CN111496254B - 一种模具冷却镶块及其制造方法 - Google Patents
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Abstract
本发明公开了一种模具冷却镶块,包括由增材制造工艺一体成型的镶块本体,所述镶块本体包括成型部和柄部,所述成型部内水平设有C形冷却通道,该C形冷却通道一开口与柄部内的进质通道连通,另一出口与柄部内的出质通道连通。其能够在成型部表面形成均匀的温度场,实现成型部表面的快速冷却,提高生产效率,使用寿命长。还公开了上述模具冷却镶块的制造方法,其包括如下步骤:S1,对上述的模具冷却镶块进行三维建模,再将得到的三维模型进行切片处理;S2,以模具钢粉末作为3D打印材料,设定打印参数后开始3D打印,得到镶块毛坯;S3,对镶块毛坯依次进行退火处理和时效处理;S4,精加工至成品尺寸,得到模具冷却镶块。
Description
技术领域
本发明涉及模具冷却技术,具体涉及一种模具冷却镶块及其制造方法。
背景技术
汽车发动机缸盖模具受传统铸造工艺影响,热效应影响严重,整个生产周期常常因降温冷却速率不足而被迫延长生产节拍。其中燃烧室部位由液态铝水在对应的模具燃烧室冷却镶块表面凝固形成。
为实现快速顺序凝固,燃烧室冷却镶块内部设计冷却管路,冷却介质为常温压缩空气或纯水。参见图1,所示的现有燃烧室冷却镶块,包括现有成型部8和现有柄部9,其制造工艺路线是:采用H13模具钢,根据气缸盖的燃烧室形状加工现有成型部8表面,现有成型部8底部的安装面加工有2或3个与模具本体底模板连接的螺纹孔81,现有成型部8顶部的表面与现有成型部8底部的安装面由加工中心加工形成。现有成型部8内部冷却通道加工过程是:先由机加工艺沿现有柄部9轴向和径向镗相互连通的竖孔91和横孔92,所述竖孔91开口端设置有堵头10,隔离板11固定设置于所述堵头10的顶端。所述竖孔91由隔离板11隔开,在其内部形成两条直线式的一进一出冷却通道,冷却介质一般选择空气或纯水。所述横孔92贯穿现有柄部9侧壁,两端开口位置均预留有与浇注机冷却管路连接的内螺纹。该镶块经过热处理与氮化工艺强化后,整体硬度在40HRC左右。
此种镶块存在三个缺点,一是内部冷却通道在镶块中心位置,无法有效冷却镶块周边,使得镶块表面温度不一,无法形成均匀的温度场,进而导致气缸盖燃烧室周边因温度不均出现拉伤。二是由于冷却的是镶块表面中心一个点的位置,冷却效果差,无法有效降低整个镶块温度,不利于铝水在燃烧室部位的快速凝固,无法提高浇注的生产节拍。三是镶块采用模具钢,即使采用氮化工艺进行强化处理,其强度与硬度依然偏低,耐磨性差,使用寿命也就在两万模次左右,在整个模具生命周期内,需要消耗5到6套燃烧室冷却镶块,生产成本偏高。
现有燃烧室冷却镶块是在内部采用机加镗孔方案,由于机加工艺能力限制,只能在镶块内部中心位置加工成直线式的一进一出冷却通道,依靠延长冷却时间或加大流量来增加冷却能力,冷却能力有限,无法均匀的冷却整个燃烧室镶块表面,低于工艺的预期效果,使得工艺无法得到优化,生产周期无法缩短。
发明内容
本发明的目的是提供一种模具冷却镶块及其制造方法,其能够在成型部表面形成均匀的温度场,实现成型部表面的快速冷却,提高生产效率,使用寿命长。
本发明所述的模具冷却镶块,包括由增材制造工艺一体成型的镶块本体,所述镶块本体包括成型部和柄部,所述成型部内水平设有C形冷却通道,该C形冷却通道一开口与柄部内的进质通道连通,另一出口与柄部内的出质通道连通。
进一步,所述成型部顶面为成型面,成型部底面设有多个与模具本体连接的连接孔。
进一步,所述进质通道和出质通道与C形冷却通道的开口连接处通过圆弧过渡。
进一步,进质通道的入口和出质通道的出口设于柄部侧壁,且所述进质通道的入口和出质通道的出口与镶块本体外部的冷却管路连通。
进一步,所述柄部底面设有减重沉孔。
一种模具冷却镶块的制造方法,其包括如下步骤:
S1,对上述的模具冷却镶块进行三维建模,再将得到的三维模型进行切片处理;
S2,以模具钢粉末作为3D打印材料,设定打印参数后开始3D打印,得到镶块毛坯;
S3,对镶块毛坯依次进行退火处理和时效处理;
S4,精加工至成品尺寸,得到模具冷却镶块。
进一步,所述S1中的切片厚度为20μm;所述S2中的打印参数具体为:基板预热温度为250~300℃,激光扫描速度为150mm/s,激光功率为130W,焦点直径75μm,扫描间距为0.1mm,铺粉厚度与切片厚度相同。
进一步,所述S3中退火处理具体为:退火温度为850±10℃,退火时间为3~3.5h;时效处理具体为:时效温度为575±10℃,时效时间为7~8h。
进一步,所述模具钢粉末按重量百分比计包括如下组分:11~13wt%的Cr,8.4~10.0wt%的Ni,1.3~1.7wt%的Mo,1.2~2.0wt%的Al,≤0.05wt%的C,≤0.4wt%的Mn,≤0.4wt%的Si,余量为Fe。
进一步,所述模具钢粉末按重量百分比计包括如下组分:12.12wt%的Cr,9.1wt%的Ni,1.48wt%的Mo,1.7wt%的Al,0.013wt%的C,0.27wt%的Mn,0.054wt%的Si,余量为Fe。
本发明与现有技术相比具有如下有益效果。
1、本发明所述的镶块本体由增材制造工艺一体成型,避免了冷却通道形状受机加工艺限制,同时所述镶块本体的成型部内水平设有C形冷却通道,使得冷却通道能够有效冷却成型面的周边位置,不再局限于中心位置的冷却,在成型面表面形成均匀的温度场,避免了气缸盖燃烧室周边因温度不均出现拉伤。
2、本发明所述的C形冷却通道能够同时冷却成型面的中心位置和周边区域,提升了冷却镶块的冷却能力,实现了金属液在成型面位置的快速冷却,加快了浇注的生产节拍,进而提高了生产效率。
3、本发明所述的制造方法为3D打印工艺,以模具钢粉末作为打印材料,保证了镶块本体的力学性能,通过对镶块毛坯依次进行退火处理和时效处理,显著提高了镶块本体的硬度和抗拉强度,延长了镶块本体的使用寿命,降低了生产制造成本。
附图说明
图1是现有燃烧室冷却镶块的结构示意图;
图2是本发明镶块本体的结构示意图;
图3是本发明镶块毛坯热处理后的金相照片;
图中,1—镶块本体,2—成型部,21—成型面,22—连接孔,3—柄部,4—C形冷却通道,5—进质通道,51—进质通道的入口,6—出质通道,61—出质通道的出口,7—减重沉孔,8—现有成型部,81—螺纹孔,9—现有柄部,91—竖孔,92—横孔,10—堵头,11—隔离板。
具体实施方式
下面结合附图对本发明作详细说明。
参见图2,所示的模具冷却镶块,包括由增材制造工艺一体成型的镶块本体1,所述镶块本体1包括成型部2和柄部3,所述成型部2内水平设有C形冷却通道4,该C形冷却通道4一开口与柄部3内的进质通道5连通,另一出口与柄部3内的出质通道6连通。需要说明的是,镶块本体1内冷却通道整体长度、冷却通道半径、冷却通道与成型面的距离以及冷却通道的最小间隔距离根据不同零部件、不同冷却需求进行合理调整。
所述成型部2顶面为成型面21,当该镶块本体1应用于缸体燃烧室冷却时,成型面21根据气缸盖的燃烧室形状。成型部2底面设有两个与模具本体连接的连接孔22,镶块本体1通过连接螺栓与连接孔22配合螺纹连接,将镶块本体1固定于模具本体的底模板上。
所述进质通道5和出质通道6与C形冷却通道4的开口连接处通过圆弧过渡,使得通道内的冷却介质流通更加顺畅,避免了因转角设置导致冷却介质流速减小,影响冷却效果。
进质通道的入口51和出质通道的出口61设于柄部3侧壁,且所述进质通道的入口51和出质通道的出口61与镶块本体1外部的冷却管路连通。
所述柄部底面中部设有减重沉孔,既不影响冷却通道的布置,同时也减轻了镶块本体的重量,节约了原材料,降低了镶块本体的制造成本。
一种模具冷却镶块的制造方法,其包括如下步骤:
S1,对上述的模具冷却镶块进行三维建模,再将得到的三维模型进行切片处理,切片厚度为20μm。
S2,以模具钢粉末作为3D打印材料,所述模具钢粉末呈球形,直径在20~50μm之间,平均粒径为38μm。所述模具钢粉末按重量百分比计包括如下组分:12.12wt%的Cr,9.1wt%的Ni,1.48wt%的Mo,1.7wt%的Al,0.013wt%的C,0.27wt%的Mn,0.054wt%的Si,余量为Fe。该模具钢粉末基本力学性能参见表1。
表1模具钢粉末基本力学性能
热处理状态 | 洛氏硬度 | 抗拉强度/MPa | 延伸率/% |
成形态 | 34.3-35.5 | 1102 | 14.0 |
热处理态 | 54.33-55.6 | 1760 | 7.0 |
表1中的热处理态指的是对成形态试样依次进行退火处理和时效处理。其中退火处理的退火温度为900℃,退火时间为1h;时效处理的时效温度为500℃,时效时间为3h。表明了热处理能够显著提高成形态模具钢粉末的硬度和抗拉强度,降低延伸率,即经过热处理后,硬度和抗拉强度提升,塑性降低。
设定打印参数后开始3D打印,打印过程采用纯度为99.999%的氮气作为保护气体,得到镶块毛坯,该镶块毛坯留有0.5mm的加工余量。所述打印参数具体为:基板预热温度为250℃,激光扫描速度为150mm/s,激光功率为130W,焦点直径75μm,扫描间距为0.1mm,铺粉厚度为20μm。
打印完成后对镶块毛坯进行探伤检测,观察零件内部是否有裂纹缺陷。若存在裂纹缺陷,则该镶块毛坯作为报废件,若不存在裂纹缺陷,则进行下一步。
S3,对镶块毛坯依次进行退火处理和时效处理;退火处理具体为:退火温度为850±10℃,退火时间为3h;时效处理具体为:时效温度为575±10℃,时效时间为8h。
采用金相仪按GB/T6394-2002对热处理后的镶块毛坯进行金相检测,腐蚀剂为5%硝酸酒精,放大倍数为100,结果参见图3,检测试样表面无明显裂纹、气孔等缺陷,表明了镶块毛坯成型质量较好。
采用HVS-1000数显硬度计按GB/T230.1-2018测定热处理后的镶块毛坯的洛氏硬度,热处理后的镶块毛坯表面洛氏硬度为53.67HRC,符合技术要求,并且大于现有镶块通过热处理和氮化工艺处理后的洛氏硬度40HRC。
采用拉伸试验机按GB/T228-2002对热处理后的镶块毛坯进行拉伸性能测试,屈服极限为1613.3Mpa,抗拉强度为1960.7Mpa,伸长率为9.68%,界面收缩率为30.82%,弹性模量为206.79Mpa,符合模具冷却镶块的技术要求。
S4,精加工至成品尺寸,得到模具冷却镶块。具体为,在精加工前对镶块本体1关键尺寸进行测量并记录,然后按照技术要求,使用专用工装对镶块本体1进行装夹定位。再去除3D打印时预留的支撑结构,按模具装配要求加工成型部2底面。以成型部2底面作为基准,去除镶块本体1表面余量,加工精度≤±0.05。打磨成型部2的成型面,使其粗糙度≤Ra6.3。按连接孔22、进质通道的入口51和出质通道的出口61的连接要求预钻φ6.8底孔,检查孔径与孔深无误后,再攻M8螺纹孔,并检查螺纹孔,清理镶块本体。最后使用蓝光三维扫描仪进行成品尺寸检测,完成模具冷却镶块的制造。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种模具冷却镶块,其特征在于:包括由增材制造工艺一体成型的镶块本体(1),所述镶块本体(1)包括成型部(2)和柄部(3),所述成型部(2)内水平设有C形冷却通道(4),该C形冷却通道(4)一开口与柄部(3)内的进质通道(5)连通,另一出口与柄部(3)内的出质通道(6)连通;
所述模具冷却镶块的制造方法包括如下步骤:
S1,对所述的模具冷却镶块进行三维建模,再将得到的三维模型进行切片处理;
S2,以模具钢粉末作为3D打印材料,设定打印参数后开始3D打印,得到镶块毛坯;所述模具钢粉末按重量百分比计包括如下组分:
11~13wt%的Cr,8.4~10.0wt%的Ni,1.3~1.7wt%的Mo,1.2~2.0wt%的Al,≤0.05wt%的C,≤0.4wt%的Mn,≤0.4wt%的Si,余量为Fe;
S3,对镶块毛坯依次进行退火处理和时效处理;
S4,精加工至成品尺寸,得到模具冷却镶块。
2.根据权利要求1所述的模具冷却镶块,其特征在于:所述镶块本体为缸盖燃烧室镶块,所述成型部(2)顶面为成型面(21),成型部(2)底面设有多个与模具本体连接的连接孔(22)。
3.根据权利要求1或2所述的模具冷却镶块,其特征在于:所述进质通道(5)和出质通道(6)与C形冷却通道(4)的开口连接处通过圆弧过渡。
4.根据权利要求1或2所述的模具冷却镶块,其特征在于:进质通道的入口(51)和出质通道的出口(61)设于柄部(3)侧壁,且所述进质通道的入口(51)和出质通道的出口(61)与镶块本体(1)外部的冷却管路连通。
5.根据权利要求1或2所述的模具冷却镶块,其特征在于:所述柄部(3)底面设有减重沉孔(7)。
6.根据权利要求1所述的模具冷却镶块,其特征在于:所述S1中的切片厚度为20μm;所述S2中的打印参数具体为:基板预热温度为250~300℃,激光扫描速度为150mm/s,激光功率为130W,焦点直径75μm,扫描间距为0.1mm,铺粉厚度与切片厚度相同。
7.根据权利要求1所述的模具冷却镶块,其特征在于,所述S3中退火处理具体为:退火温度为850±10℃,退火时间为3~3.5h;
时效处理具体为:时效温度为575±10℃,时效时间为7~8h。
8.根据权利要求1所述的模具冷却镶块,其特征在于,所述模具钢粉末按重量百分比计包括如下组分:
12.12wt%的Cr,9.1wt%的Ni,1.48wt%的Mo,1.7wt%的Al,0.013wt%的C,0.27wt%的Mn,0.054wt%的Si,余量为Fe。
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