CN115229162A - Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap - Google Patents
Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap Download PDFInfo
- Publication number
- CN115229162A CN115229162A CN202210864194.4A CN202210864194A CN115229162A CN 115229162 A CN115229162 A CN 115229162A CN 202210864194 A CN202210864194 A CN 202210864194A CN 115229162 A CN115229162 A CN 115229162A
- Authority
- CN
- China
- Prior art keywords
- die
- forging
- casting
- extrusion
- brake disc
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000005242 forging Methods 0.000 title claims abstract description 28
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 18
- 238000000034 method Methods 0.000 title claims description 31
- 238000004512 die casting Methods 0.000 title claims description 11
- 238000005266 casting Methods 0.000 claims abstract description 32
- 238000001125 extrusion Methods 0.000 claims abstract description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 18
- 238000001816 cooling Methods 0.000 claims abstract description 14
- 239000007788 liquid Substances 0.000 claims abstract description 12
- 238000010438 heat treatment Methods 0.000 claims abstract description 11
- 238000003825 pressing Methods 0.000 claims abstract description 5
- 238000001514 detection method Methods 0.000 claims abstract description 4
- 238000007670 refining Methods 0.000 claims abstract 2
- 238000005485 electric heating Methods 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 6
- 238000007664 blowing Methods 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 239000012535 impurity Substances 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 239000002893 slag Substances 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 238000007872 degassing Methods 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 9
- 239000000463 material Substances 0.000 abstract description 5
- 238000003754 machining Methods 0.000 abstract description 2
- 238000004090 dissolution Methods 0.000 abstract 1
- 238000002347 injection Methods 0.000 abstract 1
- 239000007924 injection Substances 0.000 abstract 1
- 239000000203 mixture Substances 0.000 abstract 1
- 238000005496 tempering Methods 0.000 abstract 1
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
Classifications
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
The invention relates to a liquid state squeeze forging casting process of an aluminum alloy brake disc cap in the technical field of brake disc cap manufacturing, which comprises aluminum ingot dissolution, material composition tempering, aluminum liquid refining, aluminum liquid injection into a die, closed extrusion of the die, die opening, secondary closed forging and pressing of the die, pressure maintaining cooling, die opening and part taking, casting cooling, heat treatment, comprehensive detection and machining.
Description
Technical Field
The invention relates to the technical field of brake disc cap manufacturing, in particular to a liquid-state swaging and die casting process of an aluminum alloy brake disc cap.
Background
With the increasing of new energy automobiles, light weight and emission regulations, the reduction of the weight of the whole automobile, the improvement of the endurance mileage of the automobile and the reduction of pollutant emission become inevitable trends of the development of the automobile industry. The automobile brake system is taken as a safety link, new technology is broken through continuously, the conventional brake disc cap is formed by cast iron or steel plate in a stamping mode at present, although the technical maturity is high, the factors that the weight is large and the surface treatment is not beneficial to environmental protection exist, therefore, the aluminum alloy disc cap production technology is produced at the same time, and the requirement of high mechanical property is met due to the fact that an aluminum alloy disc is extruded, so that the reliability and the stability of the casting process and the selection and the use of an aluminum alloy material are very critical.
The conventional casting process realizes the aluminum alloy brake disc cap with large casting heads and low process yield, the casting heads are cut to generate the problems of aluminum scrap waste, long solidification time, low casting efficiency and the like, and the disc cap produced by the forging process has the problem of high cost.
Based on the above, the invention designs a liquid-state swaging and die casting process of an aluminum alloy brake disc cap, so as to solve the problems.
Disclosure of Invention
The invention aims to provide a liquid-state squeeze forging and die casting process of an aluminum alloy brake disc cap, which is provided for solving the problems that the existing production process for the aluminum alloy brake disc cap has more production process modes but has the defects of certain cost, performance and efficiency, along with the increasing market demand, the aluminum alloy brake disc cap realized by the conventional casting process has the problems of larger casting head, low process yield, waste of aluminum scraps generated by casting head cutting, longer solidification time, lower casting efficiency and the like, and the disc cap produced by the forging process has the problem of higher cost.
In order to achieve the purpose, the invention provides the following technical scheme: a liquid-state squeeze forging and die casting process of an aluminum alloy brake disc cap comprises the following steps:
1.1, opening the die, blowing off impurities in the die cavity, and spraying a heat-preservation release agent;
1.2 injecting 710-725 ℃ quantitative aluminum liquid which is degassed and refined through an aluminum inlet of a fixed die of the die;
1.3 starting the equipment, closing the movable mold and the fixed mold, and extruding the molten aluminum in the mold cavity by the extruding mandrel downwards from the upper mold according to the set time and the extrusion force;
1.4, in the extrusion process, quickly cooling the aluminum liquid in the die cavity to be in a semi-solid state, and in the extrusion process, removing casting gas and oxides in the die cavity along with an exhaust and slag discharge channel;
1.5 after the set extrusion time is up, opening the die to a set position, then carrying out secondary pressurization closing, and forging and pressing the casting in the die cavity of the die;
1.6 after the set forging time is up, automatically opening the die, taking out the casting and cooling;
1.7 placing the cooled casting into a heat treatment basket according to the process requirements, and carrying out T6 heat treatment;
1.8, carrying out processing after completing comprehensive detection on the product after heat treatment.
Preferably, the upper die and the lower die of the die in the step 1.2 are provided with an electric heating rod and an ejection plate with a constant temperature device, the constant temperature device implements balanced temperature control on the die, the temperature of the die is controlled between 240 ℃ and 300 ℃, the electric heating rod is automatically closed when the temperature of the die exceeds 300 ℃, a nozzle for keeping the temperature on the ejection plate automatically releases compressed air for cooling the die, and the compressed air for cooling is automatically closed when the temperature of the die is within a set range.
Preferably, the extrusion force of the extrusion device in the steps 1.3 and 1.5 is set to be in a range of 10-15 tons, the extrusion dwell time is 10-20S, the forging pressure of the forging device is set to be in a range of 20-40 tons, the forging dwell time is 5-10S, and the pressures of the two devices are in an adjustable functional range of 10-50 tons.
Preferably, the processing amount of the product formed in the step 1.8 is 1-1.5mm, and the casting is formed in one step.
Compared with the prior art, the invention has the beneficial effects that:
the blank produced by the process is formed in one step, the feeding casting head and leftover materials existing in the conventional casting are avoided, the casting head does not need to be cut, the machining can be directly carried out after heat treatment, the cutting of the casting head is not required, the blank weight of the product is reduced, the product forming efficiency is improved, a shrinkage porosity structure does not exist in the casting, the defect is greatly reduced, the product percent of pass is greatly improved, the gas content of the internal structure of the product is greatly reduced through the process design of extruding and forging, the problem of gas holes and pin holes in the product is solved, the product quality and the production efficiency are improved, the aims of minimizing the production and manufacturing cost, being high in use reliability, strong in bearing capacity, light in weight and high in mass production efficiency are fulfilled, and the process is suitable for mass large-scale production.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the 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 invention.
The first embodiment is as follows:
a liquid-state squeeze forging and die casting process of an aluminum alloy brake disc cap comprises the following steps:
1.1, opening the die, blowing off impurities in the die cavity, and spraying a heat-preservation release agent;
1.2 injecting 710-725 ℃ quantitative aluminum liquid refined through degassing through an aluminum inlet of a fixed die of the die, wherein the upper die and the lower die of the die are provided with electric heating rods and ejection plates with constant temperature devices, the constant temperature devices implement balanced temperature control on the die, the temperature of the die is controlled between 240-300 ℃, when the temperature of the die exceeds 300 ℃, the electric heating rods are automatically closed, nozzles used for keeping constant temperature on the ejection plates automatically release compressed air for cooling the die, and when the temperature of the die is within a set range, the compressed air used for cooling is automatically closed;
1.3 starting the equipment, closing the movable mold and the fixed mold, extruding the molten aluminum in the mold cavity by the extruding mandrel downwards from the upper mold according to the set time and the extrusion force, wherein the extrusion force is set within the range of 10-15 tons, and the extrusion pressure maintaining time is 10-20S;
1.4, in the extrusion process, rapidly cooling the aluminum liquid in the die cavity to be in a semi-solid state, and in the extrusion process, removing casting gas and oxides in the die cavity along with an exhaust and slag discharge channel;
1.5 after the set extrusion time is up, opening the die to a set position, then carrying out secondary pressurization closing, and carrying out forging and pressing on the casting in the die cavity, wherein the forging pressure is set within the range of 20-40 tons, and the forging and pressing pressure maintaining time is 5-10S;
1.6 after the set forging time is up, automatically opening the die, taking out the casting and cooling;
1.7, placing the cooled castings in a heat treatment basket according to the process requirements, and carrying out T6 heat treatment;
1.8 the heat treated product and the formed product have the processing amount of 1-1.5mm, the casting is formed in one step, feeding gates and leftover materials existing in the conventional casting do not exist, the process frequency is over 90 percent, the gates do not need to be cut, and the direct processing can be carried out after the heat treatment.
The second embodiment:
the blank of the product manufactured by the process method of the invention in the first embodiment is used for analysis and detection, and the following data are obtained:
| shrinkage porosity tissue | Pore grade | Density of molten aluminum | Tensile strength | Yield strength | Elongation percentage | HB hardness | |
| Sample 1 | Is composed of | First level | 2.65 | 301Mpa | 240Mpa | 5.8％ | 101 |
| Sample 2 | Is free of | First stage | 2.63 | 297Mpa | 236Mpa | 6.3％ | 98 |
| Sample 3 | Is free of | First level | 2.65 | 302Mpa | 248Mpa | 6.0％ | 102 |
In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims (4)
1. A liquid-state squeeze forging and die casting process of an aluminum alloy brake disc cap is characterized in that: the process comprises the following steps:
1.1, opening the mould, blowing off impurities in the cavity, and spraying a heat-preservation release agent;
1.2 injecting 710-725 ℃ quantitative molten aluminum subjected to degassing refining through an aluminum inlet of a fixed die of the die;
1.3 starting equipment, closing the movable mold and the fixed mold, and extruding the aluminum liquid in the mold cavity by the extrusion mandrel downwards from the upper mold according to set time and extrusion force;
1.4, in the extrusion process, rapidly cooling the aluminum liquid in the die cavity to be in a semi-solid state, and in the extrusion process, removing casting gas and oxides in the die cavity along with an exhaust and slag discharge channel;
1.5 after the set extrusion time is up, opening the die to a set position, then carrying out secondary pressurization closing, and forging and pressing the casting in the die cavity of the die;
1.6 after the set forging time is up, automatically opening the die, taking out the casting and cooling;
1.7 placing the cooled casting into a heat treatment basket according to the process requirements, and carrying out T6 heat treatment;
1.8 carrying out heat treatment on the product, and carrying out processing after comprehensive detection is finished.
2. The liquid squeeze forging die casting process of the aluminum alloy brake disc cap as claimed in claim 1, wherein: the upper die and the lower die of the die in the step 1.2 are provided with an electric heating rod and an ejection plate with a constant temperature device, the constant temperature device is used for implementing balanced temperature control on the die, the temperature of the die is controlled between 240 ℃ and 300 ℃, the electric heating rod is automatically closed when the temperature of the die exceeds 300 ℃, a nozzle used for keeping the temperature on the ejection plate is used for automatically releasing compressed air for cooling the die, and the nozzle used for cooling the compressed air is automatically closed when the temperature of the die is within a set range.
3. The liquid squeeze forging and die casting process of the aluminum alloy brake disc cap as claimed in claim 1, wherein: in the steps 1.3 and 1.5, the extrusion force setting range of the extrusion equipment is 10-15 tons, the extrusion pressure maintaining time is 10-20S, the forging pressure setting range of the forging equipment is 20-40 tons, the forging pressure maintaining time is 5-10S, and the pressure of the two equipment is in the adjustable function range of 10-50 tons.
4. The liquid squeeze forging and die casting process of the aluminum alloy brake disc cap as claimed in claim 1, wherein: the processing amount of the product formed in the step 1.8 is 1-1.5mm, and the casting is formed in one step.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210864194.4A CN115229162A (en) | 2022-07-20 | 2022-07-20 | Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210864194.4A CN115229162A (en) | 2022-07-20 | 2022-07-20 | Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115229162A true CN115229162A (en) | 2022-10-25 |
Family
ID=83674736
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210864194.4A Pending CN115229162A (en) | 2022-07-20 | 2022-07-20 | Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN115229162A (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2004031424A1 (en) * | 2002-10-01 | 2004-04-15 | Asahi Tec Corporation | Aluminum alloy for casting-forging, aluminum cast/forged article, and method for manufacture thereof |
| CN101811338A (en) * | 2009-10-22 | 2010-08-25 | 杨东佐 | Mould capable of realizing rapid heat cycle |
| CN111715863A (en) * | 2020-07-01 | 2020-09-29 | 深圳市北工实业有限公司 | Extrusion casting and micro-forging integrated forming method and die casting system |
| CN115106512A (en) * | 2022-07-20 | 2022-09-27 | 山东昊方联合铸造有限公司 | Liquid-state squeeze forging die casting die for aluminum alloy brake disc cap |
-
2022
- 2022-07-20 CN CN202210864194.4A patent/CN115229162A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2004031424A1 (en) * | 2002-10-01 | 2004-04-15 | Asahi Tec Corporation | Aluminum alloy for casting-forging, aluminum cast/forged article, and method for manufacture thereof |
| CN101811338A (en) * | 2009-10-22 | 2010-08-25 | 杨东佐 | Mould capable of realizing rapid heat cycle |
| CN111715863A (en) * | 2020-07-01 | 2020-09-29 | 深圳市北工实业有限公司 | Extrusion casting and micro-forging integrated forming method and die casting system |
| CN115106512A (en) * | 2022-07-20 | 2022-09-27 | 山东昊方联合铸造有限公司 | Liquid-state squeeze forging die casting die for aluminum alloy brake disc cap |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN101598585B (en) | Preparation method of aluminum-alloy gas meter end cover | |
| CN100519002C (en) | Aluminum-alloy wheel gas pressure casting apparatus and casting method thereof | |
| CN106925756A (en) | A kind of low-pressure casting preparation method of aluminum alloy auxiliary vehicle frame | |
| CN111636019B (en) | Method for reducing bubbles on surface of aluminum alloy bar | |
| CN110512061B (en) | Process method for producing die steel by directly forging continuous casting billet | |
| CN110468360B (en) | Method for reducing quenching residual stress of large-size high-strength aluminum alloy frame die forging | |
| CN111069323A (en) | Extrusion production process of automobile doorsill beam profile | |
| CN107297396A (en) | A kind of aluminium alloy pedal manufacture craft | |
| US11981985B2 (en) | Method for manufacturing special vehicle wheels with 7000 series aluminum alloy | |
| CN115229162A (en) | Liquid-state squeeze forging and die casting process of aluminum alloy brake disc cap | |
| CN201042733Y (en) | Gas pressure casting device for aluminum alloy wheel | |
| JP3416036B2 (en) | Mold structure for magnesium alloy injection molding and method for molding magnesium alloy parts using the mold structure | |
| CN105081275A (en) | Method for preparing graded pressurization liquid forging aluminum alloy engine cylinder cover | |
| CN100513061C (en) | Technique for producing magnesium alloy punched thin plate | |
| CN112658226B (en) | Unequal-thickness deep cavity shell type aluminum alloy component extrusion casting device and using method thereof | |
| KR100293000B1 (en) | Method for manufacturing rotary swash plate for air conditioner using vacuum die casting for squeeze bottle | |
| CN115007814A (en) | Continuous casting production method of bloom hot work die steel H13 and bloom hot work die steel H13 casting blank | |
| CN113046584A (en) | Preparation method of thin-wall battery compartment end plate | |
| JPH08224650A (en) | Method for preventing segregation and center porosity in continuous casting slab of steel | |
| CN113528898A (en) | Aluminum alloy for automobile doorsill beam and automobile doorsill beam machining method | |
| CN112808788A (en) | Extrusion processing method of automobile anti-collision beam | |
| CN113118443A (en) | Method for preparing bar by using spray-formed high-silicon aluminum alloy powder | |
| CN106834638B (en) | A kind of manufacturing method of steel brake drum | |
| CN112091047A (en) | Superplastic forming process for automobile parts | |
| CN115233021B (en) | Preparation method of regenerated aluminum alloy and prepared aluminum alloy |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |