CN108274779A - 一种用于制造碳纤维复合车轮正面轮盘的模具和方法 - Google Patents
一种用于制造碳纤维复合车轮正面轮盘的模具和方法 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明提供一种用于制造碳纤维复合车轮正面轮盘的模具和方法,涉及轮盘、轮盘底部的铝合金预埋体、轮盘中部的铝合金预埋体、窗口嵌块、顶板、上模、下模、顶杆下板、顶杆上板、外顶杆、内顶杆、导向柱、底板、立柱、液压缸、下模热流道、上模热流道。碳纤维复合材料车轮轮盘制造工艺流程与连续性纤维复合材料相比可提升生产效率,制造成本低。
Description
技术领域
本发明涉及汽车零部件领域,具体地,涉及一种碳纤维复合材料车轮正面轮盘的制造方法。
背景技术
碳纤维复合材料具有轻质高强的特点,越来越被广泛的应用。目前,人们希望制造重量更低的汽车部件,来降低汽车的重量,从而节约能源,提高汽车的操控性能。国内外多家汽车车轮生产企业都尝试将碳纤维用于汽车车轮的生产。因为车轮降低的质量为簧下质量,减轻1kg相当于簧上质量减轻的数倍。同时,车轮轻量化有益于提升悬挂响应速度,减少刹车距离,增强加速性能,提升操控体验,节约能源,减少排放。已知的现有复合材料车轮大多采用连续纤维复合材料和相应的成型工艺。其工艺过程复杂,工艺成本高,生产效率低下。本发明提供一种碳纤维复合材料车轮轮盘成型方法,有效解决了上述问题。
发明内容
本发明提供了一种碳纤维复合材料车轮轮盘制造方法,与目前连续纤维复合材料车轮制造工艺相比能有效降低工艺成本,提升生产效率。
在本发明的一个方面,提供了一种用于制造碳纤维复合车轮正面轮盘的模具,所述的模具包括顶板、上模、下模、顶杆下板、顶杆上板、外顶杆、内顶杆、导向柱、底板、立柱、液压缸、窗口嵌块,其特征在于,所述的上模的上方安装有顶板,所述的上模内部设置有上模热流道;所述的下模的下方通过内顶杆和外顶杆支撑,所述的内顶杆位于下模下方的内圈,所述的外顶杆位于下模下方的外圈;所述的下模和上模相邻并且在闭合之后形成车轮正面轮盘形状的型腔;在上模和下模之间,型腔对应于车轮窗口的位置包括窗口嵌块;所述的内顶杆和外顶杆的下端连接到顶杆上板,顶杆上板下方固定有顶杆下板;所述的顶杆下板上设置有液压缸,并且所述的液压缸设置为驱动顶杆下板的上下运动;所述的底板上包括导向柱,并且顶杆上板和顶杆下板上包括导向柱穿过的通孔。
在本发明优选的方面,所述的上模热流道设置为纵横交叉排布;所述的下模热流道设置为弧形排布并且处于曲面上。
在本发明优选的方面,所述的内顶杆穿过底模内部的孔,和轮盘中心部位接触。
在本发明优选的方面,所述的底板和顶杆之间还包括顶杆下板,并且内顶杆和外顶杆的下方接触到顶杆下板。
在本发明优选的方面,所述的液压缸有4个并且在模具的四角对称布置。
在本发明其他的方面,还公开了使用前文所述的模具来制造碳纤维复合车轮正面轮盘的方法,所述的方法包括步骤:(1)将上模打开,将窗口嵌块放到下模中,并且在下模的对应于轮盘底部的位置放入环状的轮盘底部铝合金预埋体,并且将该轮盘底部铝合金预埋体通过下模定位柱进行准确定位,所述的轮盘底部铝合金预埋体的尺寸和中心法兰盘的尺寸一致;(2)通过下模热流道将下模升温到70-90摄氏度,并且使用的原材料为40-60mm的碳纤维复合材料预浸带,其纤维质量比例为50-65%;(3)将模具振动并且使得步骤2的碳纤维复合材料预浸带随机分布和致密化;(4)在中心法兰盘位置,铝合金预埋体上方放置轮盘中部铝合金预埋体,继续铺设碳纤维复合材料预浸带以充满型腔,其纤维质量比例为50-65%;(5)取出窗口嵌块独立体,并且通过上模热流道使上模升温到70-90摄氏度,随后闭合上模;(6)在39.7MPa压力和70-90摄氏度的条件下保持8-12分钟,随后升温到100-110摄氏度,保持8-12分钟;随手升温到130-150摄氏度,升压到41.0-45.0MPa,保持25-35分钟;(7)打开上模,通过液压缸带动顶杆底板和顶杆上板沿着导向柱向上移动,内顶杆和外顶杆上升,托出碳纤维复合材料轮盘。
在本发明优选的方面,将轮盘底部的铝合金预埋体放入下模,利用下模定位柱精确定位;然后通过下模热流道使下模升温至80℃;采用的原材料为50mm长的碳纤维复合材料预浸带,纤维质量比例为60%;通过震动,使得短切片在膜腔随机分布和致密化,将碳纤维复合材料预浸带均匀随机铺放在底模中;第一阶段铺放完成后,放入轮盘中部铝合金预埋体,继续铺放碳纤维复合材料预浸带;将窗口嵌块独立体取出,同时通过上模热流道使上模升温至80℃;压入上模,压力设定为39.7MPa;在39.7MPa压力,80℃条件下保持10分钟;升温至105℃,保持10分钟;升温至140℃,升压至43.6MPa,保持30分钟;打开上模,通过液压缸带动顶杆底板和顶杆上板沿导向柱向上移动,内顶杆和外顶杆上升,将碳纤维复合材料轮盘顶出。
在本发明优选的方面,所述的碳纤维复合材料预浸带是由连续碳纤维和环氧树脂所组成的,并且环氧树脂占碳纤维复合材料预浸带重量的35-45%。
在本发明优选的方面,所述的环氧树脂的固化温度是90-140摄氏度。
实际生产时,上模打开,将窗口嵌块放入下模中;将轮盘底部的铝合金预埋体放入下模,利用下模定位柱精确定位;然后通过下模热流道使下模升温至80℃;采用的原材料为50mm长的碳纤维复合材料预浸带,纤维质量比例为60%;通过震动,使得短切片在膜腔随机分布和致密化,将碳纤维复合材料预浸带均匀随机铺放在底模中;第一阶段铺放完成后,放入轮盘中部铝合金预埋体,继续铺放碳纤维复合材料预浸带;将窗口嵌块独立体取出,同时通过上模热流道使上模升温至80℃;压入上模,压力设定为39.7MPa;在39.7MPa压力,80℃条件下保持10分钟;升温至105℃,保持10分钟;升温至140℃,升压至43.6MPa,保持30分钟;打开上模,通过液压缸带动顶杆底板和顶杆上板沿导向柱向上移动,内顶杆和外顶杆上升,将碳纤维复合材料轮盘顶出。
本方法在使用中与连续纤维复合材料轮盘相比能够提升铺放效率,生产成本低,可实现自动化生产。
附图说明
以下,结合附图来详细说明本发明的实施方案,其中:
图1是本发明一种碳纤维复合材料车轮正面轮盘的制造方法的示意图。
图1,1-轮盘;2-轮盘底部的铝合金预埋体;3-轮盘中部的铝合金预埋体;4-窗口嵌块;5-顶板;6-上模;7-下模;8-顶杆下板;9-顶杆上板;10-外顶杆;11-内顶杆;12-导向柱;13-底板;14-立柱;15-液压缸;16-下模热流道;17-上模热流道。
图2是本发明一种碳纤维复合材料车轮正面轮盘的示意图。
具体实施方式
除非另外地说明,本发明的碳纤维复合材料预浸带购自山东中航泰达碳纤维复合材料制品公司,其厚度为420克/平方米。
实施例1
本方法涉及轮盘1、轮盘底部的铝合金预埋体2、轮盘中部的铝合金预埋体3、窗口嵌块4、顶板5、上模6、下模7、顶杆下板8、顶杆上板9、外顶杆10、内顶杆11、导向柱12、底板13、立柱14、液压缸15、下模热流道16、上模热流道17。顶板5与上模6通过螺栓连接,上模6内部设置热流道17,上模热流道17为纵横交叉排布,处于同一平面;底模7坐落在立柱14上,底模7内部设置热流道16,底模热流道16呈呈弧形排布,处于曲面上;顶模6和底模7之间为模腔。模具底部布置顶杆10和11,顶杆呈两圈布置,外顶杆10穿过底模7内部的孔与轮盘1外圆接触,内顶杆11穿过底模7内部的孔与轮盘1中心部位接触;顶杆10和11坐落在顶杆下板8上,顶杆下板8上方为顶杆上板9,顶杆下板8坐落在底板13上;液压缸15设置在顶杆下板8上,共4个对称布置。导向柱12布置在底板13上,顶杆上板9和顶杆下板8沿导向柱12上下移动。窗口嵌块4为独立体,与下模7配合。
实际生产时,上模6打开,将窗口嵌块4放入下模7中;将轮盘底部的铝合金预埋体2放入下模7,利用下模7定位柱精确定位;然后通过下模热流道16使下模7升温至80℃;采用的原材料为50mm长的碳纤维复合材料预浸带,纤维质量比例为60%;通过震动,使得短切片在膜腔随机分布和致密化,将碳纤维复合材料预浸带均匀随机铺放在底模7中;第一阶段铺放完成后,放入轮盘中部铝合金预埋体3,继续铺放碳纤维复合材料预浸带;将窗口嵌块独立体4取出,同时通过上模热流道17使上模6升温至80℃;压入上模6,压力设定为39.7MPa;在39.7MPa压力,80℃条件下保持10分钟;升温至105℃,保持10分钟;升温至140℃,升压至43.6MPa,保持30分钟;打开上模6,通过液压缸15带动顶杆底板8和顶杆上板9沿导向柱12向上移动,内顶杆11和外顶杆10上升,将碳纤维复合材料轮盘1顶出。
Claims (9)
1.一种用于制造碳纤维复合车轮正面轮盘的模具,所述的模具包括顶板、上模、下模、顶杆下板、顶杆上板、外顶杆、内顶杆、导向柱、底板、立柱、液压缸、窗口嵌块,其特征在于,所述的上模的上方安装有顶板,所述的上模内部设置有上模热流道;所述的下模的下方通过内顶杆和外顶杆支撑,所述的内顶杆位于下模下方的内圈,所述的外顶杆位于下模下方的外圈;所述的下模和上模相邻并且在闭合之后形成车轮正面轮盘形状的型腔;在上模和下模之间,型腔对应于车轮窗口的位置包括窗口嵌块;所述的内顶杆和外顶杆的下端连接到顶杆上板,顶杆上板下方固定有顶杆下板;所述的顶杆下板上设置有液压缸,并且所述的液压缸设置为驱动顶杆下板的上下运动;所述的底板上包括导向柱,并且顶杆上板和顶杆下板上包括导向柱穿过的通孔。
2.根据权利要求1所述的用于制造碳纤维复合车轮正面轮盘的模具,其特征在于,所述的上模热流道设置为纵横交叉排布;所述的下模热流道设置为弧形排布并且处于曲面上。
3.根据权利要求1所述的用于制造碳纤维复合车轮正面轮盘的模具,其特征在于,所述的内顶杆穿过底模内部的孔,和轮盘中心部位接触。
4.根据权利要求1所述的用于制造碳纤维复合车轮正面轮盘的模具,其特征在于,所述的底板和顶杆之间还包括顶杆下板,并且内顶杆和外顶杆的下方接触到顶杆下板。
5.根据权利要求1所述的用于制造碳纤维复合车轮正面轮盘的模具,其特征在于,所述的液压缸有4个并且在模具的四角对称布置。
6.使用权利要求1-5中任一项所述的模具来制造碳纤维复合车轮正面轮盘的方法,其特征在于,所述的方法包括步骤:(1)将上模打开,将窗口嵌块放到下模中,并且在下模的对应于轮盘底部的位置放入环状的轮盘底部铝合金预埋体,并且将该轮盘底部铝合金预埋体通过下模定位柱进行准确定位,所述的轮盘底部铝合金预埋体的尺寸和中心法兰盘的尺寸一致;(2)通过下模热流道将下模升温到70-90摄氏度,并且使用的原材料为40-60mm的碳纤维复合材料预浸带,其纤维质量比例为50-65%;(3)将模具振动并且使得步骤2的碳纤维复合材料预浸带随机分布和致密化;(4)在中心法兰盘位置,铝合金预埋体上方放置轮盘中部铝合金预埋体,继续铺设碳纤维复合材料预浸带以充满型腔,其纤维质量比例为50-65%;(5)取出窗口嵌块独立体,并且通过上模热流道使上模升温到70-90摄氏度,随后闭合上模;(6)在39.7MPa压力和70-90摄氏度的条件下保持8-12分钟,随后升温到100-110摄氏度,保持8-12分钟;随手升温到130-150摄氏度,升压到41.0-45.0MPa,保持25-35分钟;(7)打开上模,通过液压缸带动顶杆底板和顶杆上板沿着导向柱向上移动,内顶杆和外顶杆上升,托出碳纤维复合材料轮盘。
7.根据权利要求6所述的方法,其特征在于,将轮盘底部的铝合金预埋体放入下模,利用下模定位柱精确定位;然后通过下模热流道使下模升温至80℃;采用的原材料为50mm长的碳纤维复合材料预浸带,纤维质量比例为60%;通过震动,使得短切片在膜腔随机分布和致密化,将碳纤维复合材料预浸带均匀随机铺放在底模中;第一阶段铺放完成后,放入轮盘中部铝合金预埋体,继续铺放碳纤维复合材料预浸带;将窗口嵌块独立体取出,同时通过上模热流道使上模升温至80℃;压入上模,压力设定为39.7MPa;在39.7MPa压力,80℃条件下保持10分钟;升温至105℃,保持10分钟;升温至140℃,升压至43.6MPa,保持30分钟;打开上模,通过液压缸带动顶杆底板和顶杆上板沿导向柱向上移动,内顶杆和外顶杆上升,将碳纤维复合材料轮盘顶出。
8.根据权利要求6所述的方法,其特征在于,所述的碳纤维复合材料预浸带是由连续碳纤维和环氧树脂所组成的,并且环氧树脂占碳纤维复合材料预浸带重量的35-45%。
9.根据权利要求8所述的方法,其特征在于,所述的环氧树脂的固化温度是90-140摄氏度。
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