CN113814371A - Brake casting, die-casting die and die-casting process thereof - Google Patents

Abstract

The utility model relates to a stopper foundry goods production technical field, in particular to stopper foundry goods and die casting die and die casting technology thereof, through forming the heavy groove structure on the stopper foundry goods, make the whole thickness of stopper foundry goods tend to the equilibrium, prevent the local deformation of foundry goods, simultaneously through design organ formula distribution, and narrow and dark bar cell body, it is more abundant to make the die cavity exhaust, reduce the gas pocket in the stopper product, prevent the inside production gas pocket of stopper, realize drawing empty the effect of subtracting the material through design bar cell body, improve the die-casting shaping quality of stopper. Set up the evacuation structure on die casting die, realize controlling the filling chronogenesis of foundry goods through the mode of control into gluey position and evacuation, guarantee the plumpness of foundry goods, the bubble content in the finished product foundry goods that significantly reduces simultaneously satisfies the high-quality demand of product. And the qualified rate of casting die-casting molding is ensured through a proper die-casting process, and the requirement of high-quality production is met.

Description

Brake casting, die-casting die and die-casting process thereof

Technical Field

The application relates to the technical field of production of brake unit castings, in particular to a brake casting, a die-casting die and a die-casting process thereof.

Background

Automobile automatic driving is a key step towards future safe and comfortable personal driving experience, and with the emergence and development of automatic driving technologies, braking and deceleration are still the most important elements for guaranteeing the safety of automatic driving. Once the driver has given full responsibility to the vehicle, the Electronic Brake System (EBS) must be able to perform its braking function, without affecting the braking function even if the main electronic brake system fails very rarely. In response to these demands of highly automated driving, the existing automated driving technology employs a compact electronic brake system (MK C1) that does not require vacuum assistance. In the MK C1 brake system, the brake actuation function, brake booster and control system (ABS and ESC) are integrated into a small lightweight brake module.

The casting of the automatic driving electronic brake is a key component in the brake module, the quality of the casting is very important for the automatic driving brake module, cracks and surface quality defects are not allowed on the surface of the casting due to the requirements related to braking safety, and meanwhile, the air hole defects are easily generated during die casting production due to the complex structure and uneven wall thickness of the die casting. In the existing production, 60% of products can generate air holes and cracks inside, so that the requirement of high quality of castings can not be met, the reject ratio of the castings is high, the condition of batch scrapping occurs, and the production cost is greatly increased.

Disclosure of Invention

In order to solve the technical problem, the application provides a brake casting, which comprises a brake body, wherein a connecting hole is formed in the center of the brake body in a penetrating manner, an outward-extending mounting edge is formed on the periphery of the connecting hole, a plurality of first sinking grooves distributed in an annular shape are formed in the periphery of the connecting hole on the brake body, and mounting holes are formed in two sides of the connecting hole; a second sinking groove is formed in the edge of the brake body; the two ends of the brake body are provided with third sinking grooves; the brake body is provided with a through hole, the other side face of the brake body, which is opposite to the first sinking groove, is provided with a plurality of organ-shaped strip-shaped groove bodies, and the strip-shaped groove bodies are symmetrically distributed relative to the connecting hole;

the contour dimension of the brake body is 103 multiplied by 169 multiplied by 33mm, and the average wall thickness is 3.5 mm;

the brake body is composed of the following alloy materials in parts by weight: 85-89% of Al, 10.5-11.5% of Si, 0.6-0.9% of Fe, 0.07-0.1% of Cu, 0.1-0.55% of Mn, 0.01-0.05% of Mg, 0.01-0.15% of Zn, 0.02-0.15% of Ti and 0.02-0.1% of Sn.

A die-casting die is used for producing the brake casting and comprises a movable die, a fixed die and a vacuumizing structure arranged on the movable die and the fixed die, wherein the movable die is provided with a plurality of cores, the fixed die is provided with a cavity matched with the cores, a feeding nozzle is arranged below the cavity of the fixed die, and the movable die is provided with a plurality of feeding channels communicated with the feeding nozzle and the cores; the vacuum pumping structure is communicated with the mold core.

Preferably, the vacuumizing structure comprises connectors arranged on the movable mold and the fixed mold, a gas path channel arranged on the movable mold, and a connecting channel arranged on the fixed mold; the gas path channel is connected to the core; the connecting channel connects the gas path channel and the connector.

Preferably, the connector is provided with an air hole communicated to the connecting channel, and the air hole penetrates through the top surface and the bottom surface of the connector.

A die-casting process is based on the injection mold and used for die-casting the brake casting, and comprises the following steps:

s100, mixing the alloy materials according to the component ratio, putting the alloy materials and the returned materials into a central melting furnace for melting according to the ratio of (6-7) to (3-4), wherein the temperature of the melting furnace is 650-800 ℃, and the returned materials are Al;

s200, according to the alloy material and a refining agent (200-230): 1, adding a refining agent for refining for 4-5 hours to form a raw material in a molten state, conveying the raw material to a degassing machine for degassing, and putting the raw material into a heat preservation furnace for preserving heat for 2-3 hours at the temperature of 660-680 ℃;

s300, closing the movable die and the fixed die, communicating a connector with a negative pressure device, wherein the negative pressure of the negative pressure device is 0.2-0.5 Mpa, and introducing cooling water into the movable die and the fixed die;

s400, injecting a raw material with a material temperature of 660-680 ℃ into the die-casting die through a die-casting machine for die-casting, and forming the brake casting, wherein the casting pressure is 800-860 kgf/cm2, the injection speed is 2.2-3.4 m/S, the die temperature is 200-260 ℃, the pressure maintaining time is 2-4S, and the cooling time is 5-8S;

s500, taking out the brake casting, moving the brake casting to a cooling line for cooling, cooling and forming the casting, sequentially performing a water outlet burr removing process and a vibration shot blasting process on the casting, performing fluorescent flaw detection full detection through a flaw detector, cleaning and drying, and placing the casting at a constant temperature of 500-550 ℃ for 3-4 hours to eliminate stress; and then carrying out appearance detection and packaging.

From the above, the following beneficial effects can be obtained by applying the method provided by the present application: through forming the heavy groove structure on the stopper foundry goods, realize reducing the material volume, make the whole thickness of stopper foundry goods approach to the equilibrium, prevent the local deformation of foundry goods, simultaneously through designing a large amount of super large clearance organ formula distributions, and narrow and dark bar cell body, it is more abundant to make the die cavity exhaust, guarantee the plumpness of foundry goods die-casting, reduce the risk that there is the gas pocket in the stopper product, prevent that the inside of stopper from producing the gas pocket, realize drawing empty through designing the bar cell body and subtract the effect of material, improve the die-casting shaping quality of stopper. Set up the evacuation structure on die casting die, make the interior production vacuum of mould through the evacuation structure, and then the raw materials flows in the holding intracavity shaping from bottom to top along feedstock channel, advances the filling time sequence that glues the mode realization control foundry goods of position and evacuation through the control, guarantees the plumpness of foundry goods, and the bubble content in the finished product foundry goods that significantly reduces simultaneously satisfies the high-quality demand of product. And the qualified rate of casting die-casting molding is ensured through a proper die-casting process, and the requirement of high-quality production is met.

Drawings

In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings used in the description of the embodiments of the present application or the prior art will be briefly described below. It should be apparent that the drawings in the following description are only some embodiments of the present application, and that other drawings may be obtained by those skilled in the art without inventive exercise.

FIG. 1 is a schematic structural view of a brake casting according to an embodiment of the present application;

FIG. 2 is a perspective view of a moving mold according to an embodiment of the present application;

FIG. 3 is a schematic bottom view of a movable mold according to an embodiment of the present application;

FIG. 4 is a schematic diagram of the present application.

Detailed Description

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the embodiments described are only a few embodiments of the present application and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

In order to solve the above technical problem, the present embodiment provides a brake casting, which is applied to a brake module of an automobile, and as shown in fig. 1, the brake casting includes a brake body 10, a connection hole 11 is formed through the center of the brake body 10, a mounting edge 111 extending outward is formed on the periphery of the connection hole 11, and the brake body 10 is installed in the brake module and connected to other components through the mounting edge 111. A plurality of first sinking grooves 12 distributed in an annular shape are formed in the periphery of the connecting hole 11 on the brake body 10, mounting holes 15 are formed in two sides of the connecting hole 11, a second sinking groove 13 is formed in the edge of the brake body 10, and third sinking grooves 16 are formed in two ends of the brake body 10; through-hole 17 has been seted up to stopper body 10, stopper body 10 for the another side of first heavy groove 12 is formed with a plurality of bar cell body 14 that is the organ form, bar cell body 14 is for connecting hole 11 symmetric distribution, and then through designing a large amount of super large clearance organ formula distributions, and narrow and dark bar cell body 14, it is more abundant to make the die cavity exhaust, guarantee the plumpness of foundry goods die-casting, reduce the risk that the stopper product exists the gas pocket, prevent that the inside of stopper from producing the gas pocket, and simultaneously, the effect of taking out the air and reducing the material is realized drawing in through designing bar cell body 14, reduce the material, make thicker region approach to the equilibrium, reduce the deflection in the die-casting process, further reduce the production of bubble, improve the die-casting shaping quality of stopper.

Further, third heavy groove 16 has been seted up at the both ends of stopper body 10, and through-hole 17 has been seted up on stopper body 10, second heavy groove 13 has been seted up at the edge of stopper body 10, the first heavy groove 12 that a plurality of is cyclic annular distribution has been seted up to the periphery that lies in connecting hole 11 on stopper body 10, through designing first heavy groove 12, second heavy groove 13 and third heavy groove 16, make the whole thicker region of stopper body 10 approach to the equilibrium, reduce the production of deflection and bubble, reduce the disability rate.

Wherein, the contour dimension of the brake body 10 is 103 multiplied by 169 multiplied by 33mm, and the average wall thickness is 3.5 mm; the brake body 10 comprises the following alloy materials in parts by weight: 86-88% of Al, 10.5-11.5% of Si, 0.6-0.9% of Fe, 0.07-0.1% of Cu, 0.1-0.55% of Mn, 0.01-0.05% of Mg, 0.01-0.15% of Zn, 0.02-0.15% of Ti and 0.02-0.1% of Sn.

In order to realize the production of the brake casting by die casting, the embodiment also provides a die-casting die for producing the brake casting, which comprises a movable die 20 and a fixed die 30 and an evacuation structure 40 arranged on the movable die 20 and the fixed die 30, wherein the movable die 20 is provided with 2 cores 21, and the fixed die 30 is provided with a cavity 31 matched with the cores 21, as shown in fig. 2-4. After the movable die 20 and the fixed die 30 are assembled, the core 21 is correspondingly matched with the cavity 31, a containing cavity matched with the outline of the brake casting is formed in the core 21 and the cavity 31, the fixed die 30 is arranged below the cavity 31 and is provided with a feeding nozzle 32, the movable die 20 is provided with a plurality of feeding channels 22 communicated with the feeding nozzle 32 and the core 21, raw materials enter the feeding channels 22 through the feeding nozzle 32, and then flow into the containing cavity along the feeding channels 22 for cooling and forming. Wherein, the feeding nozzle 32 is arranged below the cavity 31, the vacuum structure 40 is arranged above the cavity 31, and the vacuum structure 40 is communicated with the mold core 21. Make the holding intracavity that core 21 and die cavity 31 formed produce the vacuum through evacuation structure 40, and then the raw materials flows into the holding intracavity shaping from bottom to top along feedstock channel 22, guarantees the plumpness of foundry goods through the mode of controlling into gluey position and evacuation, and the bubble content in the finished product foundry goods that significantly reduces simultaneously satisfies the high-quality demand of product.

Further, as shown in fig. 2 to 4, the vacuum structure 40 includes a connector 41 installed on the movable mold 20 and the fixed mold 30, an air passage 42 opened on the movable mold 20, and a connection passage 43 opened on the fixed mold 30, the air passage 42 being connected to the core 21. After the movable mold 20 and the fixed mold 30 are assembled, the air passage 42 is communicated with the connector 41 through the connecting passage 43, the connector 41 is provided with an air hole 44 communicated to the connecting passage 43, and the air hole 44 penetrates through the top surface and the bottom surface of the connector 41. The air hole 44 is connected to a negative pressure device, the negative pressure device realizes vacuumizing the air channel 42 through the air hole 44 and the connecting channel 43, and then vacuumizing the accommodating cavity formed by the movable mold 20 and the fixed mold 30, so that the raw materials are ensured to smoothly enter the accommodating cavity in the die-casting process, and meanwhile, bubbles are effectively avoided. Wherein, the feeding mouth 32 sets up in the below of die cavity 31, and vacuum structure 40 is located the top of die cavity 31, advances to glue the position and advance gluey order through control and realize controlling the foundry goods and fill the chronogenesis to guarantee that the die cavity is fully carminative, guarantee that the foundry goods die-casting is full and prevent that the bubble from producing.

In order to realize the die-casting of qualified brake castings, the die-casting process is based on the injection mold and is used for die-casting the brake castings, and the die-casting process comprises the following steps:

s100, mixing the alloy materials according to the component ratio, and putting the alloy materials and the returned materials into a central melting furnace for melting according to the ratio of (6-7) to (3-4), wherein the temperature of the melting furnace is 650-800 ℃, and the returned materials are Al;

according to the following mixture ratio, alloy materials of 86% of Al, 11.5% of Si, 0.9% of Fe, 0.1% of Cu, 0.55% of Mn, 0.05% of Mg, 0.15% of Zn, 0.15% of Ti and 0.1% of Sn are mixed, the alloy materials and a scrap return are put into a central melting furnace according to the ratio of 7:3 for melting, the scrap return is Al, and the temperature of the melting furnace is 800 ℃.

S200, according to the alloy material and a refining agent (200-230): 1, adding a refining agent for refining for 4-5 hours to form a raw material in a molten state, conveying the raw material to a degassing machine for degassing, and putting the raw material into a heat preservation furnace for preserving heat for 2-3 hours at the temperature of 660-680 ℃;

according to the following steps of 200: 1 for 4 hours, then transporting the raw material to a degassing machine for degassing, removing gas in the liquid raw material with the material temperature of 660 ℃, reducing the gas content in the raw material, reducing bubbles after casting molding, improving the finished product quality of the casting, and then putting the casting into a heat preservation furnace to preserve heat for 3 hours at the temperature of 660 ℃.

And S300, closing the movable die and the fixed die, communicating the connector with a negative pressure device, wherein the negative pressure of the negative pressure device is 0.4-0.5 Mpa, and introducing cooling water into the movable die and the fixed die.

In order to test the influence of the tank body and the vacuumizing structure on the bubbles of the product casting, a test die for manufacturing an injection mold is used for testing, different tank bodies are processed on the movable die 20 and the fixed die 30 for comparison, and the influence of the vacuumizing structure on the bubbles of the casting is tested.

Number of test groups

1

2

3

4

5

6

Strip-shaped groove body

Is provided with

Is provided with

Is free of

Is provided with

Is provided with

Is provided with

First sink

Is provided with

Is provided with

Is provided with

Is free of

Is provided with

Is provided with

Second sink tank

Is provided with

Is provided with

Is provided with

Is provided with

Is free of

Is provided with

Third sink tank

Is provided with

Is provided with

Is provided with

Is provided with

Is provided with

Is free of

Vacuum pumping structure

Is provided with

Is free of

Is provided with

Is provided with

Is provided with

Is provided with

Bubble-free qualification rate

98%

66%

72%

88%

92%

95%

TABLE 1

As shown in table 1, under the same optimal die casting process, the qualification rate of the casting product produced by the die equipped with the vacuum structure 40 is 98% without bubbles, and the qualification rate of the casting product produced by the die without the vacuum structure 40 is 66%, so that before die casting, the air in the die cavity of the die can be pumped out after the vacuum structure 40 is arranged, and the vacuum structure 40 plays a decisive role, so that bubbles can be effectively prevented from being generated in the casting, and the quality of the casting can be ensured. Meanwhile, as can be seen from the data in the table, the arrangement of the strip-shaped groove body 14 enables the thicker area to approach to balance, reduces the deformation in the die-casting process, further reduces the generation of bubbles, and improves the die-casting forming quality of the brake. And in the test group without the first, second and third settling tanks 12, 13 and 16, the yield of the product is all reduced, and for this reason, the first, second and third settling tanks 12, 13 and 16 all play a role in preventing the generation of bubbles.

S400, injecting the raw material with the material temperature of 660-680 ℃ into a die-casting die through a die-casting machine for die-casting, and forming a brake casting, wherein the casting pressure is 860kgf/cm2, the injection speed is 2.2-3.4 m/S, the die temperature is 200-260 ℃, the pressure maintaining time is 2-4S, and the cooling time is 5-8S.

After a movable die 20 and a fixed die 30 of the die-casting die are closed by the pressure of 140pa, the negative pressure device produces negative pressure of 0.5Mpa, the die-casting machine injects raw materials into the die-casting die, the raw materials enter a die cavity 31 through a feeding nozzle 32 and a feeding channel 24, wherein the casting pressure is 860kgf/cm2, the injection speed is 3.4m/s, the die temperature is 260, the pressure maintaining time is 4s, and the cooling time is 8 s. In order to find out the most suitable die casting process parameters, the die casting process was subjected to the following 5 sets of tests, and 100 finished products were taken for each set of tests to be subjected to bubble and crack detection.

Number of test groups	1	2	3	4	5
						Casting pressure kgf/cm2	800	860	860	860	860
Jet velocity m/s	3.4	3.4	2.3	3.4	3.4
						Negative pressure Mpa	0.5	0.5	0.5	0.2	0.5
Dwell time s	4	4	4	4	3.5
						The qualified rate of the casting without bubbles is percent	89	97	85	82	92

TABLE 2

As can be seen from the above table 2, the gas in the accommodating cavity may not be completely removed by the casting due to the excessively small casting pressure and injection speed parameters, so that the bubble is generated inside the casting, the bubble-free qualification rate of the casting is reduced, the negative pressure value of the negative pressure device has an important influence on the bubble generation of the casting, the lower the negative pressure value is, the higher the probability of the bubble generation of the casting is, and therefore, the generation of the bubble inside the die casting can be reduced by improving the negative pressure value. Further, the casting pressure, the injection speed and the pressure holding time all have influence on the qualified rate of the casting, and as can be seen from the results of the second group of test parameters in table 2, the second group of test parameters are the best die-casting process parameters, and the qualified rate of the casting is the highest.

S500, taking out the brake casting, moving the brake casting to a cooling line for cooling, cooling and forming the casting, sequentially performing a water outlet burr removing process and a vibration shot blasting process on the casting, performing fluorescent flaw detection full detection through a flaw detector, cleaning and drying, and placing the casting at the constant temperature of 550 ℃ for 4 hours to eliminate stress; and then carrying out appearance detection and packaging. In the step, the flaw detector is used for carrying out fluorescent flaw detection, so that whether bubbles or cracks are generated in the casting can be accurately detected.

To sum up, this application scheme realizes reducing the material volume through forming the heavy groove structure on the stopper foundry goods for the whole thickness of stopper foundry goods tends to the equilibrium, prevents the local deformation of foundry goods, simultaneously through designing a large amount of super large clearance organ formula distribution, and narrow and dark bar cell body, it is more abundant to make the die cavity exhaust, guarantee the plumpness of foundry goods die-casting, reduce the risk that the stopper product exists the gas pocket, prevent that the inside of stopper from producing the gas pocket, realize drawing out the effect of empty subtract material through designing the bar cell body, improve the die-casting shaping quality of stopper. Set up the evacuation structure on die casting die, make the interior production vacuum of mould through the evacuation structure, and then the raw materials flows in the holding intracavity shaping from bottom to top along feedstock channel, advances the filling time sequence that glues the mode realization control foundry goods of position and evacuation through the control, guarantees the plumpness of foundry goods, and the bubble content in the finished product foundry goods that significantly reduces simultaneously satisfies the high-quality demand of product. And the qualified rate of casting die-casting molding is ensured through a proper die-casting process, and the requirement of high-quality production is met.

The above-described embodiments do not limit the scope of the present invention. Any modification, equivalent replacement, and improvement made within the spirit and principle of the above-described embodiments should be included in the protection scope of the technical solution.

Claims (5)

1. A brake casting, characterized by: the brake comprises a brake body (10), a connecting hole (11) is formed in the center of the brake body (10) in a penetrating mode, a mounting edge (111) extending outwards is formed on the periphery of the connecting hole (11), a plurality of first sinking grooves (12) distributed in an annular mode are formed in the periphery of the connecting hole (11) on the brake body (10), and mounting holes (15) are formed in two sides of the connecting hole (11); a second sinking groove (13) is formed in the edge of the brake body (10); third sinking grooves (16) are formed in two ends of the brake body (10); the brake body (10) is provided with a through hole (17), the other side face, opposite to the first sinking groove (12), of the brake body (10) is provided with a plurality of organ-shaped strip-shaped groove bodies (14), and the strip-shaped groove bodies (14) are symmetrically distributed relative to the connecting hole (11);

the contour dimension of the brake body (10) is 103 multiplied by 169 multiplied by 33mm, and the average wall thickness is 3.5 mm;

the brake body (10) is composed of the following alloy materials in parts by weight: 86-88% of Al, 10.5-11.5% of Si, 0.6-0.9% of Fe, 0.07-0.1% of Cu, 0.1-0.55% of Mn, 0.01-0.05% of Mg, 0.01-0.15% of Zn, 0.02-0.15% of Ti and 0.02-0.1% of Sn.

2. The die-casting die is characterized in that: the brake casting production method is used for producing the brake casting of claim 1 and comprises a movable die (20) and a fixed die (30) and a vacuum-pumping structure (40) arranged on the movable die (20) and the fixed die (30), wherein the movable die (20) is provided with a plurality of cores (21), the fixed die (30) is provided with a die cavity (31) matched with the cores (21), the fixed die (30) is provided with a feeding nozzle (32) below the die cavity (31), and the movable die (20) is provided with a plurality of feeding channels (22) communicated with the feeding nozzle (32) and the cores (21); the vacuum-pumping structure (40) is communicated with the mold core (21).

3. The die casting mold of claim 2, wherein: the vacuumizing structure (40) comprises a connector (41) arranged on the movable mold (20) and the fixed mold (30), a gas path channel (42) arranged on the movable mold (20), and a connecting channel (43) arranged on the fixed mold (30); the air passage (42) is connected to the core (21); the connection passage (43) communicates the air passage (42) with the connector (41).

4. A die casting mold as claimed in claim 3, wherein: the connector (41) is provided with an air hole (44) communicated to the connecting channel (43), and the air hole (44) penetrates through the top surface and the bottom surface of the connector (41).

5. A die casting process is characterized in that: the die casting mold for die-casting the brake casting according to claim 4, comprising the steps of:

s100, mixing alloy materials according to the weight ratio of the alloy materials of the brake body (10), and putting the alloy materials and a returned material into a central melting furnace for melting according to the ratio of (6-7) to (3-4), wherein the temperature of the melting furnace is 650-800 ℃, and the returned material is Al;

s200, according to the alloy material and a refining agent (200-230): 1, adding a refining agent for refining for 4-5 hours to form a raw material in a molten state, conveying the raw material to a degassing machine for degassing, and putting the raw material into a heat preservation furnace for preserving heat for 2-3 hours at the temperature of 660-680 ℃;

s300, closing the movable die and the fixed die, communicating a connector with a negative pressure device, wherein the negative pressure of the negative pressure device is 0.4-0.5 Mpa, and introducing cooling water into the movable die and the fixed die;

s400, injecting a raw material with a material temperature of 660-680 ℃ into the die-casting die through a die-casting machine for die-casting, and forming the brake casting, wherein the casting pressure is 820-860 kgf/cm2, the injection speed is 2.2-3.4 m/S, the die temperature is 200-260 ℃, the pressure maintaining time is 2-4S, and the cooling time is 5-8S;

s500, taking out the brake casting, moving the brake casting to a cooling line for cooling, cooling and forming the casting, sequentially performing a water outlet burr removing process and a vibration shot blasting process on the casting, performing fluorescent flaw detection full detection through a flaw detector, cleaning and drying, and placing the casting at a constant temperature of 500-550 ℃ for 3-4 hours to eliminate stress; and then carrying out appearance detection and packaging.

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