CN112691874A - 一种耐久性汽车空调阀板的加工工艺 - Google Patents
一种耐久性汽车空调阀板的加工工艺 Download PDFInfo
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Abstract
本发明公开了一种耐久性汽车空调阀板的加工工艺,包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂50‑60份、纳米氧化锌10‑16份、锆类偶联剂1‑1.6份、溶剂10‑15份、二氧化钛5‑7份、分散剂3‑5份、消泡剂0.1‑0.3份、金属钨10‑12份和碳10‑12份,与其它处理工艺相比,工艺成熟,先采用冲压机对钢板进行冲切处理,通过在防腐涂层内部添加的纳米氧化锌,可以提高涂层的耐腐蚀性和机械物理性能,进而增加了阀板的使用寿命和抗腐蚀能力,防腐涂层喷涂固化后将碳化钨喷涂至阀板的表面,碳化钨涂层高度致密,结合强度高,进一步提高了空调阀板的耐磨性,能消除或减少阀板的磨损问题,延长阀板使用寿命,提升其耐久性。
Description
技术领域
本发明涉及冲压技术生产工艺,更具体地说,尤其涉及一种耐久性汽车空调阀板的加工工艺。
背景技术
压缩机可分类为冰箱压缩机,空调压缩机,气体压缩机,制冷压缩机,多数压缩机都是起到制冷作用,只有气体压缩机用于特殊气体压缩,压缩机阀板质量优劣,阀板的精度,都直接影响到压缩机的寿命,制冷效果,在汽车空调的压缩机工作过程中,需要使用到压缩机阀板来辅助工作,汽车空调阀板在汽车空调系统中的作用十分重要,汽车阀板在生产加工时一般采用冲压加工工艺。
现有的汽车空调阀板生产加工工艺,多是只采用冲压机冲压钢板制成,冲压成型后制成的钢板直接打磨使用,在实际使用过程中,外界水分容易在阀板表面老化受损后直接对阀板本体进行侵蚀,导致阀板的使用寿命受到影响,需要立刻更换,增加了使用维护成本,同时由于阀板的使用年限需求较长,长期控制水流的进出,在水体长时间的流通过程中,容易因不断的摩擦造成阀板的磨损,影响阀板的密封性和密闭效果,使用耐久性不高,为此,我们提出一种耐久性汽车空调阀板的加工工艺。
发明内容
本发明的目的是为了解决现有技术中存在的缺点,而提出的一种耐久性汽车空调阀板的加工工艺,工艺成熟,先采用冲压机对钢板进行冲切处理,得到符合图纸要求的阀板雏形,随后采用多种原料配制防腐漆,并将制备的防腐漆喷涂至阀板的表面,通过在防腐涂层内部添加的纳米氧化锌,可以提高涂层的耐腐蚀性和机械物理性能,纳米颗粒的高特效区域形成了可以有效抵御腐蚀的物理屏障,阻止水体等腐蚀体进入阀板的表面,进而增加了阀板的使用寿命和抗腐蚀能力,减少水体对空调阀板的腐蚀,防腐涂层喷涂固化后制备碳化钨,并将制备的碳化钨喷涂至阀板的表面,碳化钨涂层高度致密,结合强度高,气孔率小于1%,结合强度大于70Mpa,可以降低阀板表面冲突系数,减少磨损、咬合等,阀板外观可达到100%润滑,冲突系数可降低到0.06,进一步提高了空调阀板的耐磨性,能消除或减少阀板的磨损问题,延长阀板使用寿命,提升其耐久性。
为实现上述目的,本发明提供如下技术方案:一种耐久性汽车空调阀板的加工工艺,包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂50-60份、纳米氧化锌10-16份、锆类偶联剂1-1.6份、溶剂10-15份、二氧化钛5-7份、分散剂3-5份、消泡剂0.1-0.3份、金属钨10-12份和碳10-12份。
优选的,包括如下步骤:
S1、钢板切割:根据图纸上阀板设计规格在钢板上画出对应规格尺寸的钢板基体并采用等离子切割机进行切割,切割出符合尺寸要求的钢板,并对切割面进行检查,确保无毛刺和残缺,同时复核钢板尺寸;
S2、钢板冲压:选用合适规格的阀板模具置于冲压机上安装固定,将切割出的钢板置于阀板模具内部,并操作冲压机进行冲压处理,冲压后得到阀板雏形,再次对照图纸复核阀板雏形的尺寸规格;
S3、防腐漆制备:选用酚醛环氧树脂55份、溶剂12.5份和锆类偶联剂1.3份置于球磨机内部进行球磨,随后加入纳米氧化锌13份、二氧化钛6份、分散剂4份和消泡剂0.2份继续球磨,得到防腐底漆;
S4、防腐漆喷涂:将制备的防腐底漆均匀喷涂至阀板雏形的外表面,随后高温固化处理;
S5、碳化钨制备:将平均粒径为 3~5μm 的金属钨11份和碳11份置于球磨机内部干混,充分混合后加压成型并放入石墨盘,在感应电炉中持续加热得到碳化钨;
S6、碳化钨喷涂:将制备的碳化钨采用高温热源使其融化,并采用超音速喷涂的方法将碳化钨喷至阀板雏形外表面,固化冷却后即得到生产完成的阀板。
优选的,分散剂材质为聚丙烯酰胺,消泡剂材质为磷酸三丁酯。
优选的,防腐漆制备过程中球磨机转速为180-220r/min,球磨时间为5-7h,防腐漆喷涂时固化温度为800-1100℃。
优选的,碳化钨制备过程中球磨机转速为200-220r/min,球磨时间为1-2h,感应电炉加热温度为1550-1650℃。
本发明的技术效果和优点:
本发明工艺成熟,先采用冲压机对钢板进行冲切处理,得到符合图纸要求的阀板雏形,随后采用多种原料配制防腐漆,并将制备的防腐漆喷涂至阀板的表面,通过在防腐涂层内部添加的纳米氧化锌,可以提高涂层的耐腐蚀性和机械物理性能,纳米颗粒的高特效区域形成了可以有效抵御腐蚀的物理屏障,阻止水体等腐蚀体进入阀板的表面,进而增加了阀板的使用寿命和抗腐蚀能力,减少水体对空调阀板的腐蚀,防腐涂层喷涂固化后制备碳化钨,并将制备的碳化钨喷涂至阀板的表面,碳化钨涂层高度致密,结合强度高,气孔率小于1%,结合强度大于70Mpa,可以降低阀板表面冲突系数,减少磨损、咬合等,阀板外观可达到100%润滑,冲突系数可降低到0.06,进一步提高了空调阀板的耐磨性,能消除或减少阀板的磨损问题,延长阀板使用寿命,提升其耐久性。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合具体实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
实施例1
一种耐久性汽车空调阀板的加工工艺,包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂55份、纳米氧化锌13份、锆类偶联剂1.3份、溶剂12.5份、二氧化钛6份、分散剂4份、消泡剂0.2份、金属钨11份和碳11份。
优选的,包括如下步骤:
S1、钢板切割:根据图纸上阀板设计规格在钢板上画出对应规格尺寸的钢板基体并采用等离子切割机进行切割,切割出符合尺寸要求的钢板,并对切割面进行检查,确保无毛刺和残缺,同时复核钢板尺寸;
S2、钢板冲压:选用合适规格的阀板模具置于冲压机上安装固定,将切割出的钢板置于阀板模具内部,并操作冲压机进行冲压处理,冲压后得到阀板雏形,再次对照图纸复核阀板雏形的尺寸规格;
S3、防腐漆制备:选用酚醛环氧树脂55份、溶剂12.5份和锆类偶联剂1.3份置于球磨机内部进行球磨,随后加入纳米氧化锌13份、二氧化钛6份、分散剂4份和消泡剂0.2份继续球磨,得到防腐底漆;
S4、防腐漆喷涂:将制备的防腐底漆均匀喷涂至阀板雏形的外表面,随后高温固化处理;
S5、碳化钨制备:将平均粒径为 4μm 的金属钨11份和碳11份置于球磨机内部干混,充分混合后加压成型并放入石墨盘,在感应电炉中持续加热得到碳化钨;
S6、碳化钨喷涂:将制备的碳化钨采用高温热源使其融化,并采用超音速喷涂的方法将碳化钨喷至阀板雏形外表面,固化冷却后即得到生产完成的阀板。
优选的,分散剂材质为聚丙烯酰胺,消泡剂材质为磷酸三丁酯。
优选的,防腐漆制备过程中球磨机转速为200r/min,球磨时间为6h,防腐漆喷涂时固化温度为950℃。
优选的,碳化钨制备过程中球磨机转速为210r/min,球磨时间为1.5h,感应电炉加热温度为1600℃。
实施例2
一种耐久性汽车空调阀板的加工工艺,包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂50份、纳米氧化锌10份、锆类偶联剂1份、溶剂10份、二氧化钛5份、分散剂3份、消泡剂0.1份、金属钨10份和碳10份。
优选的,包括如下步骤:
S1、钢板切割:根据图纸上阀板设计规格在钢板上画出对应规格尺寸的钢板基体并采用等离子切割机进行切割,切割出符合尺寸要求的钢板,并对切割面进行检查,确保无毛刺和残缺,同时复核钢板尺寸;
S2、钢板冲压:选用合适规格的阀板模具置于冲压机上安装固定,将切割出的钢板置于阀板模具内部,并操作冲压机进行冲压处理,冲压后得到阀板雏形,再次对照图纸复核阀板雏形的尺寸规格;
S3、防腐漆制备:选用酚醛环氧树脂50份、溶剂10份和锆类偶联剂1份置于球磨机内部进行球磨,随后加入纳米氧化锌10份、二氧化钛5份、分散剂3份和消泡剂0.1份继续球磨,得到防腐底漆;
S4、防腐漆喷涂:将制备的防腐底漆均匀喷涂至阀板雏形的外表面,随后高温固化处理;
S5、碳化钨制备:将平均粒径为 3μm 的金属钨10份和碳10份置于球磨机内部干混,充分混合后加压成型并放入石墨盘,在感应电炉中持续加热得到碳化钨;
S6、碳化钨喷涂:将制备的碳化钨采用高温热源使其融化,并采用超音速喷涂的方法将碳化钨喷至阀板雏形外表面,固化冷却后即得到生产完成的阀板。
优选的,分散剂材质为聚丙烯酰胺,消泡剂材质为磷酸三丁酯。
优选的,防腐漆制备过程中球磨机转速为180r/min,球磨时间为5h,防腐漆喷涂时固化温度为800℃。
优选的,碳化钨制备过程中球磨机转速为200r/min,球磨时间为1h,感应电炉加热温度为1550℃。
实施例3
一种耐久性汽车空调阀板的加工工艺,包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂60份、纳米氧化锌16份、锆类偶联剂1.6份、溶剂15份、二氧化钛7份、分散剂5份、消泡剂0.3份、金属钨12份和碳12份。
优选的,包括如下步骤:
S1、钢板切割:根据图纸上阀板设计规格在钢板上画出对应规格尺寸的钢板基体并采用等离子切割机进行切割,切割出符合尺寸要求的钢板,并对切割面进行检查,确保无毛刺和残缺,同时复核钢板尺寸;
S2、钢板冲压:选用合适规格的阀板模具置于冲压机上安装固定,将切割出的钢板置于阀板模具内部,并操作冲压机进行冲压处理,冲压后得到阀板雏形,再次对照图纸复核阀板雏形的尺寸规格;
S3、防腐漆制备:选用酚醛环氧树脂60份、溶剂15份和锆类偶联剂1.6份置于球磨机内部进行球磨,随后加入纳米氧化锌16份、二氧化钛7份、分散剂5份和消泡剂0.3份继续球磨,得到防腐底漆;
S4、防腐漆喷涂:将制备的防腐底漆均匀喷涂至阀板雏形的外表面,随后高温固化处理;
S5、碳化钨制备:将平均粒径为 5μm 的金属钨12份和碳12份置于球磨机内部干混,充分混合后加压成型并放入石墨盘,在感应电炉中持续加热得到碳化钨;
S6、碳化钨喷涂:将制备的碳化钨采用高温热源使其融化,并采用超音速喷涂的方法将碳化钨喷至阀板雏形外表面,固化冷却后即得到生产完成的阀板。
优选的,分散剂材质为聚丙烯酰胺,消泡剂材质为磷酸三丁酯。
优选的,防腐漆制备过程中球磨机转速为220r/min,球磨时间为7h,防腐漆喷涂时固化温度为1100℃。
优选的,碳化钨制备过程中球磨机转速为220r/min,球磨时间为2h,感应电炉加热温度为1650℃。
综上所述:本发明提供的一种耐久性汽车空调阀板的加工工艺,与其它处理工艺相比,具备以下优点:工艺成熟,先采用冲压机对钢板进行冲切处理,得到符合图纸要求的阀板雏形,随后采用多种原料配制防腐漆,并将制备的防腐漆喷涂至阀板的表面,通过在防腐涂层内部添加的纳米氧化锌,可以提高涂层的耐腐蚀性和机械物理性能,纳米颗粒的高特效区域形成了可以有效抵御腐蚀的物理屏障,阻止水体等腐蚀体进入阀板的表面,进而增加了阀板的使用寿命和抗腐蚀能力,减少水体对空调阀板的腐蚀,防腐涂层喷涂固化后制备碳化钨,并将制备的碳化钨喷涂至阀板的表面,碳化钨涂层高度致密,结合强度高,气孔率小于1%,结合强度大于70Mpa,可以降低阀板表面冲突系数,减少磨损、咬合等,阀板外观可达到100%润滑,冲突系数可降低到0.06,进一步提高了空调阀板的耐磨性,能消除或减少阀板的磨损问题,延长阀板使用寿命,提升其耐久性。
最后应说明的是:以上所述仅为本发明的优选实施例而已,并不用于限制本发明,尽管参照前述实施例对本发明进行了详细的说明,对于本领域的技术人员来说,其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分技术特征进行等同替换,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (5)
1.一种耐久性汽车空调阀板的加工工艺,其特征在于:包括下列机械和重量份的原料:冲压机、阀板模具、钢板、离子切割机、球磨机、酚醛环氧树脂50-60份、纳米氧化锌10-16份、锆类偶联剂1-1.6份、溶剂10-15份、二氧化钛5-7份、分散剂3-5份、消泡剂0.1-0.3份、金属钨10-12份和碳10-12份。
2.根据权利要求1所述的一种耐久性汽车空调阀板的加工工艺,其特征在于:包括如下步骤:
S1、钢板切割:根据图纸上阀板设计规格在钢板上画出对应规格尺寸的钢板基体并采用等离子切割机进行切割,切割出符合尺寸要求的钢板,并对切割面进行检查,确保无毛刺和残缺,同时复核钢板尺寸;
S2、钢板冲压:选用合适规格的阀板模具置于冲压机上安装固定,将切割出的钢板置于阀板模具内部,并操作冲压机进行冲压处理,冲压后得到阀板雏形,再次对照图纸复核阀板雏形的尺寸规格;
S3、防腐漆制备:选用酚醛环氧树脂55份、溶剂12.5份和锆类偶联剂1.3份置于球磨机内部进行球磨,随后加入纳米氧化锌13份、二氧化钛6份、分散剂4份和消泡剂0.2份继续球磨,得到防腐底漆;
S4、防腐漆喷涂:将制备的防腐底漆均匀喷涂至阀板雏形的外表面,随后高温固化处理;
S5、碳化钨制备:将平均粒径为 3~5μm 的金属钨11份和碳11份置于球磨机内部干混,充分混合后加压成型并放入石墨盘,在感应电炉中持续加热得到碳化钨;
S6、碳化钨喷涂:将制备的碳化钨采用高温热源使其融化,并采用超音速喷涂的方法将碳化钨喷至阀板雏形外表面,固化冷却后即得到生产完成的阀板。
3.根据权利要求2所述的一种耐久性汽车空调阀板的加工工艺,其特征在于:分散剂材质为聚丙烯酰胺,消泡剂材质为磷酸三丁酯。
4.根据权利要求2所述的一种耐久性汽车空调阀板的加工工艺,其特征在于:防腐漆制备过程中球磨机转速为180-220r/min,球磨时间为5-7h,防腐漆喷涂时固化温度为800-1100℃。
5.根据权利要求2所述的一种耐久性汽车空调阀板的加工工艺,其特征在于:碳化钨制备过程中球磨机转速为200-220r/min,球磨时间为1-2h,感应电炉加热温度为1550-1650℃。
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