CN107214318A - A kind of metal liquid die forging process system - Google Patents
A kind of metal liquid die forging process system Download PDFInfo
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- CN107214318A CN107214318A CN201710364032.3A CN201710364032A CN107214318A CN 107214318 A CN107214318 A CN 107214318A CN 201710364032 A CN201710364032 A CN 201710364032A CN 107214318 A CN107214318 A CN 107214318A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
A kind of metal liquid die forging process system described herein, including liquid forging machine (1), electric induction furnace (2), casting machine (3), numerical control press (4), automatic part picking machine (5) and automatic spraying machine (6), wherein, metal is dissolved by heating and is poured onto in casting machine (3) by electric induction furnace (2) and poured into a mould, simultaneously, liquid forging machine (1) is pressurizeed after being cast, take out to numerical control press (4) and be processed through automatic part picking machine (5) after metal extrusion forming, taken to automatic spraying machine (6) and sprayed by automatic part picking machine (5) again, it is high with mechanical performance, formability is high, high yield rate, stock utilization is high, equipment investment is small, product cost is low；Metal casting realizes no sand, without rising head, high-quality environmental protection under the technique, the effect that operating personnel are freed from cumbersome production work.
Description
Technical field
The application is related to Industrial Metal forming technique field, specially a kind of metal liquid die forging process system, the technique
System, which is particularly suitable for use in, to be formed various simple in construction and simple shape or general complicated strength member or not to need substantially
The production technology of the parts of processing.
Background technology
In the prior art：
At present the part blank of work added by many industries or general complicated strength member or need not process substantially zero
Part is mainly sand casting.But cast member has stomata, scab, burning into sand, sand holes, buckle, cold shut, misrun, shrinkage porosite, contracting
Hole, misrun, the common defect such as sarcoma.These casting flaws are always that casting industry can not be avoided and insoluble problem.
The conventional method for repairing rejected casting at present is mainly carry out soldering, and this technique needs knack workman, repairs simultaneously
Time length simultaneously consumes a large amount of valuable materials.Sometimes influenceed by repaired components material, welding also results in damage aggravation, causes portion
Part is scrapped, and increases the production cost of enterprise.
For example：Chinese Patent Application No. CN201320216093.2；Applying date 2013.04.25；The utility model is related to one
Kind of aluminium alloy heavy-duty wheel liquid forging system, including aluminium water stove, manipulator, liquid forging machine, transmission belt, drilling machine, heating furnace,
Lathe and passivation heap, order is set simultaneously successively for the liquid forging machine, transmission belt, drilling machine, heating furnace, lathe and passivation heap
Connected by transmission belt, the side between liquid forging machine and transmission belt is provided with the manipulator for grabbing workpiece, liquid mould
An aluminium water stove is installed at the opposite side interval of forging machine, and be provided with one between liquid forging machine and aluminium water stove send raw material aluminium water for area
Manipulator.The present invention uses liquid forging machine instead of the shaping of traditional air injection machine completion aluminum-alloy wheel, and
Using transmission production line connection between equipment, system structure design rationally, optimizes the production technology of liquid forging, and bulk article is closed
Lattice rate reaches more than 95%, and improving production efficiency reduces production cost, improves product quality.
In this application, the cast member produced have stomata, scab, burning into sand, sand holes, buckle, cold shut, misrun, shrinkage porosite,
Shrinkage cavity, misrun, the common defect such as sarcoma.
In consideration of it, how to design a kind of metal liquid die forging process system, in the presence of overcoming above-mentioned prior art
Defect, is those skilled in the art's technical problem urgently to be resolved hurrily.
The content of the invention
The application's aims to overcome that technical problem present in prior art, and provides a kind of metal liquid die forging work
Process system.
The purpose of the application is completed by following technical solution, a kind of metal liquid die forging process system, including
Liquid forging machine, electric induction furnace, casting machine, numerical control press, automatic part picking machine and automatic spraying machine, wherein, metal is by electric induction furnace
Dissolve by heating and be poured onto in casting machine and poured, meanwhile, liquid forging machine is pressurizeed after pouring, and is passed through after metal extrusion forming
Automatic part picking machine takes out to be processed to numerical control press, then is taken and sprayed to automatic spraying machine by automatic part picking machine.
Liquid forging machine includes being located at the master cylinder and auxiliary cylinder of both sides above and below it, and the top of auxiliary cylinder is lived provided with master cylinder
Plug, the centre position of master cylinder piston is provided with special operations crossbeam, and liquid forging machine sidepiece is provided with side thick stick and pressurized cylinder.
Electric induction furnace includes crucible, and the top of crucible is provided with cover plate, and crucible both sides are provided with refractory brick frame, and the sidepiece of crucible encloses
Induction coil and protective plate are wound with, protective plate lateral wall is provided with the water pipe that cooling water enters, and the bottom of electric induction furnace is provided with bottom
Seat.
Casting machine includes rollover stand, and rollover stand bottom side is provided with gravity sensor, and rollover stand top is provided with basket pouring, turned over
The side of pivoted frame is provided with displacement transducer, and the low side of displacement transducer is provided with casting machine servomotor, and gravity sensor is with watching
The unified PLC control system on the outside of casting machine of motor is taken to be controlled.
Numerical control press includes hydraulic type bascule and is disposed thereon the heavily loaded leading screw in portion, and the sidepiece of heavily loaded leading screw is set
There is punch press servomotor, the centre position of bascule is provided with symmetrical toggle link.
Automatic part picking machine includes pedestal and the hydraulic pressure arm being arranged on pedestal, and the front end of hydraulic pressure arm is provided with gripping hand
Pawl.
Automatic spraying machine includes bearing, and bearing is provided with adjusting rod, and adjusting rod top is provided with horizontal cylinder, the end of cylinder
Head is provided with shower nozzle.
The application compared with prior art, with following obvious advantage and effect：
1st, mechanical performance height, formability height, high yield rate, stock utilization are high, equipment investment is small, product cost is low.
2nd, metal casting realizes no sand, without rising head, high-quality environmental protection under the technique, by operating personnel from cumbersome
Freed in production work.
Brief description of the drawings
Accompanying drawing described herein is used for providing further understanding of the present application, constitutes the part of the application, this Shen
Schematic description and description please is used to explain the application, does not constitute the improper restriction to the application.In the accompanying drawings：
Fig. 1 is the structural representation of liquid forging machine in the application.
Fig. 2 is the structural representation of electric induction furnace in the application.
Fig. 3 is the structural representation of casting machine in the application.
Fig. 4 is the structural representation of numerical control press in the application.
Fig. 5 is the structural representation of automatic part picking machine in the application.
Fig. 6 is the structural representation of automatic spraying machine in the application.
Fig. 7 is the process chart of system in the application.
Embodiment
To make the purpose, technical scheme and advantage of the application clearer, below in conjunction with the application specific embodiment and
Technical scheme is clearly and completely described corresponding accompanying drawing.Obviously, described embodiment is only the application one
Section Example, rather than whole embodiments.Based on the embodiment in the application, those of ordinary skill in the art are not doing
Go out the every other embodiment obtained under the premise of creative work, belong to the scope of the application protection.
A kind of metal liquid die forging process system described herein, including liquid forging machine 1, electric induction furnace 2, casting machine 3,
Numerical control press 4, automatic part picking machine 5 and automatic spraying machine 6, wherein, metal is dissolved by heating by electric induction furnace 2 and is poured onto cast
Poured into a mould in machine 3, meanwhile, liquid forging machine 1 is pressurizeed after being cast, metal extrusion forming after through automatic part picking machine 5 take out to
It is processed on numerical control press 4, then is taken to automatic spraying machine 6 and sprayed by automatic part picking machine 5.；With mechanical performance it is high,
Formability height, high yield rate, stock utilization are high, equipment investment is small, product cost is low；Metal casting realizes nothing under the technique
Sand, without rising head, high-quality environmental protection, the effect that operating personnel are freed from cumbersome production work.
In the embodiment of the present application,
The present invention proposes a kind of metal liquid die forging process system, and the technique is a kind of gold between casting and die forging
Belong to forming technology, be to make the metal of injection die cavity coagulation forming under high pressure, then apply mechanical static pressure, utilize metal casting
Easily flowing and FMT are plastically deformed the closing duricrust solidified during solidification forming, metal is crystallized under stress solidifying
Consolidate and force to eliminate because of the shrinkage cavity of solidification shrinkage formation, to obtain the liquid forging without any casting flaw.Liquid forging process skill
Art integrate casting broad applicability and forging high-performance, the casting of any material can be realized broad sense without rising head
Casting is no sand without rising head high-quality green casting technology.The technique has that technological process is short, can significantly improve production efficiency,
Material consumption is few, energy resource consumption is few, reduce labor intensity, automation shaping operation is realized, by operating personnel from cumbersome production
Freed in work.
Shown in Fig. 7；The core of technological process is main by cast, pressurization, four basic working procedure groups of pressurize and the demoulding
Into.The cast process is that the automatic pouring machine pours into melting qualified metal bath in mould cavity or pressure chamber；It is described
Pressurization operation applies pressure using the double acting liquid forging machine of the vertical extrusion to metal bath；The pressurize process is that metal bath fills
After full die cavity, the double acting liquid forging machine of vertical extrusion persistently applies certain value to metal bath and obtains pressure, until metal bath is complete
Untill portion solidifies；The stripping process is that automatic part picking machine takes out Forming Workpiece from the die cavity of mould.
Referring to Fig. 1 to shown in Fig. 7, a kind of metal liquid die forging process system, including liquid forging machine 1, electric induction furnace 2, pour
Note machine 3, numerical control press 4, automatic part picking machine 5 and automatic spraying machine 6, wherein, metal is dissolved by heating and toppled over by electric induction furnace 2
Poured into a mould into casting machine 3, meanwhile, liquid forging machine 1 is pressurizeed after pouring, through automatic part picking machine 5 after metal extrusion forming
Take out to being processed on numerical control press 4, then taken to automatic spraying machine 6 and sprayed by automatic part picking machine 5.
In the embodiment of the present application,
Liquid forging machine 1 includes being located at its master cylinder 101 of both sides and auxiliary cylinder 102, the top of auxiliary cylinder 102 up and down
Provided with master cylinder piston 103, the centre position of master cylinder piston 103 is provided with special operations crossbeam 104, and the sidepiece of liquid forging machine 1 is provided with side thick stick
105 with pressurized cylinder 106.
The double acting liquid forging machine 1 of the vertical extrusion by master cylinder, auxiliary cylinder, master cylinder piston and its liquid forging pressure head,
Special operations crossbeam, side cylinder, booster composition.The double acting liquid of vertical extrusion forges the size range of machine workpieces：Chang Du≤
1000mm, width degree≤1000mm, Gao Du≤1000mm.The double acting liquid forging machine 1 of the vertical extrusion pressurization operation apply it is close
Even if the pressure (pressure that metal bath is born during liquid forging) that real pressure ratio liquid metal shrinks is：Non-ferrous metal and
Its alloy：15~100MPa, ironware：15~100MPa, steel part：50~200MPa；The closely knit pressure ratio parameter selection gist is：
Liquid forges the ratio between power and liquid forging pressure head bearing area；The liquid forges power scope：20~200MPa.The double acting liquid of vertical extrusion
Forging machine is the support expansive force for overcoming liquid metal to mould in the clamp force that pressurize process applies, and can make what mould was tightly closed all the time
Applying power：≤ 5000000 kgfs；Dwell time：1~3min.The double acting liquid forging machine of vertical extrusion is in stripping process
The resistance that knockout press is subject to when being and workpiece being ejected into die cavity： FKnockout press=μ × PPressure；μ=0.3~0.5 is that workpiece is ejected
Coefficient of friction during die cavity；The PPressure=10~20MPa.
The double acting liquid forging machine 1 of the vertical extrusion is liquid forging process nucleus equipment, i.e. can be with pressure function is held
In the contraction process for tracking metal bath, pressure is set to remain at the pressure of die forging setting；Required according to liquid forging process, can be certainly
Move the movement velocity of regulation oil cylinder piston and movement velocity is big；Span is opened from big.
In the embodiment of the present application,
Electric induction furnace 2 includes crucible 203, and the top of crucible 203 is provided with cover plate 201, and the both sides of crucible 203 are provided with refractory brick frame
202, the sidepiece of crucible 203 is surrounded with induction coil 204 and protective plate 205, and the lateral wall of protective plate 205 is provided with cooling water 206
The water pipe of entrance, the bottom of electric induction furnace 2 is provided with base 207.
The general step of the technological process of electric induction furnace melting " Tao Shi " high-wear-resistant alloy is：Charge melted, slag making
Deoxidation, come out of the stove.Parameter in the charge melted process：Current value：900~1000A, magnitude of voltage：3000~5000V, temperature：
1500~1800 DEG C, smelting time：60 minutes.
The electric induction furnace, to convert electrical energy into the equipment that heat energy carries out smelting metal using electromagnetic induction principle,
Realized under PLC control system and automatically control power.
In the embodiment of the present application,
Casting machine 3 includes rollover stand 302, and the bottom side of rollover stand 302 is provided with gravity sensor 31, and the top of rollover stand 302 is provided with
Basket pouring 303, the side of rollover stand 302 is provided with displacement transducer 305, and the low side of displacement transducer 305 is provided with cast
Machine servomotor 306, gravity sensor 31 is carried out with the unified PLC control system 304 by the outside of casting machine 3 of servomotor 306
Control.
The automatic casting machine 3 is passed by middle pouring ladle, overturning frame, servomotor propulsion plant, weight and displacement
Sensor, PLC control system composition.The amount of pouring of the automatic pouring machine is the technique auxiliary materials such as workpiece blank, material cake, running gate system
Summation；The quality for pouring fluence is workpiece quality and technique auxiliary material quality sum；It is described pour fluence mass range be：1
~500kg；It is described to pour fluence volume： VWorkpiece blank+VShrink+VTechnique clout≤VCast≤VPressure chamber；Pouring temperature：1000~1800 DEG C；Cast
When ingate flow velocity：0.05~1.5mm/s.
The full automatic casting machine 3, is the visual plant of metal liquid die forging process system, can automatically control cast
Amount and interrupted pour time.
In the embodiment of the present application,
Numerical control press 4 includes hydraulic type bascule 401 and is disposed thereon the heavily loaded leading screw 402 in portion, heavily loaded leading screw
402 sidepiece is provided with punch press servomotor 403, and the centre position of bascule 401 is provided with symmetrical toggle link 404.
The numerical control press 4 is made up of hydraulic type bascule, heavily loaded leading screw, servomotor, symmetrical toggle link etc..The number
Control punch press 4 drives heavily loaded leading screw to realize and automatically removes the technique clouts such as material cake, running channel by servomotor；The numerical control press 4 is marked
Claim pressure：FNominal pressure≤ 40 tons；The slider stroke of the numerical control press 4：sSlider stroke≤500mm；The numerical control press maximum is die-filling
Highly：HMAX≤1000mm。
The numerical control press 4, under the control of digital control system, automatically removes the technique clouts such as material cake, running channel.
The product that the present invention is produced has covered each major class part such as axle sleeve, disk cover, crotch and casing, the material being related to
There are aluminium, copper, zinc, magnesium, steel and its composite.
In the embodiment of the present application,
Automatic part picking machine 5 includes pedestal 503 and the hydraulic pressure arm 502 being arranged on pedestal 503, hydraulic pressure arm 502
Front end is provided with gripping paw 501.
The automatic part picking machine 5 is made up of gripping paw, hydraulic pressure arm, support.The gripping paw is driven by hydraulic system
It is dynamic；The gripping workpiece quality of the automatic part picking machine：1kg≤WWorkpiece≤500kg；The gripping workpiece size of the automatic part picking machine：
20mm≤φWorkpiece≤600mm；The gripping workpiece pulling stroke of the automatic part picking machine 5：20mm≤sPulling stroke≤500mm；It is described from
Pulling power during the gripping workpiece of dynamic extractor 5： 10kgf≤FPulling power≤2000kgf。
The automatic part picking machine 5, in PLC control system control under PLC, automatically on request takes out the product after depanning
And it is placed on assigned position.
In the embodiment of the present application,
Automatic spraying machine 6 includes bearing 603, and bearing 603 is provided with adjusting rod 602, and the top of adjusting rod 602 is provided with transverse direction
Cylinder 601, the termination of cylinder 601 is provided with shower nozzle 604.
The automatic spraying machine 6 can be sprayed automatically, can adjust its automatic spraying position by vertical adjusting rod 602
Height, pass through the length of the horizontal lateral attitude of 601 adjusting shower nozzle of cylinder 604.
The liquid forging process system of the present invention has feature：
1 mechanical performance is high.Because the molten metal of half curdled appearance is crystallized in sufficient Under Pressure Solidification, dense structure is brilliant
Grain it is tiny, therefore the mechanical performance of gained product can close to or up forging part level.
2 formabilities are high.It is high when the mobility of liquid metal liquid is than solid-state, can be uniform not by any resistance during metal flow
Mold cavity is filled on ground, therefore can produce complex-shaped part.
3 high yield rates.During liquid forging, processing temperature than casting when it is much lower, product is small in mould contract, and by
The influence of three-dimensional compressive stress, therefore the defects such as stomata and microporosity will not be formed.
4 stock utilizations are high.Compared with die forging, by the metal material for not having flash and solid hole to be lost, therefore material is sharp
With rate up to more than 95%.If compared with extrusion process, liquid forging process need not set sprue bush, nozzle, running gate system
Metal material Deng auxiliary consumption accounts for the 20%~30% of product.
5 equipment investments are small.Contour forging technique will be using the higher equipment of the investment such as hotdie forging press or friction press.Pressure
Power casting needs special die casting machine, and equipment investment is expensive, and liquid forging both available dedicated hydraulic press, it is also possible to general oil pressure
Machine, equipment investment is smaller.
6 product costs are low.Due to substantially increasing the stock utilization of product, equipment investment and mould expense are significantly reduced
With, and the consumed heat energy of heating is reduced, therefore product cost is than the reduction of other techniques.
Steel-casting is produced using the technology of the present invention, due to eliminating the remelting energy consumption of rising head, ton product comprehensive energy consumption does not surpass
700kgce is crossed, 30% or so is lowered than Foundry Production.Due to replacing sand mold using metal mold, the discharge of ton casting antiquated sand is no more than
1kg, than Foundry Production reduction by more than 99%；Because the product yield without rising head, molten metal generally reaches more than 90%, than casting
Make production and improve 20~30 percentage points；Due to pressurization cooling, solidification and feeding, casting quality stability is significantly improved, and is cast
Percent defective is less than 1%, and more than 1 times is reduced than Foundry Production；Because without sand operation, solid waste discharge is substantially reduced, casting is thoroughly eradicated
Make the anthraco-silicosis of industry.Equally by 50,000,000 tons of calculating of casting annual production, after the present invention, 50,000,000 can be reduced every year
More than ton antiquated sand discharge or processing；Can reduce at least 400,000 tons of the material scaling loss brought by the remelting of waste product and rising head with
On, it is worth more than 50 hundred million yuan；Reduce by 12,500,000 tons of melting power consumption, by 800 degree of calculating of ton steel melting power consumption, electricity can be reduced every year
Consume 10,000,000,000 degree
Embodiments herein is the foregoing is only, moreover, the title that parts are taken in the application can not also
Together, it is not intended to limit the title in the application.To those skilled in the art, the application can have various modifications and variations.
All any modification, equivalent substitution and improvements made within the design of the application and principle etc., should be included in the power of the application
Within sharp claimed range.
Claims (7)
1. a kind of metal liquid die forging process system, including liquid forging machine (1), electric induction furnace (2), casting machine (3), numerical control press
(4), automatic part picking machine (5) and automatic spraying machine (6), it is characterised in that：Metal is dissolved by heating and toppled over by electric induction furnace (2)
Poured into a mould into casting machine (3), meanwhile, liquid forging machine (1) is pressurizeed after being cast, through automatic part picking after metal extrusion forming
Machine (5) is taken out to being processed on numerical control press (4), then is taken to automatic spraying machine (6) and sprayed by automatic part picking machine (5)
Apply.
2. metal liquid die forging process system according to claim 1, it is characterised in that：Liquid forging machine (1) includes being located at it
The master cylinder (101) of both sides and auxiliary cylinder (102) up and down, the top of auxiliary cylinder (102) is provided with master cylinder piston (103), main
The centre position of cylinder piston (103) is provided with special operations crossbeam (104), and liquid forging machine (1) sidepiece is provided with side thick stick (105) and pressurized cylinder
(106)。
3. metal liquid die forging process system according to claim 1, it is characterised in that：Electric induction furnace (2) includes crucible
(203), the top of crucible (203) is provided with cover plate (201), and crucible (203) both sides are provided with refractory brick frame (202), crucible (203)
Sidepiece is surrounded with induction coil (204) and protective plate (205), and protective plate (205) lateral wall enters provided with cooling water (206)
Water pipe, the bottom of electric induction furnace (2) is provided with base (207).
4. metal liquid die forging process system according to claim 1, it is characterised in that：Casting machine (3) includes rollover stand
(302), rollover stand (302) bottom side is provided with gravity sensor (31), and rollover stand (302) top is provided with basket pouring (303), turned over
The side of pivoted frame (302) is provided with displacement transducer (305), and the low side of displacement transducer (305) is provided with casting machine servomotor
(306), gravity sensor (31) is carried out with the unified PLC control system (304) on the outside of casting machine (3) of servomotor (306)
Control.
5. metal liquid die forging process system according to claim 1, it is characterised in that：Numerical control press (4) includes oil pressure
Formula bascule (401) and the heavily loaded leading screw (402) for being disposed thereon portion, the sidepiece of heavily loaded leading screw (402) are watched provided with punch press
Motor (403) is taken, the centre position of bascule (401) is provided with symmetrical toggle link (404).
6. metal liquid die forging process system according to claim 1, it is characterised in that：Automatic part picking machine (5) includes base
Seat (503) and the hydraulic pressure arm (502) being arranged on pedestal (503), the front end of hydraulic pressure arm (502) is provided with gripping paw
(501)。
7. metal liquid die forging process system according to claim 1, it is characterised in that：Automatic spraying machine (6) includes branch
Seat (603), bearing (603) is provided with adjusting rod (602), and adjusting rod (602) top is provided with horizontal cylinder (601), cylinder
(601) termination is provided with shower nozzle (604).
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| CN111266551A (en) * | 2020-02-04 | 2020-06-12 | 西安交通大学 | Semi-solid short-process intelligent manufacturing system and method for steel flat flange |
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