CN109909471B - Multi-metal injection molding system and method with online adjustable alloy components - Google Patents
Multi-metal injection molding system and method with online adjustable alloy components Download PDFInfo
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- CN109909471B CN109909471B CN201910230239.0A CN201910230239A CN109909471B CN 109909471 B CN109909471 B CN 109909471B CN 201910230239 A CN201910230239 A CN 201910230239A CN 109909471 B CN109909471 B CN 109909471B
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Abstract
A multi-metal injection molding system and method with online adjustable alloy components are disclosed, the system comprises a plurality of injection devices, a transition module, a mixing module and a mold, inlet channels of each transition chamber are downward from the transition chamber to the outside, and the included angle between the axis of each inlet channel of the transition chamber and the horizontal plane is beta; the axes of the pressure chambers of the plurality of injection devices are diameter extension lines of the same circle, and the center of the circle is positioned on the axis of the transition chamber; the method comprises the following steps: (1) preparing alloy raw materials; (2) preheating a crucible and preheating an injection device; (3) melting the alloy raw materials and pouring the melted alloy raw materials into each liquid storage tank; (4) calculating the preset temperatures of the transition chamber and the mixing chamber; (5) setting the stroke (6) of each injection hydraulic cylinder and setting the propelling speed; (7) electromagnetic stirring in a mixing chamber; heating the transition chamber and the mixing chamber to a preset temperature; (8) and starting the injection hydraulic cylinders of the injection devices until the multi-metal injection molding is completed. The method improves the stability and uniformity of alloy components in different time periods.
Description
Technical Field
The invention belongs to the technical field of metallurgy, and particularly relates to a multi-metal injection molding system and method with online adjustable alloy components.
Background
The metal injection molding technology has the advantages of capability of molding metal parts with complex shapes at one time, low rejection rate, high production efficiency, easiness in realizing automation and the like, and is widely applied to preparation of small metal parts with complex shapes; the metal injection molding technology can be classified into a liquid metal injection molding technology, a powder metallurgy injection molding technology, and a semi-solid metal injection molding technology according to the form of raw materials.
The liquid metal injection molding technology directly injects liquid metal into a mold, and the final product is obtained through the working procedures of cooling, demolding, surface treatment and the like; the technology has simple process and low cost, but the product has uneven structure performance, more bubbles and poor product quality; the powder metallurgy injection molding technology is a molding technology developed on the basis of a plastic injection molding technology and a powder metallurgy technology, a mixture of metal powder and a binder is taken as a raw material, the mixture in a viscous state is injected into a mold, and a final product is obtained through the working procedures of cooling, demolding, binder removal, sintering, surface treatment and the like; the product produced by the technology has good quality, but the raw material preparation is difficult, the process is complex and the cost is high; the semi-solid metal injection molding technology directly injects the semi-solid metal slurry into a mold, and the final product is obtained after the processes of cooling, demolding, surface treatment and the like; the technology has the advantages of low molding temperature, stable filling, fine crystal grains, greatly improved product quality compared with a product produced by a liquid metal injection molding technology, easy preparation of raw materials, simple process and greatly reduced production cost compared with a powder metallurgy injection molding technology.
The semi-solid metal injection molding machine is more and more widely applied because the semi-solid metal injection molding machine can produce high-quality metal workpieces at lower cost; however, the raw materials of the existing semi-solid metal injection molding machine need to be mixed in advance, the alloy components are fixed, and the online adjustment of the alloy components cannot be realized, so that only a single alloy component metal workpiece can be produced; when workpieces with different alloy components are produced by switching, semi-solid slurry needs to be proportioned and mixed again, a pressure chamber needs to be cleaned, and the like, so that the head and tail waste materials are increased, the efficiency is reduced, and the yield is reduced.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a multi-metal injection molding system and method with online adjustable alloy components, which realize online adjustment of the alloy components by controlling the injection speed of different injection devices, simplify the switching time of preparation of workpieces with different alloy components and improve the efficiency and the yield.
The multi-metal injection molding system with the online adjustable alloy components comprises a mechanical part and a control part, wherein the mechanical part comprises a plurality of injection devices, a transition module, a mixing module and a mold, and the control part comprises a main control computer and an operation console provided with a PLC; the mould, the mixing module and the transition module are simultaneously positioned in the fixed mould plate and arranged from top to bottom; the transition module is provided with a plurality of transition chamber inlet channels for communicating the transition chambers with the outside of the transition module; the inlet channels of the transition chambers are downward from the transition chambers to the outside, and the included angle between the axis of each inlet channel of the transition chambers and the horizontal plane is beta; the injection device comprises a pressure chamber, an injection punch and an injection hydraulic cylinder, the pressure chamber penetrates through the fixed die plate to be communicated with the inlet channel of the transition chamber, the pressure chamber is downward from the inlet channel of the transition chamber to the outside, the included angle between the axis of the pressure chamber and the horizontal plane is alpha, the injection punch is positioned in the pressure chamber, and the injection punch and the injection hydraulic cylinder are assembled together; a pressure chamber feeding hole is arranged above the injection punch head, communicates the pressure chamber with the outside and is provided with a gooseneck conduit connecting sleeve; a pressure chamber heat preservation device is covered outside the pressure chamber, a pressure chamber heat preservation resistance wire is arranged in the pressure chamber heat preservation device and used for heating, and an injection temperature measurement element is arranged in the pressure chamber heat preservation device; the axes of the pressure chambers of the plurality of injection devices are diameter extension lines of the same circle, and the center of the circle is positioned on the axis of the transition chamber; the injection device consists of a gooseneck conduit device, an injection hydraulic device and a liquid storage tank; the gooseneck conduit device consists of a gooseneck conduit and a gooseneck conduit heat preservation device, wherein the gooseneck conduit heat preservation device is sleeved outside the outlet end of the gooseneck conduit, and an injection heat preservation resistance wire is arranged inside the gooseneck conduit heat preservation device and used for heating and heat preservation; the gooseneck conduit connecting sleeve fixedly connects the outlet end of the gooseneck conduit with the feed inlet of the pressure chamber, so that the discharge outlet of the gooseneck conduit is communicated with the feed inlet of the pressure chamber; the inlet end of the gooseneck conduit is provided with an injection hydraulic device, the gooseneck conduit is provided with a gooseneck conduit feeding hole, and the gooseneck conduit feeding hole is used for communicating the interior of the gooseneck conduit with the interior of a crucible of the liquid storage tank; an injection hydraulic cylinder of the injection hydraulic device is assembled with an injection punch, wherein the injection punch is positioned above a feed inlet of the gooseneck conduit in the gooseneck conduit; the crucible outside of liquid reserve tank is equipped with the heat preservation stove, is equipped with the heat preservation stove resistance wire in the heat preservation stove and is used for the heating, inside crucible temperature element inserted the crucible, still is equipped with the protection gas pipe on the crucible and is used for letting in the protection gas.
In the system, the bottom end of the gooseneck conduit is positioned at the bottom in the crucible, the outlet end of the gooseneck conduit is positioned outside the crucible, the injection hydraulic cylinder is positioned outside the crucible, and the injection punch is positioned inside the crucible.
In the system, the top of the transition chamber of the transition module is communicated with the bottom of the mixing chamber of the mixing module, and the top of the mixing chamber of the mixing module is communicated with the inner space of the mold.
In the system, a transition resistance wire is arranged in the transition module and surrounds the outside of the transition chamber, and a transition module temperature measuring element is also arranged in the transition module; the transition chamber is composed of an upper cylindrical portion and a lower inverted conical portion, wherein the transition chamber inlet passage is located at the top of the inverted conical portion.
In the system, a mixing resistance wire is arranged in a mixing module and surrounds the mixing chamber, and an electromagnetic induction coil is arranged in the mixing module and surrounds the mixing chamber for electromagnetic stirring; a mixed module temperature measuring element is also arranged in the mixed module; the mixing chamber is composed of an upper cylindrical portion and a lower frustoconical portion, the cylindrical portion having a cross-sectional area equal to the area of the top surface of the frustoconical portion.
In the system, the die resistance wire is arranged in the die and surrounds the inner space of the die.
The injection hydraulic cylinder is provided with an injection servo valve; the control ends of the injection servo valve and the injection servo valve are assembled with the operating platform; the signal output ends of the injection temperature measuring element, the transition module temperature measuring element and the mixing module temperature measuring element are assembled with the operating platform; the signal output ends of the injection heat-preservation resistance wire, the pressure chamber heat-preservation resistance wire, the heat-preservation furnace resistance wire, the transition resistance wire, the mixed resistance wire and the mold resistance wire are connected with an operation console through data wires, and the operation console is assembled with a computer.
β =20 ° -30 ° above.
α = β described above.
The multi-metal injection molding method with the online adjustable alloy components adopts the system, and comprises the following steps:
1. preparing alloy raw materials; when the alloy raw materials are N, selecting transition modules with N transition chamber inlet channels; each transition chamber inlet channel is connected with an injection device, and each injection device is provided with an injection device;
2. presetting an injection device and an injection device corresponding to each alloy raw material, respectively preheating crucibles in a liquid storage tank of the injection device, wherein the preheating temperature is 10-30 ℃ higher than the melting point of the corresponding alloy raw material, and simultaneously respectively heating pressure chambers of the injection device assembled with the injection device to the same temperature;
3. respectively heating the alloy raw materials to be molten into liquid alloy raw materials, and then respectively pouring the liquid alloy raw materials into liquid storage tanks of corresponding injection devices;
4. calculating the preset temperatures of the transition chamber and the mixing chamber; firstly, determining the melting point temperature of each alloy raw material, and setting the melting point of each alloy raw material as M in sequence from high to low0、M1、M2……Mn-1、MnWhen M is0When the mass of (A) is 50% or more of the total mass of all alloy raw materials, M is used0The melting point of the alloy raw material is used as a preset temperature; when M is0When the mass of (A) is less than 50% of the total mass of all alloy raw materials, the mass is expressed as M1、M2……Mn-1The mass of each alloy raw material is calculated to M one by one0Until the total mass reaches or exceeds 50 percent of the total mass of all the alloy raw materials, calculating the melting point of the alloy raw material with the lowest melting point temperature in all the alloy raw materials as a preset temperature; alloy raw material M when melting point temperature is lowestnWhen the mass of the alloy raw material reaches or exceeds 50% of the total mass of all the alloy raw materials, taking the melting point of the alloy raw material with the lowest melting point temperature higher than 10-20 ℃ as a preset temperature;
5. setting the stroke of each injection hydraulic cylinder, and controlling the injection device to inject once, wherein the liquid alloy raw material conveyed to the pressure chamber just fills the pressure chamber; starting the injection hydraulic cylinders of the injection devices to respectively inject the liquid alloy raw materials in the injection devices into the pressure chambers;
6. the propelling speeds of the injection hydraulic cylinders of the hydraulic devices are respectively set as
、
、
…
And each satisfies the following formula:
in the formula (I), the compound is shown in the specification,
the propelling speed of an injection hydraulic cylinder in the hydraulic device is in m/s;
the density of the liquid alloy material in the hydraulic device in the solidified state is expressed in kg/m3；
The liquid alloy raw material in the hydraulic device accounts for the mass fraction of all the alloy raw materials, and the unit is;
7. electromagnetic stirring is applied to a mixing chamber in the mixing module through an electromagnetic stirring device; heating the transition chamber and the mixing chamber to a preset temperature;
8. simultaneously starting the injection hydraulic cylinders of the injection devices according to the set propelling speed
、
、
…
Respectively pressing the liquid alloy raw materials in each pressing chamber intoAnd a transition chamber, wherein the transition chamber forms semi-solid slurry under the action of electromagnetic stirring through a mixing chamber, and then the semi-solid slurry enters a die to complete multi-metal injection molding.
In the method, after the previous multi-metal injection molding is finished, when the next multi-metal injection molding with different shapes and components is carried out, the mold is opened, demolded and cleaned, then the mold is replaced, residual metals in the transition chamber and the mixing chamber are removed, the preset temperature is reset according to the melting point temperature and the mass percentage of each alloy raw material, the propelling speed is reset according to the above mode according to the solidification state density and the mass percentage of each alloy component, and then the multi-metal injection molding is carried out again.
In the above method, the total volume of the pressure chambers is equal to the total volume of the transition chamber, the mixing chamber and the inner space of the mold; pressing all the liquid alloy raw materials in each pressing chamber out of the pressing chamber by the pressing punch heads of the pressing devices; the sum of the cross-sectional areas of the pressure chambers is the same as the area of the bottom surface of the circular truncated cone portion in the mixing chamber.
In the method, a main control computer of a control part is provided with a human-computer interface, each injection device and each injection device switch are arranged on the human-computer interface, an injection hydraulic cylinder stroke input-output domain is arranged, each liquid storage tank temperature setting input-output domain is arranged, each pressure chamber temperature setting input-output domain is arranged, each injection hydraulic cylinder propulsion speed input-output domain is arranged, a transition chamber temperature setting input-output domain is arranged, and a mixing chamber temperature setting input-output domain is arranged; the main control computer is assembled with the operation table through a PLC, and an injection starting switch, an electromagnetic stirring starting switch, temperature setting execution switches of all liquid storage tanks, temperature setting execution switches of all pressure chambers, a temperature setting execution switch of a transition chamber and a temperature setting execution switch of a mixing chamber are arranged on the operation table.
The invention has the beneficial effects that:
1. compared with the traditional metal injection molding machine, the process of specially preparing the semi-solid slurry is omitted, and the production efficiency is greatly improved; according to the melting point of each alloy raw material, the solid-liquid ratio of the semi-solid slurry can be ensured to be close to 1:1 by setting the preset temperature of the transition chamber and the mixing chamber; the selection of the temperature set value of the mixing chamber ensures that the solid-liquid ratio of the semi-solid slurry is close to 1:1, the filling stability is improved, and the quality of a workpiece is improved;
2. by controlling the injection speeds of different injection devices, the online adjustment of alloy components is realized, the adjustment is simple and convenient, the switching time for preparing workpieces with different alloy components is greatly simplified, head and tail waste materials are reduced, and the efficiency and the yield are improved;
3. all the injection devices are distributed on the same arc, the mixing chambers are distributed on a straight line which passes through the center of the arc and is perpendicular to the arc, and all the transition chambers in the same transition module are identical in shape and have the same included angle with the mixing chambers, so that all the raw material metal flows from the pressure chambers to the mixing chambers through equal-length paths, and the stability and uniformity of alloy components in different time periods are improved;
4. the number of the pressure chambers is more than that of the mixing chambers, and the flow speed of the semi-solid slurry in the mixing chambers is greater than that in the pressure chambers under the condition that the cross sectional area of the pressure chambers is greater than that of the mixing chambers, so that the turbulence is increased, and the uniformity of alloy components is greatly improved.
Drawings
FIG. 1 is a schematic structural view of a multi-metal injection molding system with on-line adjustable alloy components according to the present invention;
FIG. 2 is a schematic structural diagram of a mechanical part in an embodiment of the present invention;
FIG. 3 is a schematic view of an injection device according to an embodiment of the present invention;
fig. 4 is a schematic diagram showing an arrangement structure of a plurality of injection devices in embodiment 1 of the present invention;
FIG. 5 is a schematic side elevational cross-sectional view of the shot device of FIG. 4;
FIG. 6 is a cross-sectional view of a transition module according to an embodiment of the present invention;
FIG. 7 is a schematic top cross-sectional view of FIG. 6;
FIG. 8 is a cross-sectional view of a hybrid module according to an embodiment of the present invention;
in the figure, 1, mechanical part, 2, main control computer, 3, operation desk equipped with PLC, 4, fixed template, 5, die, 6, mixing module, 7, transition module, 8, injection device, 9, injection device, 10, injection servo valve, 11, injection hydraulic cylinder, 12, crucible temperature measuring element, 13, holding furnace, 14, crucible, 15, gooseneck conduit holding device, 16, protective gas conduit, 17, gooseneck conduit, 18, injection holding resistance wire, 19, pressure chamber, 20, injection punch, 21, injection hydraulic cylinder, 22, injection servo valve, 23, injection temperature measuring element, 24, pressure chamber holding device, 25, holding pressure chamber, 26, gooseneck conduit connecting sleeve, 27, pressure chamber feed inlet, 28, transition resistance wire, 29, transition chamber, 30, transition chamber inlet channel, 31, transition module temperature measuring element, 32, mixing resistance wire, 33. electromagnetic induction coil, 34, mixing chamber, 35, mixing module temperature measuring element, 36, injection punch, 37, gooseneck conduit feed inlet.
Detailed Description
The alloy raw materials adopted in the embodiment of the invention are commercial industrial products.
In the embodiment of the invention, the frequency of electromagnetic stirring is 10-50 Hz.
In the embodiment of the invention, the transition module, the mixing module and the die are made of steel.
The embodiments are not intended to limit the scope of the present invention, and all equivalent implementations or modifications without departing from the scope of the present invention are intended to be included in the present invention.
Example 1
The structure of the multi-metal injection molding system with the online adjustable alloy components is shown in figure 1 and consists of a mechanical part and a control part;
the mechanical part structure is as shown in fig. 2, and comprises a plurality of injection devices 8, a plurality of injection devices 9, a transition module 7, a mixing module 6 and a mold 5;
the control part consists of a main control computer and an operation platform provided with a PLC;
the mould 5, the mixing module 6 and the transition module 7 are positioned in the fixed mould plate 4 at the same time and are arranged from top to bottom;
the transition module 7 is structurally shown in FIGS. 6 and 7; a plurality of transition chamber inlet passages 30 are provided to communicate the transition chamber 29 with the exterior of the transition module 7; each transition chamber inlet channel 30 is downward from the transition chamber 7 to the outside, and the included angle between the axis of each transition chamber inlet channel 30 and the horizontal plane is beta;
the structure of the injection device is shown in fig. 5, and comprises a pressure chamber 19, an injection punch 20 and an injection hydraulic cylinder 21, wherein the pressure chamber 19 passes through the fixed die plate 4 and is communicated with the inlet channel 30 of the transition chamber, the pressure chamber 19 faces downwards from the inlet channel 30 of the transition chamber to the outside, the included angle between the axis of the pressure chamber 19 and the horizontal plane is alpha, the injection punch 20 is positioned in the pressure chamber 19, and the injection punch 20 and the injection hydraulic cylinder 21 are assembled together; a pressure chamber feeding hole 27 is arranged above the injection punch 20, the pressure chamber feeding hole 27 is communicated with the gooseneck conduit 17 of the injection device 8 of the pressure chamber 20 and is provided with a gooseneck conduit connecting sleeve 26; a pressure chamber heat preservation device 24 is coated outside the pressure chamber 19; a pressure chamber heat preservation resistance wire 25 is arranged in the pressure chamber heat preservation device 24 and used for heating, and an injection temperature measuring element 23 is arranged;
the axes of the pressure chambers 19 of the plurality of injection devices 9 are diameter extension lines of the same circle, and the center of the circle is positioned on the axis of the transition chamber 29; the arrangement is shown in FIG. 4;
the structure of the injection device 8 is shown in figure 3 and consists of a gooseneck conduit device, an injection hydraulic device and a liquid storage tank;
the gooseneck conduit device consists of a gooseneck conduit 17 and a gooseneck conduit heat preservation device 15, wherein the gooseneck conduit heat preservation device 15 is sleeved outside the outlet end of the gooseneck conduit 17, an injection heat preservation resistance wire 18 is arranged inside the gooseneck conduit heat preservation device 15 and used for heating and heat preservation, and an injection temperature measurement element 12 is arranged;
the gooseneck conduit connecting sleeve 26 fixedly connects the outlet end of the gooseneck conduit 17 with the pressure chamber feeding port 27, so that the discharge port of the gooseneck conduit 17 is communicated with the pressure chamber feeding port 27;
the inlet end of the gooseneck conduit 17 is provided with an injection hydraulic device, the gooseneck conduit 17 is provided with a gooseneck conduit feeding port 37, and the gooseneck conduit feeding port 37 communicates the interior of the gooseneck conduit with the interior of the crucible 14 of the liquid storage tank;
the injection cylinder 11 of the injection hydraulics is assembled with the injection ram 36, wherein the injection ram 36 is located in the gooseneck conduit 17 above the gooseneck conduit feed opening 37; a holding furnace 13 is assembled outside a crucible 14 of the liquid storage tank, a holding furnace resistance wire is arranged in the holding furnace 13 and used for heating, a crucible temperature measuring element 12 is inserted into the crucible 14, and a protective gas guide pipe 16 is also arranged on the crucible 14 and used for introducing protective gas;
the bottom end of the gooseneck conduit 17 is positioned at the bottom in the crucible 14, the outlet end of the gooseneck conduit 17 is positioned outside the crucible 14, the injection hydraulic cylinder 11 is positioned outside the crucible 14, and the injection punch 36 is positioned inside the crucible 14;
the top of the transition chamber 29 of the transition module 7 is communicated with the bottom of the mixing chamber 34 of the mixing module 6, and the top of the mixing chamber 34 of the mixing module 6 is communicated with the inner space of the mold 5;
a transition resistance wire 28 is arranged in the transition module 7 and surrounds the transition chamber 29, and a transition module temperature measuring element 31 is also arranged in the transition module 7; the transition chamber 29 consists of an upper cylindrical portion and a lower inverted conical portion, wherein the transition chamber inlet passage 30 is located at the top of the inverted conical portion;
the structure of the mixing module 6 is shown in fig. 8, a mixing resistance wire 32 is arranged in the mixing module 6 and surrounds the mixing chamber 34, and an electromagnetic induction coil 33 is arranged in the mixing module 6 and surrounds the mixing chamber 34 for electromagnetic stirring; a mixed module temperature measuring element 35 is also arranged in the mixed module 6; the mixing chamber 34 is composed of an upper cylindrical portion having a cross-sectional area equal to the area of the top surface of the lower frustoconical portion;
a die resistance wire is arranged in the die 5 and surrounds the inner space of the die;
the injection hydraulic cylinder 21 is provided with an injection servo valve 22, and the injection hydraulic cylinder 11 is provided with an injection servo valve 10; the control ends of the injection servo valve 22 and the injection servo valve 10 are assembled with the operation table 3 equipped with the PLC;
the signal output ends of the crucible temperature measuring element 12, the injection temperature measuring element 23, the transition module temperature measuring element 31 and the mixing module temperature measuring element 35 are assembled with the operating platform 3 provided with the PLC;
the signal output ends of the injection heat-preservation resistance wire 18, the pressure chamber heat-preservation resistance wire 25, the heat-preservation furnace resistance wire, the transition resistance wire 28, the mixed resistance wire 32 and the die resistance wire are connected with the operation table 3 equipped with the PLC through data wires, and the operation table 3 equipped with the PLC is assembled with a computer;
β=25°；α=β；
the method comprises the following steps:
preparing three alloy raw materials, namely industrial pure aluminum, alloy ZL101A and alloy Y113, wherein the melting points of the alloy raw materials are 660 ℃, 613 ℃ and 577 ℃ respectively; according to the components of the target alloy ADC10 alloy casting, the mass percentages of the three alloy raw materials are respectively 20%, 35% and 45%;
the alloy raw materials are three, and the number of inlet channels of the transition chamber is 3; each transition chamber inlet channel is connected with an injection device, and each injection device is provided with an injection device;
presetting an injection device and an injection device corresponding to each alloy raw material, respectively preheating crucibles in a liquid storage tank of the injection device, wherein the preheating temperature is 10-30 ℃ higher than the melting point of the corresponding alloy raw material, and simultaneously respectively heating pressure chambers of the injection device assembled with the injection device to the same temperature;
respectively heating the alloy raw materials to be molten into liquid alloy raw materials, and then respectively pouring the liquid alloy raw materials into liquid storage tanks of corresponding injection devices;
calculating the preset temperatures of the transition chamber and the mixing chamber; the industrial pure aluminum is M0The alloy ZL101A is M1，M0+ M1More than 50% of the total mass of all alloy raw materials, as M1The melting point temperature of the alloy ZL101A is 613 ℃ as a preset temperature;
setting the stroke of each injection hydraulic cylinder, and controlling the injection device to inject once, wherein the liquid alloy raw material conveyed to the pressure chamber just fills the pressure chamber; starting the injection hydraulic cylinders of the injection devices to respectively inject the liquid alloy raw materials in the injection devices into the pressure chambers;
the propelling speeds of the injection hydraulic cylinders of the hydraulic devices are respectively set as
、
、
According to the formula (1), the advancing speeds of the industrial pure aluminum, the alloy ZL101A and the alloy Y113 are 1m/s, 1.75m/s and 2.25m/s respectively;
electromagnetic stirring is applied to a mixing chamber in the mixing module through an electromagnetic stirring device; heating the transition chamber and the mixing chamber to a preset temperature;
simultaneously starting the injection hydraulic cylinders of the injection devices according to the set propelling speed
、
、
Respectively pressing the liquid alloy raw materials in each pressure chamber into a transition chamber, forming semi-solid slurry under the action of electromagnetic stirring through a mixing chamber, and then entering a mold to finish multi-metal injection molding;
the total volume of the pressure chambers is equal to the total volume of the transition chamber, the mixing chamber and the inner space of the mould; pressing all the liquid alloy raw materials in each pressing chamber out of the pressing chamber by the pressing punch heads of the pressing devices; the sum of the cross sectional areas of the pressure chambers is the same as the area of the bottom surface of the circular table body part in the mixing chamber;
the main control computer of the control part is provided with a human-computer interface, each injection device and each injection device switch are arranged on the human-computer interface, an injection hydraulic cylinder stroke input-output domain is arranged, each liquid storage tank temperature setting input-output domain is arranged, each pressure chamber temperature setting input-output domain is arranged, each injection hydraulic cylinder propulsion speed input-output domain is arranged, a transition chamber temperature setting input-output domain is arranged, and a mixing chamber temperature setting input-output domain is arranged; the main control computer is assembled with the operating platform through a PLC, and an injection starting switch, an electromagnetic stirring starting switch, temperature setting execution switches of all liquid storage tanks, temperature setting execution switches of all pressure chambers, a temperature setting execution switch of a transition chamber and a temperature setting execution switch of a mixing chamber are arranged on the operating platform;
the operation of the control section includes the steps of:
starting switches of 3 injection devices and injection devices on a human-computer interface of a main control computer;
setting the temperature of a liquid storage tank and a pressure chamber of industrial pure aluminum to be 670 ℃, the temperature of the liquid storage tank and the pressure chamber of alloy ZL101A to be 630 ℃, the temperature of the liquid storage tank and the pressure chamber of alloy Y113 to be 590 ℃ on a human-computer interface of a main control computer, starting a liquid storage tank temperature setting execution switch and a pressure chamber temperature setting execution switch on an operation table, heating corresponding heat preservation furnaces and pressure chambers, and respectively injecting the three melted alloys into the corresponding liquid storage tanks after the temperature reaches a specified temperature;
starting temperature setting execution switches of a transition chamber and a mixing chamber on an operation platform to ensure that the solid-liquid ratio of the semi-solid slurry is close to 1: 1;
setting the stroke of the injection hydraulic cylinder on a human-computer interface of the main control computer 2, and controlling the stroke value to ensure that the injection hydraulic cylinder can inject liquid raw material once to just fill a pressure chamber 19;
on a human-computer interface of a main control computer, inputting and outputting the propelling speed of the injection hydraulic cylinder into a propelling speed domain;
starting an injection starting switch on an operation table, pressing liquid metal raw materials into a transition chamber and a mixing chamber at a set speed by each injection hydraulic cylinder to form semi-solid slurry close to Y112 alloy components, and further completing mold filling in a mold 5;
example 2
By adopting the device of the embodiment 1, the mould is replaced, the residual metals in the transition chamber and the mixing chamber are removed, the preset temperature is reset according to the melting point temperature and the mass percentage of each alloy raw material in the above mode, the advancing speed is reset according to the solidification state density and the mass percentage of each alloy component in the above mode, and then the multi-metal injection molding is carried out again;
the method is the same as example 1, except that:
(1) according to the components of the target alloy ZL105 alloy casting, the mass percentages of the three alloy raw materials are respectively 55%, 15% and 35%;
(2) the industrial pure aluminum is M0More than 50% of the total mass of all alloy raw materials, in terms of M0The melting point temperature of the industrial pure aluminum is 660 ℃ as a preset temperature;
(3) the advancing speeds of commercial pure aluminum, alloy ZL101A and alloy Y113 were 2.75m/s, 0.75m/s and 1.5m/s, respectively.
The embodiments are not intended to limit the scope of the present invention, and all equivalent implementations or modifications without departing from the scope of the present invention are intended to be included in the scope of the present invention.
Claims (10)
1. A multi-metal injection molding system with online adjustable alloy components comprises a mechanical part and a control part, wherein the mechanical part comprises a plurality of injection devices, a transition module, a mixing module and a mold, and the control part comprises a main control computer and an operation console provided with a PLC; the mould, the mixing module and the transition module are simultaneously positioned in the fixed mould plate and arranged from top to bottom; the method is characterized in that: the transition module is provided with a plurality of transition chamber inlet channels for communicating the transition chambers with the outside of the transition module; the inlet channels of the transition chambers are downward from the transition chambers to the outside, and the included angle between the axis of each inlet channel of the transition chambers and the horizontal plane is beta; the injection device comprises a pressure chamber, an injection punch and an injection hydraulic cylinder, the pressure chamber penetrates through the fixed die plate to be communicated with the inlet channel of the transition chamber, the pressure chamber is downward from the inlet channel of the transition chamber to the outside, the included angle between the axis of the pressure chamber and the horizontal plane is alpha, the injection punch is positioned in the pressure chamber, and the injection punch and the injection hydraulic cylinder are assembled together; a pressure chamber feeding hole is arranged above the injection punch head, communicates the pressure chamber with the outside and is provided with a gooseneck conduit connecting sleeve; a pressure chamber heat preservation device is covered outside the pressure chamber, a pressure chamber heat preservation resistance wire is arranged in the pressure chamber heat preservation device and used for heating, and an injection temperature measurement element is arranged in the pressure chamber heat preservation device; the axes of the pressure chambers of the plurality of injection devices are diameter extension lines of the same circle, and the center of the circle is positioned on the axis of the transition chamber; the injection device consists of a gooseneck conduit device, an injection hydraulic device and a liquid storage tank; the gooseneck conduit device consists of a gooseneck conduit and a gooseneck conduit heat preservation device, wherein the gooseneck conduit heat preservation device is sleeved outside the outlet end of the gooseneck conduit, and an injection heat preservation resistance wire is arranged inside the gooseneck conduit heat preservation device and used for heating and heat preservation; the gooseneck conduit connecting sleeve fixedly connects the outlet end of the gooseneck conduit with the feed inlet of the pressure chamber, so that the discharge outlet of the gooseneck conduit is communicated with the feed inlet of the pressure chamber; the inlet end of the gooseneck conduit is provided with an injection hydraulic device, the gooseneck conduit is provided with a gooseneck conduit feeding hole, and the gooseneck conduit feeding hole is used for communicating the interior of the gooseneck conduit with the interior of a crucible of the liquid storage tank; an injection hydraulic cylinder of the injection hydraulic device is assembled with an injection punch, wherein the injection punch is positioned above a feed inlet of the gooseneck conduit in the gooseneck conduit; the crucible outside of liquid reserve tank is equipped with the heat preservation stove, is equipped with the heat preservation stove resistance wire in the heat preservation stove and is used for the heating, inside crucible temperature element inserted the crucible, still is equipped with the protection gas pipe on the crucible and is used for letting in the protection gas.
2. A polymetallic injection moulding system with in-line adjustable alloy composition according to claim 1, characterized in that the bottom end of the gooseneck conduit is located at the bottom inside the crucible, the outlet end of the gooseneck conduit is located outside the crucible, the injection cylinder is located outside the crucible and the injection punch is located inside the crucible.
3. A multi-metal injection molding system with in-line adjustable alloy composition as claimed in claim 1, wherein the transition chamber of the transition module has a top portion communicating with a bottom portion of the mixing chamber of the mixing module, and the mixing chamber of the mixing module has a top portion communicating with the inner space of the mold.
4. The system of claim 1, wherein a transition resistance wire is disposed in the transition module and surrounds the outside of the transition chamber, and a temperature measuring element of the transition module is disposed in the transition module; the transition chamber is composed of an upper cylindrical portion and a lower inverted conical portion, wherein the transition chamber inlet passage is located at the top of the inverted conical portion.
5. The system of claim 1, wherein the mixing module is provided with a mixing resistance wire around the outside of the mixing chamber, and the mixing module is provided with an electromagnetic induction coil around the outside of the mixing chamber for electromagnetic stirring; a mixed module temperature measuring element is also arranged in the mixed module; the mixing chamber is composed of an upper cylindrical portion and a lower frustoconical portion, the cylindrical portion having a cross-sectional area equal to the area of the top surface of the frustoconical portion.
6. A multi-metal injection molding system with in-line adjustable alloy composition as defined in claim 1, wherein said injection hydraulic cylinder is equipped with an injection servo valve, and said injection hydraulic cylinder is equipped with an injection servo valve; the control ends of the injection servo valve and the injection servo valve are assembled with the operating platform; the signal output ends of the injection temperature measuring element, the transition module temperature measuring element and the mixing module temperature measuring element are assembled with the operating platform; the signal output ends of the injection heat-preservation resistance wire, the pressure chamber heat-preservation resistance wire, the heat-preservation furnace resistance wire, the transition resistance wire, the mixed resistance wire and the mold resistance wire are connected with an operation console through data wires, and the operation console is assembled with a computer.
7. The system of claim 1, wherein β =20 ° -30 °; α = β.
8. A multi-metal injection molding method with on-line adjustable alloy composition, characterized in that the system of claim 1 is adopted, comprising the following steps:
(1) preparing alloy raw materials; when the alloy raw materials are N, selecting transition modules with N transition chamber inlet channels; each transition chamber inlet channel is connected with an injection device, and each injection device is provided with an injection device;
(2) presetting an injection device and an injection device corresponding to each alloy raw material, respectively preheating crucibles in a liquid storage tank of the injection device, wherein the preheating temperature is 10-30 ℃ higher than the melting point of the corresponding alloy raw material, and simultaneously respectively heating pressure chambers of the injection device assembled with the injection device to the same temperature;
(3) respectively heating the alloy raw materials to be molten into liquid alloy raw materials, and then respectively pouring the liquid alloy raw materials into liquid storage tanks of corresponding injection devices;
(4) calculating the preset temperatures of the transition chamber and the mixing chamber; firstly, determining the melting point temperature of each alloy raw material, and setting the melting point of each alloy raw material as M in sequence from high to low0、M1、M2……Mn-1、MnWhen M is0When the mass of (A) is 50% or more of the total mass of all alloy raw materials, M is used0The melting point of the alloy raw material is used as a preset temperature; when M is0When the mass of (A) is less than 50% of the total mass of all alloy raw materials, the mass is expressed as M1、M2……Mn-1The mass of each alloy raw material is calculated to M one by one0Until the total mass reaches or exceeds 50 percent of the total mass of all the alloy raw materials, calculating the melting point of the alloy raw material with the lowest melting point temperature in all the alloy raw materials as a preset temperature; alloy raw material M when melting point temperature is lowestnWhen the mass of the alloy raw material reaches or exceeds 50% of the total mass of all the alloy raw materials, taking the melting point of the alloy raw material with the lowest melting point temperature higher than 10-20 ℃ as a preset temperature;
(5) setting the stroke of each injection hydraulic cylinder, and controlling the injection device to inject once, wherein the liquid alloy raw material conveyed to the pressure chamber just fills the pressure chamber; starting the injection hydraulic cylinders of the injection devices to respectively inject the liquid alloy raw materials in the injection devices into the pressure chambers;
(6) the propelling speeds of the injection hydraulic cylinders of the hydraulic devices are respectively set as
、
、
…
And each satisfies the following formula:
in the formula (I), the compound is shown in the specification,
the propelling speed of an injection hydraulic cylinder in the hydraulic device is in m/s;
the density of the liquid alloy material in the hydraulic device in the solidified state is expressed in kg/m3；
The liquid alloy raw material in the hydraulic device accounts for the mass fraction of all the alloy raw materials, and the unit is;
(7) electromagnetic stirring is applied to a mixing chamber in the mixing module through an electromagnetic stirring device; heating the transition chamber and the mixing chamber to a preset temperature;
(8) simultaneously starting the injection hydraulic cylinders of the injection devices according to the set propelling speed
、
、
…
Liquid alloy raw materials in the pressure chambers are respectively pressed into the transition chambers, form semi-solid slurry under the action of electromagnetic stirring through the mixing chambers, and then enter the die to complete multi-metal injection molding.
9. A multi-metal injection molding method with in-line adjustable alloy composition according to claim 8, wherein the total volume of each pressure chamber is equal to the total volume of the transition chamber, the mixing chamber and the inner space of the mold; pressing all the liquid alloy raw materials in each pressing chamber out of the pressing chamber by the pressing punch heads of the pressing devices; the sum of the cross-sectional areas of the pressure chambers is the same as the area of the bottom surface of the circular truncated cone portion in the mixing chamber.
10. A method for multi-metal injection molding with on-line adjustable alloy composition as defined in claim 8, wherein the main control computer of the control part is provided with a man-machine interface on which each injection device and each injection device switch are provided, an injection cylinder stroke input-output field is provided, a tank temperature setting input-output field is provided, a chamber temperature setting input-output field is provided, a ram speed input-output field is provided, a transition chamber temperature setting input-output field is provided, and a mixing chamber temperature setting input-output field is provided; the main control computer is assembled with the operation table through a PLC, and an injection starting switch, an electromagnetic stirring starting switch, temperature setting execution switches of all liquid storage tanks, temperature setting execution switches of all pressure chambers, a temperature setting execution switch of a transition chamber and a temperature setting execution switch of a mixing chamber are arranged on the operation table.
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