CN113263159A - Method for manufacturing magnesium alloy car hub - Google Patents
Method for manufacturing magnesium alloy car hub Download PDFInfo
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- CN113263159A CN113263159A CN202110536041.2A CN202110536041A CN113263159A CN 113263159 A CN113263159 A CN 113263159A CN 202110536041 A CN202110536041 A CN 202110536041A CN 113263159 A CN113263159 A CN 113263159A
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- 229910000861 Mg alloy Inorganic materials 0.000 title claims abstract description 132
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- 238000005266 casting Methods 0.000 claims abstract description 23
- 238000007733 ion plating Methods 0.000 claims abstract description 18
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- 238000011282 treatment Methods 0.000 claims abstract description 16
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- 238000001514 detection method Methods 0.000 claims abstract description 12
- 238000010438 heat treatment Methods 0.000 claims abstract description 12
- 238000003723 Smelting Methods 0.000 claims abstract description 11
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
- B22D31/002—Cleaning, working on castings
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/34—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tyres; for rims
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/06—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of magnesium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/16—Metallic material, boron or silicon on metallic substrates or on substrates of boron or silicon
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
- C23C14/32—Vacuum evaporation by explosion; by evaporation and subsequent ionisation of the vapours, e.g. ion-plating
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- C23F17/00—Multi-step processes for surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by subclass C21D or C22F or class C25
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Abstract
The invention belongs to the technical field of automobile part manufacturing, and discloses a method for manufacturing a magnesium alloy car hub, which comprises the steps of carrying out experimental design simulation modeling, preparing corresponding raw materials according to a model, smelting magnesium alloy melt by using a reverberatory furnace, and controlling a resistance furnace to keep warm; preparing a forming machine and a die, preparing the forming machine, carrying out no-load action, and preheating the die; carrying out die assembly, and controlling a magnesium alloy quantitative pouring system to pour; performing extrusion forming through a magnesium alloy hub die, and solidifying and cooling; after solidification and cooling, demolding, removing a casting system and flash burrs, and detecting the return of the returned material; carrying out heat treatment through X-ray real-time image detection; performing sand blasting treatment on the surface of the casting, performing numerical control machining, and performing decontamination and cleaning; vacuum ion plating, detecting, cleaning, drying and packaging; the industrialization of the product of the invention has great influence on the production of the car hub in China due to high technical level and large industrialization scale.
Description
Technical Field
The invention belongs to the technical field of automobile part manufacturing, and particularly relates to a method for manufacturing a magnesium alloy car hub.
Background
At present, an important development direction of the modern car industry is light weight so as to meet the increasing requirements of energy conservation, consumption reduction and emission reduction. One of the main means of light weight is to use advanced lightweight materials instead of traditional materials. The hub is a high-speed moving part with the largest use amount on a car, and the magnesium alloy is used for the hub, so that the weight of the hub can be greatly reduced (the weight is reduced by 30 percent, and 0.6kg of fuel can be saved by 100kg per unit), and the dynamic moment of inertia of the hub is reduced; therefore, after the magnesium alloy hub is adopted, the dynamic performances of the car such as starting, braking, acceleration, deceleration and the like can be obviously improved, the purposes of energy conservation, consumption reduction and environmental protection are achieved, and the driving comfort degree of the car can be greatly improved by using the magnesium alloy hub due to the inherent vibration reduction and noise reduction capability of the magnesium alloy.
The magnesium alloy has the advantages of small specific gravity (about 23 percent of steel and 64 percent of aluminum), high specific strength and specific stiffness, good cutting processing and die-casting process performance and the like as the current lightest structural material, and the magnesium alloy car hub applied as the product has the advantages of good dynamic performance, vibration and noise reduction, vehicle driving comfort improvement, energy conservation, consumption reduction, low emission, low cost, recyclability and the like.
China is one of the largest car producing countries and consuming countries in the world, and according to expert analysis and data measurement, the car market in China is in a mature development stage, so that about 1 hundred million car hubs are required to be used for updating the car loading, export and accessory markets every year. However, most of car hubs are aluminum alloy and steel products, so that the car hubs are poor in strength and heavy in weight, and the development of cars to be light and energy-saving is influenced all the time.
Since the beginning of the 90 s of the 20 th century, light metal materials represented by magnesium alloys have been rapidly developed and have been continuously increased at a rate of 20% per year, and magnesium alloys are classified into cast magnesium alloys and wrought magnesium alloys. The magnesium alloy is mainly divided into Mg-AT-Zn-Zr system, Mg-AT-Mn system, Mg-AT-Si-Mn system, Mg-AT-RE system, Mg-Zn-Zr system and Mg-Zn-RE system according to different alloy components. Magnesium alloy parts are widely used in the automotive field. Every 100kg of automobile weight is reduced, oil consumption can be reduced by 0.6 liter per hundred kilometers, and automobile manufacturers try to reduce the dead weight of the automobile in order to save energy and improve efficiency.
Meanwhile, the magnesium alloy also has a series of advantages of high specific strength, specific elastic modulus, good rigidity, vibration damping property, machinability, anti-electromagnetic interference shielding property and the like, and is easy to be reutilized: the magnesium alloy wheel hub does not corrode or alloy with iron or steel, has prolonged service life, and is a global subject of automobile manufacturing industry. The automobile wheel hub not only aims at reducing the weight of the automobile, but also continuously improves the cost performance of the automobile, and has good application prospect in the automobile industry. The prediction shows that the aluminizing rate of the car hub in China reaches or approaches the level of 50% in developed countries in the next 10 years. Along with the reduction of the cost of raw materials, the improvement of the forming technology and the improvement of the anticorrosion process, the magnesium alloy wheel hub also plays an increasingly important role in the process of automobile light weight.
The hub of the car is the main bearing and moving part of the car. The magnesium alloy car hub can be used for various cars. The magnesium alloy car hub has the characteristics of good dynamic characteristics, energy conservation, vibration and noise reduction effect and the like, and is more and more widely applied. The magnesium alloy car hub has excellent performance and is a substitute product of the aluminium alloy car hub. The magnesium alloy is taken as the lightest structural material at present, is widely applied to industries and departments such as automobiles, motorcycles, aviation, aerospace, household appliances, communication, medical treatment, outdoor leisure articles and the like, and has huge potential application market. The magnesium alloy car hub can reduce material consumption, vehicle weight and fuel consumption, reduce vibration and noise of the vehicle, improve the dynamic characteristics of vehicle acceleration and deceleration, greatly improve the comfort and safety of vehicle driving, and has great significance for reducing the weight and pollution of the whole car and improving the operation performance. Therefore, the magnesium alloy car hub produced has wide market prospect.
Through the above analysis, the problems and defects of the prior art are as follows: the existing car hub has large weight, vibration and noise and does not have good dynamic characteristics.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method for manufacturing a magnesium alloy car hub.
The invention is realized in this way, a method for manufacturing a magnesium alloy car hub, which comprises the following steps:
firstly, carrying out experimental design simulation modeling, preparing corresponding raw materials according to a model, smelting magnesium alloy melt by using a reverberatory furnace, and controlling a resistance furnace to preserve heat;
step two, preparing a forming machine and a die, preparing the forming machine, carrying out no-load action, and preheating the die;
step three, closing the die, and controlling a magnesium alloy quantitative pouring system to pour; performing extrusion forming through a magnesium alloy hub die, and solidifying and cooling;
step four, after solidification and cooling, demolding, removing a pouring system and flash burrs, and detecting the processing return of the returned furnace burden; carrying out heat treatment through X-ray real-time image detection;
fifthly, performing sand blasting treatment on the surface of the casting, performing numerical control machining, and performing decontamination and cleaning; vacuum ion plating (chromium), detecting, cleaning, drying and packaging;
in the first step, the specific process of experimental design simulation modeling is as follows:
the strength and toughness of the magnesium alloy are improved, and mechanical simulation and hub structure design are carried out;
computer aided process design and simulation, and magnesium alloy car hub forming process test;
a machining and heat treatment process test, a magnesium alloy car hub surface treatment technology;
testing the performance of the magnesium alloy car hub, performing a bench test and driving on a road;
in the fifth step, the decontamination cleaning method comprises the following steps:
the method is characterized in that the surface of the magnesium alloy is cleaned to facilitate subsequent treatment by removing pollutants such as oxides, lubricants, grease and the like easily mixed on the surface of the magnesium alloy, and the magnesium alloy is mainly cleaned by two methods: mechanical cleaning, namely, achieving the required surface roughness in different modes of grinding, rough polishing, dry and wet abrasion jet and the like;
chemical cleaning, solvent cleaning, alkaline cleaning, acid cleaning, and different surface states are caused.
The passivation treatment is that a non-electrolytic chemical reaction between the metal surface and the solution is utilized to generate a thin film on the surface of inorganic salt, the corrosion resistance is improved, and the passivation film is used as a substrate for coating to increase the adhesive force of the coating;
anodizing to generate an anodic oxide film and improve the corrosion resistance; the texture of metallic luster is generated, and the oxide film is used as a subsequent coating substrate to increase the adhesive force of coating;
the method comprises the following steps of (1) coating pretreatment, namely changing the surface color and appearance of a magnesium alloy material to achieve the required functionality and decoration, and performing priming pretreatment for a plurality of times before coating;
the metal coating further prevents corrosion and increases the mechanical property and hardness of the surface in a vacuum state, so that the aim of finally selecting the light magnesium alloy under special environmental conditions is fulfilled;
in the fourth step, after the real-time image detection of the X-ray, the process of denoising the image comprises the following steps:
selecting a reference block in an image containing noise, and searching in a region around the reference block; finding a plurality of blocks with the minimum difference degree, establishing the found blocks into a 3-dimensional matrix,
the model for finding similar blocks is:
G(P)＝{Q：d(P，Q)≤τstep1}；
wherein d (P, Q) represents the Euclidean distance between two blocks;
the specific process of collaborative filtering is as follows:
in this formula, two-dimensional transformation and one-dimensional transformation use one T3DhardTo indicate, γ is a threshold operation;
each two-dimensional block is used for estimating a denoised image, the blocks are respectively fused to the original positions in the step, the gray value of each pixel is weighted and averaged through the value of the block at each corresponding position, and the weight depends on the number of 0 s and the noise intensity;
the final estimation model is:
in the above formula, the two-dimensional transformation and the one-dimensional transformation use one T3DweinIs shown by WpIs the wiener filter coefficient;
where σ is the standard deviation of the noise, representing the strength of the noise.
Further, the improvement of the toughness of the magnesium alloy comprises the following steps: optimizing alloy components, performing multi-component microalloying, performing fine grain strengthening and performing heat treatment strengthening;
the mechanical simulation and the hub structural design comprise: finite element stress analysis and hub geometric design;
the computer aided process design and simulation comprises the following steps: designing a mould and an auxiliary process, simulating filling and simulating solidification;
further, the magnesium alloy car hub forming process test comprises the following steps: a gas protection process, smelting and casting equipment and casting process parameters;
the magnesium alloy car hub surface treatment technology comprises the following steps: and (5) vacuum ion plating.
Further, the performance test of the magnesium alloy car hub comprises the following steps: bending fatigue, warp fatigue, impact test.
Further, in the first step, the raw materials include: magnesium alloy ingot, alloy elements and solvent.
Further, in the fourth step, after demolding, the mold is cleaned; spraying a cooling release agent, and carrying out die assembly; and after die assembly, controlling the magnesium alloy quantitative pouring system.
Further, in the fifth step, vacuum ion plating is performed by using a vacuum ion plating device.
Further, in the fifth step, the numerical control machining includes: and (5) turning and milling.
Furthermore, in the fifth step, in the production process from the sand blasting treatment to the detection of the casting surface, sampling inspection and destructive experiments are carried out.
Further, in the fifth step, the specific packaging process comprises:
during packaging, a balance testing machine, an air tightness testing machine testing device, a cleaning and hot air drying machine and a packaging workbench are arranged, and an internal transmission device is arranged in a workshop, so that the productivity is improved, and the labor intensity is reduced.
By combining all the technical schemes, the invention has the advantages and positive effects that: the magnesium alloy car hub has good dynamic characteristics, saves energy and reduces vibration and noise. Therefore, the magnesium alloy has become the most remarkable green and environment-friendly engineering material in the world, and national technical policy support enterprises develop and produce magnesium alloy and application products and realize industrialization so as to improve the application level of magnesium alloy in China, thereby providing opportunities for the production of magnesium alloy car hubs. The industrialization of the product of the invention has great technical level and large scale of industrialization, and has important influence on the production of the car hub in China.
Drawings
FIG. 1 is a flow chart of a method for manufacturing a magnesium alloy car hub according to an embodiment of the invention.
Figure 2 is a technical production route diagram provided by an embodiment of the present invention.
FIG. 3 is a main process flow diagram provided by an embodiment of the present invention.
Fig. 4 is a flowchart of an experimental design simulation modeling method provided in the embodiment of the present invention.
Fig. 5 is a flow chart of a packaging method provided by an embodiment of the invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Aiming at the problems in the prior art, the invention provides a method for manufacturing a magnesium alloy car hub, and the invention is described in detail below with reference to the accompanying drawings.
The magnesium alloy car hub manufacturing method provided by the invention can be implemented by other steps by persons skilled in the art, and the magnesium alloy car hub manufacturing method provided by the invention in fig. 1 is only one specific embodiment.
As shown in fig. 1, a method for manufacturing a magnesium alloy car hub provided by an embodiment of the present invention includes:
s101: carrying out experimental design simulation modeling, preparing corresponding raw materials according to a model, smelting magnesium alloy melt by using a reverberatory furnace, and controlling a resistance furnace to preserve heat;
s102: preparing a forming machine and a die, preparing the forming machine, carrying out no-load action, and preheating the die;
s103: carrying out die assembly, and controlling a magnesium alloy quantitative pouring system to pour; performing extrusion forming through a magnesium alloy hub die, and solidifying and cooling;
s104: after solidification and cooling, demolding, removing a casting system and flash burrs, and detecting the return of the returned material; carrying out heat treatment through X-ray real-time image detection;
s105: sand blasting treatment of the surface of the casting, numerical control machining (turning and milling), and decontamination cleaning; vacuum ion plating (chromium), detecting, cleaning, drying and packaging.
In S101 provided by the embodiment of the present invention, a specific process of experimental design simulation modeling is as follows:
s201: the strength and toughness of the magnesium alloy are improved, and mechanical simulation and hub structure design are carried out;
s202: computer aided process design and simulation, and magnesium alloy car hub forming process test;
s203: a machining and heat treatment process test, a magnesium alloy car hub surface treatment technology;
s204: the performance test of the magnesium alloy car hub, the bench test and the road driving.
The improvement on the strength and toughness of the magnesium alloy comprises the following steps: optimizing alloy components, performing multi-component microalloying, performing fine grain strengthening and performing heat treatment strengthening;
the mechanical simulation and the hub structural design comprise: finite element stress analysis and hub geometric design;
the computer aided process design and simulation comprises the following steps: designing a mould and an auxiliary process, simulating filling and simulating solidification;
the magnesium alloy car hub forming process test comprises the following steps: gas protection process, smelting and casting equipment and casting process parameters;
the magnesium alloy car hub surface treatment technology comprises the following steps: vacuum ion plating;
the performance test of the magnesium alloy car hub comprises the following steps: bending fatigue, warp fatigue, impact test.
In S101 provided by the embodiment of the present invention, the raw materials include: magnesium alloy ingot, alloy elements and solvent.
In S104 provided by the embodiment of the present invention, after demolding, the mold is cleaned; spraying a cooling release agent, and carrying out die assembly; and after die assembly, controlling the magnesium alloy quantitative pouring system.
In S104 provided by the embodiment of the present invention, after the real-time X-ray image detection, the image denoising process includes:
selecting a reference block in an image containing noise, and searching in a region around the reference block; finding a plurality of blocks with the minimum difference degree, establishing the found blocks into a 3-dimensional matrix,
the model for finding similar blocks is:
G(P)＝{Q：d(P，Q)≤τstep1}；
wherein d (P, Q) represents the Euclidean distance between two blocks;
the specific process of collaborative filtering is as follows:
in this formula, two-dimensional transformation and one-dimensional transformation use one T3DhardTo indicate, γ is a threshold operation;
each two-dimensional block is used for estimating a denoised image, the blocks are respectively fused to the original positions in the step, the gray value of each pixel is weighted and averaged through the value of the block at each corresponding position, and the weight depends on the number of 0 s and the noise intensity;
the final estimation model is:
in the above formula, the two-dimensional transformation and the one-dimensional transformation use one T3DweinIs shown by WpIs the wiener filter coefficient;
where σ is the standard deviation of the noise, representing the strength of the noise.
In S105 provided in this embodiment of the present invention, vacuum ion plating (cr) is performed using a vacuum ion plating apparatus.
In S105 provided by the embodiment of the present invention, the numerical control processing includes: and (5) turning and milling.
In step S105 provided in the embodiment of the present invention, a sampling test and a destructive test are performed during a production process from the sand blasting of the casting surface to the inspection.
In S105 provided by the embodiment of the present invention, the decontamination cleaning method includes:
the method is characterized in that the surface of the magnesium alloy is cleaned to facilitate subsequent treatment by removing pollutants such as oxides, lubricants, grease and the like easily mixed on the surface of the magnesium alloy, and the magnesium alloy is mainly cleaned by two methods: mechanical cleaning, namely, achieving the required surface roughness in different modes of grinding, rough polishing, dry and wet abrasion jet and the like;
chemical cleaning, solvent cleaning, alkaline cleaning, acid cleaning, and different surface states are caused.
The passivation treatment is that a non-electrolytic chemical reaction between the metal surface and the solution is utilized to generate a thin film on the surface of inorganic salt, the corrosion resistance is improved, and the passivation film is used as a substrate for coating to increase the adhesive force of the coating;
anodizing to generate an anodic oxide film and improve the corrosion resistance; the texture of metallic luster is generated, and the oxide film is used as a subsequent coating substrate to increase the adhesive force of coating.
The pretreatment of coating, which changes the surface color and appearance of the magnesium alloy material to achieve the required functionality and decoration, and the pretreatment of priming for several times before coating.
And in a vacuum state, the metal coating further prevents corrosion and increases the mechanical property and hardness of the surface, so that the aim of finally selecting the light magnesium alloy under special environmental conditions is fulfilled.
In S105 provided by the embodiment of the present invention, the specific packaging process is as follows:
s301: during packaging, a balance testing machine, an air tightness testing machine testing device, a cleaning and hot air drying machine and a packaging workbench are configured;
s302: the workshop is provided with internal transmission equipment, so that the productivity is improved, and the labor intensity is reduced.
The technical solution of the present invention is further described with reference to the following specific examples.
The invention is based on the principle of advanced technology, reliable production, high quality, low consumption, economy and practicality, and on the basis of fully utilizing the prior art of enterprises, key equipment and detecting instruments which are necessary are newly added aiming at the industrialized production of the invention according to market demands, so as to form a complete, systematic and advanced production line and achieve the production capacity required by the production outline of the invention. Strive for obtaining the maximum economic benefit with the minimum investment.
1 technical scheme
The technical scheme is based on the principle of advanced applicability, safety, reliability, economy and reasonability, and on the technical basis of the investigation on the production of the hub of the magnesium alloy car at home and abroad, the technical scheme is determined to be as follows through comparison of multiple schemes: the capability of producing the magnesium alloy car wheel hub is built by utilizing the extrusion casting magnesium alloy wheel hub production application technology and research and development facilities, and the aim of producing 40 ten thousand sets of magnesium alloy car wheel hubs every year is achieved.
The technical scheme is characterized in that a complete and systematic advanced magnesium alloy car hub die-casting production line, a thermal surface treatment production line, a machining production line, a vacuum ion plating production line and a cleaning and packaging line are built, and a complete product quality detection system, a performance test system, an after-sale service system and the like are built.
The method is implemented, the fixed asset investment is mainly used for purchasing key production equipment such as smelting, die casting, heat meter, machining, vacuum ion plating and the like, performance test equipment, quality detection equipment and productivity facilities, and the mobile capital is all used for production operation of the method.
2 production scheme (including raw material route)
3 production workshop and technical scheme
a. Die casting workshop
The die-casting workshop is mainly used for carrying out smelting, refining, die-casting and cleaning on hubs of 40 ten thousand sets of magnesium alloy cars produced annually, and the production capacity of guaranteeing the quality and the quantity and meeting the production compendium requirements is guaranteed.
According to the technological characteristics of the magnesium alloy car hub, a die-casting workshop improves the strength and toughness of the magnesium alloy by adding different alloy elements and rare earth elements on the basis of the existing AZ91D and AM60 alloys, and improves the plasticity of the magnesium alloy by adding high-grain inoculation elements to refine the alloy grains, so that the qualified magnesium alloy is smelted and used for die-casting a magnesium alloy car hub blank.
The casting of the magnesium alloy has holes and looseness, and the holes and the looseness cause the mechanical property of the magnesium alloy to be poor, so that the casting is not suitable for being directly used as a bearing part. Therefore, the scientific and reasonable die-casting equipment and the extrusion casting molding process technology are key technologies for eliminating holes and looseness of the magnesium alloy to the maximum extent and obtaining high-strength and high-toughness magnesium alloy castings; therefore, the invention designs and selects a protective smelting quantitative automatic casting system which is independently developed by enterprises, and the system comprises equipment such as smelting, refining, a holding furnace, an extruder (pressure casting), a degasser, a die and the like. The physical property, mechanical property and microstructure of the magnesium alloy are improved by advanced equipment and processing technology, and the quality and yield of products are ensured.
b. Workshop in pretreatment
The heat meter workshop undertakes the heat treatment and the micro fox oxidation treatment of 40 ten thousand sets of magnesium alloy car hubs, carries out online flaw detection on the treated hubs, and separates damaged hubs in time. Further improves product performance through heat surface treatment. At this time, key production equipment such as a tunnel type heat treatment furnace (gas protection annealing furnace), a double-track shot blasting machine, a gate cap opening cutting machine, an X-ray image real-time flaw detector and the like are newly added to ensure the product quality and the yield.
c. Machining workshop
The machining workshop mainly undertakes the machining of the wheel hub. According to the shape processing of the car hub and the maintenance characteristics of production molds of enterprises and the like, equipment such as a numerical control hub lathe, a numerical control punching tapping machine and the like are mainly configured to form a complete, systematic and advanced machining production line so as to improve the processing quality of the magnesium alloy car hub, improve the production efficiency, ensure the product quality and achieve the production capacity required by a production outline.
d. Coating workshop
Magnesium is active in chemical property, and oxidation and corrosion of magnesium alloy products are easy to occur in the using process and are one of key factors influencing industrial application of the magnesium alloy products. The coating workshop undertakes surface treatment and protection of 40 ten thousand sets of magnesium alloy car hubs. The product performance is further improved through thermal surface treatment, and the appearance quality is improved through vacuum ion plating (aluminum). And key production equipment such as a vacuum ion plating production line and the like is configured to ensure the product quality and the yield.
Because the magnesium alloy has low melting point, is extremely easy to burn and has extremely active performance, the surface of the magnesium alloy is often provided with a layer of oxide, the magnesium has low chemical stability, the electrode potential is negative (-2.34V), the corrosion resistance is poor, in addition, the wear resistance, the hardness and the high temperature resistance of the magnesium alloy are also poor, and the wide application of the magnesium alloy material is limited to a certain extent, so the surface treatment process of the magnesium alloy has great difficulty, the magnesium alloy material is usually processed by die casting, the surface treatment is carried out on a die casting piece, the difference of different products and application environments thereof is caused, and the surface treatment processes and methods of parts of different parts of the same product are different. The process method generally adopted is as follows.
(1) Surface precleaning (pretreatment): the method is used for removing pollutants such as oxides, lubricants, grease and the like easily mixed on the surface of the magnesium alloy, and aims to clean the surface of the magnesium alloy for subsequent treatment, and mainly comprises the following two methods: mechanical cleaning, namely, achieving the required surface roughness in different modes of grinding, rough polishing, dry and wet abrasion jet and the like; ② chemical cleaning, solvent cleaning, alkali cleaning and acid cleaning to form different surface states.
(2) Passivating: the passivation treatment is to use the non-electrolytic chemical reaction between the metal surface and the solution to generate a film on the surface of the insoluble inorganic salt, which not only can improve the corrosion resistance, but also can use the passivation film as the substrate of the coating to increase the adhesion force of the coating.
(3) Anodizing: an anodic oxide film is generated, and the corrosion resistance is improved; the coating has the advantages of generating metallic luster texture, having beautiful decoration effect, and increasing the adhesive force of coating by using the oxide film as the subsequent coating substrate.
(4) Film coating pretreatment: the surface color and appearance of the magnesium alloy material are changed to achieve the required functional and decorative purposes, and generally, when the surface adhesion is considered to be improved, a plurality of pre-treatments such as zinc replacement, copper replacement and the like are performed before film coating.
(5) Metal coating: under the vacuum state, the metal coating can further resist corrosion and increase the mechanical property and hardness of the surface, thereby achieving the purpose of finally selecting the light magnesium alloy under special environmental conditions.
e. Packaging workshop
The magnesium alloy car hub is a part, is processed into a finished product through the working procedures of casting, machining, vacuum ion plating and the like, is subjected to delivery test in the workshop, and is packaged after being cleaned and dried. And (4) assembling the whole automobile hub by an automobile manufacturer after the hub leaves the factory. Therefore, the quality of the hub parts must be guaranteed. Therefore, the invention is provided with a balance testing machine, an air tightness testing machine and other testing devices, a cleaning and hot air drying machine, a packaging workbench and the like. The workshop is provided with internal transmission equipment so as to improve the productivity and reduce the labor intensity.
In the description of the present invention, "a plurality" means two or more unless otherwise specified; the terms "upper", "lower", "left", "right", "inner", "outer", "front", "rear", "head", "tail", and the like, indicate orientations or positional relationships that are based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing and simplifying the description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
It should be noted that the embodiments of the present invention can be realized by hardware, software, or a combination of software and hardware. The hardware portion may be implemented using dedicated logic; the software portions may be stored in a memory and executed by a suitable instruction execution system, such as a microprocessor or specially designed hardware. Those skilled in the art will appreciate that the apparatus and methods described above may be implemented using computer executable instructions and/or embodied in processor control code, such code provided on a carrier medium such as a diskette, CD-or DVD-ROM, a programmable memory such as read-only memory (firmware), or a data carrier such as an optical or electronic signal carrier, for example. The apparatus and its modules of the present invention may be implemented by hardware circuits such as very large scale integrated circuits or gate arrays, semiconductors such as logic chips, transistors, or programmable hardware devices such as field programmable gate arrays, programmable logic devices, etc., or by software executed by various types of processors, or by a combination of hardware circuits and software, e.g., firmware.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any modification, equivalent replacement, and improvement made by those skilled in the art within the technical scope of the present invention disclosed in the present invention should be covered within the scope of the present invention.
Claims (10)
1. The manufacturing method of the magnesium alloy car hub is characterized by comprising the following steps:
firstly, carrying out experimental design simulation modeling, preparing corresponding raw materials according to a model, smelting magnesium alloy melt by using a reverberatory furnace, and controlling a resistance furnace to keep warm;
step two, preparing a forming machine and a die, wherein the forming machine is prepared to carry out no-load action and preheat the die;
step three, closing the die, and controlling a magnesium alloy quantitative pouring system to pour; performing extrusion forming through a magnesium alloy hub die, and solidifying and cooling;
step four, after solidification and cooling, demolding, removing a pouring system and flash burrs, and detecting the return of the returned material; carrying out heat treatment through X-ray real-time image detection;
fifthly, performing sand blasting treatment on the surface of the casting, performing numerical control machining, and performing decontamination and cleaning; vacuum ion plating (chromium), detecting, cleaning, drying and packaging;
in the first step, the specific process of experimental design simulation modeling is as follows:
the strength and toughness of the magnesium alloy are improved, and mechanical simulation and hub structure design are carried out;
computer aided process design and simulation, and magnesium alloy car hub forming process test;
a machining and heat treatment process test, a magnesium alloy car hub surface treatment technology;
testing the performance of the magnesium alloy car hub, performing a bench test and driving on a road;
in the fifth step, the decontamination cleaning method comprises the following steps:
the method is characterized in that the surface of the magnesium alloy is cleaned to facilitate subsequent treatment by removing pollutants such as oxides, lubricants, grease and the like easily mixed on the surface of the magnesium alloy, and the magnesium alloy is mainly cleaned by two methods: mechanical cleaning, namely, achieving the required surface roughness in different modes of grinding, rough polishing, dry and wet abrasion jet and the like;
chemical cleaning, solvent cleaning, alkaline cleaning, acid cleaning, and different surface states are caused.
The passivation treatment is that the surface film of inorganic salt is formed by utilizing the non-electrolytic chemical reaction between the metal surface and the solution to generate insolubility, and the corrosion resistance is improved, and the passivation film is used as the substrate of coating to increase the adhesive force of coating;
anodizing to generate an anodic oxide film and improve the corrosion resistance; the texture of metallic luster is generated, and the oxide film is used as a subsequent coating substrate to increase the adhesive force of coating;
the method comprises the following steps of (1) coating pretreatment, namely changing the surface color and appearance of a magnesium alloy material to achieve the required functionality and decoration, and performing a plurality of priming pretreatments before coating;
the metal coating is further subjected to corrosion prevention and surface mechanical property and hardness increase in a vacuum state, so that the aim of finally selecting the light magnesium alloy under a special environmental condition is achieved;
in the fourth step, after the real-time image detection of the X-ray, the process of denoising the image comprises the following steps:
selecting a reference block in an image containing noise, and searching in a region around the reference block; finding a plurality of blocks with the minimum difference degree, establishing the found blocks into a 3-dimensional matrix,
the model for finding similar blocks is:
G(P)＝{Q：d(P，Q)≤τstep1}；
wherein d (P, Q) represents the Euclidean distance between two blocks;
the specific process of collaborative filtering is as follows:
in this formula, two-dimensional transformation and one-dimensional transformation use one T3DhardTo indicate, γ is a threshold operation;
each two-dimensional block is used for estimating a denoised image, the blocks are respectively fused to the original positions in the step, the gray value of each pixel is weighted and averaged through the value of the block at each corresponding position, and the weight depends on the number of 0 pixels and the noise intensity;
the final estimation model is:
in the above formula, the two-dimensional transformation and the one-dimensional transformation use one T3DweinIs shown by wpIs the wiener filter coefficient;
where σ is the standard deviation of the noise, representing the strength of the noise.
2. The method for manufacturing the magnesium alloy car hub according to claim 1, wherein the improvement of the toughness of the magnesium alloy comprises the following steps: optimizing alloy components, performing multi-component microalloying, performing fine grain strengthening and performing heat treatment strengthening;
the mechanical simulation and the hub structural design comprise: finite element stress analysis and hub geometric design;
the computer aided process design and simulation comprises the following steps: designing a mould and an auxiliary process, simulating filling and simulating solidification.
3. The manufacturing method of the magnesium alloy car hub as claimed in claim 1, wherein the magnesium alloy car hub forming process test comprises: a gas protection process, smelting and casting equipment and casting process parameters;
the magnesium alloy car hub surface treatment technology comprises the following steps: and (5) vacuum ion plating.
4. The method for manufacturing the magnesium alloy car hub according to claim 1, wherein the performance test of the magnesium alloy car hub comprises the following steps: bending fatigue, warp fatigue, impact test.
5. The method for manufacturing the magnesium alloy car hub as claimed in claim 1, wherein in the first step, the raw materials comprise: magnesium alloy ingot, alloy elements and solvent.
6. The method for manufacturing the magnesium alloy car hub according to claim 1, wherein in the fourth step, after demolding, the mold is cleaned; spraying a cooling release agent, and carrying out die assembly; and after die assembly, controlling the magnesium alloy quantitative pouring system.
7. The method for manufacturing the magnesium alloy car hub according to claim 1, wherein in the fifth step, vacuum ion plating is performed by using a vacuum ion plating device.
8. The manufacturing method of the magnesium alloy car hub as claimed in claim 1, wherein in the fifth step, the numerical control machining comprises the following steps: and (5) turning and milling.
9. The method for manufacturing the magnesium alloy car hub according to claim 1, wherein in the fifth step, sampling inspection and destructive experiment are performed in the production process from the sand blasting treatment to the detection of the surface of the casting.
10. The manufacturing method of the magnesium alloy car hub as claimed in claim 1, wherein in the fifth step, the specific packaging process comprises the following steps:
during packaging, a balance testing machine, an air tightness testing machine testing device, a cleaning and hot air drying machine and a packaging workbench are arranged, and an internal transmission device is arranged in a workshop, so that the productivity is improved, and the labor intensity is reduced.
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| CN1439539A (en) * | 2003-04-03 | 2003-09-03 | 重庆镁业科技股份有限公司 | Magnesium alloy hub manufacture |
| CN108405827A (en) * | 2018-04-08 | 2018-08-17 | 仝仲盛 | The preparation process of automobile magnesium alloy hub |
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| CN1439539A (en) * | 2003-04-03 | 2003-09-03 | 重庆镁业科技股份有限公司 | Magnesium alloy hub manufacture |
| CN108405827A (en) * | 2018-04-08 | 2018-08-17 | 仝仲盛 | The preparation process of automobile magnesium alloy hub |
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