt aluminium liquid air content quantitative measurement technology, the air content test point is in the preceding holding furnace of die casting machine.
In a word, the specific implementation step of the inventive method is as follows:
1, between the near-end of the close ingate of large aluminum alloy housing die casting and far-end, increases express passway, the established technology bridge structure, the flow direction of guide wire liquid makes the quick filling distal site of aluminium liquid, and carry out pressure and transmit rapidly, reach the effect that reduces pore and shrinkage cavity generation.
2, the width of general bridge structure is 20～40mm, and thickness is 2～4mm, is removed by cleaning easily so that pass a bridge when removing running gate system after the foundry goods moulding.
3, adopt aluminium liquid cast cold, high pressure to fill type technology, promptly aluminium liquid pours into die casting machine to press the temperature of chamber is above 30～50 ℃ of aluminium alloy liquidus temperature, than low 20～40 ℃ of traditional die casting pouring temperature.Simultaneously, the degree of filling that has just watered fashionable pressure chamber require 〉=50%.Descend by aluminium liquid pouring temperature, the liquid contraction reduced, and casting compactness is improved.
4, the extrusion process of large-scale housing component adopts three grades of injections: according to pressure chamber degree of filling situation, and slow shot rate request 0.3～0.7m/s, fast shot speed 〉=5m/s, supercharging feeding pressure 〉=80MPa is than the high 20～40MPa of boost pressure of conventional liquid die casting.
5, adopt evacuated die-casting process system supplymentary filling process and control.To the large-scale housing die casting of leak test requirement is arranged, adopt the high vacuum extrusion process (be the vacuum 〉=91kPa in the die cavity, or absolute pressure≤10kPa).
6, the control pumpdown time is 0.8～1.5s, punch stroke 50～120mm when vacuum starts, and punch stroke 300～800mm when vacuum stops is more than the die cavity vacuum 91kPa.
7, the low tolerance melt cast technology of control aluminium liquid air content, control die casting aluminium liquid air content≤0.12cm
3/ 100g.
Example:
Embodiment 1
Large-size cylinder body class die casting as shown in Figure 1, the long 360mm of part, wide 260mm, high 280mm, minimum wall thickness (MINI W.) 4mm, die-cast aluminum alloy material are YL112.According to the present invention, gap bridge B is added in the drawings position, wide 40mm, thickness 4mm, with foundry goods junction width be 3mm.Pouring temperature is elected 660 ℃ (for above 50 ℃ of aluminium alloy liquidus temperature) as, and the air content of aluminium liquid is 0.12cm
3/ 100g; Pressing the degree of filling of chamber when pouring is 50%, and slow shot speed is 0.7m/s, when the stroke of injection punch head is 300mm, begins to carry out fast shot and fills type, and the injection filling velocity is 5m/s; The pressure in supercharging feeding stage is 80MPa.The vacuum suction valve is installed at overflow launder place, part top simultaneously, is begun to vacuumize during for 120mm at the injection punch head stroke, the control pumpdown time is 0.8 second, and the injection punch head stroke stops to vacuumize the vacuum 〉=91kPa when stopping in the die cavity during for 800mm.Said method has been optimized extrusion process, has improved the performance at part A place, and the porosity reaches in 5%, the ne-leakage phenomenon.
Embodiment 2
Disc structure die casting as shown in Figure 3, integrated disc portions is of a size of external diameter 340mm, and internal diameter 240mm, die-cast aluminum alloy material are YL112.According to the present invention, and position in the drawings adds gap bridge D, wide 20mm, thickness 2mm, with foundry goods junction width be 1mm.Pouring temperature is elected 640 ℃ (for above 30 ℃ of liquidus temperature) as, and the air content of aluminium liquid is 0.11cm
3/ 100g; Pressing the degree of filling of chamber when pouring is 60%, and slow shot speed is 0.3m/s, when the stroke of injection punch head is 100mm, begins to carry out fast shot and fills type, and the injection filling velocity is 5.2m/s; The pressure in supercharging feeding stage is 100MPa.This part C of optimization place pore of technology obviously reduces, and has met instructions for use.
Embodiment 3
Frame structure die casting as shown in Figure 4, the long 350mm of part, wide 300mm, high 310mm, die-cast aluminum alloy material are YL113.For guaranteeing that position, part top meets instructions for use, according to the present invention, F place adds and passes a bridge in the drawings, wide 25mm, thickness 3mm, with foundry goods junction width be 1.5mm, the guide wire flow direction.Adopt low tolerance melt cast technology, control aluminium liquid air content is 0.10cm
3/ 100g; Pouring temperature is elected 650 ℃ (for above 40 ℃ of liquidus temperature) as; Pressing the degree of filling of chamber when pouring is 65%, and slow shot speed is 0.5m/s, when the stroke of injection punch head is 200mm, begins to carry out fast shot and fills type, and the injection filling velocity is 5m/s; The pressure in supercharging feeding stage is 90MPa.The vacuum suction valve is installed at overflow launder place, part top simultaneously, is begun to vacuumize during for 50mm at the injection punch head stroke, the control pumpdown time is 1.5 seconds, and the injection punch head stroke stops to vacuumize during for 300mm, and the vacuum when stopping in the die cavity is 100kPa.Owing to optimized the extrusion process of part, reduced the air vent content of part, density improves.
The above is preferred embodiment of the present invention, but the present invention should not be confined to the disclosed content of this embodiment and accompanying drawing.So everyly do not break away from the equivalence of finishing under the spirit disclosed in this invention or revise, all fall into the scope of protection of the invention.
Claims (2)
1. the method for squeeze forming of an Al-alloy casing die casting, its step is as follows:
(1) increases the manufacturability bridge structure, the flow direction of guide wire liquid at mold cavity near the position of ingate and between away from the position of ingate; The width of described manufacturability bridge structure is 20～40mm, and thickness is 2～4mm, with foundry goods junction width be 1～3mm;
(2) adopt aluminium liquid to carry out cast cold, the air content≤0.12cm of aluminium liquid
3/ 100g, cast cold be meant and pour into die casting machine by aluminium liquid to press the temperature of chamber be above 30～50 ℃ of aluminium alloy liquidus temperature, the degree of filling that has just watered fashionable pressure chamber requires 〉=and 50%;
(3) carry out casting forming according to following process:
(3.1) at first carry out slow shot, its speed is 0.3～0.7m/s;
(3.2) when the stroke of injection punch head is 100～300mm, begins to carry out fast shot and fill type, injection filling velocity 〉=5m/s;
(3.3) carry out the supercharging feeding then, make the pressure 〉=80MPa that acts on aluminium liquid, obtain the Al-alloy casing die casting at last.
2. method of squeeze forming according to claim 1 is characterized in that,
In step (3), the injection punch head stroke begins to vacuumize when being 50～120mm, and the control pumpdown time is 0.8 second～1.5 seconds, and the injection punch head stroke stops to vacuumize when being 300～800mm, the vacuum 〉=91kPa when stopping in the die cavity.
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