CN113618040A - Gearbox valve plate die-casting die, die-casting method and die maintenance method - Google Patents
Gearbox valve plate die-casting die, die-casting method and die maintenance method Download PDFInfo
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- CN113618040A CN113618040A CN202110727178.6A CN202110727178A CN113618040A CN 113618040 A CN113618040 A CN 113618040A CN 202110727178 A CN202110727178 A CN 202110727178A CN 113618040 A CN113618040 A CN 113618040A
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- 238000004512 die casting Methods 0.000 title claims abstract description 40
- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000012423 maintenance Methods 0.000 title claims abstract description 9
- 238000000605 extraction Methods 0.000 claims abstract description 12
- 239000003818 cinder Substances 0.000 claims abstract description 8
- 230000005484 gravity Effects 0.000 claims abstract description 4
- 238000001816 cooling Methods 0.000 claims description 65
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 43
- 238000007789 sealing Methods 0.000 claims description 26
- 238000004140 cleaning Methods 0.000 claims description 20
- 238000012360 testing method Methods 0.000 claims description 18
- 238000001514 detection method Methods 0.000 claims description 17
- 238000005266 casting Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 15
- 239000000498 cooling water Substances 0.000 claims description 12
- 239000007788 liquid Substances 0.000 claims description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 9
- 239000000956 alloy Substances 0.000 claims description 9
- 229910045601 alloy Inorganic materials 0.000 claims description 9
- 230000005540 biological transmission Effects 0.000 claims description 8
- 239000012535 impurity Substances 0.000 claims description 8
- 238000002844 melting Methods 0.000 claims description 8
- 230000008018 melting Effects 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 239000002893 slag Substances 0.000 claims description 7
- 238000007664 blowing Methods 0.000 claims description 6
- 238000002347 injection Methods 0.000 claims description 6
- 239000007924 injection Substances 0.000 claims description 6
- 238000003723 Smelting Methods 0.000 claims description 5
- 230000007704 transition Effects 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 238000009825 accumulation Methods 0.000 claims description 3
- 238000005452 bending Methods 0.000 claims description 3
- 238000005422 blasting Methods 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 239000003350 kerosene Substances 0.000 claims description 3
- 235000006408 oxalic acid Nutrition 0.000 claims description 3
- 230000036961 partial effect Effects 0.000 claims description 3
- 238000007639 printing Methods 0.000 claims description 3
- 230000001681 protective effect Effects 0.000 claims description 3
- 238000002791 soaking Methods 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 230000003068 static effect Effects 0.000 claims description 3
- 230000000007 visual effect Effects 0.000 claims description 3
- 238000003466 welding Methods 0.000 claims description 3
- 239000004277 Ferrous carbonate Substances 0.000 claims description 2
- 238000005553 drilling Methods 0.000 claims description 2
- 230000000149 penetrating effect Effects 0.000 claims 1
- 238000012797 qualification Methods 0.000 abstract description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 13
- 238000013461 design Methods 0.000 description 4
- 235000014347 soups Nutrition 0.000 description 3
- 239000004411 aluminium Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000006227 byproduct Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 239000013049 sediment Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/2272—Sprue channels
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a gearbox valve plate die-casting die, a die-casting method and a die maintenance method, which are characterized in that: the oil groove of gearbox valve plate is located movable mould one side, with the ingate setting of die cavity intercommunication is under the gearbox valve plate, be provided with cake, sprue, cross gate, the branch cross gate that connects gradually along the negative direction of gravity between movable mould and the cover half, branch cross gate divide into two one-level branch cross gates that parallel, two the outside of one-level branch cross gate all is provided with vacuum drainage way, vacuum drainage way is connected with the hydraulic vacuum valve the afterbody in die cavity filling path is provided with a plurality of cinder ladles and a plurality of air extraction, and is a plurality of air extraction one end intercommunication the cinder ladle, other end intercommunication vacuum valve. The beneficial effects of the invention include: various valve plate products produced by the scheme have the advantages of high qualification rate, good stability, low cost, high efficiency, long service life of the die and low failure rate.
Description
Technical Field
The invention relates to the field of die casting, in particular to a gearbox valve plate die casting die, a die casting method and a die maintenance method.
Background
The die casting is a casting process of smelting a specific alloy ingot into liquid, pouring the alloy liquid into a die cavity, and molding, solidifying and cooling under high speed and high pressure, the process has high efficiency and low cost, parts are close to the final use state, and the die casting process is particularly suitable for various cavity and shell products.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a gearbox valve plate die-casting die which is reasonable in structural design, high in qualification rate of produced products and long in service life.
In order to achieve the purpose, the invention adopts the following technical scheme:
the utility model provides a gearbox valve plate die casting die, includes movable mould and cover half, the die cavity that has the gearbox valve plate between movable mould and the cover half, its characterized in that: the oil groove of gearbox valve plate is located movable mould one side, with the ingate setting of die cavity intercommunication is under the gearbox valve plate, be provided with cake, sprue, cross gate, the branch cross gate that connects gradually along the negative direction of gravity between movable mould and the cover half, branch cross gate divide into two one-level branch cross gates that parallel, two the outside of one-level branch cross gate all is provided with vacuum drainage way, vacuum drainage way is connected with the hydraulic vacuum valve the afterbody in die cavity filling path is provided with a plurality of cinder ladles and a plurality of air extractions, and is a plurality of air extraction one end intercommunication the cinder ladles, other end intercommunication vacuum valve, just the junction of vacuum valve and air extraction is provided with vacuum valve transition buffer board.
Furthermore, the sprue, the runner, the primary branch runner and the vacuum drainage channel are all arranged on the movable mould side, the thickness of the inner sprue is 3mm, the thickness part of 0.5mm is located on the fixed mould side, and the thickness part of 2.5mm is located on the movable mould side.
Furthermore, a sprue bush used for connecting the melting cup is arranged on the fixed die, a sprue spreader is arranged on the inner side of the sprue bush, a material cake forming part, a sprue forming part and a partial cross runner forming part are arranged on the sprue spreader, and a cold material collecting bag forming part is arranged in the opposite direction of the material cake forming part relative to the sprue forming part.
Furthermore, a first insert corresponding to left and right valve core holes of a transmission valve plate is arranged on a fixed mold core of the fixed mold; a second insert corresponding to the forming position of a valve plate of a transmission valve plate is arranged on a mold core of the movable mold; the movable die is provided with a sliding seat and an oil cylinder, the sliding seat is used for driving the sliding seat, the piston of the oil cylinder is connected with the sliding seat, and the sliding seat is provided with a core fixing block for fixing the core of the valve core hole.
Further, a high-pressure spot cooling pipe is arranged in the valve core hole mold core, the outer diameter of the spot cooling pipe is 3mm, and the spot cooling depth is 4mm from the forming end face of the valve core hole mold core.
Further, a first rectangular sealing groove is formed in the edge, connected with the fixed die core, of the fixed die, and a sealing strip is installed in the sealing groove; a second rectangular sealing groove is formed in the contact end face of the core fixing block and the movable mold core of the movable mold, and a sealing strip is arranged in the second rectangular sealing groove; and a sealing ring is arranged on the contact end surface of the valve core hole mold core and the mold core fixing block.
Further, the movable mould core with the die joint of cover half core is unsmooth die joint, the auxiliary block with all connect through boss location between movable mould core, the cover half core, case hole core front end is provided with the sleeve pipe, the sleeve pipe sets up in the auxiliary block.
Further, the fixed die is provided with 11 positions where the hot joint parts of the product forming positions are uniformly arranged
Cooling common points, wherein the depth of a cooling water hole is 25mm away from the surface of the mold core, and each point is controlled by an independent switch; a group of linear molded line cooling is arranged at the position of an upper sprue of the fixed die, a group of Z-shaped line cooling is arranged at the positions of the slag ladle and the air extraction passage, and the depth of a cooling water hole is 50mm away from the surface of the die core; and two groups of L-shaped line cooling are arranged on the movable die corresponding to the pouring gate, and a group of Z-shaped line cooling is arranged on the movable die corresponding to the slag ladle and the air extraction passage.
The invention also aims to provide a pressure casting method for the valve plate of the gearbox, which is characterized by comprising the following steps: comprises the following process steps of the following steps,
s1, smelting, wherein the alloy is smelted according to the following steps: alloy scrap returns are 8: 2, setting the melting temperature of 780-3The K value is less than or equal to 0.1, and the temperature is 660+/-10 ℃ and is qualified aluminum liquid;
s2, die casting, namely, adopting an 800T horizontal cold chamber die casting machine, and preparing the gearbox valve plate die casting die, a vacuum machine and a high-pressure point cooling machine; the die casting process comprises die assembly, quantitative feeding, simultaneous starting of 3 groups of vacuum after the punch head crosses a feeding port at a low speed, closing of the hydraulic vacuum valves 1 and 2 when the punch head reaches a position of 340 +/-20 mm at a low speed, starting of high-speed injection when the punch head reaches 390 +/-20 mm at a low speed, starting of pressurization when the punch head reaches 570 +/-20 mm, automatic closing of the mechanical valve when aluminum liquid reaches the mechanical valve position, finally, die opening until a casting is cooled, taking of the casting, spraying and entering the next cycle; wherein the technological parameters are as follows: the thickness of a material handle is 27 +/-5 mm, the injection delay is 0.5s, the proportion of a release agent is 1.1 +/-0.2%, the low-speed is 0.18 +/-0.05 m/s, the high-speed is 3.8 +/-0.2 m/s, the casting pressure is 85 +/-5 Mpa, the vacuum delay is 0.8-1.2s, the vacuum degree of a tail end mechanical valve is less than or equal to 200mbar, the pollution degree of the tail end mechanical valve is less than or equal to 250mbar, the closing position of a hydraulic vacuum valve at a pouring gate position is 340 +/-20 mm, the high-speed position is 390 +/-20 mm, the pressurization starting position is 570 +/-20 mm, the mold opening time is 10 +/-2 s, the high-pressure point cooling is 1 (delay: 1 +/-0.5 s, the water passage is 15 +/-5 s, the air blowing is 20 +/-5 s), the high-pressure point cooling is 2 (delay: 3 +/-1 s, the water passage is 15 +/-5 s; the air blowing is 20 +/-5 s), and the mold temperature is 230-;
s3, performing internal quality detection on the casting by using a flaw detector, and controlling the primary and the other secondary of the valve core hole of the die casting according to the quality standard of ASTM E505 per 2 pieces/2 h; visual 100% detection is carried out by an appearance operator; size: detecting the position size of the valve core hole and the position size of the valve plate by three coordinates: 1 piece per shift, the valve hole is dissected along the valve core hole vertical direction and is examined whether the valve block has the detection of bending, collapsing: 1 piece/every 3h, positioning hole size: 1 piece per 4h, wall thickness detection: 1 piece/every time of die change;
the invention also aims to provide a maintenance method of the die-casting die for the valve plate of the gearbox, which is characterized by comprising the following steps of: comprises the following steps of (a) carrying out,
s11, cleaning the appearance of the mold, cleaning and repairing parts of each part of the mold, cleaning and repairing the strain part, the thermal junction part and the coating accumulation part of the cavity by using gold-phase paper or oilstone, taking out the push rod, cleaning the push rod by using metallographic abrasive paper, reaming the hole of the push rod by using a reamer to remove impurities, and cleaning the impurities of each slideway by using kerosene;
s12, checking the movable matching part of the die: detecting whether the push plate is deformed or not and whether the push rod hole is damaged or not by using a detection flat plate and a feeler gauge, detecting whether the movable/static mold core profile/slide block/forming position is deformed or not by using a knife edge ruler, an angle ruler and a detection measuring tool, and detecting whether the fit clearance of the guide pillar and the guide sleeve meets H8/e7 or not by using a caliper and an inner diameter dial indicator;
s13, cooling water overhaul:
a. line cooling: disassembling all the line cold plugs, cleaning the water holes by using drill bits smaller than the apertures, and inserting ejector pins smaller than the apertures and longer than the hole depths into the water holes to test whether scale is blocked in the line cold plugs;
b. ordinary point cooling: cleaning the water hole by using a drill bit with the diameter smaller than the hole diameter, drilling until the bottom die core of the hole is drilled, and inserting an ejector pin with the diameter smaller than the hole diameter and longer than the hole depth to test whether scale blockage exists in the cold water hole of the common point;
c. high-pressure point cooling: disassembling the high-pressure point cold insert needle, soaking the high-pressure point cold insert needle by oxalic acid, and inserting a welding wire with the diameter smaller than the aperture and the depth longer than the aperture to test whether scale is blocked in the high-pressure point cold water aperture;
checking whether the water flow meets the process requirements after checking no blockage, testing water by using circulating water for common point cooling and line cooling, wherein the water pressure is 0.4 MPa; testing water by using a water testing machine in a high-pressure point cooling mode, wherein the water pressure is 1 MPa;
s14, maintenance and replacement of the wearing parts,
a. the left valve core hole core and the right valve core hole core are replaced every 5000 die times;
b. the fixed die insert block is replaced according to the number of dies per 10000;
c. the holes of the left and right valve cores of the movable die are quickly embedded and replaced every 20000 die times;
d. the valve core of the mold vacuumizing mechanical valve is replaced every 30000 mold times;
e. the mold oil cylinder sealing ring, the oil cylinder screw rod and the oil cylinder connector are replaced every 30000 and 40000 molds;
f. the mold core sealing strip is replaced every 5000 times;
s15, assembling the dies, wherein the slide block is matched to meet H7/d8, the push rod hole is matched with the push rod to meet H7/e8, each fastening connection part is firm, the assembly is complete, the die spotting machine and the red lead are adopted to detect the matched condition, the thickness of the red lead coated is less than 0.12, more than 90% of the contact area of the red lead printing surface is qualified, and the positions of all cooling water are consistent with the serial numbers;
s16, removing stress of the die, wherein the stress removing process is to remove stress in a vacuum furnace or a protective atmosphere furnace at 530 ℃ for 2.5h, and then slowly cool the die in the furnace to room temperature; the surface shot blasting treatment can be carried out when the service life of the die reaches 30000-40000; reference to the standard of destressing: for the first time: the production reaches 5k times; and (3) for the second time: producing for 1.5 w-2 w mold times; and thirdly: the production is carried out for 3.5 w-4 w times.
The beneficial effects of the invention include: all kinds of valve plate products of this scheme production are high in qualification rate, and stability is good, and is with low costs, efficient, and the mould is longe-lived, and the fault rate is low, the effectual die-casting of having solved this kind of product makes the bottleneck.
Drawings
FIG. 1 is a top view of the mold casting system of the present invention;
FIG. 2 is a cross-sectional view of the mold casting system of the present invention;
FIG. 3 is a schematic view of the structure of the tap of the present invention;
FIG. 4 is a schematic view of a stationary mold core structure of the present invention;
FIG. 5 is a schematic view of the structure of the movable mold core of the present invention;
FIG. 6 is a schematic view of the core pulling configuration of the valve core hole of the present invention;
FIG. 7 is a schematic view of the stationary mold core cooling configuration of the present invention;
FIG. 8 is a schematic view of the cooling structure of the moving core of the present invention;
FIG. 9 is a schematic side view of the moving mold side portion of the present invention;
FIG. 10 is a schematic view of the stationary mold side portion structure of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the following embodiments and the accompanying drawings.
A die-casting die for a gearbox valve plate shown in figures 1-10 comprises a pouring scheme, an inlaying scheme, a cooling scheme and a structural scheme.
Pouring scheme, designing punch diameter
The length of the melting cup is 660mm, the filling rate is 36 percent, and the area of the inner sprue is 320mm2Gate ratio 12, S sprue: s ingate 3.58, S runner: 2.57, the thickness of the inner gate is 3mm, the inner gates are three and are respectively corresponding to three areas for filling products, the sectional area of the inner gate is proportional to the size of the product area, and the sectional area of the inner gate is 1: sectional area of ingate 2: the cross-sectional area of the inner gate 3 is 3.2: 1: 1.
the mould scheme is that the valve plate oil groove side is movable mould 1, and the oil groove reverse side is cover half 2, and left and right valve core hole is for controlling the structure of loosing core, and the ingate setting is in the middle base plate position under the valve plate minor face, and the material cake 4 that has cold burden collection sediment function is connected the sprue 5 along the negative direction of gravity in proper order, and the cross gate 6, branch cross gate 7, wherein branch cross gate 7 includes two one-level cross gates 8 again, and wherein 8 subdividings in the one-level cross gate in right side are two second grade cross gates. Two groups of vacuum drainage channels 9 are arranged at the outer side positions of the two primary cross runners 8, two groups of hydraulic vacuum valves 10 are arranged at the left side and the right side of the cross runners, and the melting cups and the runners are vacuumized. The inner pouring gate, a product, a slag ladle 11, an air exhaust passage 13, a vacuum valve transition buffer plate 14 and a vacuum valve 13; the area of the sprue 5, the sprue 6 and the branch sprue 7 is reduced in sequence, the sprue is opposite to a central base plate of a product, and the material cake 4, the sprue 5, the sprue 6 and the branch sprue 7 are arranged on the side of the movable mould. The inner gate is designed into a lap joint structure consisting of two parts, wherein one part of the inner gate is 0.5mm thick and is arranged on the movable die 1, and the other part of the inner gate is 2.5mm thick and is arranged on the fixed die 2. All via holes on the side of the gate are plugged, so that aluminum liquid can be smoothly filled conveniently, and the filling quality of all oil grooves is ensured.
A plurality of cinder ladles 11 and the air exhaust passage 12 of product afterbody design, cinder ladles 11 and air exhaust passage 12 through different positions are through synchronous design principle for aluminium liquid can arrive vacuum valve transition buffer board 14 positions simultaneously, and vacuum valve transition buffer board 14 is 3 tooth structures, and its cross-section thickness is 1.5mm, and the afterbody directly passes through the position to vacuum valve 13, and the effectual aluminium liquid that slows down directly erodees vacuum valve 13, has improved vacuum valve 13's life.
2-3, the mold spreader cone is designed with a cold material collecting bag, and a flat groove structure is a cold material collecting bag forming position 154 at 1/3 below the cake 4, and the position collects and stores the cold material poured into the bottom of the melting cup first, thereby greatly reducing the cold material poured into the pressing chamber to enter the product and simultaneously improving the fullness degree of the pressing chamber. The tap cone 15 further comprises a cake forming section 151, a sprue forming section 152, and a partial runner forming section 153.
4-6, in order to maximize the service life of the die, the die adopts a large number of splicing structures; the fixed die 2 is provided with a first insert 202 on the five binding surfaces of the left valve core hole, a first insert 202 on the right valve core hole, and the first insert 202 is fixed by bolts on the back side of the die core. In order to ensure the dimensional accuracy of the valve core hole and the service life of the die, two groups of auxiliary blocks 101, a left valve core hole auxiliary block and a right valve core hole auxiliary block are designed at the left valve core hole position and the right valve core hole position of the movable die 1, and a valve core hole core 102 penetrates through the auxiliary blocks 101. The back side of the valve core hole core 102 is fixed on a valve core hole core fixing block 108, the rear end of the valve core hole core fixing block 108 is connected with the sliding seat 103 and the oil cylinder 104, and all the valve core hole cores 102 are driven by the left and right oil cylinders to perform core pulling and core inserting. The valve plate forming position corresponding to the left valve core hole at the 6 position on the movable die 1 is designed into a second insert 106, the valve plate forming position corresponding to the right valve core hole at the 3 position on the movable die 1 is designed into the second insert 106, all the inserts adopt a mode of bolt fixing at the back side of the die core, and the design clearance between the second insert 106 and the die core 102 of the valve core hole is 0.05 mm.
As shown in fig. 7-8, the mold cooling adopts a scheme of combining line cooling, ordinary point cooling and high-pressure point cooling, and different cooling schemes are arranged at different positions of the mold structure in combination with the product pyrolysis analysis; the hot joint part of the molding position of the fixed die side product is uniformly provided with 11 parts
Cooling common points, wherein the depth of a cooling water hole is 25mm away from the surface of the mold core, and each point is controlled by an independent switch; 1 group of linear molded line cooling is arranged at the position of a gate of the fixed die, 1 group of Z-shaped line cooling is arranged at the position of a vacuum exhaust channel of a far-end slag ladle, and the depth of a cooling water hole is 50 degrees from the surface of a die core; high-pressure point cooling is arranged in the cores of the left valve core hole at the position 6 and the right valve core hole at the position 3 of the movable die, the high-pressure point cooling of the 6 left valve core holes is integrated into high-pressure point cooling 1, the high-pressure point cooling of the 3 right valve core holes is integrated into high-pressure point cooling 2, and the outer diameter of the point cooling pipe is
The point cooling depth is 4mm from the end surface of the water inlet and outlet pipe to the forming surface; two groups of L-shaped lines are arranged at the position of a pouring gate of the movable mould for cooling, and 1 group of Z-shaped lines are arranged at the position of a slag ladle vacuum exhaust passage at the far end of the movable mould for cooling.
In order to ensure the sealing performance and realize high vacuum die casting of the die shown in fig. 6 and 10, the positions of the fixed die core 201, the sliding seat 103 and the die core hole 102 are sealed, a rectangular sealing groove of 7.5 to 7.5 is designed at the connecting position of the outer edge of the fixed die core 201 and the die frame, and the fixed die core 201 and the die frame are installed
The outer side of the joint surface of the inner side surface of the sliding block valve core hole core fixing block 108 and the movable mold core 105 is provided with a rectangular sealing groove of 7.5 x 7.5, and the rectangular sealing groove is provided withClothes (CN)
The position of the valve core hole mold core 102 hanging table on the outer side of the valve core hole mold core fixing block 108 is matched with the mold core hanging table to install the sealing ring, and the sealing performance of mold vacuumizing is effectively guaranteed.
As shown in fig. 9-10, the requirement on the dimensional accuracy of the valve core hole is high, the die is designed in various positioning modes, and a, the movable die core and the fixed die core are subjected to concave-convex parting, so that the die assembly accuracy of the movable die and the fixed die is ensured; b. a plurality of groups of valve core holes are integrated on the same auxiliary block 101, and corresponding precise positioning rectangular bosses and rectangular grooves are designed on the auxiliary block 101 and the mold core; c. the front end of the valve core hole core is guided by the sleeve 110, so that the stability of the core pulling process is ensured; d. 6 support columns are uniformly designed on the back side of the movable mold core, and two support blocks are arranged at the positions of a sprue spreader and a vacuum valve of the movable mold core, so that the strength of the mold under pressure is ensured.
The die casting method comprises the following steps:
1. smelting: alloy smelting is carried out according to the following steps: alloy scrap returns are 8: 2 (reducing impurity content in molten alloy), setting the melting temperature of 780-3The K value is less than or equal to 0.1, and the temperature is 660+/-10 ℃ and is qualified aluminum liquid;
2. the impurities of the product obtained by die casting are prevented, and the pouring process adopts a quantitative furnace and a ceramic diversion trench to realize high-precision and high-purity soup feeding;
3. die casting: selecting an 800T horizontal cold chamber die casting machine, and preparing a vacuum machine and a high-pressure point cooling machine;
the process comprises the following steps: closing the die, quantitatively feeding soup, simultaneously starting 3 groups of vacuum after the punch head crosses a soup feeding port at a low speed, closing the hydraulic vacuum valves 1 and 2 when the punch head reaches the position of 340 +/-20 mm, starting high-speed injection when the punch head reaches 390 +/-20 mm, starting pressurization when the punch head reaches 570 +/-20 mm, automatically closing the mechanical valve when aluminum liquid reaches the mechanical valve, and finally, taking and spraying the aluminum liquid until the casting is cooled and opened, and entering the next cycle;
the technological parameters are as follows: the thickness of a material handle is 27 +/-5 mm, the injection delay is 0.5s, the proportion of a release agent is 1.1 +/-0.2%, the low-speed is 0.18 +/-0.05 m/s, the high-speed is 3.8 +/-0.2 m/s, the casting pressure is 85 +/-5 Mpa, the vacuum delay is 0.8-1.2s, the vacuum degree of a tail end mechanical valve is less than or equal to 200mbar, the pollution degree of the tail end mechanical valve is less than or equal to 250mbar, the closing positions of the hydraulic vacuum valves 1 and 2 at a pouring gate position are 340 +/-20 mm, the high-speed position is 390 +/-20 mm, the pressurization starting position is +/-20 mm, the mold opening time is 10 +/-2 s, the high-pressure point cooling is 1 (delay: 1 +/-0.5 s; water supply: 15 +/-5 s; air blowing: 20 +/-5 s), the high-pressure point cooling is 2 (delay: 3 +/-1 s; water supply: 15 +/-5 s; air blowing: 20 +/-5 s), and the mold temperature is 230 ℃;
4. and (3) process control:
detecting the internal quality of the casting by using a flaw detector, and controlling according to ASTM E505-valve core hole primary and other secondary control steps every 2 pieces/2 h;
visual 100% detection is carried out by an appearance operator;
size: detecting the position size of the valve core hole and the position size of the valve plate by three coordinates: 1 piece per shift, the valve hole is dissected along the valve core hole vertical direction and is examined whether the valve block has the detection of bending, collapsing: 1 piece/every 3h, positioning hole size: 1 piece per 4h, wall thickness detection: 1 piece/every time of die change;
mold maintenance method
Performing mould prevention maintenance every 3000 plus 5000 moulds:
1. cleaning the appearance of the mould, cleaning and repairing parts of each part of the mould, cleaning and repairing a strain part, a hot junction part and a coating accumulation part of the cavity by using gold-phase paper or oilstone, taking out the push rod, cleaning the push rod by using metallographic abrasive paper, reaming out impurities from a hole of the push rod by using a reamer, and cleaning the impurities of each slideway by using kerosene;
2. checking the movable matching part of the die: detecting whether the push plate is deformed or not and whether the push rod hole is damaged or not by using a detection flat plate and a feeler gauge, detecting whether the movable/static mold core profile/slide block/forming position is deformed or not by using a knife edge ruler, an angle ruler and a detection measuring tool, and detecting whether the fit clearance of the guide pillar and the guide sleeve meets H8/e7 or not by using a caliper and an inner diameter dial indicator;
3. and (3) cooling water overhaul:
a. line cooling: and (4) disassembling all the wire cold plugs, cleaning the water holes by using drill bits smaller than the apertures, and inserting ejector pins smaller than the apertures and longer than the hole depths into the drill bits to test whether scale is blocked in the cold water holes of the wires.
b. Ordinary point cooling: the water hole is cleaned by a drill bit with the diameter smaller than the hole diameter, the drill bit drills until the bottom die core of the hole, and an ejector pin with the diameter smaller than the hole diameter and longer than the hole depth is inserted to test whether scale blockage exists in the cold water hole of the common point. .
c. High-pressure point cooling: and (4) disassembling the high-pressure point cold insert needle, soaking the high-pressure point cold insert needle by oxalic acid, and inserting a welding wire with the diameter smaller than the aperture and the depth longer than the aperture to test whether scale is blocked in the high-pressure point cold water hole.
Checking whether the water flow meets the process requirements after checking no blockage, testing water by using circulating water for common point cooling and line cooling, wherein the water pressure is 0.4 MPa; testing water by using a water testing machine in a high-pressure point cooling mode, wherein the water pressure is 1 MPa;
4. maintaining and replacing the core, the insert and the vulnerable part;
a. the left valve core hole core and the right valve core hole core are replaced every 5000 die times;
b. the fixed die insert block is replaced according to the number of dies per 10000;
c. the holes of the left and right valve cores of the movable die are quickly embedded and replaced every 20000 die times;
d. the valve core of the mold vacuumizing mechanical valve is replaced every 30000 mold times;
e. the mold oil cylinder sealing ring, the oil cylinder screw rod and the oil cylinder connector are replaced every 30000 and 40000 molds;
f. the mold core sealing strip is replaced every 5000 times;
5. assembling the dies, wherein the matching of the slide block meets H7/d8, the matching of the push rod hole and the push rod meets H7/e8, each fastening and connecting part is firm, the assembly is complete, the die spotting machine and the red lead are adopted to detect the matching condition of the dies, the thickness of the red lead coating is less than 0.12, more than 90% of the contact area of the red lead printing surface is qualified, and the positions of all cooling water are consistent with the serial number;
6. the stress removal standard is as follows: for the first time: the production reaches 5k times; and (3) for the second time: producing for 1.5 w-2 w mold times; and thirdly: the production is carried out for 3.5 w-4 w times. The stress relief process is to relieve stress in a vacuum furnace or a protective atmosphere furnace at 530 ℃ for 2.5h, and then slowly cool the furnace to room temperature; the surface shot blasting treatment can be carried out when the service life of the die reaches 30000-40000;
the technical solutions provided by the embodiments of the present invention are described in detail above, and the principles and embodiments of the present invention are explained herein by using specific examples, and the descriptions of the embodiments are only used to help understanding the principles of the embodiments of the present invention; meanwhile, for a person skilled in the art, according to the embodiments of the present invention, there may be variations in the specific implementation manners and application ranges, and in summary, the content of the present description should not be construed as a limitation to the present invention.
Claims (10)
1. The utility model provides a gearbox valve plate die casting die, includes movable mould (1) and cover half (2), have die cavity (3) of gearbox valve plate between movable mould (1) and cover half (2), its characterized in that: the oil groove of gearbox valve plate is located movable mould (1) one side, with the ingate setting of die cavity (3) intercommunication is under the gearbox valve plate, be provided with between movable mould (1) and cover half (2) along gravity burden direction connected gradually cake (4), sprue (5), cross gate (6), branch cross gate (7) divide into two one-level branch cross gates (8) that parallel, two the outside of one-level branch cross gate (8) all is provided with vacuum drainage way (9), vacuum drainage way (9) are connected with hydraulic vacuum valve (10) the afterbody in die cavity (3) filling path is provided with a plurality of cinder ladles (11) and a plurality of air extraction way (12), and is a plurality of air extraction way (12) one end intercommunication cinder ladles (11), other end intercommunication vacuum valve (13), just vacuum valve (13) are provided with vacuum valve transition buffer board (14) with the junction of air extraction way (12).
2. The transmission valve plate die-casting mold as claimed in claim 1, wherein: the sprue gate is characterized in that the sprue gate (5), the cross gate (6), the first-level branch cross gate (8) and the vacuum drainage channel (9) are arranged on the movable die side, the thickness of the inner sprue gate is 3mm, the thickness of the inner sprue gate is 0.5mm and the thickness of the inner sprue gate is 2.5mm, and the thickness of the inner sprue gate is located on the fixed die side and the movable die side.
3. The transmission valve plate die-casting mold as claimed in claim 1, wherein: the improved sprue structure is characterized in that a sprue bush (203) used for connecting a melting cup is arranged on the fixed die (2), a sprue spreader (15) is arranged on the inner side of the sprue bush, a material cake forming part (151), a sprue forming part (152) and a partial cross runner forming part (153) are arranged on the sprue spreader (15), and the material cake forming part (151) is provided with a cold material collecting bag forming part (154) in the opposite direction of the sprue forming part (152).
4. The transmission valve plate die-casting mold as claimed in claim 1, wherein: a first insert (202) corresponding to left and right valve core holes of a transmission valve plate is arranged on a fixed mold core (201) of the fixed mold (2); a second insert (106) corresponding to the forming position of a valve plate of a transmission valve plate is arranged on a movable mold core (105) of the movable mold (1); the novel gearbox valve core structure is characterized in that auxiliary blocks (101) are arranged on positions, corresponding to left and right valve core holes of a gearbox valve plate, of the movable die (1), valve core hole cores (102) penetrating through the auxiliary blocks (101) are arranged on the movable die (1), the valve core hole cores (102) are arranged in a horizontal movement mode, a sliding seat (103) and an oil cylinder (104) of the valve core hole cores (102) are arranged on the movable die (1), a piston of the oil cylinder (104) is connected with the sliding seat (103), and core fixing blocks (108) of the valve core hole cores (102) are fixed on the sliding seat (103).
5. The gearbox valve plate die casting die of claim 4, wherein: the high-pressure spot cooling device is characterized in that a high-pressure spot cooling pipe (107) is arranged in the valve core hole mold core (102), the outer diameter of the high-pressure spot cooling pipe (107) is 3mm, and the spot cooling depth is 4mm from the forming end face of the valve core hole mold core (102).
6. The gearbox valve plate die casting die of claim 4, wherein: a first rectangular sealing groove is formed in the connecting edge of the fixed die (2) and the fixed die core (201), and a sealing strip is arranged in the sealing groove; a second rectangular sealing groove is formed in the contact end face of the core fixing block (108) and the movable mold core (105) of the movable mold (1), and a sealing strip is arranged in the second rectangular sealing groove; and a sealing ring is arranged on the contact end surface of the valve core hole core (102) and the core fixing block (108).
7. The gearbox valve plate die casting die of claim 4, wherein: the movable mould core (105) and the parting surface of the fixed mould core (201) are concave-convex parting surfaces, the auxiliary block (101) is connected with the movable mould core (105) and the fixed mould core (201) through boss positioning, a sleeve (110) is arranged at the front end of the valve core hole core (102), and the sleeve (110) is arranged in the auxiliary block (101).
8. The transmission valve plate die-casting mold as claimed in claim 1, wherein: the fixed die (2) is provided with 11 positions where the hot joint parts of the product forming positions are uniformly arranged
Common point cooling (203), wherein the depth of a cooling water hole is 25mm away from the surface of the mold core, and each common point is controlled by an independent switch; a group of linear molded line cooling is arranged at the position of an upper sprue of the fixed die (2), a group of Z-shaped line cooling is arranged at the positions of the slag ladle (11) and the air extraction channel (12), and the depth of a cooling water hole is 50mm from the surface of the die core; two groups of L-shaped line cooling are arranged on the movable mould (1) corresponding to the pouring channel, and a group of Z-shaped line cooling is arranged on the movable mould (1) corresponding to the slag ladle (11) and the air extraction channel (12).
9. A pressure casting method for a gearbox valve plate is characterized by comprising the following steps: comprises the following process steps of the following steps,
s1, smelting, wherein the alloy is smelted according to the following steps: alloy scrap returns are 8: 2, setting the melting temperature of 780-3Qualified aluminum liquid is obtained when the temperature is 660+/-10 ℃;
s2, die casting, namely, adopting an 800T horizontal cold chamber die casting machine, and providing a gearbox valve plate die casting die, a vacuum machine and a high-pressure point cooling machine according to any one of claims 1 to 5; the die casting process comprises die assembly, quantitative feeding, simultaneous starting of 3 groups of vacuum after the punch head crosses a feeding port at a low speed, closing of the hydraulic vacuum valves 1 and 2 when the punch head reaches a position of 340 +/-20 mm at a low speed, starting of high-speed injection when the punch head reaches 390 +/-20 mm at a low speed, starting of pressurization when the punch head reaches 570 +/-20 mm, automatic closing of the mechanical valve when aluminum liquid reaches the mechanical valve position, finally, die opening until a casting is cooled, taking of the casting, spraying and entering the next cycle; wherein the technological parameters are as follows: the thickness of a material handle is 27 +/-5 mm, the injection delay is 0.5s, the proportion of a release agent is 1.1 +/-0.2%, the low-speed is 0.18 +/-0.05 m/s, the high-speed is 3.8 +/-0.2 m/s, the casting pressure is 85 +/-5 Mpa, the vacuum delay is 0.8-1.2s, the vacuum degree of a tail end mechanical valve is less than or equal to 200mbar, the pollution degree of the tail end mechanical valve is less than or equal to 250mbar, the closing position of a hydraulic vacuum valve at a pouring gate position is 340 +/-20 mm, the high-speed position is 390 +/-20 mm, the pressurization starting position is 570 +/-20 mm, the mold opening time is 10 +/-2 s, the high-pressure point cooling is 1 (delay: 1 +/-0.5 s, the water passage is 15 +/-5 s, the air blowing is 20 +/-5 s), the high-pressure point cooling is 2 (delay: 3 +/-1 s, the water passage is 15 +/-5 s; the air blowing is 20 +/-5 s), and the mold temperature is 230-;
s3, performing internal quality detection on the casting by using a flaw detector, and controlling the primary and the other secondary of the valve core hole of the die casting according to the quality standard of ASTM E505 per 2 pieces/2 h; visual 100% detection is carried out by an appearance operator; size: detecting the position size of the valve core hole and the position size of the valve plate by three coordinates: 1 piece per shift, the valve hole is dissected along the valve core hole vertical direction and is examined whether the valve block has the detection of bending, collapsing: 1 piece/every 3h, positioning hole size: 1 piece per 4h, wall thickness detection: 1 piece/every time of die change;
10. a method of maintaining a die casting mould for a valve plate of a gearbox as claimed in any one of claims 1 to 5, characterised in that: comprises the following steps of (a) carrying out,
s11, cleaning the appearance of the mold, cleaning and repairing parts of each part of the mold, cleaning and repairing the strain part, the thermal junction part and the coating accumulation part of the cavity by using gold-phase paper or oilstone, taking out the push rod, cleaning the push rod by using metallographic abrasive paper, reaming the hole of the push rod by using a reamer to remove impurities, and cleaning the impurities of each slideway by using kerosene;
s12, checking the movable matching part of the die: detecting whether the push plate is deformed or not and whether the push rod hole is damaged or not by using a detection flat plate and a feeler gauge, detecting whether the movable/static mold core profile/slide block/forming position is deformed or not by using a knife edge ruler, an angle ruler and a detection measuring tool, and detecting whether the fit clearance of the guide pillar and the guide sleeve meets H8/e7 or not by using a caliper and an inner diameter dial indicator;
s13, cooling water overhaul:
a. line cooling: disassembling all the line cold plugs, cleaning the water holes by using drill bits smaller than the apertures, and inserting ejector pins smaller than the apertures and longer than the hole depths into the water holes to test whether scale is blocked in the line cold plugs;
b. ordinary point cooling: cleaning the water hole by using a drill bit with the diameter smaller than the hole diameter, drilling until the bottom die core of the hole is drilled, and inserting an ejector pin with the diameter smaller than the hole diameter and longer than the hole depth to test whether scale blockage exists in the cold water hole of the common point;
c. high-pressure point cooling: disassembling the high-pressure point cold insert needle, soaking the high-pressure point cold insert needle by oxalic acid, and inserting a welding wire with the diameter smaller than the aperture and the depth longer than the aperture to test whether scale is blocked in the high-pressure point cold water aperture;
checking whether the water flow meets the process requirements after checking no blockage, testing water by using circulating water for common point cooling and line cooling, wherein the water pressure is 0.4 MPa; testing water by using a water testing machine in a high-pressure point cooling mode, wherein the water pressure is 1 MPa;
s14, maintenance and replacement of the wearing parts,
a. the left valve core hole core and the right valve core hole core are replaced every 5000 die times;
b. the fixed die insert block is replaced according to the number of dies per 10000;
c. the holes of the left and right valve cores of the movable die are quickly embedded and replaced every 20000 die times;
d. the valve core of the mold vacuumizing mechanical valve is replaced every 30000 mold times;
e. the mold oil cylinder sealing ring, the oil cylinder screw rod and the oil cylinder connector are replaced every 30000 and 40000 molds;
f. the mold core sealing strip is replaced every 5000 times;
s15, assembling the dies, wherein the slide block is matched to meet H7/d8, the push rod hole is matched with the push rod to meet H7/e8, each fastening connection part is firm, the assembly is complete, the die spotting machine and the red lead are adopted to detect the matched condition, the thickness of the red lead coated is less than 0.12, more than 90% of the contact area of the red lead printing surface is qualified, and the positions of all cooling water are consistent with the serial numbers;
s16, removing stress of the die, wherein the stress removing process is to remove stress in a vacuum furnace or a protective atmosphere furnace at 530 ℃ for 2.5h, and then slowly cool the die in the furnace to room temperature; the surface shot blasting treatment can be carried out when the service life of the die reaches 30000-40000; reference to the standard of destressing: for the first time: the production reaches 5k times; and (3) for the second time: producing for 1.5 w-2 w mold times; and thirdly: the production is carried out for 3.5 w-4 w times.
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| CN202110727178.6A CN113618040B (en) | 2021-06-29 | 2021-06-29 | Gearbox valve plate die-casting die, die-casting method and die maintenance method |
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| CN115156500A (en) * | 2022-06-14 | 2022-10-11 | 中国第一汽车股份有限公司 | Development method of integrated die-casting large automobile body die |
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