CN111390139B

CN111390139B - Semi-solid forming equipment and process for non-ferrous metal particles

Info

Publication number: CN111390139B
Application number: CN201911192341.2A
Authority: CN
Inventors: 刘兴军; 刘绍东
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-11-28
Filing date: 2019-11-28
Publication date: 2021-10-29
Anticipated expiration: 2039-11-28
Also published as: CN111390139A

Abstract

The invention discloses a semi-solid forming device for non-ferrous metal particles, which comprises: the horizontal feeding mechanism of a section is used for realizing the conveying, melting, mixing, storing and sending of metal particles into a molding die cavity; the horizontal feeding mechanism of one section is provided with: the device comprises a horizontally arranged material barrel device, a segmented gradient heating system sleeved outside the material barrel device, a material storage device in shear-port structure butt joint with the material barrel device and a drying system arranged outside the material storage device; the two-section vertical forming mechanism is used for realizing die forging and die casting forming; the working direction of the first-section horizontal feeding mechanism is vertical to that of the second-section vertical forming mechanism, the first-section horizontal feeding mechanism is communicated with the interior of the second-section vertical forming mechanism, and horizontal feeding and vertical forming are realized through a smooth discharge port in a sealing butt joint mode. Also discloses a semi-solid forming process of the non-ferrous metal particles.

Description

Semi-solid forming equipment and process for non-ferrous metal particles

Technical Field

The invention relates to the technical field of non-ferrous metal particle semi-solid forming technology and equipment, in particular to non-ferrous metal particle semi-solid forming technology and equipment.

Background

The existing semi-solid die-casting forming equipment for the non-ferrous metal particles of aluminum, magnesium and zinc is the latest metal material forming process equipment after liquid metal die-casting forming process equipment, various thin-wall parts die-cast by the semi-solid forming process equipment have better quality than liquid die-casting and good compactness, and the mechanical properties of the parts are better than those of the parts die-cast by liquid metal. For example, the tensile strength of the aluminum-magnesium-zinc alloy after semi-solid forming is obviously improved by more than 20 to 25 percent. However, the existing vertical or bedroom semi-solid die-casting molding equipment at home and abroad adopts axial movement, feeding, material conveying, melting, material storage and one-way high-pressure high-speed injection molding process equipment. Only suitable for thin-wall parts with lighter weight. Various parts and large blanks with overlarge size, super thickness and overweight can not be molded. And products with thick walls and thin walls which are greatly different in the same part cannot be formed. The wall thickness is easy to shrink loose, shrink hole and bubble.

For example, the Chinese patent documents have the following publication numbers: CN 106925729, announcement date is: 23/8/2019; the Chinese patent document has a publication number of CN205324678, and a publication date of 2016, 6 months and 22 days. The semi-solid magnesium-aluminum alloy injection molding machine disclosed by the invention can be used for molding various small parts at high pressure and high speed, and has good quality and high speed, such as mobile phone shells, computer shells and the like, and has higher quality than metal liquid state die casting. But the equipment belongs to axial motion load one-way high-pressure high-speed injection molding. Thus determining the applicable scope. Large parts cannot be molded and various blanks cannot be preformed.

The present large-scale pre-formed blank and cast rod of Al, Mg and Zn are made through semi-continuous casting process, in which molten metal of Al, Mg and Zn is cast into circular or square crystallizer and cooled and solidified gradually, the bottom supporting plate of crystallizer is lowered gradually, and the cooling water is used to wash the rod blank to speed up cooling and solidification. And (4) drawing to a bar stock of 6-8 meters long according to the depth of the well. Particularly, the magnesium alloy needs the protection of inert gas in the casting process to avoid the corrosion of oxidizing substances, and the solidified bar stock is flushed by cooling water to oxidize and blacken the surface. Aluminum alloy bars are somewhat better. In the application process, for example, the automobile hub is forged, a certain diameter is cut according to the size of the hub, and the weight of the automobile hub is round blank. Magnesium alloy bars must be peeled and cut off due to severe surface oxidation blackening.

Disclosure of Invention

The invention provides semi-solid forming equipment for non-ferrous metal particles such as aluminum, magnesium, zinc and the like, which breaks through the bottleneck of the existing semi-solid forming equipment for metals, namely solves the problems that the existing forming equipment can only form part products with small specification, light weight and small wall thickness drop, is difficult to form oversized, ultra-thick and overweight large parts and prefabricate various large blanks, and solves the problems that the existing horizontal and vertical semi-solid forming equipment for aluminum, magnesium and zinc metals adopts an axial material conveying, melting and high-pressure high-speed one-way injection forming process, and the application range of the existing semi-solid forming equipment for aluminum, magnesium and zinc metals is greatly restricted.

The semi-solid forming equipment for non-ferrous metal particles such as aluminum, magnesium, zinc and the like adopts a two-step pressure die forging forming process, can successfully die-cast ultra-large, ultra-thick and overweight aluminum and magnesium parts and large prefabricated blanks, and has the advantages of high surface smoothness of formed parts, no segregation of internal alloy components, good compactness, no shrinkage cavity and foaming, and obviously improved mechanical properties, tensile strength and other indexes.

The invention adopts the technical scheme that the invention achieves the aim that: a non-ferrous metal particle semi-solid forming apparatus comprising:

the horizontal feeding mechanism of a section is used for realizing the conveying, melting, mixing, storing and sending of metal particles into a molding die cavity;

the horizontal feeding mechanism of one section is provided with: the device comprises a horizontally arranged material barrel device, a segmented gradient heating system sleeved outside the material barrel device, a material storage device in shear-port structure butt joint with the material barrel device and a drying system arranged outside the material storage device;

the two-section vertical forming mechanism is used for realizing die forging and die casting forming;

the working direction of the first-section horizontal feeding mechanism is vertical to that of the second-section vertical forming mechanism, the first-section horizontal feeding mechanism is communicated with the interior of the second-section vertical forming mechanism, and horizontal feeding and vertical forming are realized through a smooth discharge port in a sealing butt joint mode.

The semi-solid composite molding equipment for nonferrous metals such as aluminum, magnesium, zinc and the like breaks through the bottleneck of the existing semi-solid molding equipment, adopts a two-step method of horizontal feeding and vertical molding, and effectively overcomes the defects existing in the prior art that horizontal feeding and horizontal injection are adopted: because large parts generally have super-thick walls and large material capacity, if the large parts are horizontally fed, high-pressure and high-injection are injected into a die cavity, although the high pressure is high, the flow is small (the aperture of the high-pressure and high-injection material is generally about 8 mm, and the aperture area of the horizontal feeding and high-injection material is more than 50 times larger than that of the high-pressure and high-injection aperture), the interval between the high-pressure and high-injection material and the subsequent injection material is long, so that the temperature of the materials is inconsistent, and temperature difference is generated to cause interlayer, cracks and bubbles. And adopt horizontal feeding in this application, vertical forming just adopts the sealed butt joint of heavy-calibre discharge gate, and horizontal feeding, heavy-calibre discharge gate aperture is big, and the flow is big, and the time is short, and material thermal capacity is good, and the material temperature is unanimous, has guaranteed various part quality after the shaping like this.

A two-step method is adopted, in the first step, non-ferrous metal particles in a horizontal feeding mechanism in a first section are melted, mixed and stored, and semi-solid storage materials are quickly fed into a die cavity in a forming mechanism at low pressure; the particles in the application do not need to be melted in a smelting furnace in advance, and multi-step composite operation is directly realized in a charging barrel device; and secondly, forming in a two-section vertical forming mechanism, and performing die forging and die casting on the parts and various prefabricated blanks with the ultra-large, ultra-thick and ultra-heavy thicknesses by using hydraulic machinery provided with an upper die and a lower die. Because the horizontal feeding mechanism of the first section is in sealed butt joint with the vertical forming mechanism of the second section through the smooth discharge port (large-caliber), the smooth discharge port can be designed according to the discharge amount, the large-caliber discharge port reduces the transfer resistance, the non-ferrous metal particles are ensured to be quantitatively die-cast and formed in closed equipment, all forming processes are in a sealed state, no air enters, the surface of a formed product is smooth, peeling is not needed, oxide erosion is not needed, cutting is not needed, and the material compactness is far better than that of a semi-continuous casting bar. Large-scale casting equipment and smelting equipment are saved, and pollution caused by smelting of a smelting furnace is avoided; and the investment of devices such as a peeling machine, a lathe, a cutting machine and the like can be saved, and the manufacturing time and the cost of the aluminum magnesium automobile hub blank are saved by times.

Preferably, the charging barrel device is internally provided with screws with unequal pitches and unequal bottom diameters, the screw pitches of the screws are sequentially and progressively decreased from the feeding end to the discharging end, and the groove depths of the screw grooves of the screws are sequentially and progressively decreased from the feeding end to the discharging end. The special screw rod is adopted in the charging barrel device, the groove-shaped screw groove screw rod is adopted, the screw rods with unequal pitches and unequal bottom diameters are adopted, the pitch of the groove-shaped screw groove screw rod at the feeding port end is obviously larger than that of the discharging port end, the bottom diameter of the screw thread at the feeding port end is deeper than that of the screw thread at the discharging port end, the design is that the volume of the initial metal particles which are not softened is large when entering, meanwhile, the discharging end of the screw rod is provided with a material distribution sealing ring automatic opening and closing device, the material distribution sealing ring automatically opens the semi-solid slurry along with the rotating force when the screw rod rotates to smoothly enter a storage area, and the valve is closed along with the pressure when the material is pushed. The screw is designed according to the particularity of the non-ferrous metal particle materials, and meets the requirements of melting, mixing, feeding, wrapping and spiral propulsion of the metal particles in a high-temperature section above 500 ℃. And is designed according to the extremely large required quantity of metal particles of the large-sized part hub blank. The conventional screw with the constant pitch taper groove can cause the metal particles to be adhered to the screw to slide and rotate to prevent the metal particles from advancing when the metal particles are converted from a solid state to a semi-solid state after the front-end pitch is full of the materials, and cause the particles which are stagnated at an inlet to enter the screw to be turned outwards, and the design of the screw well solves the problems in the prior art.

Preferably, the screw at least comprises three conveying melting spiral sections with different pitches and different bottom diameters and a mixing chute screw section. The screw is provided with three sections of conveying melting thread spinning sections, so that metal particles are gradually converted into a semi-solid state from a solid state after the screw at the feeding port end is fully charged, and are not adhered to the screw to prevent the metal particles from moving forward, and effective melting and conveying of the particles are realized.

Preferably, a storage section is arranged in the charging barrel device, a check valve is arranged at a discharge port end of the storage section, and a material distribution closed ring is arranged at a feed end of the storage section; the material distributing closed ring is automatically opened when a screw in the charging barrel device rotates, and the material distributing closed ring is automatically closed along with the generation of pressure when the storage section pushes materials to the two-section vertical forming mechanism, and is synchronously opened and closed with the rotation of the screw and the rod withdrawing.

Preferably, the segmented gradient heating system is coated outside the barrel device; the sectional gradient heating system is at least provided with three sections of temperature control areas with sequentially increasing temperatures from the feeding end to the discharging end of the charging barrel device. The charging barrel device is externally sleeved with a far infrared heating segmented gradient heating system, the temperature of the discharging port end is higher than that of the charging port end, a self-power control system is adopted, at least three temperature control areas are adopted to carry out heating melting and mixing on particles, a temperature control three area is arranged at the charging port end, metal particles enter the charging barrel device after being preheated by a drying system outside the storage device, heating melting is carried out through the temperature control three area, the temperature control three area is controlled at 350-450 ℃, the middle section of a screw is a temperature control two area, further heating melting and mixing on the particles heated and dissolved by the temperature control three area is realized, the temperature control two area is 450-550 ℃, the discharging port end of the screw is arranged as a temperature control one area, the temperature of the temperature control one area is 550-650 ℃, the screw section where the temperature control one area is located realizes the final melting, mixing and storage of the metal particles, and the segmented gradient heating structural mode is adopted, each section has different heating temperatures, and the metal particles can be effectively conveyed, melted, mixed, stored, fed and other process steps at one time through gradient heating while conveying, stirring and heating for melting, so that the semisolid forming effect is better, and the product quality is higher.

Preferably, the storage device is vertically arranged on the charging barrel device and is communicated with the interior of the charging barrel device through an inclined-opening feeding sleeve; the inclined direction of the inclined opening feeding sleeve is obliquely arranged from top to bottom along the feeding direction of the charging barrel device and is matched with the rotating direction of a screw rod in the charging barrel device. The storage device is communicated with the interior of the charging barrel device through an inclined opening feeding sleeve, so that metal particles can effectively enter the interior of the charging barrel device and keep consistent with the screw precession direction of the interior of the charging barrel, and feeding, conveying and melting of the metal particles are realized. The bevel feeding sleeve is made of hard alloy into a rectangular structure, and the smooth shearing feeding is guaranteed according to the characteristic requirement of high melting temperature of metal particle hardness.

Preferably, the feeding pressure system, the feeding rotating system and the charging barrel device are coaxially and horizontally arranged; the drying system cladding in the outside of storage device. The drying system is directly arranged outside the material storage device to realize the function of rapidly drying and exhausting the moisture of the metal particle material, the moisture exhausted gas is brought into the mixing drum to influence the product quality to preheat the particles, and the temperature of the drying system is controlled to be 100-150 ℃.

Preferably, the two-section vertical forming mechanism comprises a forming pressure system, a forming die and an ejection mechanism. The two-section vertical forming mechanism is provided with a forming pressure system to realize the die closing and pressurization of a forming die, and the ejection mechanism is used for facilitating the taking out of a formed product.

The technical scheme adopted by the invention for realizing the second invention purpose is as follows: a non-ferrous metal particle semi-solid forming process adopts a two-step composite process to realize horizontal feeding, and the vertical forming process comprises the following steps:

the first step of the process is that metal particles enter a barrel body of a charging barrel to realize horizontal conveying, melting, mixing and storage until the metal particles are sent into a forming die cavity, so that one-time automatic horizontal melting, mixing, storage, heat preservation and feeding are realized; the first step of the process is completed by a horizontal feeding mechanism in a section, and specifically comprises the following steps:

1) adding the aluminum, magnesium and zinc nonferrous metal particles into a funnel-type storage device, and starting a preheating and drying system;

2) granular materials gradually enter the charging barrel device through a shearing opening of the bevel opening feeding sleeve, a segmented gradient heating system of the outer sleeve of the charging barrel device is started to heat at the moment, metal granular materials are gradually conveyed to a discharging opening end through screw grooves with unequal pitches and unequal bottom diameters, the granular materials are melted and mixed into semisolid paste through temperature control areas of different sections in the conveying process, and the semisolid paste is conveyed to a storage section through a material distribution sealing ring;

3) the semi-solid paste in the storage section is conveyed to the two-section vertical forming mechanism through the non-return valve and the smooth discharge port;

the second step is forming; the semi-solid paste is formed by die forging and die casting of an upper die and a lower die of a forming die in a forming die cavity of the two-section vertical forming mechanism; and ejecting the formed part through an ejection mechanism to finish vertical forming.

In the semi-solid forming process of the nonferrous metal particles, when a horizontal feeding machine in one section melts and mixes the metal particles into a semi-solid state, semi-solid slurry is quickly fed into a die cavity of a vertical forming machine in two sections from an unblocked discharge port which can be closed and opened at low pressure in a closed butt joint facility, and the unblocked discharge port can meet the requirement of a large-flow forming material and can also ensure the temperature consistency of the flow rate. The forming process adopts the design of horizontal feeding and vertical forming, is completely different from the small nozzle process flow of axial load movement high-pressure high-jetting, and adopts two-zone-in-one process flow to complete the forming of large parts and automobile hub blanks.

The semi-solid forming process of the non-ferrous metal particles can form various large and small parts by horizontal feeding and vertical forming, has wide application range, and is particularly suitable for forming overweight parts such as automobile hub forged blanks and the like of large parts; multiple processes such as casting of an ultra-long bar, cutting, peeling, turning and the like are avoided; the forming process is high in speed and short in turnover period, the metal particles are directly processed into blanks through the forming process, the blanks are formed in one step, and the blank manufacturing cost is saved by more than 90%; the formed material has better compactness than a natural state casting rod, and has no air holes and separation marks; the horizontal feeding and the vertical forming are to extrude the semi-solid slurry with consistent heat capacity, and the physical property of the material strength is far 20-25% higher than that of a natural casting bar.

Preferably, the smooth discharge port is a large-caliber discharge port with a constant caliber, and the caliber of the discharge port is 30-50 mm.

Preferably, the proportion of the solid phase in the semi-solid paste is 45-55%.

The invention has the beneficial effects that: the semi-solid forming equipment for nonferrous metals such as aluminum, magnesium, zinc and the like breaks through the bottleneck of the existing semi-solid forming equipment, and adopts a horizontal feeding and vertical forming two-step method; firstly, melting, mixing, storing and quickly feeding a stored material into a die cavity at low pressure by a non-ferrous metal particle feeding cylinder; and secondly, performing die forging and die casting on the hydraulic machinery provided with the upper die and the lower die to form oversized, super-thick and overweight parts and various prefabricated blanks. The method comprises the steps of conveying, melting, mixing and conveying metal particles in closed machine equipment, die-casting and molding, wherein the molded blank has standard weight, does not need to be machined or cut, has good surface smoothness and no oxide inclusion, and is superior to a semi-continuously cast round billet; and the material manufacturing links are reduced. The forming process is high in speed and short in turnover period, the metal particles are directly processed into blanks through the forming process, the blanks are formed in one step, and the blank manufacturing cost is saved by more than 90%; the formed material has better compactness than a natural state casting rod, and has no air holes and separation marks; the horizontal feeding and the vertical forming are to extrude the semi-solid slurry with consistent heat capacity, and the physical property of the material strength is far 20-25% higher than that of a natural casting bar. The automobile hub forging blank forming device adopts horizontal feeding and vertical forming, can form parts of various sizes, and is wide in application range, especially forms super heavy parts such as large parts and automobile hub forging blanks; the casting of super-long bars, the cutting, peeling and turning are avoided, and a plurality of process operations are carried out.

Drawings

FIG. 1 is a schematic structural view of a non-ferrous metal particle semi-solid forming apparatus according to the present invention;

FIG. 2 is a schematic view of a screw according to the present invention;

FIG. 3 is a schematic view of a bevel feed sleeve according to the present invention;

FIG. 4 is a bottom view of FIG. 3;

in the figure: 1. quantitative control system, 2, feeding pressure system, 3, feeding rotation system, 4, storage device, 5, drying system, 6, charging barrel device, 7, segmented gradient heating system, 71, temperature control three-zone, 72, temperature control two-zone, 73, temperature control one-zone, 8, discharge port, 9, screw, 91, front thrust surface, 92, rear inclined surface support, 93, spiral groove, 10, conveying melting spiral section, 101, one-section conveying melting spiral section, 102, two-section conveying melting spiral section, 103, three-section conveying melting spiral section, 11, mixing spiral groove section, 12, storage section, 13, check valve, 14, material-dividing closed ring, 15, inclined-mouth feeding sleeve, 16, forming pressure system, 17, forming die, 18, ejection mechanism, 19, upper die, 20, lower die, 21, forming die cavity, 22, charging barrel body, 23, butt body, 24, sealing cover, 25, charging barrel device, 6, Total control system, 26, french dish seal structure.

Detailed Description

The technical solution of the present invention is further described in detail by the following specific embodiments and with reference to the accompanying drawings, and all the devices and processes not further described in the embodiments can be implemented by commercially available devices and existing processes.

Example 1:

in the embodiment shown in fig. 1 and 2, a non-ferrous metal particle semi-solid forming apparatus comprises:

the horizontal feeding mechanism I of a section is used for realizing the conveying, melting, mixing, storing and sending of metal particles into a molding die cavity; the horizontal feeding mechanism of a section comprises a quantitative control system 1, a feeding pressure system 2, a feeding rotating system 3, a storage device 4, a drying system 5, a charging barrel device 6 and a segmented gradient heating system 7;

the two-section vertical forming mechanism II is used for realizing die forging die-casting forming;

the working direction of the first-section horizontal feeding mechanism is vertical to that of the second-section vertical forming mechanism, the first-section horizontal feeding mechanism is communicated with the interior of the second-section vertical forming mechanism, and horizontal feeding and vertical forming are achieved through a smooth discharging hole 8 in a sealing butt joint mode. The unblocked discharge hole can meet the discharge requirement of a large-flow molding material and can also ensure the temperature consistency of the flow quantity.

The screw 9 with unequal pitches and unequal bottom diameters is arranged in the charging barrel device 6, the thread pitches of the screw 9 are sequentially and progressively decreased from the feeding end to the discharging end, and the groove depths of the screw grooves 93 of the screw are sequentially and progressively decreased from the feeding end to the discharging end. The screw 9 at least comprises three sections of conveying melting spiral sections 10 with different pitches and different bottom diameters and a section of mixing chute screw section 11. The screw is provided with three sections of conveying melting thread spinning sections, so that metal particles are gradually converted into a semi-solid state from a solid state after the screw at the feeding port end is fully charged, and are not adhered to the screw to prevent the metal particles from moving forward, and effective melting and conveying of the particles are realized, and the screw section of the mixing chute is used for mixing semi-solid slurry and pushing the semi-solid slurry to the storage section 12.

A storage section 12 is arranged in the charging barrel device 6, a check valve 13 is arranged at the discharge port end of the storage section 12, and a material separating closed ring 14 is arranged at the feed end of the storage section; the material distributing closed ring is automatically opened when a screw in the material barrel device 6 rotates, and the material distributing closed ring is automatically closed along with the generation of pressure when the storage section pushes and feeds materials to the two-section vertical forming mechanism, and is synchronously opened and closed with the rotation of the screw and the rod withdrawal.

The sectional gradient heating system 7 is coated outside the charging barrel device 6; the sectional gradient heating system 7 is at least provided with three sections of temperature control areas with sequentially increasing temperatures from the feeding end and the discharging end of the charging barrel device 6.

The storage device 4 is vertically arranged on the charging barrel device 6 and is communicated with the interior of the charging barrel device 6 through an inclined-opening feeding sleeve 15; the inclined direction of the beveled feeding sleeve 15 is inclined from top to bottom along the feeding direction of the charging barrel device and is matched with the rotating direction of the screw rod in the charging barrel device. The storage device is communicated with the interior of the charging barrel device through an inclined opening feeding sleeve, so that metal particles can effectively enter the interior of the charging barrel device and keep consistent with the screw precession direction of the interior of the charging barrel, and feeding, conveying and melting of the metal particles are realized. The bevel feeding sleeve is made of hard alloy into a rectangular structure, and the smooth shearing feeding is guaranteed according to the characteristic requirement of high melting temperature of metal particle hardness.

The feeding pressure system 2, the feeding rotating system 3 and the charging barrel device 6 are coaxially and horizontally arranged; the drying system 5 is coated outside the storage device 4. The two-section vertical forming mechanism comprises a forming pressure system 16, a forming die 17 and an ejection mechanism 18. The two-section vertical forming mechanism is provided with a forming pressure system to realize the die closing and pressurization of a forming die, and the ejection mechanism is used for facilitating the taking out of a formed product.

In this embodiment, the molding apparatus is provided with a master control system 25, which realizes temperature control, pressure control, signal control and the like of the whole apparatus, realizes quantitative control of materials for different products through a certain amount control system 1, provides pressure for a horizontal feeding mechanism in a section through a feeding pressure system 2, and drives a screw 9 to rotationally advance feeding, melting, mixing and retreating through a feeding rotation system 3. In this embodiment, the forming pressure system 16 of the two-section vertical forming mechanism adopts an upper pressure system, the forming pressure system drives the upper die to move up and down to realize die forging forming of a product, the forming die 17 includes an upper die 19, a lower die 20 and a forming die cavity 21, the ejection mechanism 18 is a lower ejection system, and moves up and down along the forming die cavity 21 in the lower die 20 to eject a formed product.

The storage device 4 adopts a funnel-type storage hopper, the charging barrel device 6 comprises a charging barrel body 22 arranged horizontally and an abutting body 23 integrally or separately arranged at the discharging port end of the charging barrel body, the abutting body 23 is preferably of a conical structure and is used for realizing abutting joint with the molding die cavity 21, and a flange sealing structure 26 and/or a sealing cover 24 are arranged at the joint of the abutting body 23 and the molding die cavity 21 for carrying out sealing abutting joint on a section and a section, so that the sealing operation of the whole process is realized, and no air enters.

The bevel feeding sleeve 15 made of hard alloy materials is embedded at the joint of the storage hopper and the cylinder body 22 of the charging barrel, the opening of the bevel feeding sleeve 15 is in a rectangular structure design (see fig. 3 and 4), the inclination angle alpha of the bevel feeding sleeve 15 is matched with the rotation inclination angle beta of the screw 9, and the inclination angle alpha of 25-30 degrees is preferably selected, so that the design structure is required according to the characteristic that the hardness of metal particles is high in melting temperature, and smooth shearing and feeding are guaranteed. And the drying system 5 is arranged outside the storage hopper, so that the function of rapidly drying and exhausting the moisture of the metal particle materials is realized, the moisture exhausted by the drying system is brought into the mixing barrel to influence the product quality to preheat the particles, and the temperature of the drying system is controlled to be 100-150 ℃.

The sectional gradient heating system 7 is arranged at the outer diameter of the charging barrel device and is heated by adopting a high-temperature ceramic electric heating coil, and the temperature control area is at least divided into three sections of control systems, wherein the temperature control range is 350-650 ℃. And three or four or more sections can be set according to production requirements. The segmentation gradient heating system that the feed cylinder barrel overcoat has the far infrared to generate heat specifically sets up to, and the temperature of feed cylinder barrel discharge gate end is higher than the temperature of feed cylinder barrel feed gate end, adopts automatic control system, and this embodiment adopts three-section control by temperature change district to add hot melt, mixing to the granule. A temperature control three area 71 is arranged at a feed inlet end, metal particles enter a cylinder body of the charging barrel after being preheated by a drying system outside a storage device, heating melting is carried out through the temperature control three area 71, the temperature of the temperature control three area 71 is controlled at 350-450 ℃, a temperature control two area 72 is arranged in the middle section of a screw, further heating melting of the particles heated and melted through the temperature control three area is realized, the temperature of the temperature control two area 72 is 450-550 ℃, a temperature control one area 73 is arranged at a screw discharge outlet end, the temperature of the temperature control one area 73 is 550-650 ℃, the screw section where the temperature control one area 73 is positioned realizes the final melting, mixing and storage of the metal particles, the sectional gradient heating structural mode is that each section has different heating temperatures, and the metal particles can be effectively conveyed, melted and melted through gradient heating while being stirred and heated, so that the metal particles can be effectively conveyed, melted and melted at one time, The semi-solid forming effect is better and the product quality is higher through the process steps of mixing, storing, feeding and the like.

In the embodiment, the screw thread of the screw adopts an outer diameter flat tooth, and the width of the screw is about 8 mm and is loosely matched with the inner diameter of the charging barrel by 0.5-0.8 mm. The inclined angle beta between the spiral inclination of the screw thread and the axial lead is 25-30 degrees. The front thrust surface 91 of the thread is R sunken by 0.3-0.9 mm, and the rear inclined surface support 92 of the thread has the transition strength of 20-25R (see figure 2). The screw 9 comprises three sections of conveying melting spiral sections 10 with different pitches and different bottom diameters and a section of mixing chute screw section 11. The pitch of the screw of the first conveying melting spiral section 101 close to the feed end of the screw is preferably 50-60 mm, the second conveying melting spiral section 102 is arranged at the middle section of the screw, the pitch of the screw is preferably 40-50 mm, the third conveying melting spiral section 103 is arranged close to the discharge end of the screw, the pitch of the screw is preferably 30-40 mm, the discharge port section of the screw is provided with a mixing chute screw section 11, and the chute is of a straight chute structure; the first conveying melting spiral section is located in the third temperature control area, the second conveying melting spiral section is located in the second temperature control area, and the third conveying melting spiral section and the mixing chute screw section are located in the first temperature control area. A material-distributing closed ring 14 is arranged in the cylinder body of the charging barrel on one side of the discharge port of the screw section 11 of the mixing chute, the material-distributing closed ring 14 is automatically opened when paste materials enter the storage section at the front end of the charging barrel, the paste materials smoothly pass through the mixing straight chute at the screw end, and the material-distributing closed ring closes the straight chute when the screw pushes the materials. And a check valve 13 is arranged at the joint of the storage section 12 and the molding die cavity 21, and the check valve 13 is automatically closed after the slurry is pushed into the molding die cavity so as to prevent the slurry paste from drooling. The mixing chute screw section 11, the material dividing closed ring 14 and the storage section 12 are located in a mixing area, and the mixing area is in a temperature control area.

This application aluminium, magnesium, the semi-solid compound moulding equipment of non ferrous metal such as zinc has broken through the bottleneck of current semi-solid forming equipment, adopts horizontal feeding, and the defect that adopts horizontal feeding, horizontal injection to exist among the effective solution prior art of perpendicular fashioned two-step method: because large parts generally have super-thick walls and large material capacity, if the large parts are horizontally fed, high-pressure and high-injection are injected into a die cavity, although the high pressure is high, the flow is small (the aperture of the high-pressure and high-injection material is generally about 8 mm, and the aperture area of the horizontal feeding and high-injection material is more than 50 times larger than that of the high-pressure and high-injection aperture), the interval between the high-pressure and high-injection material and the subsequent injection material is long, so that the temperature of the materials is inconsistent, and temperature difference is generated to cause interlayer, cracks and bubbles. And adopt horizontal feeding in this application, vertical forming just adopts the sealed butt joint of heavy-calibre discharge gate, and horizontal feeding, heavy-calibre discharge gate aperture is big, and the flow is big, and the time is short, and material thermal capacity is good, and the material temperature is unanimous, has guaranteed various part quality after the shaping like this.

A screw rod with a self-stirring function is arranged in a charging barrel device, and the screw rod is provided with a groove-shaped hidden type section-entering retaining screw groove 93 for smoothly conveying, melting and mixing metal granules to a paste-like storage section; a sectional gradient heating system with a gradient heating function and an automatic constant temperature control function is arranged outside the charging barrel device, and a metal aggregate inlet with a shearing stopping function is arranged at a feeding port of the charging barrel device. The paste storage section at the discharge port end of the charging barrel device is separately smelted with the front end of the screw rod, a separating closed ring with a grinding function is matched, the size of the discharge port of the charging barrel is set into a smooth large-caliber discharge port according to the discharge amount, so that the transfer resistance can be reduced, the opening and the closing can be facilitated, the paste storage section is closed when the paste is stored and opened when the paste is discharged, a one-way check valve which is automatically closed and opened is arranged at the joint of the first section and the second section, the paste storage section is automatically closed after the paste is discharged, and the paste in the storage section is prevented from being discharged in the storage process. The metal charging barrel device is connected with a funnel-shaped storage device for storing metal particles at a feeding hole, and a drying system with a function of quickly drying and dehumidifying metal particles is arranged outside the storage device so as to exhaust humid gas and prevent the particles from being brought into the mixing barrel to influence the product quality.

The semi-solid metal granules of the horizontal feeding mechanism of the first section are conveyed, melted, mixed and stored to a discharge port, and a die-casting forming sealing cover is arranged between the semi-solid metal granules and the vertical forming mechanism of the second section, and a flange plate or taper sleeve sealing connecting mechanism is arranged in the die cavity, so that the aluminum magnesium metal granules are conveyed, melted and mixed and sent into the die cavity without air invasion, and the products are not oxidized in the forming process.

The special screw rod that the feed cylinder device inside adopted is flute type thread groove screw rod, the screw rod of the base footpath that varies of unequal pitch, the flute type thread groove screw rod pitch of feed inlet end is obviously greater than discharge gate end pitch, feed inlet end screw thread base footpath is darker than discharge gate end screw thread base footpath, these designs are that the volume of not softening when initial metal particle gets into is big, and the discharge end design of screw rod has the automatic device that closes of branch material seal ring simultaneously, and the screw rod divides the material seal ring automatic opening semi-solid-state thick liquids along with revolving force when rotatory to get into the storage area smoothly, produces the valve of closing along with pressure when the propelling movement material. The screw is designed according to the particularity of the non-ferrous metal particle materials, and meets the requirements of melting, mixing, feeding, wrapping and spiral propulsion of the metal particles in a high-temperature section above 500 ℃. And is designed according to the extremely large required quantity of metal particles of the large-sized part hub blank. The conventional screw with the constant pitch taper groove can cause the metal particles to be adhered to the screw to slide and rotate to prevent the metal particles from advancing when the metal particles are converted from a solid state to a semi-solid state after the front-end pitch is full of the materials, and cause the particles which are stagnated at an inlet to enter the screw to be turned outwards, and the design of the screw well solves the problems in the prior art.

The semi-solid forming process of the non-ferrous metal particles adopts a two-step composite process to realize horizontal feeding and a vertical forming process:

the first step of the process is that metal particles enter a barrel body of a charging barrel to realize horizontal conveying, melting, mixing and storage until the metal particles are sent into a forming die cavity, so that one-time automatic horizontal melting, mixing, storage, heat preservation and feeding are realized; the first step of the process is completed in a section of horizontal feeding mechanism I, and specifically comprises the following steps:

1) adding non-ferrous metal particles of aluminum, magnesium and zinc into a funnel-shaped storage device 4, and starting a preheating and drying system 5;

2) granular materials gradually enter the charging barrel device 6 through a shearing opening of the bevel opening feeding sleeve 15, at the moment, a sectional gradient heating system 7 sleeved outside the charging barrel device 6 is started to heat, metal granular materials are gradually conveyed to a discharging opening end through screw thread grooves 93 with unequal pitches and unequal bottom diameters, the granular materials are melted and mixed into semisolid slurry through temperature control areas of different sections in the conveying process, and the semisolid slurry is conveyed into the storage section 12 through the material separating closed ring 14;

3) the semi-solid paste in the storage section 12 is conveyed to a second section vertical forming mechanism II through a smooth discharge hole 8 through a check valve 13;

the second step is forming; the semi-solid paste is formed in a forming die cavity 21 of the two-section vertical forming mechanism II through die forging and die casting of an upper die and a lower die of the forming die; and ejecting the formed part through an ejection mechanism to finish vertical forming. The proportion of solid phase in the semi-solid paste is 45-55 percent;

in this embodiment, non-ferrous metal particles such as aluminum, magnesium, zinc, etc. are added into the funnel-shaped storage device, and the preheating and drying system is started. The granular materials gradually enter a shearing opening of an inclined-opening feeding sleeve 15 of the charging barrel device 6, the metal granular materials are conveyed forward by a screw 9 in a groove latent mode, are melted and mixed into paste, enter a material separating closed ring 14 and reach a storage section 12. The far infrared heating gradient heating subsection gradient heating system 7 is sleeved outside the charging barrel body, the temperature of the discharging port end is higher than that of the feeding port, and the self-power control system is adopted for control. The discharge port of the charging barrel device adopts a smooth type large-caliber discharge port which is far larger than the existing high-pressure injection process nozzle, the discharge port takes the principle that paste materials can smoothly pass through the discharge port, and the discharge port is provided with a one-way check valve which is automatically closed after being discharged, so that the paste materials in a storage section are prevented from being discharged. The charging barrel device and the outlet are provided with a flange sealing structure to be communicated with the inside of a die cavity, or a sealing cover is adopted to ensure that the metal particles are input, melted, mixed, ground, output and molded under the condition of no atmospheric invasion. After the parts are molded, the parts are ejected out by a piston ejection cylinder and are extracted by a robot or a manipulator.

In the non-ferrous metal particle semi-solid forming process, a horizontal feeding mechanism in one section melts and dissolves metal particles, and when the metal particles are mixed into a semi-solid state, semi-solid slurry is quickly fed into a die cavity of a vertical forming machine in two sections from an unblocked and openable discharge port at low pressure in a closed butt joint facility, and the unblocked discharge port can meet the requirement of a large-flow forming material and can also ensure the temperature consistency of the flow rate. The forming process adopts the design of horizontal feeding and vertical forming, is completely different from the small nozzle process flow of axial load movement high-pressure high-jetting, and adopts two-zone-in-one process flow to complete the forming of large parts and automobile hub blanks.

According to the semi-solid forming process of the non-ferrous metal particles, a quantitative control system is arranged on a horizontal feeding mechanism in a section in the first step according to the quality requirement of a formed product so as to meet the forming supply requirement of parts with different specifications.

The specific process technical route is as follows: the two sections are combined into a forming device. Non-ferrous metal particles in one section are stored in a funnel-shaped storage device, are dehumidified and preheated by external drying and withering, and enter a charging barrel device. The design is designed according to the unsoftened large volume of initial metal particles when entering and the special characteristics of non-ferrous metal particle materials and conventional resin plastics, and the design meets the requirements of melting, mixing, eating and wrapping material input and spiral propulsion of metal particles in a high-temperature section above 500 ℃, and simultaneously is designed according to the extra-large requirement of the metal particles of a large-sized part hub blank. The screw of the conventional resin plastic is an inclined taper screw groove screw of an equal pitch standard type, and is only suitable for being fed into and spirally propelled by low-temperature resin plastic particles below 500 ℃. As the metal particles are melted and mixed and propelled in a high-temperature region above 500 ℃, the conventional conical screw groove screw with equal pitch can cause the metal particles to be adhered to the screw to slide and rotate to prevent the metal particles from advancing when the metal particles are converted from a solid state to a semi-solid state after the front end pitch is full of the material, and cause the particles which are stagnated at an inlet to enter the screw to be turned outwards and emerge.

The semi-solid slurry is quickly sent into the die cavity of the second section from the discharge port which is unblocked and can be closed and opened under low pressure in a closed butt joint facility when the metal particles are melted and mixed into the semi-solid state in the first section. Smooth type export, the design that does not have the reducing in bore promptly, bore front and back unanimity can guarantee the demand of large-traffic shaping material, can guarantee again that the temperature of material flow is unanimous.

The semi-solid composite die forging forming equipment for the non-ferrous metals such as aluminum, magnesium, zinc and the like breaks through the bottleneck of the existing semi-solid metal forming equipment, and solves the problems that the existing equipment can only form part products with small specifications, light weight and small wall thickness drop, and is difficult to form large parts with super-large, super-thick and super-heavy thicknesses and prefabricate various large blanks. The existing horizontal and vertical non-ferrous metal semi-solid forming equipment such as aluminum, magnesium, zinc and the like adopts the processes of axial material conveying, material melting and high-pressure high-speed one-way injection forming, so that the application range of the equipment is restricted. Only suitable for thin-wall parts with lighter weight. Various parts and large blanks with overlarge size, super thickness and overweight can not be molded. And products with thick walls and thin walls which are greatly different in the same part cannot be formed. The wall thickness is easy to shrink loose, shrink hole and bubble. The semi-solid composite molding equipment for non-ferrous metals such as aluminum, magnesium, zinc and the like adopts a two-step pressure die forging molding process. Can successfully die-cast ultra-large, ultra-thick and ultra-heavy aluminum and magnesium parts and large prefabricated blanks. The surface finish of the formed part is high, the internal alloy components have no segregation, the compactness is good, shrinkage porosity and foaming are avoided, and various indexes such as mechanical property tensile strength and the like are obviously improved.

The semi-solid forming process and equipment for non-ferrous metals such as Al, Mg, Zn and the like are quantitative die-cast in closed equipment, the surface is smooth, peeling and oxide erosion are avoided, cutting is avoided, and the compactness of the material is far higher than that of a semi-continuous casting bar. Not only large-scale casting equipment and smelting equipment are saved, but also pollution caused by smelting of a smelting furnace is avoided. And the investment of peeling machines, lathes, cutting machines and other equipment can be saved. The manufacturing time and cost of the aluminum-magnesium automobile hub blank are saved in multiples. And the material manufacturing links are reduced, and the process flow of the application comprises the steps of feeding metal alloy ingots, crushed metal particles and the metal alloy ingots into equipment for directly die-casting blanks. In the existing semi-continuous casting process flow, metal alloy ingots are melted, bar blanks are cast, cut, peeled, cut again and both ends are turned flat. The manufacturing process flow greatly shortens the manufacturing process flow of large-scale blanks such as hubs and the like, reduces the cost by about 90 percent, and has better blank quality than semi-continuous casting in all aspects.

The semi-solid forming process and the semi-solid forming equipment for the nonferrous metal particles are not only suitable for aluminum, magnesium and zinc, but also suitable for other nonferrous metal particle materials.

The above-described embodiments are only preferred embodiments of the present invention, and are not intended to limit the present invention in any way, and other variations and modifications may be made without departing from the spirit of the invention as set forth in the claims. The semi-solid composite die forging forming equipment for the aluminum, magnesium and zinc nonferrous metals is slightly modified by adopting any other method, and the forging blank or large part of the aluminum, magnesium and zinc automobile hub is formed by adopting a two-step method. Or the liquid metal forming process adopts the two-step method to die-cast the automobile hub blanks of aluminum, magnesium and zinc and the forming equipment of large parts, which belong to the protection scope of the invention.

Claims

1. A non-ferrous metal particle semi-solid forming device is characterized by comprising:

the horizontal feeding mechanism (I) of a section is used for realizing the conveying, melting, mixing, storing and feeding of metal particles into a forming die cavity;

horizontal feed mechanism of a district section (I) laid: the device comprises a material cylinder device (6) which is horizontally arranged, a segmented gradient heating system (7) which is sleeved outside the material cylinder device, a material storage device (4) which is butted with the material cylinder device in a shearing opening structure, and a drying system (5) which is arranged outside the material storage device; the screw rods (9) with unequal pitches and unequal bottom diameters are arranged in the charging barrel device (6), the screw pitches of the screw rods (9) are sequentially and progressively decreased from the feeding end to the discharging end, and the groove depths of screw grooves (93) of the screw rods (9) are sequentially and progressively decreased from the feeding end to the discharging end; the screw (9) at least comprises three sections of conveying melting spiral sections (10) with different pitches and different bottom diameters and a section of mixing chute screw section (11);

the two-section vertical forming mechanism (II) is used for realizing die forging and die casting forming;

the working direction of the first-section horizontal feeding mechanism (I) and the working direction of the second-section vertical forming mechanism (II) are vertically arranged, the first-section horizontal feeding mechanism (I) and the second-section vertical forming mechanism (II) are communicated with each other and are in sealed butt joint through a smooth discharge hole (8) to realize horizontal feeding and vertical forming.

2. The semi-solid forming apparatus for nonferrous metal particles according to claim 1, wherein: a storage section (12) is arranged in the charging barrel device (6), a check valve (13) is arranged at the discharge port end of the storage section (12), and a distributing closed ring (14) is arranged at the feed end of the storage section (12); the material-distributing closed ring (14) is automatically opened when a screw (9) in the material barrel device (6) rotates, the material-distributing closed ring (14) is automatically closed along with the generation of pressure when the storage section (12) pushes and feeds materials to the two-section vertical forming mechanism, and the material-distributing closed ring (14) and the rotation and the rod withdrawing of the screw are synchronously opened and closed.

3. The semi-solid forming apparatus for nonferrous metal particles according to claim 1, wherein: the segmented gradient heating system (7) is coated outside the charging barrel device (6); the sectional gradient heating system (7) is at least provided with three sections of temperature control areas with sequentially increasing temperatures from the feeding end to the discharging end of the charging barrel device (6).

4. The semi-solid forming apparatus for nonferrous metal particles according to claim 1, wherein: the material storage device (4) is vertically arranged on the material cylinder device (6) and is communicated with the interior of the material cylinder device (6) in a shearing mode through an inclined opening feeding sleeve (15); the inclined direction of the inclined opening feeding sleeve (15) is obliquely arranged from top to bottom along the feeding direction of the charging barrel device (6) and is matched with the rotating direction of a screw (9) in the charging barrel device (6).

5. The semi-solid forming apparatus of non-ferrous metal particles as set forth in any one of claims 1 to 4, wherein: the horizontal feeding mechanism (I) of one section further comprises a quantitative control system (1), a feeding pressure system (2) and a feeding rotating system (3); the feeding pressure system (2), the feeding rotating system (3) and the charging barrel device (6) are coaxially and horizontally arranged.

6. The semi-solid forming apparatus of non-ferrous metal particles as set forth in any one of claims 1 to 4, wherein: the two-section vertical forming mechanism (II) comprises a forming pressure system (16), a forming die (17) and an ejection mechanism (18).

7. A semi-solid forming process of non-ferrous metal particles, which adopts the semi-solid forming equipment of non-ferrous metal particles as claimed in any one of claims 1 to 6, characterized in that: the semi-solid forming process of the non-ferrous metal particles adopts a two-step composite process to realize horizontal feeding and a vertical forming process:

the first step of the process is that metal particles enter a barrel body of a charging barrel to realize horizontal conveying, melting, mixing and storage until the metal particles are sent into a forming die cavity, so that one-time automatic horizontal melting, mixing, storage, heat preservation and feeding are realized; the first step of the process is completed by a horizontal feeding mechanism (I) in one section, and specifically comprises the following steps:

adding the non-ferrous metal particles of aluminum, magnesium and zinc into a funnel-shaped storage device (4), and starting a drying system (5);

granular materials gradually enter the charging barrel device (6) through a shearing opening of an inclined opening feeding sleeve (15) with a rectangular opening structure, a segmented gradient heating system (7) sleeved outside the charging barrel device (6) is started to heat at the moment, metal granular materials are gradually conveyed to a discharging opening end by screws with unequal pitches and unequal bottom diameters, the granular materials are melted and mixed into semi-solid paste through temperature control areas of different sections in the conveying process, and the semi-solid paste is conveyed into a storage section (12) through a material distribution closed ring (14);

the semi-solid paste in the storage section (12) is conveyed to a two-section vertical forming mechanism (II) through a smooth discharge hole (8) by a check valve (13);

the second step is forming; the semi-solid paste is formed in a forming die cavity (21) of the two-section vertical forming mechanism (II) through die forging and die casting of an upper die and a lower die of a forming die; and ejecting the formed part through an ejection mechanism to finish vertical forming.

8. A non-ferrous metal particle semi-solid forming process as claimed in claim 7, wherein: the smooth discharge port (8) is a large-caliber discharge port with a constant caliber, and the caliber of the smooth discharge port (8) is 30-50 mm.