CN110014265B - Manufacturing process of thermally modified two-wheel hub - Google Patents
Manufacturing process of thermally modified two-wheel hub Download PDFInfo
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- CN110014265B CN110014265B CN201810020435.0A CN201810020435A CN110014265B CN 110014265 B CN110014265 B CN 110014265B CN 201810020435 A CN201810020435 A CN 201810020435A CN 110014265 B CN110014265 B CN 110014265B
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
- B60B27/00—Hubs
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Mold Materials And Core Materials (AREA)
- Forging (AREA)
Abstract
The invention relates to the field of hub manufacturing processes, in particular to a manufacturing process of a thermally modified two-wheel hub. The metallographic structure of the product is changed through modification heat treatment, so that the performance of the two-wheel hub product is improved, and the stress effect is better borne. Step 1, sanding core: manufacturing a sand core die, and refining an aluminum material in step 2: preparing aluminum material, wherein 80-98% of aluminum is mixed, and modified alloy material components (%). Si 6.5-7.5, Mg0.3-0.4, Ti0.08-0.2, Sr0.02-0.03, Fe is less than or equal to 0.3, Cn is less than or equal to 0.1, Zn is less than or equal to 0.1 are mixed, the addition amount of a modified aluminum titanium carbon strontium alloy refiner is added, modification heat treatment and solid solution are carried out, the wheel hub body is continuously placed in a flow heat treatment furnace, the modified wheel hub is shifted to a wheel hub machining center machine tool to be machined in a sequence procedure, after the machining procedure in the sequence procedure is finished, the temperature reduction detection is carried out, the two-sequence machining center machining is carried out again, the surface is modified and chromized, and the modified wheel hub is purified, sprayed and packaged.
Description
Technical Field
The invention relates to the field of hub manufacturing processes, in particular to a manufacturing process of a thermally modified two-wheel hub.
Background
The wheel hub is a core component in a vehicle frame system, and is mainly responsible for direct contact between a vehicle and the ground, and the development of a modern vehicle is obtained after the wheel hub is loaded with a tire, the modern wheel hub is basically made of iron alloy and aluminum alloy, and three manufacturing methods of the aluminum alloy wheel hub are provided: gravity casting, forging and low-pressure precision casting. 1. The gravity casting method utilizes gravity to pour the aluminum alloy solution into the mold, and the aluminum alloy solution is processed and polished by a lathe after being formed, so that the production can be completed. The manufacturing process is simple, a precise casting process is not needed, the cost is low, the production efficiency is high, but bubbles (air holes) are easily generated, the density is uneven, the surface smoothness is not enough, the situation exists in small hubs, namely hubs of two wheels (electric vehicles, motorcycles and motor tricycles which can also be used for mopeds), the improvement process is particularly outstanding because the manufacturing machinery and cost of the small hubs are severely limited, and the manufacturing process of the hubs, which can adapt to the existing equipment and technology, has more advantages, is more close to large-scale industrial production and is more environment-friendly in manufacturing engineering, is manufactured.
Disclosure of Invention
The invention aims to provide a manufacturing process of a thermal phase modified two-wheel vehicle hub, which changes the metallographic structure of a product through modification heat treatment, so that the performance of the two-wheel vehicle hub product is improved, and the stress effect is better borne.
The invention is realized by the following technical scheme: a manufacturing process of a thermally modified two-wheel hub comprises the following steps:
1, step 1, sanding core: manufacturing a sand core mould, stably installing the sand core mould into a sand core machine, and adjusting the parallelism and perpendicularity of the mould and a machine table;
injecting sand after the sand is filled, and taking the condition that the precoated sand is not ejected from a parting surface as a standard;
starting a sand core machine for heating, setting the mold temperature of the sand core machine to be 250 +/-20 ℃, keeping the temperature to be 2 ℃ per second, raising the temperature to 230-270 ℃, keeping the temperature to exceed the range, and immediately adding the temperature for recovering;
after the temperature reaches 230-255 ℃, adding high-temperature lubricating oil at each ejector rod position of the sand core machine, checking that the air pressure is above 0.6Mpa, drying the compressed air without moisture, and draining accumulated water in an oil-water filter, wherein the high-temperature lubricating oil is GPL21 die high-temperature lubricating oil or HP-500 GREAE and is mixed with 20-30% of Yamaichi NS 1001; the sand core is manufactured and coated with sand to make a mold, and the sand core is checked to check whether exhaust holes of all parts are smooth or not after the manufacture is finished, so that the good molding of the sand core is ensured; checking the appearance plumpness of the sand core in a normal process, and if a defect is found, cleaning the exhaust hole in time;
2, step 2, refining the aluminum material: preparing an aluminum material, wherein 80-98% of aluminum is mixed, modified alloy material components (percent) are mixed, namely, 6.5-7.5 parts of Si, 0.3-0.4 part of Mg0.08-0.2 part of Ti0.08-0.2 part of Sr0.02-0.03 part of Fe, less than or equal to 0.1 part of Cn and less than or equal to 0.1 part of Zn, and the addition amount of a modified aluminum titanium carbon strontium alloy refiner is added, wherein 3-4 parts (about 800 Kg/furnace) of each heat preservation furnace are added, the mixture is uniformly mixed and then introduced into a cabin of an aluminum liquid refiner for preheating, the preheating and starting nitrogen injection and degassing can be carried out, the nitrogen size is adjusted to be accurate to the uniform distribution of small bubbles on the liquid surface, and the degassing time is half an hour; moving an aluminum liquid refiner with a graphite tool for degassing to the upper surface of the heat preservation furnace, immersing the graphite turntable into the aluminum liquid, adjusting the air flow, then placing the refiner to the furnace end, and starting degassing; sampling by a small spoon after degassing for 10 minutes in an assay, and delivering to an assay laboratory; adding 0.8-1Kg of slag removing agent into the slag, uniformly stirring, covering for 10 minutes, and then washing the slag; measuring the temperature to ensure that the temperature meets the standard; filling aluminum water in the small iron cup after hydrogen measurement and red baking, placing the small iron cup in an iron cover of a nitrogen measurement instrument, starting vacuumizing and cooling, taking out the small iron cup after 3 minutes, placing the small iron cup in water for full cooling, leveling the sample block, and checking the pinhole level; the over-tolerance of Si and Fe elements in the component test must be returned to a large furnace, and the too low Mg and Sr must be added; the refining temperature is 715 +/-15 degrees; the aluminum water is used up within 1 hour after being refined, and needs to be refined again after time out; the holding furnace cannot be reused when the aluminum water capacity is less than 1/3. Measuring hydrogen, namely vacuumizing the small iron cup for 3 minutes at the baking temperature of about 700 ℃ and under the vacuumizing pressure of 0.08-0.1 MPa; the turning surface is required to be flat, and the roughness is 3.2; the number of visual pinhole stages is less than or equal to 2, and no pore slag hole appears; refining again when the pinhole grade is unqualified;
3, pouring and forming in the step 3, wherein the step 1 and the step 3 can be carried out synchronously, or aluminum liquid is poured according to sand molds to manufacture and form after correction is finished respectively, the adopted machine is a casting machine, a baking head is clamped to the center of the mold by a baking mold, the fire is adjusted to start baking, a spraying material spray gun is about 20cm away from the spraying material part and is uniformly sprayed, a sand core is placed into the mold, the sand core is ensured to be stably matched with the mold, sundries on the mold are blown off, the mold is firstly closed, then the side molds are closed, the side molds are closed for 1-2 times, and the side molds are determined to be closed in place. Pouring molten aluminum into the pouring gate of the mold, placing a square filter screen (or a round filter screen) into the funnel, then placing the square filter screen (or the round filter screen) into the middle of the triangular filter screen, taking out the funnel, taking out the molten aluminum from the heat preservation furnace by the filter screen pouring ladle, pouring the molten aluminum into the funnel, leaving a proper amount of molten aluminum for feeding, taking the filter screen into the barrel after the molten aluminum flows out, and placing the funnel on the baking mold of the baking machine for heat preservation. And taking out the molten aluminum left by the product casting ladle, and directly pouring the molten aluminum into the pouring gate until the pouring gate is full. And taking out the rest steel pouring groove, lightly placing the steel pouring groove on a platform, shaping the steel pouring groove after the inspection is qualified, marking a job number, and transferring the steel pouring groove to a rotating plate. Spraying a material on the die: the distance between the spray gun and the spray coating part is about 20cm, and the spraying is uniform. The performance of the paint is as follows: 34# improves the fluidity of aluminum water and has a function of preventing outward shrinkage porosity; keeping the temperature at 1/4 of the demolding temperature, and proportioning: coating 34 #: water = 1: 4; coating 39 #: water = 1: 5, spraying: heating the mould by using coal gas for about half an hour (250-300 ℃), wherein the mould must be clean and cannot have impurities; priming a layer by using the mixture ratio II, and continuously heating for half an hour (about 350 ℃); pouring a first wheel, opening the upper die and the side die (the wheel is not ejected firstly); the side mould and riser are sprayed with a layer of coating in proportion. And (c) coating is additionally sprayed according to the condition (by using the ratio II), and the mould produced normally does not need to be sprayed and heated. The surface quality requirement is as follows: the non-processed surface can not have salient points, cracks, paint scars, wrinkles, roughness and obvious exhaust spots. The ladle and the funnel for taking water must be ensured to be dry and insulated, and the walking is stable and fast after taking water; the channel is ensured to be smooth, and pedestrians beside the channel are noticed to avoid the aluminum water from splashing to hurt people; non-workers must not approach the holding furnace.
And 4, changing the baked and heat-insulated die to a cutting machine after the die is finished, installing a cutting piece of the cutting machine, adjusting the size, starting a switch, and cutting. The cutting piece is firmly fixed, and the cutting position can not be corrected by swinging left and right (trial assembly swinging degree of a first-starting machine) according to the cutting line of the blank which is higher than 1-2 mm;
after clamping, the flatness of the product matched with the clamp must be checked; lubricating oil is required to be added in the cutting process, so that the saw blade is prevented from being adhered with aluminum; and adjusting the rotation speed of the power head according to various products.
And 5, deburring, namely after the blank is cut, putting the hub body into a bench drill to drill a valve hole, wherein the diameter of a drill bit is 8.5+ 0.20, the concentricity of the hole and the blank ring is within 1mm, and the out-of-roundness of the hole is less than 0.1 mm. Adjusting the clamp, and starting the rotating speed of the switch bench drill: 800 revolutions per minute. (ii) a Placing the product on a fixture, and starting drilling; after the valve hole is drilled, the existence of no burr, no tool vibration and no aluminum adhesion is ensured.
And 6, modifying, carrying out solid solution treatment, continuously putting the hub body into a flow heat treatment furnace, starting the machine according to the operating rules (adopting automatic circulation and adjusting the temperature and time) to carry out thermal modification treatment on the hub body, putting the product into the steel pipe for the time till the furnace door is opened, automatically pushing the product into a high-temperature furnace, and then carrying out treatment. The coated sand is loosened and conveniently removed by heat treatment of the glue in the high-temperature combustion sand core; temperature parameters: solid solution is carried out at 535 +/-5 ℃, and the baking time is 5.5 +/-0.5 hours; the actual effect is 150 +/-5 ℃, and the baking time is 3.5 +/-0.5 hours; 4. Setting the temperature of the high-temperature furnace zone: 1 zone 500 deg.C, 2 zone 535 deg.C, 3 zone 535 deg.C, 4 zone 535 deg.C, 5 zone 535 deg.C, 6 zone 538 deg.C; the water temperature of the quenching water is kept at 60-90 ℃, the quenching time is about 5 minutes, and when the time is up, the product is pushed out of the high-temperature furnace, and the product which is immersed in the water tank within the time is taken out of the high-temperature furnace and is necessarily immersed in the quenching water tank within 20 +/-5 seconds; the hardness center part HB 70-85 ℃ of the treated product is ground, the measuring point part is ground flat, and the average value of 3 points is measured. Shaping a plane: and (4) after shaping according to requirements, marking a job number, and then penetrating and installing a backflow rotating frame to enter the actual effect of the actual effect furnace. The end face of the large excircle of the product is close to the shaping flat plate, and each gap is less than 0.5 mm. Axial reshaping: the product is measured according to the corresponding measuring bar, and the deformation degree is +/-0.5 mm. The wheel is arranged on the frame, the excircle of the product is not reliable, and a gap of more than 3cm is reserved. And (4) performing spot check on the hardness.
Step 7, sand removal is carried out on the modified hub body, and precoated sand in the hub is removed, so that a hollow effect is achieved; hanging the product on a support, and beating a rim to enable the precoated sand to flow out along the positioning hole; and removing the residual precoated sand in each sand core positioning hole by using a steel wire brush.
Step 8, continuously shifting the modified hub to an argon arc welding machine for welding repair, welding repair of the positioning hole of the sand core and improvement of the appearance defect of the spoke; hanging the product on a support, and welding and repairing the product to the center of the positioning hole by using an aluminum wire along the excircle of the positioning hole by one circle until the sand core hole is completely closed; current of argon arc welding machine: 220-250A; and (3) welding handle cooling water inspection: 4 h/time;
and 9, shifting the modified hub to a hub machining center machine tool to perform a sequence of processes, cutting by using a jump cutter of a numerical control lathe, and ensuring the accuracy before 3 and machining or after changing a clamp: jumping of the faceplate and the backup plate is less than or equal to 0.10mm, jumping of the core rod is less than or equal to 0.03mm, diameter tolerance of the core rod is two times of minus 0.08 to minus 0.10mm, and lubricating oil is added into a guide rail of the numerical control lathe. The back plate has no aluminum scraps and impurities.
The cutting fluid adopts: emulsified cutting fluid with the concentration of 5 percent; and (4) starting a power supply according to the operation rule of the machine tool, inputting the program to the numerical control machine, and trying to ensure that the track is normal. And (5) installing a cutter and adjusting the program. And (4) erasing aluminum scraps and sundries on the backup plate, and clamping the upper workpiece. And starting the main shaft, starting a start button of the numerical control machine, and starting machining at the moment. And after the machine is stopped, taking the workpiece out of the clamp and lightly placing the workpiece on a sequence rotating frame. One workpiece is kept at a constant speed for 3-7 minutes, and 3-5 times of repetition is allowed under the condition that a sequence is not finished; avoid direct contact with the ground or aluminum scraps; avoiding collision. The processed product is not sticky with aluminum, and the bright surface is not scratched.
And step 10, cooling and detecting after the machining first-sequence process is finished, entering a second-sequence machining center again for machining, starting a power supply according to the operation rules of the machine tool, inputting the program to the numerical control machine, and trying to ensure that the track is normal. And (5) installing a cutter, and adjusting the program by using waste products. The run-out of the positioning backup plate is less than or equal to 0.05mm, the center of the positioning core rod is set as the zero point of the coordinate of the workpiece, the diameter tolerance of the core rod is-0.08 to-0.10 mm, and the requirements of the pressing plate are as follows: the clamping is kept simultaneously, and the length of the pressing plate is adjusted to be consistent; 3. the cutting fluid adopts: emulsified cutting fluid with the concentration of 8 percent; and (4) erasing aluminum scraps and sundries on the backup plate, and clamping the upper workpiece. And starting the main shaft, starting a start button of the numerical control machine, and starting machining at the moment. And after the machine is stopped, taking the workpiece out of the clamp and lightly placing the workpiece on a sequence rotating frame.
Step 11, starting a polishing step, namely putting the hub processed by the two sequences on a pneumatic polishing machine, and exhausting air for 60-120 seconds by an air pipe to ensure that accumulated water is drained completely; a proper amount of lubricating oil is filled into the polishing machine to ensure the normal operation of the equipment; polishing each part of the hub smoothly by using 240-mesh abrasive paper, and particularly polishing the argon arc welding spot position; the polished part is required to be uniform and smooth without concave-convex phenomenon;
step 12, performing shot blasting, namely putting the wheel hub into a shot blasting machine after polishing is completed, and starting the machine according to an operation procedure after shot blasting sand is loaded, wherein the specification of the shot blasting machine is 1: 0.4-0.6 cast steel shots; 2. adjusting a sand inlet gate: shot blasting current is 20-30A, and the upper requirement and the lower requirement are uniform; 3. when the adjustment is invalid, shot blasting sand is added, and products with 20-30 Kg.4 and more than 7 air holes are selected for scrapping treatment each time;
step 13, surface modification chromizing, immersing a manipulator to take out a hub, washing the hub with preheated water at 50 ℃ and over-temperature range of 5 ℃, immersing the hub in a washing pool or a washing room for spraying, then brushing with flannelette, sequentially entering a pre-degreasing groove (room), a pre-oxidation groove (room), an oxidation groove (room) and a washing groove (room), pouring 80% deionized water and 20% JM-83B acid degreasing agent into the pre-degreasing groove, mixing uniformly, then putting the hub into the hub, soaking at 50 ℃ and over-temperature range of 5 ℃ for 5 minutes, pouring 23.3-31.3% JM-83B acid degreasing agent into a main degreasing groove, mixing uniformly with deionized water, then putting the hub into the hub, soaking at 60-73 ℃ for 5-8 minutes, finishing post-washing, washing according to a primary washing process, finishing liquid immersion and deoxidation, introducing the hub into a deoxidation tank or a deoxidation room, at least 20% of JM-56A or JM-56 oxidant in the deoxidizing tank is at the normal temperature +/-1-5 ℃, the oxidizing agent enters after being immersed and deoxidized strongly, pre-deoxidation is carried out for supplementary deoxidation, the materials and the process adopt the same mode, and the time is controlled to be about 1-3 minutes; then cleaning again, namely cleaning with clear water at normal temperature, then washing with pure water, dehydrating and baking the chromized involucra, wherein the dehydrating and baking temperature is 125 +/-10 ℃; finally, the line is switched to step 14;
step 14, purifying, spraying and packaging, wherein the surface of a sprayed product cannot contain water and dirt, and the distance between a gun head and a spraying surface is 20-30 cm during spraying; the surface is uniformly sprayed with no paint, no bottom leakage and no sundries on the surface; air sundries are prevented from being adhered to the paint surface, the paint spray booth and the baking oven are kept clean, and the ground is kept moist; the paint is evenly stirred before being poured into the spray gun, so that no sediment is left at the bottom of the barrel; baking temperature: molding powder at 195 +/-5 ℃ and painting at 145 +/-5 ℃, and finally packaging.
Preferably, after the step 10, an air-tight test is performed, and the steps include that the hub after the two sequences of processing are put into an air-tight testing machine, the hydraulic pump starts to work, and the operating rod is twisted to lift the oil cylinder to a certain height (only products can be put in). Clean water is put in and the water level is adjusted (the water can not overflow after the product is pressed in). The product to be tested is placed on the air-tight pad, the valve plug tightly plugs the valve hole, and the operation rod is operated and twisted to press the product into the water in place. Open the vent valve, the air pressure requirement: 0.4-0.5Mpa, and 20 seconds of pressure maintaining time. Rotating the machine body, and checking the periphery of the machine body to ensure that no bubbles exist in water. Closing the air valve, discharging air in the machine body → operating the torsion bar to make the oil cylinder rise to a certain height → taking out the product and placing the product on a sequence transferring vehicle to be drilled.
Preferably, in the step 2, aluminum material refining: the aluminum material comprises 5-15% of silicon, 0-0.25% of magnesium, 0-0.25% of titanium, 0.2-0.65% of manganese, 0.1-0.6% of iron, 1-4% of copper and 0-3% of zinc.
Preferably, in the step 2, aluminum material refining: the prepared aluminum material is also added with additives of potassium fluotitanate and potassium fluoborate.
Preferably, the welding material selected by the argon arc welding machine is cobalt-based alloy welding flux, the welding material is heated within the range of 10-20cm around the repair welding position during repair welding, the heating temperature is 200-330 ℃, then the front edge of the defect position is heated to form a molten pool, the molten pool is protected by carbon dioxide gas by paying attention to the angle of a welding nozzle, the repair welding end position is at the edge of a sealing surface, the molten pool is full when arc is closed, a certain lag quantity is provided for gas protection, the time is 3-5 seconds, the meat deficiency of the surfacing part is deep, a welding material close to a parent metal is firstly used for bottoming, the bottoming welding height is not more than the original thickness of the repaired surface, plasma or argon arc welding is used for surfacing, the repair welding is FFe-1 carried out by using a D577 welding rod, the repair welding curved surface is controlled to be phi 3.2, the current is used for 200A, and the included angle between the welding rod and the workpiece plane is kept to be more than 75 degrees, short arc welding and uniform strip conveying are carried out, in the repair welding process, the welding wire head is in the argon protection range, the shielding gas can cover the defect depth of the weld overlay of the molten pool to exceed 0.3mm, the weld overlay can be subjected to layered repair welding, and the height after welding is not higher than the original sealing surface by 0.2-1 mm.
The invention has the following beneficial effects: the manufacturing process is characterized in that secondary modification is adopted in aluminum liquid manufacturing, mechanical center secondary alternate manufacturing is adopted under the condition of finished product manufacturing, surface modified chromizing is also utilized after shot blasting is finished, the quality of the aluminum liquid is higher, so a precise casting process is not needed in the process of die casting, the cost is low, the production efficiency is high, bubbles are not easy to generate, the density is uniform, meanwhile, the mechanical center secondary alternate manufacturing is adopted, the surface modified chromizing is utilized after shot blasting is finished, the wheel surface of a hub and the covering surface smoothness of a tire are high, the wheel surface is also corrosion-resistant, and the wheel surface is particularly suitable for small-sized vehicles without maintenance or with less maintenance in the whole using process, and the situation is very popular in small-sized vehicles hubs, namely two-wheel hubs (electric vehicles, motorcycles and three-wheeled motorcycles capable of being used for towing buckets) and is not limited by cost too seriously, the method can be used for carrying out an optimized improvement process under the requirement of not being influenced by price, further adding aluminum alloy raw materials with quality capable of being improved, and is more close to large-scale industrial production, and the manufacturing process of the hub with more environment-friendly manufacturing engineering is realized.
Drawings
FIG. 1: the overall flow structure is schematic.
Detailed Description
The technical scheme of the invention is described in detail as the optimization by the embodiment and the attached drawings:
as shown in fig. 1, a manufacturing process of a thermally modified two-wheel hub includes the following steps:
1, step 1, sanding core: manufacturing a sand core mould, stably installing the sand core mould into a sand core machine, and adjusting the parallelism and perpendicularity of the mould and a machine table;
injecting sand after the sand is filled, and taking the condition that the precoated sand is not ejected from a parting surface as a standard;
starting a sand core machine for heating, setting the mold temperature of the sand core machine to be 250 +/-20 ℃, keeping the temperature to be 2 ℃ per second, raising the temperature to 230-270 ℃, keeping the temperature to exceed the range, and immediately adding the temperature for recovering;
after the temperature reaches 230-255 ℃, adding high-temperature lubricating oil at each ejector rod position of the sand core machine, checking that the air pressure is above 0.6Mpa, drying the compressed air without moisture, and draining accumulated water in an oil-water filter, wherein the high-temperature lubricating oil is GPL21 die high-temperature lubricating oil or HP-500 GREAE and is mixed with 20-30% of Yamaichi NS 1001; the sand core is manufactured and coated with sand to make a mold, and the sand core is checked to check whether exhaust holes of all parts are smooth or not after the manufacture is finished, so that the good molding of the sand core is ensured; checking the appearance plumpness of the sand core in a normal process, and if a defect is found, cleaning the exhaust hole in time;
2, step 2, refining the aluminum material: preparing an aluminum material, wherein 80-98% of aluminum is mixed, modified alloy material components (percent) are mixed, namely, 6.5-7.5 parts of Si, 0.3-0.4 part of Mg0.08-0.2 part of Ti0.08-0.2 part of Sr0.02-0.03 part of Fe, less than or equal to 0.1 part of Cn and less than or equal to 0.1 part of Zn, and the addition amount of a modified aluminum titanium carbon strontium alloy refiner is added, wherein 3-4 parts (about 800 Kg/furnace) of each heat preservation furnace are added, the mixture is uniformly mixed and then introduced into a cabin of an aluminum liquid refiner for preheating, the preheating and starting nitrogen injection and degassing can be carried out, the nitrogen size is adjusted to be accurate to the uniform distribution of small bubbles on the liquid surface, and the degassing time is half an hour; moving an aluminum liquid refiner with a graphite tool for degassing to the upper surface of the heat preservation furnace, immersing the graphite turntable into the aluminum liquid, adjusting the air flow, then placing the refiner to the furnace end, and starting degassing; sampling by a small spoon after degassing for 10 minutes in an assay, and delivering to an assay laboratory; adding 0.8-1Kg of slag removing agent into the slag, uniformly stirring, covering for 10 minutes, and then washing the slag; measuring the temperature to ensure that the temperature meets the standard; filling aluminum water in the small iron cup after hydrogen measurement and red baking, placing the small iron cup in an iron cover of a nitrogen measurement instrument, starting vacuumizing and cooling, taking out the small iron cup after 3 minutes, placing the small iron cup in water for full cooling, leveling the sample block, and checking the pinhole level; the over-tolerance of Si and Fe elements in the component test must be returned to a large furnace, and the too low Mg and Sr must be added; the refining temperature is 715 +/-15 degrees; the aluminum water is used up within 1 hour after being refined, and needs to be refined again after time out; the holding furnace cannot be reused when the aluminum water capacity is less than 1/3. Measuring hydrogen, namely vacuumizing the small iron cup for 3 minutes at the baking temperature of about 700 ℃ and under the vacuumizing pressure of 0.08-0.1 MPa; the turning surface is required to be flat, and the roughness is 3.2; the number of visual pinhole stages is less than or equal to 2, and no pore slag hole appears; refining again when the pinhole grade is unqualified;
3, pouring and forming in the step 3, wherein the step 1 and the step 3 can be carried out synchronously, or aluminum liquid is poured according to sand molds to manufacture and form after correction is finished respectively, the adopted machine is a casting machine, a baking head is clamped to the center of the mold by a baking mold, the fire is adjusted to start baking, a spraying material spray gun is about 20cm away from the spraying material part and is uniformly sprayed, a sand core is placed into the mold, the sand core is ensured to be stably matched with the mold, sundries on the mold are blown off, the mold is firstly closed, then the side molds are closed, the side molds are closed for 1-2 times, and the side molds are determined to be closed in place. Pouring molten aluminum into the pouring gate of the mold, placing a square filter screen (or a round filter screen) into the funnel, then placing the square filter screen (or the round filter screen) into the middle of the triangular filter screen, taking out the funnel, taking out the molten aluminum from the heat preservation furnace by the filter screen pouring ladle, pouring the molten aluminum into the funnel, leaving a proper amount of molten aluminum for feeding, taking the filter screen into the barrel after the molten aluminum flows out, and placing the funnel on the baking mold of the baking machine for heat preservation. And taking out the molten aluminum left by the product casting ladle, and directly pouring the molten aluminum into the pouring gate until the pouring gate is full. And taking out the rest steel pouring groove, lightly placing the steel pouring groove on a platform, shaping the steel pouring groove after the inspection is qualified, marking a job number, and transferring the steel pouring groove to a rotating plate. Spraying a material on the die: the distance between the spray gun and the spray coating part is about 20cm, and the spraying is uniform. The performance of the paint is as follows: 34# improves the fluidity of aluminum water and has a function of preventing outward shrinkage porosity; keeping the temperature at 1/4 of the demolding temperature, and proportioning: coating 34 #: water = 1: 4; coating 39 #: water = 1: 5, spraying: heating the mould by using coal gas for about half an hour (250-300 ℃), wherein the mould must be clean and cannot have impurities; priming a layer by using the mixture ratio II, and continuously heating for half an hour (about 350 ℃); pouring a first wheel, opening the upper die and the side die (the wheel is not ejected firstly); the side mould and riser are sprayed with a layer of coating in proportion. And (c) coating is additionally sprayed according to the condition (by using the ratio II), and the mould produced normally does not need to be sprayed and heated. The surface quality requirement is as follows: the non-processed surface can not have salient points, cracks, paint scars, wrinkles, roughness and obvious exhaust spots. The ladle and the funnel for taking water must be ensured to be dry and insulated, and the walking is stable and fast after taking water; the channel is ensured to be smooth, and pedestrians beside the channel are noticed to avoid the aluminum water from splashing to hurt people; non-workers must not approach the holding furnace.
And 4, changing the baked and heat-insulated die to a cutting machine after the die is finished, installing a cutting piece of the cutting machine, adjusting the size, starting a switch, and cutting. The cutting piece is firmly fixed, and the cutting position can not be corrected by swinging left and right (trial assembly swinging degree of a first-starting machine) according to the cutting line of the blank which is higher than 1-2 mm;
after clamping, the flatness of the product matched with the clamp must be checked; lubricating oil is required to be added in the cutting process, so that the saw blade is prevented from being adhered with aluminum; and adjusting the rotation speed of the power head according to various products.
And 5, deburring, namely after the blank is cut, putting the hub body into a bench drill to drill a valve hole, wherein the diameter of a drill bit is 8.5+ 0.20, the concentricity of the hole and the blank ring is within 1mm, and the out-of-roundness of the hole is less than 0.1 mm. Adjusting the clamp, and starting the rotating speed of the switch bench drill: 800 revolutions per minute. (ii) a Placing the product on a fixture, and starting drilling; after the valve hole is drilled, the existence of no burr, no tool vibration and no aluminum adhesion is ensured.
And 6, modifying, carrying out solid solution treatment, continuously putting the hub body into a flow heat treatment furnace, starting the machine according to the operating rules (adopting automatic circulation and adjusting the temperature and time) to carry out thermal modification treatment on the hub body, putting the product into the steel pipe for the time till the furnace door is opened, automatically pushing the product into a high-temperature furnace, and then carrying out treatment. The coated sand is loosened and conveniently removed by heat treatment of the glue in the high-temperature combustion sand core; temperature parameters: solid solution is carried out at 535 +/-5 ℃, and the baking time is 5.5 +/-0.5 hours; the actual effect is 150 +/-5 ℃, and the baking time is 3.5 +/-0.5 hours; 4. Setting the temperature of the high-temperature furnace zone: 1 zone 500 deg.C, 2 zone 535 deg.C, 3 zone 535 deg.C, 4 zone 535 deg.C, 5 zone 535 deg.C, 6 zone 538 deg.C; the water temperature of the quenching water is kept at 60-90 ℃, the quenching time is about 5 minutes, and when the time is up, the product is pushed out of the high-temperature furnace, and the product which is immersed in the water tank within the time is taken out of the high-temperature furnace and is necessarily immersed in the quenching water tank within 20 +/-5 seconds; the hardness center part HB 70-85 ℃ of the treated product is ground, the measuring point part is ground flat, and the average value of 3 points is measured. Shaping a plane: and (4) after shaping according to requirements, marking a job number, and then penetrating and installing a backflow rotating frame to enter the actual effect of the actual effect furnace. The end face of the large excircle of the product is close to the shaping flat plate, and each gap is less than 0.5 mm. Axial reshaping: the product is measured according to the corresponding measuring bar, and the deformation degree is +/-0.5 mm. The wheel is arranged on the frame, the excircle of the product is not reliable, and a gap of more than 3cm is reserved. And (4) performing spot check on the hardness.
Step 7, sand removal is carried out on the modified hub body, and precoated sand in the hub is removed, so that a hollow effect is achieved; hanging the product on a support, and beating a rim to enable the precoated sand to flow out along the positioning hole; and removing the residual precoated sand in each sand core positioning hole by using a steel wire brush.
Step 8, continuously shifting the modified hub to an argon arc welding machine for welding repair, welding repair of the positioning hole of the sand core and improvement of the appearance defect of the spoke; hanging the product on a support, and welding and repairing the product to the center of the positioning hole by using an aluminum wire along the excircle of the positioning hole by one circle until the sand core hole is completely closed; current of argon arc welding machine: 220-250A; and (3) welding handle cooling water inspection: 4 h/time;
and 9, shifting the modified hub to a hub machining center machine tool to perform a sequence of processes, cutting by using a jump cutter of a numerical control lathe, and ensuring the accuracy before 3 and machining or after changing a clamp: jumping of the faceplate and the backup plate is less than or equal to 0.10mm, jumping of the core rod is less than or equal to 0.03mm, diameter tolerance of the core rod is two times of minus 0.08 to minus 0.10mm, and lubricating oil is added into a guide rail of the numerical control lathe. The back plate has no aluminum scraps and impurities.
The cutting fluid adopts: emulsified cutting fluid with the concentration of 5 percent; and (4) starting a power supply according to the operation rule of the machine tool, inputting the program to the numerical control machine, and trying to ensure that the track is normal. And (5) installing a cutter and adjusting the program. And (4) erasing aluminum scraps and sundries on the backup plate, and clamping the upper workpiece. And starting the main shaft, starting a start button of the numerical control machine, and starting machining at the moment. And after the machine is stopped, taking the workpiece out of the clamp and lightly placing the workpiece on a sequence rotating frame. One workpiece is kept at a constant speed for 3-7 minutes, and 3-5 times of repetition is allowed under the condition that a sequence is not finished; avoid direct contact with the ground or aluminum scraps; avoiding collision. The processed product is not sticky with aluminum, and the bright surface is not scratched.
And step 10, cooling and detecting after the machining first-sequence process is finished, entering a second-sequence machining center again for machining, starting a power supply according to the operation rules of the machine tool, inputting the program to the numerical control machine, and trying to ensure that the track is normal. And (5) installing a cutter, and adjusting the program by using waste products. The run-out of the positioning backup plate is less than or equal to 0.05mm, the center of the positioning core rod is set as the zero point of the coordinate of the workpiece, the diameter tolerance of the core rod is-0.08 to-0.10 mm, and the requirements of the pressing plate are as follows: the clamping is kept simultaneously, and the length of the pressing plate is adjusted to be consistent; 3. the cutting fluid adopts: emulsified cutting fluid with the concentration of 8 percent; and (4) erasing aluminum scraps and sundries on the backup plate, and clamping the upper workpiece. And starting the main shaft, starting a start button of the numerical control machine, and starting machining at the moment. And after the machine is stopped, taking the workpiece out of the clamp and lightly placing the workpiece on a sequence rotating frame.
Step 11, starting a polishing step, namely putting the hub processed by the two sequences on a pneumatic polishing machine, and exhausting air for 60-120 seconds by an air pipe to ensure that accumulated water is drained completely; a proper amount of lubricating oil is filled into the polishing machine to ensure the normal operation of the equipment; polishing each part of the hub smoothly by using 240-mesh abrasive paper, and particularly polishing the argon arc welding spot position; the polished part is required to be uniform and smooth without concave-convex phenomenon;
step 12, performing shot blasting, namely putting the wheel hub into a shot blasting machine after polishing is completed, and starting the machine according to an operation procedure after shot blasting sand is loaded, wherein the specification of the shot blasting machine is 1: 0.4-0.6 cast steel shots; 2. adjusting a sand inlet gate: shot blasting current is 20-30A, and the upper requirement and the lower requirement are uniform; 3. when the adjustment is invalid, shot blasting sand is added, and products with 20-30 Kg.4 and more than 7 air holes are selected for scrapping treatment each time;
step 13, surface modification chromizing, immersing a manipulator to take out a hub, washing the hub with preheated water at 50 ℃ and over-temperature range of 5 ℃, immersing the hub in a washing pool or a washing room for spraying, then brushing with flannelette, sequentially entering a pre-degreasing groove (room), a pre-oxidation groove (room), an oxidation groove (room) and a washing groove (room), pouring 80% deionized water and 20% JM-83B acid degreasing agent into the pre-degreasing groove, mixing uniformly, then putting the hub into the hub, soaking at 50 ℃ and over-temperature range of 5 ℃ for 5 minutes, pouring 23.3-31.3% JM-83B acid degreasing agent into a main degreasing groove, mixing uniformly with deionized water, then putting the hub into the hub, soaking at 60-73 ℃ for 5-8 minutes, finishing post-washing, washing according to a primary washing process, finishing liquid immersion and deoxidation, introducing the hub into a deoxidation tank or a deoxidation room, at least 20% of JM-56A or JM-56 oxidant in the deoxidizing tank is at the normal temperature +/-1-5 ℃, the oxidizing agent enters after being immersed and deoxidized strongly, pre-deoxidation is carried out for supplementary deoxidation, the materials and the process adopt the same mode, and the time is controlled to be about 1-3 minutes; then cleaning again, namely cleaning with clear water at normal temperature, then washing with pure water, dehydrating and baking the chromized involucra, wherein the dehydrating and baking temperature is 125 +/-10 ℃; finally, the line is switched to step 14;
step 14, purifying, spraying and packaging, wherein the surface of a sprayed product cannot contain water and dirt, and the distance between a gun head and a spraying surface is 20-30 cm during spraying; the surface is uniformly sprayed with no paint, no bottom leakage and no sundries on the surface; air sundries are prevented from being adhered to the paint surface, the paint spray booth and the baking oven are kept clean, and the ground is kept moist; the paint is evenly stirred before being poured into the spray gun, so that no sediment is left at the bottom of the barrel; baking temperature: molding powder at 195 +/-5 ℃ and painting at 145 +/-5 ℃, and finally packaging.
Preferably, after the step 10, an air-tight test is performed, and the steps include that the hub after the two sequences of processing are put into an air-tight testing machine, the hydraulic pump starts to work, and the operating rod is twisted to lift the oil cylinder to a certain height (only products can be put in). Clean water is put in and the water level is adjusted (the water can not overflow after the product is pressed in). The product to be tested is placed on the air-tight pad, the valve plug tightly plugs the valve hole, and the operation rod is operated and twisted to press the product into the water in place. Open the vent valve, the air pressure requirement: 0.4-0.5Mpa, and 20 seconds of pressure maintaining time. Rotating the machine body, and checking the periphery of the machine body to ensure that no bubbles exist in water. Closing the air valve, discharging air in the machine body → operating the torsion bar to make the oil cylinder rise to a certain height → taking out the product and placing the product on a sequence transferring vehicle to be drilled.
Preferably, in the step 2, aluminum material refining: the aluminum material comprises 5-15% of silicon, 0-0.25% of magnesium, 0-0.25% of titanium, 0.2-0.65% of manganese, 0.1-0.6% of iron, 1-4% of copper and 0-3% of zinc.
Preferably, in the step 2, aluminum material refining: the prepared aluminum material is also added with additives of potassium fluotitanate and potassium fluoborate.
Preferably, the welding material selected by the argon arc welding machine is cobalt-based alloy welding flux, the welding material is heated within the range of 10-20cm around the repair welding position during repair welding, the heating temperature is 200-330 ℃, then the front edge of the defect position is heated to form a molten pool, the molten pool is protected by carbon dioxide gas by paying attention to the angle of a welding nozzle, the repair welding end position is at the edge of a sealing surface, the molten pool is full when arc is closed, a certain lag quantity is provided for gas protection, the time is 3-5 seconds, the meat deficiency of the surfacing part is deep, a welding material close to a parent metal is firstly used for bottoming, the bottoming welding height is not more than the original thickness of the repaired surface, plasma or argon arc welding is used for surfacing, the repair welding is FFe-1 carried out by using a D577 welding rod, the repair welding curved surface is controlled to be phi 3.2, the current is used for 200A, and the included angle between the welding rod and the workpiece plane is kept to be more than 75 degrees, short arc welding and uniform strip conveying are carried out, in the repair welding process, the welding wire head is in the argon protection range, the shielding gas can cover the defect depth of the weld overlay of the molten pool to exceed 0.3mm, the weld overlay can be subjected to layered repair welding, and the height after welding is not higher than the original sealing surface by 0.2-1 mm.
The specific embodiments described herein are merely illustrative of the spirit of the invention. Various modifications or additions may be made to the described embodiments or alternatives may be employed by those skilled in the art without departing from the spirit or ambit of the invention as defined in the appended claims.
Claims (5)
1. A manufacturing process of a thermal phase modified two-wheel hub is characterized by comprising the following steps: the method comprises the following steps:
step 1, sanding core: manufacturing a sand core mould, stably installing the sand core mould into a sand core machine, and adjusting the parallelism and perpendicularity of the mould and a machine table; injecting sand after the sand is filled, and taking the condition that the precoated sand is not ejected from a parting surface as a standard; starting a sand core machine for heating, setting the mold temperature of the sand core machine to be 250 +/-20 ℃, keeping the temperature to be 2 ℃ per second, raising the temperature to 230-270 ℃, keeping the temperature to exceed the range, and immediately adding the temperature for recovering;
after the temperature reaches 230-255 ℃, adding high-temperature lubricating oil at each ejector rod position of the sand core machine, checking that the air pressure is above 0.6Mpa, drying the compressed air without moisture, and draining accumulated water in an oil-water filter, wherein the high-temperature lubricating oil is GPL21 die high-temperature lubricating oil or HP-500 GREAE and is mixed with 20-30% of Yamaichi NS 1001; the sand core is manufactured and coated with sand to make a mold, and the sand core is checked to check whether exhaust holes of all parts are smooth or not after the manufacture is finished, so that the good molding of the sand core is ensured; checking the appearance plumpness of the sand core in a normal process, and if a defect is found, cleaning the exhaust hole in time;
step 2, refining of aluminum materials: preparing an aluminum material, wherein 80-98% of aluminum is mixed into the aluminum material, and the aluminum material is mixed into the modified alloy material by weight percent: 6.5-7.5 parts of Si, 0.3-0.4 part of Mg0.08-0.2 part of Ti0.08-0.2 part of Sr0.02-0.03 part of Fe, less than or equal to 0.3 part of Cu, less than or equal to 0.1 part of Zn, 3-4 parts of modified Al-Ti-C-Sr alloy refiner is added into each heat preservation furnace, the mixture is uniformly mixed and then introduced into a bin body of an aluminum liquid refiner for preheating, nitrogen injection and degassing are started after preheating, the nitrogen size is adjusted on the basis of uniform distribution of small bubbles on the liquid surface, and the degassing time is half an hour; degassing: moving an aluminum liquid refiner with a graphite tool to the upper surface of the heat preservation furnace, immersing the graphite turntable into the aluminum liquid, adjusting the air flow, then placing the refiner to the furnace end, and starting degassing; testing and sampling: degassing for 10 minutes, and then sampling by using a small spoon and delivering to a laboratory technician for testing; slag removal: adding 0.8-1Kg of slag removal agent, uniformly stirring, covering for 10 minutes, and then washing the slag; temperature measurement: measuring that the temperature meets the standard; hydrogen measurement: filling aluminum water in the small iron cup after being baked with red, placing the small iron cup in an iron cover of a nitrogen measuring instrument, starting vacuumizing and cooling, taking out the small iron cup after 3 minutes, placing the small iron cup in water for full cooling, leveling the sample block, and checking the pinhole level; and (4) component assay: si and Fe elements are required to return to a large furnace due to out-of-tolerance, and Mg and Sr are required to be added if too low; the refining temperature is 715 +/-15 degrees; the aluminum water is used up within 1 hour after being refined, and needs to be refined again after time out; the holding furnace can not be used when the aluminum water capacity is less than 1/3;
hydrogen measurement: the small iron cup is heated to 700 ℃ and vacuumized for 3 minutes, and the vacuumizing pressure is 0.08-0.1 MPa; the turning surface is required to be flat, and the roughness is 3.2; the number of visual pinhole stages is less than or equal to 2, and no pore slag hole appears; refining again when the pinhole grade is unqualified;
step 3, casting and forming, wherein the step 1 and the step 3 can be synchronously performed, or the manufacturing and forming are started according to the sand mold casting aluminum liquid after the correction is finished, and the adopted machine is a casting machine and a baking mold: clamping a baking head to the center of a die, adjusting the fire to bake, uniformly spraying a spray coating spray gun 20cm away from the spray coating position, and placing a sand core: put into the mould with the psammitolite in, guarantee that psammitolite locating point and mould are steady to be cooperated, blow away the debris on the mould, the compound die: firstly, closing the upper die, closing the side die for 1-2 times, and determining to close the side die in place;
pouring molten aluminum: put the mould runner with the triangle filter screen of rolling up, put square filter screen or circular filter screen in the funnel, in the middle of putting the triangle filter screen later, take out the funnel, the filter screen waters the package: taking out the molten aluminum from the heat preservation furnace, pouring the molten aluminum into a funnel, and reserving a proper amount of molten aluminum for feeding: after the aluminum water flow is finished, taking the filter screen and placing the filter screen into a barrel, and placing the funnel on a baking die of a baking machine for heat preservation; taking out the molten aluminum left by the hub casting ladle, and directly pouring the molten aluminum into a pouring gate on the basis of filling;
the inverted steel groove is taken out and lightly placed on a platform to be inspected to be qualified, and then is shaped, provided with a job number and transferred to a rotating plate; spraying a material on the die: the distance between the spray gun and the spray coating part is 20cm, and the spray coating is uniform; the performance of the paint is as follows: 34# improves the fluidity of aluminum water and has a function of preventing outward shrinkage porosity; keeping the temperature at 1/4 of the demolding temperature, and proportioning: coating 34 #: water = 1: 4; coating 39 #: water = 1: 5, spraying: heating the mould by using coal gas at 250-300 ℃ for half an hour, wherein the mould must be kept clean and cannot have impurities; priming a layer by using the ratio II, and continuously heating for half an hour until the temperature is raised to 350 ℃; pouring a first wheel hub, opening the upper die and the side die, and not ejecting the wheel hub; spraying a layer of coating in proportion to the side die and the riser; the paint is additionally sprayed according to the proportion, so that the paint is not required to be additionally sprayed and heated for the die meeting the surface quality requirement; the surface quality requirement is as follows: the non-processing surface can not have salient points, cracks, paint scars, wrinkles, roughness and obvious exhaust spots; the ladle and the funnel for taking water must be ensured to be dry and insulated, and the walking is stable and fast after taking water; the channel is ensured to be smooth, and pedestrians beside the channel are noticed to avoid the aluminum water from splashing to hurt people; non-workers cannot approach the holding furnace;
step 4, changing the baked and heat-insulated mold to a cutting machine after the mold is baked, installing a cutting blade of the cutting machine, adjusting the size, starting a switch, and cutting; the cutting piece is fixed firmly, the machine is started to try on the swinging degree first, and the swinging cannot be performed; the cutting position is corrected according to the fact that the cutting line of the blank is 1-2mm higher; after clamping, the matching flatness of the hub and the clamp must be checked; lubricating oil is required to be added in the cutting process, so that the saw blade is prevented from being adhered with aluminum; adjusting the rotation speed of the power head according to various types of hubs;
step 5, deburring, namely after the blank is cut, putting the hub into a bench drill to drill a valve hole, wherein the diameter of a drill bit is 8.5+ 0.20, the concentricity of the hole and the blank ring is within 1mm, and the out-of-roundness of the hole is less than 0.1 mm; adjusting the clamp and starting a switch; rotating speed of the bench drill: 800 revolutions per minute;
placing a clamp on the hub, and starting drilling; after the valve hole is drilled, the existence of no burr, no tool vibration and no aluminum adhesion is ensured;
step 6, modifying, carrying out solid solution treatment, continuously putting the hub into a flow heat treatment furnace, starting up according to an operation rule, carrying out automatic circulation, adjusting the temperature and time, carrying out hub thermal modification treatment, putting the hub into a steel pipe for a time till a furnace door is opened, automatically pushing the hub into a high-temperature furnace, and then carrying out treatment; the coated sand is loosened and conveniently removed by heat treatment of the glue in the high-temperature combustion sand core; temperature parameters: solid solution is carried out at 535 +/-5 ℃, and the baking time is 5.5 +/-0.5 hours; aging at 150 + -5 deg.C for 3.5 + -0.5 hr; setting the temperature of the high-temperature furnace zone: 1 zone 500 deg.C, 2 zone 535 deg.C, 3 zone 535 deg.C, 4 zone 535 deg.C, 5 zone 535 deg.C, 6 zone 538 deg.C; the water quenching temperature is kept at 60-90 ℃, the water quenching time is 5 minutes, and when the time is up, the hub is pushed out of the high-temperature furnace, and the hub which is immersed in the water tank within the time is taken out of the high-temperature furnace and is necessarily immersed in the water quenching tank within 20 +/-5 seconds; after treatment, the hardness center part HB 70-85 degrees of the hub is obtained, the measuring point part must be ground flat, and the average value of 3 points is measured;
shaping a plane: after shaping according to requirements, punching a job number, then mounting a backflow rotating frame in a penetrating way, and entering an aging furnace for aging; the end face of the large excircle of the hub leans against the shaping flat plate, and each gap is less than 0.5 mm; axial reshaping: measuring the hub according to the corresponding measuring bar, wherein the deformation degree is +/-0.5 mm;
the hub is arranged on the frame, the excircle of the hub is not reliable, and a gap of more than 3cm is reserved; performing spot check on the hardness;
step 7, modifying the hub, removing sand from the hub, and removing precoated sand in the hub to achieve a hollow effect; hanging a bracket on the hub, and knocking a rim to enable the precoated sand to flow out along the positioning hole; removing residual precoated sand in each sand core positioning hole by using a steel wire brush;
step 8, continuously shifting the modified hub to an argon arc welding machine for welding repair, welding repair of the positioning hole of the sand core and improvement of the appearance defect of the spoke; hanging the wheel hub on a support, and welding and repairing the wheel hub to the center of the positioning hole by using an aluminum wire along the excircle of the positioning hole by one circle until the sand core hole is completely closed; current of argon arc welding machine: 220-250A; and (3) welding handle cooling water inspection: 4 h/time;
and 9, shifting the modified hub to a hub machining center machine tool to perform a sequence of processes, cutting by using a jump cutter of a numerical control lathe, and ensuring the accuracy before machining or after replacing a clamp: the runout of the faceplate and the backup plate is less than or equal to 0.10mm, the runout of the core rod is less than or equal to 0.03mm, and the diameter tolerance of the core rod is as follows: secondly, adding lubricating oil into a guide rail of the numerical control lathe, wherein the diameter of the guide rail is-0.08 to-0.10 mm;
the backup plate has no aluminum scraps and sundries; the cutting fluid adopts: emulsified cutting fluid with the concentration of 5 percent; turning on a power supply according to the operation rules of the machine tool, inputting a program to the numerical control machine, and trying to ensure that the track is normal; installing a cutter and adjusting a program; wiping off aluminum scraps and sundries on the backup plate, and clamping the upper hub;
starting the main shaft, starting a numerical control machine starting button, and starting machining at the moment; after the machine is stopped, the hub is taken out from the clamp and is lightly placed on a rotating frame; one hub is arranged in 3-7 minutes at a constant speed, and 3-5 times of repetition is allowed under the condition that a sequence is not finished; avoid direct contact with the ground or aluminum scraps; avoiding collision; the processed hub is not adhered with aluminum, and the bright surface is not scratched;
step 10, cooling and detecting after the machining first-sequence process is finished, entering a second-sequence machining center again for machining, starting a power supply according to the operation rules of the machine tool, inputting a program to a numerical control machine, and trying to ensure that the track is normal; installing a cutter, and adjusting a program by using waste products; the runout of the positioning backup plate is less than or equal to 0.05mm, the center of the positioning core rod is set as the zero point of the coordinate of the hub, the diameter tolerance of the core rod is-0.08 to-0.10 mm, and the requirements of a pressing plate are as follows: the clamping is kept simultaneously, and the length of the pressing plate is adjusted to be consistent; the cutting fluid adopts: emulsified cutting fluid with the concentration of 8 percent; wiping off aluminum scraps and sundries on the backup plate, and clamping the upper hub;
starting the main shaft, starting a numerical control machine starting button, and starting machining at the moment; after the machine is stopped, the hub is taken out from the clamp and is lightly placed on a rotating frame;
step 11, starting a polishing step, putting the hubs processed by the two sequences into a pneumatic polishing machine, exhausting air through an air pipe for 60-120 seconds, and ensuring that accumulated water is drained completely; a proper amount of lubricating oil is filled into the polishing machine to ensure the normal operation of the equipment; polishing each part of the hub smoothly by using 240-mesh abrasive paper, and particularly polishing the argon arc welding spot position; the polished part is required to be uniform and smooth without concave-convex phenomenon;
step 12, performing shot blasting, namely putting the wheel hub into a shot blasting machine after polishing is completed, and starting the machine according to an operation procedure after shot blasting sand is loaded, wherein the specification of the shot blasting machine is 1: 0.4-0.6 cast steel shots; 2. adjusting a sand inlet gate: shot blasting current is 20-30A, and the upper requirement and the lower requirement are uniform; 3. when the adjustment is invalid, shot blasting sand is added, and hubs with 20-30 Kg.4 and more than 7 air holes are selected for scrapping each time;
step 13, surface modification chromizing, immersing a wheel hub taken by a manipulator, immersing the wheel hub in hot water with the maximum temperature exceeding 5 ℃ of 50 ℃, immersing the wheel hub in a cleaning pool or a washing room for spraying, then scrubbing the wheel hub by using flannelette, sequentially entering a pre-degreasing tank, a pre-oxidation tank, an oxidation tank and a washing tank, pouring 80% deionized water and 20% JM-83B acid degreasing agent into the pre-degreasing tank, uniformly mixing the deionized water and the JM-83B acid degreasing agent, putting the wheel hub into the main degreasing tank, immersing the wheel hub at the temperature exceeding 5 ℃ of 50 ℃ for 5 minutes, immersing the wheel hub in 23.3-31.3% JM-83B acid degreasing agent, pouring the other components of deionized water into the main degreasing tank, uniformly mixing the deionized water and putting the wheel hub into the wheel hub at the temperature of 60-73 ℃, immersing for 5-8 minutes, completing post-cleaning, immersing and deoxidizing the wheel hub into liquid according to the primary cleaning flow, introducing the wheel hub into a deoxidizing tank or a deoxidizing room, wherein the deoxidizing tank contains at least 20% JM-56A type or JM-56 type oxidant, the temperature is normal temperature +/-1-5 ℃, the pre-deoxidation program is carried out after the soaking deoxidation is finished, the supplementary deoxidation is carried out, the material and the process adopt the same mode, the time is controlled to be 1-3 minutes, then the cleaning is carried out again, the normal temperature clean water is used, then the chromium oxide involucra is washed by pure water and is dehydrated and baked, and the dehydration and baking temperature is 125 +/-10 ℃; finally, the line is switched to step 14;
step 14, purifying, spraying and packaging, wherein moisture and dirt cannot exist on the surface of the sprayed hub, and the distance between a gun head and a spraying surface is 20-30 cm during spraying; the surface is uniformly sprayed with no paint, no bottom leakage and no sundries on the surface; air sundries are prevented from being adhered to the paint surface, the paint spray booth and the baking oven are kept clean, and the ground is kept moist; the paint is evenly stirred before being poured into the spray gun, so that no sediment is left at the bottom of the barrel; baking temperature: molding powder at 195 +/-5 ℃ and painting at 145 +/-5 ℃, and finally packaging.
2. The process according to claim 1, wherein the step of manufacturing a thermally modified two-wheeled wheel hub comprises the steps of: after the step 10, an air tightness test is required, and the steps are that the hub is placed into an air tightness testing machine after the two sequences are processed, the hydraulic pump starts to work, the operating rod is twisted, the oil cylinder is lifted, and the height of the hub can be reached; clean water is put in, the water level is adjusted, and water cannot overflow after the hub is pressed in; placing the hub to be tested on the airtight pad, firmly plugging the valve hole by the valve plug, operating and twisting the operating rod to press the hub into water in place;
open the vent valve, the air pressure requirement: 0.4-0.5Mpa, and the pressure maintaining time is 20 seconds; rotating the machine body, and checking the periphery of the machine body to ensure that no bubbles exist in water;
closing the air valve, discharging air in the machine body → operating the torsion bar to enable the oil cylinder to rise to a certain height → taking out the wheel hub to be placed on the sequence transferring vehicle to be drilled.
3. The process according to claim 1, wherein the step of manufacturing a thermally modified two-wheeled wheel hub comprises the steps of: step 2, refining of aluminum materials: the aluminum material comprises 5-15% of silicon, 0-0.25% of magnesium, 0-0.25% of titanium, 0.2-0.65% of manganese, 0.1-0.6% of iron, 1-4% of copper and 0-3% of zinc.
4. The process for manufacturing a thermally modified two-wheeled wheel hub according to claim 1 or 3, wherein: step 2, refining of aluminum materials: the prepared aluminum material is also added with additives of potassium fluotitanate and potassium fluoborate.
5. The process according to claim 1, wherein the step of manufacturing a thermally modified two-wheeled wheel hub comprises the steps of: the welding material selected by the argon arc welding machine is cobalt-based alloy welding flux, the welding material is heated within the range of 10-20cm around the repair welding position during repair welding, the heating temperature is 200-330 ℃, then the front edge of the defect position is heated to form a molten pool, the molten pool is protected by carbon dioxide gas by paying attention to the angle of a welding nozzle, the repair welding end position is at the edge of a sealing surface, the molten pool is full when arc is closed, a certain lag quantity is required to be provided for the gas protection, the time is 3-5 seconds, the meat deficiency of a surfacing part is deep, a welding material close to a base metal is firstly used for bottoming, the bottoming welding height is not more than the original thickness of the repaired surface, plasma or argon arc welding is used for surfacing, repair welding FFe-1 is performed by a D577 welding rod, the repair welding curved surface is controlled to be phi 3.2, a current of 170 and 200A are used, the included angle between the welding rod and the plane of the wheel hub is kept to be more than 75 degrees, short arc welding and uniform strip conveying are carried out, in the repair welding process, the welding wire head is in the argon protection range, the shielding gas can cover the defect depth of the weld overlay of the molten pool to exceed 0.3mm, the weld overlay can be subjected to layered repair welding, and the height after welding is not higher than the original sealing surface by 0.2-1 mm.
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| CN110508776A (en) * | 2019-08-20 | 2019-11-29 | 宁波孚士威机械有限公司 | A kind of processing technology of high intensity bracket |
| CN110496952A (en) * | 2019-09-06 | 2019-11-26 | 江苏新安驰铝业有限公司 | A kind of type core sand removal method of the turbocharger shell of low pressure casting |
| CN112076931B (en) * | 2020-09-16 | 2021-11-09 | 宝武集团马钢轨交材料科技有限公司 | Track traffic integral wheel coating production line and use method thereof |
| CN112338454B (en) * | 2020-10-26 | 2022-04-05 | 宜昌船舶柴油机有限公司 | Three-dimensional simulation machining tool and method for special-shaped stainless steel thin-wall part |
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