CN117753811A - Device and method for semi-solid extrusion forming of thin-wall component - Google Patents
Device and method for semi-solid extrusion forming of thin-wall component Download PDFInfo
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Abstract
The invention discloses a device and a method for semi-solid extrusion forming of a thin-wall component, which relate to the technical field of metal processing, wherein the device for semi-solid extrusion forming of the thin-wall component comprises a pretreatment unit, an extrusion unit and a heat treatment unit, the pretreatment unit comprises a first gradient heating temperature control device and a pretreatment die, the extrusion unit comprises a second gradient heating temperature control device and an extrusion die, the heat treatment unit comprises a third gradient heating temperature control device and a heat treatment carrier, and the method for semi-solid extrusion forming of the thin-wall component comprises the steps of obtaining a cylindrical semi-solid blank, preheating, spraying lubricant, remelting and heating, extruding the thin-wall component and heat treatment; the device and the method for semi-solid extrusion molding of the thin-wall component reduce extrusion force requirements and have better molding effect.
Description
Technical Field
The invention relates to the technical field of metal processing, in particular to a device and a method for semi-solid extrusion molding of a thin-wall component.
Background
The high-strength aluminum alloy has the remarkable advantages of high strength, corrosion resistance, high temperature resistance and strong designability, has extremely wide application temperature range, or becomes a key material of high-end equipment components such as aerospace, ship navigation, weapons and the like. The thin-wall pipe is an ideal blank structure for forming the integral complex curved thin-wall part due to the closed geometric structure of the thin-wall pipe.
The large thin-wall aluminum alloy cylindrical part is one of typical workpieces in the aerospace industry, and the large thin-wall aluminum alloy cylindrical part is mainly characterized in that the overall external dimension of the cylindrical part is large, and is usually more than 500mm; "thin wall" means that the average wall thickness of the casting is small, typically less than 10mm. Moreover, the inner wall of the workpiece is often provided with criss-cross reinforcing ribs and bosses, so that the structure of the workpiece is more complex, and the manufacturing difficulty is further increased. The large thin-wall cylindrical part is usually manufactured by adopting a casting process, and then the final mechanical property and the dimensional accuracy of the product are ensured by heat treatment and mechanical processing. The traditional casting process adopts the gravity casting of a common sand mould, and because the casting has complex structure, the defects of under casting, cold shut, shrinkage cavity shrinkage, deformation, ultra-poor size and the like are easily generated, and the qualification rate of the casting is lower.
Compared with the traditional casting process, the plastic extrusion molding of the aluminum alloy has the characteristics of high production efficiency, capability of realizing one-step extrusion molding of the profile with the complex section, high molding precision, high stability and the like, and is gradually applied to the field of manufacturing aerospace large-sized high-performance aluminum alloy components. However, the extrusion mode is adopted to manufacture the wide integral wallboard, and the requirements on the tonnage level of the press and tooling equipment are high. An extruder of 125MN is needed for extrusion manufacturing of a plate with the width of 800 mm; the plate with the width of 1000mm is manufactured by extrusion, the requirement for extrusion force is increased to 225MN, and the plate is high in extrusion difficulty, easy to be unstable and high in cost.
Disclosure of Invention
The invention aims to provide a device and a method for semi-solid extrusion forming of a thin-wall component, which are used for solving the problems in the prior art, reducing the extrusion force requirement and having better forming effect.
In order to achieve the above object, the present invention provides the following solutions:
the invention provides a device for semi-solid extrusion forming of a thin-wall component, which comprises a pretreatment unit, an extrusion unit and a heat treatment unit, wherein the pretreatment unit is used for carrying out semi-solid extrusion forming on the thin-wall component;
the pretreatment unit comprises a first gradient heating temperature control device and a pretreatment die, the pretreatment die comprises an extrusion barrel, an extrusion punch, a connecting rod and a die frame, two ends of the extrusion barrel are opened, the inside of the extrusion barrel is used for accommodating semi-solid blanks, one end of the extrusion punch is fixedly connected with the die frame through the connecting rod, the extrusion punch can extend into the extrusion barrel from one end opening of the extrusion barrel, which is close to the die frame, a gap is reserved between the outer side wall of the extrusion punch and the inner side wall of the extrusion barrel, the extrusion punch can reciprocate in the axis direction of the extrusion barrel, one end, which is far away from the extrusion punch, of the die frame is used for being connected with a pressurizing shaft of an extruder, the first gradient heating temperature control device is fixedly arranged outside the extrusion barrel, and the first gradient heating temperature control device can heat the extrusion barrel;
The extrusion unit comprises a second gradient heating temperature control device and an extrusion die, the extrusion die comprises a male die and a female die, the female die is fixedly arranged at one end of the extrusion barrel far away from the die carrier, the male die is fixedly arranged between the female die and the extrusion barrel, one end of the extrusion barrel far away from the die carrier can be plugged by the male die through opening, an annular welding chamber and an annular working belt are formed by combining the male die with the female die, one end of the annular working belt is communicated with the welding chamber, a plurality of portholes are formed in the male die, the portholes can enable the welding chamber to be communicated with the inside of the extrusion barrel, so that semi-solid blanks enter the welding chamber through the portholes, the second gradient heating temperature control device is fixedly arranged outside the extrusion die, and the second gradient heating temperature control device can heat the extrusion die;
the heat treatment unit comprises a third gradient heating temperature control device and a heat treatment supporting body, an annular channel is formed in the heat treatment supporting body, one end of the annular channel is communicated with one end, far away from the welding chamber, of the annular working belt, the third gradient heating temperature control device is fixedly arranged outside the heat treatment supporting body, and the third gradient heating temperature control device heats the heat treatment supporting body.
Preferably, the first gradient heating temperature control device is fixedly sleeved on the outer wall of the extrusion cylinder, the second gradient heating temperature control device is fixedly sleeved on the outer wall of the extrusion die, and the third gradient heating temperature control device is fixedly sleeved on the outer wall of the heat treatment carrier; the outer walls of the first gradient heating temperature control device, the second gradient heating temperature control device and the third gradient heating temperature control device are fixedly sleeved with heat preservation and insulation layers; and heat insulation connecting plates are fixedly arranged between the die frame and the pressurizing shaft of the extruding machine, between the extruding cylinder and the male die, and between the female die and the heat treatment supporting body.
Preferably, a first temperature measuring channel is formed in the extrusion cylinder, a first temperature measuring element is fixedly installed in the first temperature measuring channel, a second temperature measuring channel is formed in the extrusion die, a second temperature measuring element is fixedly installed in the second temperature measuring channel, a third temperature measuring channel is formed in the heat treatment supporting body, and a third temperature measuring element is fixedly installed in the third temperature measuring channel; the first gradient heating temperature control device and the first temperature measuring element are connected with the heating temperature control system, the second gradient heating temperature control device and the second temperature measuring element are connected with the heating temperature control system, and the third gradient heating temperature control device and the third temperature measuring element are connected with the heating temperature control system.
Preferably, the outer wall of the first gradient heating temperature control device is fixedly sleeved with a prestress ring.
Preferably, the annular channel comprises a front channel and a rear channel which are sequentially connected and communicated, the front channel is arranged between the annular working belt and the rear channel, the length of the front channel is larger than 500mm, the length of the rear channel is larger than 100mm, the radius of the front channel is 5-10mm larger than that of the annular working belt, and the radius of the rear channel is 20-30mm larger than that of the front channel.
The invention also provides a method for semi-solid extrusion forming the thin-wall component, which uses the device for semi-solid extrusion forming the thin-wall component, and comprises the following steps:
s1, preparing a semi-solid blank, performing crane cutting on the semi-solid blank to remove oxide skin, and then performing machining and cutting to obtain a cylindrical semi-solid blank;
s2, preheating the extrusion cylinder by using a first gradient heating temperature control device; preheating the extrusion die by using a second gradient heating temperature control device; preheating the heat treatment carrier by using a third gradient heating temperature control device;
s3, uniformly spraying the lubricant on the working surfaces of the extrusion cylinder, the male die, the female die and the annular channel;
S4, remelting and heating the semi-solid blank by adopting a resistance furnace, and placing the cylindrical semi-solid blank obtained in the S1 into the resistance furnace, heating and preserving heat;
s5, taking the heated and insulated semi-solid blank out of the resistance furnace, clamping the semi-solid blank into an extrusion cylinder, driving an extrusion punch to extrude the semi-solid blank in the extrusion cylinder to enter an extrusion die by the operation of the extruder, and extruding a thin-wall member from an annular working belt;
s6, the thin-wall component extruded from the annular working belt enters the annular channel and slowly moves along the annular channel, and heat treatment is carried out to adjust the performance;
s7, after the semi-solid blank in the extrusion cylinder is extruded, the extruder works to drive the extrusion punch to exit the extrusion cylinder;
s8, circularly carrying out S1-S7, and continuously carrying out semi-solid extrusion molding on the thin-wall component.
Preferably, in S4, the remelting heating temperature is 300-700 ℃, and the remelting heating and heat preserving time is 5-40min.
Preferably, in S2, after the extrusion barrel is preheated by the first gradient heating temperature control device, the temperature of the semi-solid billet close to the male die is 400-700 ℃, i.e. the semi-solid billet close to the male die has 10-60% of liquid billet, and the temperature of the semi-solid billet close to the extrusion punch is 200-450 ℃, i.e. the semi-solid billet close to the extrusion punch is completely solid.
Preferably, in S2, the extrusion die is preheated by a second gradient heating temperature control device, so that the temperatures of the male die and the female die are 200-650 ℃ and the temperature at the annular working belt is 200-450 ℃; and preheating the heat treatment carrier by using a third gradient heating temperature control device to ensure that the temperature in the annular channel is 250-550 ℃.
Preferably, in S5, the extrusion speed of the extrusion punch is 1-20mm/S.
Compared with the prior art, the invention has the following technical effects:
according to the device and the method for semi-solid extrusion forming the thin-wall component, the integral forming of the large-sized thin-wall component is realized through extrusion, the aim of producing the large-sized thin-wall component is realized through small forming force, compared with the casting forming of the traditional large-sized thin-wall component, the dislocation substructure is further accumulated by utilizing the high strain rate hardening effect of materials under the extrusion of large strain quantity, the wall thickness uniformity is improved, the extruded large-sized thin-wall component enters an annular channel for heat treatment, so that the large-sized thin-wall component with good tissue performance is obtained, the forming quality of the large-sized thin-wall component is improved, the problems that the mechanical processing amount is large, the manufacturing cost is high, the forming precision is poor, the rheological tissue is damaged and the like in the traditional processing method are solved, and the performance of the large-sized thin-wall component extruded from an extrusion die is regulated through the annular channel structure.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic structural view of an apparatus for semi-solid extrusion forming of thin-walled members provided by the present invention;
FIG. 2 is a flow chart of a method of semi-solid extrusion forming a thin-walled member provided by the present invention;
fig. 3 is a half cross-sectional view of the female and male dies of fig. 1.
Fig. 4 is a flow chart of a strain induced melting activation method for preparing a semi-solid billet in accordance with the first embodiment.
Fig. 5 is a flow chart of a recrystallization partial remelting method for preparing a semi-solid billet in example two.
Fig. 6 is a schematic diagram of the male die structure in the second embodiment.
Fig. 7 is a rear view of the punch in the second embodiment.
Fig. 8 is a schematic structural view of a thin-walled ribbed member in the second embodiment.
FIG. 9 is a schematic view of grain size at various stages in a method of semi-solid extrusion forming a thin-walled member provided by the present invention;
In the figure: 101. a mould frame; 102. a connecting rod; 103. extruding a punch; 104. an extrusion cylinder; 105. semi-solid billets; 106. a first gradient heating temperature control device; 107. a pre-stress ring; 201. a male die; 202. a female die; 203. an endless working belt; 204. a welding chamber; 205. porthole; 206. a second gradient heating temperature control device; 207. a male die mandrel; 208. a male die body; 301. an annular channel; 302. a front channel; 303. a rear channel; 304. a third gradient heating temperature control device; 401. a heat insulation connection plate; 402. a first temperature measurement channel; 403. a second temperature measurement channel; 404. a third temperature measurement channel; 405. a first temperature measuring element; 406. a second temperature measuring element; 407. a third temperature measuring element; 408. and a heat preservation and insulation layer.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention aims to provide a device and a method for semi-solid extrusion forming of a thin-wall component, which are used for solving the problems in the prior art, reducing the extrusion force requirement and having better forming effect.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
As shown in fig. 1 to 9, the present invention provides an apparatus for semi-solid extrusion molding of a thin-walled member, comprising a pretreatment unit, an extrusion unit, and a heat treatment unit;
the pretreatment unit comprises a first gradient heating temperature control device 106 and a pretreatment die, the pretreatment die comprises an extrusion barrel 104, an extrusion punch 103, a connecting rod 102 and a die frame 101, two ends of the extrusion barrel 104 are opened, the inside of the extrusion barrel 104 is used for accommodating a semi-solid blank 105, one end of the extrusion punch 103 is fixedly connected with the die frame 101 through the connecting rod 102, the extrusion punch 103 can extend into the extrusion barrel 104 from one end opening of the extrusion barrel 104, which is close to the die frame 101, a gap is reserved between the outer side wall of the extrusion punch 103 and the inner side wall of the extrusion barrel 104, the extrusion punch 103 can reciprocate in the axial direction of the extrusion barrel 104, one end, far away from the extrusion punch 103, of the die frame 101 is used for being connected with a pressurizing shaft of an extruder, the first gradient heating temperature control device 106 is fixedly arranged outside the extrusion barrel 104, and the first gradient heating temperature control device 106 can heat the extrusion barrel 104;
The extrusion unit comprises a second gradient heating temperature control device 206 and an extrusion die, the extrusion die comprises a male die 201 and a female die 202, the female die 202 is fixedly arranged at one end of the extrusion barrel 104 far away from the die carrier 101, the male die 201 is fixedly arranged between the female die 202 and the extrusion barrel 104, the male die 201 can seal an opening at one end of the extrusion barrel 104 far away from the die carrier 101, the male die 201 and the female die 202 are combined to form an annular welding chamber 204 and an annular working belt 203, one end of the annular working belt 203 is communicated with the welding chamber 204, a plurality of portholes 205 are formed in the male die 201, the portholes 205 can enable the welding chamber 204 to be communicated with the interior of the extrusion barrel 104, so that semi-solid blanks 105 enter the welding chamber 204 through the portholes 205, the second gradient heating temperature control device 206 is fixedly arranged outside the extrusion die, and the second gradient heating temperature control device 206 can heat the extrusion die;
the heat treatment unit comprises a third gradient heating temperature control device 304 and a heat treatment carrier body, the heat treatment carrier body is provided with an annular channel 301, one end of the annular channel 301 is communicated with one end of the annular working belt 203, which is far away from the welding chamber 204, the third gradient heating temperature control device 304 is fixedly arranged outside the heat treatment carrier body, and the third gradient heating temperature control device 304 heats the heat treatment carrier body.
The device for semi-solid extrusion forming the thin-wall component is suitable for the production of the thin-wall component, particularly suitable for the production of large-scale thin-wall components, the first gradient heating temperature control device 106 in the pretreatment unit can heat and preserve heat of the extrusion cylinder 104 and the semi-solid blank 105, after the heat preservation is finished, the extrusion punch 103 extrudes and forms the semi-solid blank 105, and after the forming, the heat treatment unit is utilized for heat treatment, so that the thin-wall component with good tissue performance is obtained, the structural performance of the thin-wall component is good, and the dimensional precision is high.
As a preferable implementation mode, the semi-solid blank 105 needs to be processed into a cylindrical structure, the semi-solid blank 105 and the extrusion punch 103 are in clearance fit with the extrusion barrel 104 so as to realize extrusion ratio of 10-50 intervals, the thickness of the extrusion pipe wall is 0.5-5mm, extrusion molding of a large thin-wall component is realized, dislocation substructure is further accumulated by utilizing high strain rate hardening effect of the material under large strain extrusion, and the uniformity of the wall thickness is improved; in practical applications, a specific heating mode may be selected according to a specific working condition, so that the semi-solid billet 105 is extruded in a suitable environment. The cylindrical semi-solid billet 105 is preferably, but not limited to, an aluminum alloy or a magnesium alloy, and the microstructure of the cylindrical semi-solid billet 105 is in the form of fine equiaxed crystals.
In the present embodiment, the punch 201 includes a punch mandrel 207 and a punch body 208, and the punch mandrel 207 is integrally connected to the punch body 208.
Further, the first gradient heating temperature control device 106 is fixedly sleeved on the outer wall of the extrusion barrel 104, the second gradient heating temperature control device 206 is fixedly sleeved on the outer wall of the extrusion die, and the third gradient heating temperature control device 304 is fixedly sleeved on the outer wall of the heat treatment carrier; the outer walls of the first gradient heating temperature control device 106, the second gradient heating temperature control device 206 and the third gradient heating temperature control device 304 are fixedly sleeved with a heat preservation and insulation layer 408; a heat insulation connection plate 401 is fixedly arranged between the die frame 101 and the pressurizing shaft of the extruding machine, between the extruding cylinder 104 and the male die 201, and between the female die 202 and the heat treatment carrier; the heat preservation and insulation layer 408 and the heat insulation connection plate 401 are made of heat preservation and insulation materials, so that heat exchange between the semi-solid extrusion molding thin-wall component device and the external environment is reduced, different temperature conditions of the pretreatment unit, the extrusion unit and the heat treatment unit are guaranteed, and the molding quality of the large thin-wall component is improved; as a more preferable embodiment, the first gradient heating temperature control device 106, the second gradient heating temperature control device 206 and the third gradient heating temperature control device 304 are all annular, the first gradient heating temperature control device 106 is located on the outer wall of the extrusion barrel 104 and can heat the extrusion barrel 104 and the semi-solid blank 105 in the extrusion barrel 104, the second gradient heating temperature control device 206 is located on the outer wall of the male die 201 and the female die 202 and can heat the male die 201 and the female die 202 and the semi-solid blank 105 extruded into the male die 201 and the female die 202, the third gradient heating temperature control device 304 is located on the outer wall of the heat treatment carrier where the annular channel 301 is located and can heat the annular channel 301 and the large thin-wall member extruded from the extrusion die; as a more preferable implementation manner, the first gradient heating temperature control device 106, the second gradient heating temperature control device 206 and the third gradient heating temperature control device 304 are all made of induction heating coils, the induction heating coils are connected with induction heaters, the induction heaters output power of the induction heating coils, the induction heating coils are controlled by the induction heaters to output power, the gradient control of the temperature is realized by changing the degree of density of the coils, namely the pitch, so that the heating power obtained by different parts of the semi-solid blank 105 is different, the heating efficiency of the denser part of the coils is higher, the heating efficiency of the thinner part of the coils is lower, so that the temperature gradient is generated, and the semi-solid blank 105 and the extrusion die are heated by the gradient, so that the semi-solid blank 105 and the extrusion die can be heated to the required temperature and kept warm.
Further, a first temperature measuring channel 402 is formed on the extrusion barrel 104, a first temperature measuring element 405 is fixedly installed in the first temperature measuring channel 402, a second temperature measuring channel 403 is formed on the extrusion die, a second temperature measuring element 406 is fixedly installed in the second temperature measuring channel 403, a third temperature measuring channel 404 is formed on the heat treatment carrier, and a third temperature measuring element 407 is fixedly installed in the third temperature measuring channel 404; the first gradient heating temperature control device 106 and the first temperature measuring element 405 are both connected with a heating temperature control system, the second gradient heating temperature control device 206 and the second temperature measuring element 406 are both connected with the heating temperature control system, and the third gradient heating temperature control device 304 and the third temperature measuring element 407 are both connected with the heating temperature control system; the first temperature measuring element 405 can monitor the temperature of the pre-treatment die and the semi-solid billet 105 in the pre-treatment die, the second temperature measuring element 406 can monitor the temperature of the extrusion die and the semi-solid billet 105 in the extrusion die, the third temperature measuring element 407 can monitor the temperature of the annular channel 301 and the semi-solid billet 105 in the annular channel 301, and as a more preferable embodiment, the first temperature measuring element 405, the second temperature measuring element 406 and the third temperature measuring element 407 can be thermocouples, the temperature measuring range is 0 ℃ to 1200 ℃, wherein the first temperature measuring element 405 is contacted with the extrusion cylinder 104, the second temperature measuring element 406 is contacted with the male die 201, and the third temperature measuring element 407 is contacted with the side wall of the annular channel 301; the heating temperature control system is used for controlling the temperature of the whole device, so that a proper high-temperature environment is provided for the semi-solid blank 105.
Further, a prestress ring 107 is fixedly sleeved on the outer wall of the first gradient heating temperature control device 106; the inner wall of the pre-stress ring 107 is in interference fit with the outer wall of the first gradient heating temperature control device 106 to ensure that the extrusion barrel 104 is in a circumferential compressive stress state, and the bearing capacity and durability of the extrusion barrel 104 are improved by applying a pre-defined amount of circumferential compressive stress, wherein the pre-stress ring 107 is preferably but not limited to be made of a high-toughness die material without cold embrittlement, and the extrusion punch 103 and the extrusion barrel 104 are preferably but not limited to be made of a hard alloy die material without cold embrittlement, and particularly tungsten steel, high-speed tool steel or cold work die steel can be selected.
Further, the annular channel 301 includes a front channel 302 and a rear channel 303 which are sequentially connected and communicated, the front channel 302 is disposed between the annular working belt 203 and the rear channel 303, the length of the front channel 302 is greater than 500mm, the length of the rear channel 303 is greater than 100mm, the radius of the front channel 302 is 5-10mm greater than the radius of the annular working belt 203, and the radius of the rear channel 303 is 20-30mm greater than the radius of the front channel 302; here, it is necessary to lubricate the inner wall of the annular channel 301 with a lubricant such as graphite powder in advance to prevent scratches and even clogging of the surface of the extruded large thin-walled member.
The invention also provides a method for semi-solid extrusion molding of the thin-wall component, which uses the device for semi-solid extrusion molding of the thin-wall component, and comprises the following steps:
s1, preparing a semi-solid blank 105, turning the semi-solid blank 105 to remove oxide skin, and then processing and cutting to obtain a cylindrical semi-solid blank 105;
s2, preheating the extrusion barrel 104 by utilizing a first gradient heating temperature control device 106; preheating the extrusion die by using a second gradient heating temperature control device 206; preheating the heat treatment carrier by using a third gradient heating temperature control device 304;
s3, uniformly spraying the lubricant on the working surfaces of the extrusion cylinder 104, the male die 201, the female die 202 and the annular channel 301;
s4, remelting and heating the semi-solid blank 105 by adopting a resistance furnace, and placing the cylindrical semi-solid blank 105 obtained in the S1 into the resistance furnace, heating and preserving heat;
s5, taking the heated and insulated semi-solid blank 105 out of the resistance furnace, clamping the semi-solid blank 105 into the extrusion barrel 104, driving the extrusion punch 103 to extrude the semi-solid blank 105 in the extrusion barrel 104 into an extrusion die by the extruder, and extruding a thin-wall member from the annular working belt 203;
s6, the thin-wall member extruded from the annular working belt 203 enters the annular channel 301 and slowly moves along the annular channel 301, and is subjected to heat treatment to adjust the performance;
S7, after the semi-solid blank 105 in the extrusion barrel 104 is extruded, the extrusion punch 103 is driven to exit the extrusion barrel 104 by the operation of the extruder;
s8, circularly carrying out S1-S7, and continuously carrying out semi-solid extrusion molding on the thin-wall component.
In S1, the semi-solid ingot 105 may be prepared by a mechanical stirring method, an electromagnetic stirring method, a strain-induced melting activation method, or a re-crystallization partial re-melting method, for example, as shown in fig. 4, the strain-induced melting activation method is to produce a metal ingot with fine grains by using a continuous casting method, heat the metal ingot to a temperature range of recovering and re-crystallizing the metal, apply hot extrusion processing to the metal ingot, fully break an as-cast dendrite structure of the ingot by large deformation, then perform a small amount of cold deformation to the deformed metal ingot, store a part of deformation energy in the ingot, and finally cut the semi-solid ingot 105 into a proper size and shape according to the shape of the part.
In S3, the lubricant can be grease graphite, and the grease graphite can be uniformly sprayed on the working surfaces of the extrusion cylinder 104, the male die 201, the female die 202 and the annular channel 301 by using a high-pressure air pump, so that the semi-solid blank 105 can be prevented from being stuck to the die and the surface of the die from being scratched, and the surface quality of a formed part can be ensured; the semi-solid billet 105 has a certain liquid phase at semi-solid temperature, so that the semi-solid billet 105 is easy to be bonded by a die in thixotropic extrusion molding, and is critical to lubrication of the device.
In S4, remelting and heating the semi-solid blank 105 by adopting a resistance furnace, when the furnace temperature reaches the set remelting and heating temperature, putting the processed cylindrical alloy blank into the resistance furnace, and starting timing when the furnace temperature reaches the set temperature again; when the remelting heat preservation time of the blank reaches a preset value, preserving heat for a certain time to obtain a semi-solid blank 105 with spherical microstructure and thixotropic property; the remelting heating temperature of the semi-solid blank 105 determines the liquid phase ratio and fluidity of the semi-solid blank 105, when the remelting heating temperature of the semi-solid blank 105 is too low, the liquid phase volume fraction of the semi-solid blank 105 in molding is smaller, the liquid phase cannot continuously wet grain boundaries, and as part of solid phase particles cannot be continuously wrapped by the liquid phase, the solid phase is difficult to flow together with the liquid phase to complete the filling process, the liquid phase in the molding process cannot play a role in lubrication among the solid phase particles, so that the fluidity of the material is poor; in addition, when the liquid phase in the metal is less for some difficult-to-deform aluminum alloys, the recrystallization and spheroidization processes are insufficient, and the fluidity of the blank is further reduced; when the remelting heating temperature of the semi-solid billet 105 is too high, the liquid phase volume fraction of the semi-solid billet 105 in the forming is larger, while the flow stress of the semi-solid billet 105 can be reduced, and extrusion forming can be performed under smaller pressure, the clamping strength of the semi-solid billet 105 is lower at high temperature, the semi-solid billet 105 is difficult to be clamped and carried into the extrusion barrel 104 smoothly, and the coarsening of solid particles is serious; in addition, the excessive liquid phase ratio can easily lead the semi-solid blank 105 to generate solid-liquid segregation in the forming process, thereby obtaining a part with uneven structure; when the remelting heating temperature is proper, the volume fraction of the liquid phase in the semi-solid blank 105 is more suitable for thixotropic molding, and in the molding process, the liquid phase wraps the solid phase particles to flow together to complete the molding process, at the temperature, the semi-solid blank 105 has good thixotropic property, can be smoothly clamped to the extrusion cylinder 104 and has good fluidity, and the microstructure of the semi-solid blank 105 is relatively fine, so that the extrusion with good tissue and performance is obtained.
In S2, the extrusion cylinder 104 is preheated by the first gradient heating temperature control device 106; preheating the extrusion die by using a second gradient heating temperature control device 206; the third gradient heating temperature control device 304 is utilized to preheat the heat treatment carrier, the extrusion barrel 104, the male die 201, the female die 202 and the annular channel 301 are preheated to a proper temperature, the extrusion of the semi-solid blank 105 is greatly affected, when the preheating temperature is low, the heat dissipation of the semi-solid blank 105 is quick, after the semi-solid blank 105 is put into an extrusion die, the blank contacted with the extrusion die is firstly quickly cooled to form a shell layer with low liquid phase, the uniformity of the structure of an extruded part is affected, and surface cracks are caused; when the preheating temperature is higher, the mold mucosa and larger flash can appear, and the solidification time is prolonged because the cooling of the workpiece is slower, the workpiece is easy to have defects such as microcosmic shrinkage porosity, thermal cracking and the like, and the structure grains are thicker.
In S5, the extruder works to drive the extrusion punch 103 to extrude the semi-solid blank 105 in the extrusion barrel 104 into an extrusion die, the extrusion punch 103 upsets and extrudes the semi-solid blank 105, shrinkage porosity and shrinkage cavity defects of the semi-solid blank 105 are eliminated through dislocation accumulation, a dislocation substructure is further accumulated by utilizing the high strain rate hardening effect of the material under high strain quantity extrusion, and the wall thickness uniformity is improved; the semi-solid blank 105 is a solid-liquid mixture, the extrusion speed greatly affects the cooperative application and specific distribution of solid and liquid phases in the forming process of the semi-solid blank 105, when the extrusion speed is too high, the solid and liquid phases in the semi-solid blank 105 cannot move synchronously in time, the solid and liquid phases are easily separated, and the structure distribution of a finished product is uneven; the small extrusion speed is favorable for good filling of the semi-solid billet 105, but is not suitable to be too small, the liquid phase in the workpiece is easy to solidify in advance due to too slow pressure transmission, the extrusion forming pressure is difficult to transmit to the micro-area in the workpiece, and thus the phenomenon of uneven structure is generated, so that the extrusion speed needs to be reasonably selected according to the actual requirements and the specific properties of the semi-solid billet 105.
In S6, the thin-walled member extruded from the endless working belt 203 enters the endless passage 301, and moves slowly along the endless passage 301, and is heat-treated to adjust the properties, thereby obtaining a large thin-walled member with good tissue properties, and improving the molding quality of the large thin-walled member.
According to the device and the method for semi-solid extrusion forming the thin-wall component, the integral forming of the large-sized thin-wall component is realized through extrusion, the aim of producing the large-sized thin-wall component is realized through small forming force, compared with the casting forming of the traditional large-sized thin-wall component, the dislocation substructure is further accumulated by utilizing the high strain rate hardening effect of materials under the extrusion of large strain quantity, the wall thickness uniformity is improved, the extruded large-sized thin-wall component enters the annular channel 301 to be subjected to heat treatment, so that the large-sized thin-wall component with good tissue performance is obtained, the forming quality of the large-sized thin-wall component is improved, the problems of large machining quantity, high manufacturing cost, poor forming precision, damaged rheological tissue and the like of the traditional machining method can be solved, compared with the heat treatment of the traditional large-sized thin-wall component, the step of transferring from extrusion equipment to a heat preservation furnace can be omitted, the time is saved, the production efficiency is improved, and the device and the method for semi-solid extrusion forming the thin-wall component have the advantages of high efficiency, greenness, energy conservation and the like, the extrusion force is reduced, the requirement is lowered, and the requirement is better in forming effect is reduced.
As a more preferable embodiment, in S4, the remelting heating temperature is 300-700 ℃ and the remelting heating holding time is 5-40min.
In S2, after the extrusion barrel 104 is preheated by the first gradient heating temperature control device 106, the semi-solid billet 105 near the male die 201 is made to have a temperature of 400-700 ℃, i.e. the semi-solid billet 105 near the male die 201 has a liquid billet of 10-60%, the semi-solid billet 105 near the extrusion punch 103 is made to have a temperature of 200-450 ℃, i.e. the semi-solid billet 105 near the extrusion punch 103 is completely solid, and the extrusion punch 103 and the extrusion barrel 104 are in clearance fit, so that the semi-solid billet 105 is prevented from being extruded from the joint of the extrusion punch 103 and the extrusion barrel 104 in the extrusion process.
Further, the semi-solid billet 105 needs to be heated in the extrusion barrel 104 for a period of time, so that the surface and the inside of the semi-solid billet 105 reach the set temperature and then are extruded, and in practical application, the heating temperature and the heat preservation time of the billet and the extrusion die can be determined according to the specific material of the semi-solid billet 105.
As a more preferable embodiment, in S2, the extrusion die is preheated by using the second gradient heating temperature control device 206, so that the temperatures of the male die 201 and the female die 202 are 200-650 ℃, the blank is kept in a semi-solid state, the blank flow is facilitated to reduce extrusion force, the temperature at the annular working belt 203 is 200-450 ℃, and the extruded large thin-wall component is cooled and solidified; the third gradient heating temperature control device 304 is utilized to preheat the heat treatment carrier, so that the temperature in the annular channel 301 is 250-550 ℃, in practical application, the heat treatment temperature and the heat preservation time length can be determined according to the specific material of the semi-solid blank 105, and the speed of the extrusion punch 103 can be determined according to the heat preservation time length and the length of the front channel 302.
Further, if the material strength still does not meet the requirement after the heat treatment of the front channel 302, the solution aging treatment can be performed on the large thin-wall member, the solution temperature is 300-550 ℃, and the solution time is 1-8 hours; the aging temperature is 100-300 ℃, and the aging time is 4-48h.
As a more preferable embodiment, in S5, the extrusion speed of the extrusion punch 103 is 1 to 20mm/S.
Example 1
The semi-solid billet 105 is a 7075 aluminum alloy which is difficult to deform; the extrusion punch 103 and the extrusion barrel 104 are both made of D2 cold-working die steel, and are subjected to surface nitriding treatment and grinding and polishing; the pre-stressing ring 107 is made of 316L stainless steel. The method comprises the following specific steps:
s1, as shown in FIG. 4, preparing 7075 aluminum alloy semi-solid blank 105 by using a strain-induced melting activation method, and performing machining and cutting after descaling the semi-solid blank 105 to prepare cylindrical 7075 aluminum alloy semi-solid blank 105 with the radius of 50mm and the length of 200 mm; after machining, the outer diameter of the semi-solid billet 105 is the same as the outer diameter of the extrusion barrel 104, and the semi-solid billet is in clearance fit; the semi-solid billet 105 has a length less than the length of the extrusion barrel 104;
s2, performing gradient heating treatment on the extrusion barrel 104 and the semi-solid blank 105 by using a first gradient heating temperature control device 106 to enable the temperature of the extrusion barrel 104 near the male die 201 to be 540 ℃ and the temperature of the extrusion barrel 104 near the extrusion punch 103 to be 400 ℃; carrying out gradient heating treatment on the male die 201 and the female die 202 by using a second gradient heating temperature control device 206, wherein the temperature of the main body parts of the male die 201 and the female die 202 is 450 ℃, and the temperature of the annular working belt 203 is 400 ℃; heating the annular channel 301 by using a third gradient heating temperature control device 304, wherein the heating temperature of the annular channel 301 is 400 ℃;
S3, uniformly spraying grease graphite on the working surfaces of the extrusion cylinder 104, the male die 201, the female die 202 and the annular channel 301 by adopting a high-pressure air pump;
s4, remelting and heating the semi-solid blank 105 by adopting a resistance furnace, when the furnace temperature reaches 540 ℃, putting the processed cylindrical alloy blank into the resistance furnace, and starting timing when the furnace temperature reaches the set temperature again; when the remelting heat preservation time of the blank reaches a preset value, preserving heat for 5min;
s5, rapidly taking out the semi-solid blank 105 from the hearth and clamping the semi-solid blank 105 into the extrusion cylinder 104, extruding the semi-solid blank 105 into the male die 201 and the female die 202 by the extrusion punch 103, and extruding a large thin-wall member from the annular working belt 203, wherein the wall thickness is only 1mm, the radius is 200mm, and the moving speed of the extrusion punch 103 is 2mm/s;
s6, the extruded large thin-wall member enters the annular channel 301 and slowly moves along the annular channel 301, and heat treatment is carried out to adjust the performance of the large thin-wall member;
s7, after the semi-solid blank 105 is extruded, the extrusion punch 103 is retracted;
s8, circularly carrying out S1-S7, and continuously carrying out semi-solid extrusion molding on the thin-wall component.
It should be explained that, in the extrusion molding process, the extrusion press is used to drive the connecting rod 102 and the extrusion punch 103 to move, the extrusion force of the extrusion press is greater than 6000tons, the connecting rod 102 is fixed on the die carrier 101, the die carrier 101 is fixed on the upper table surface of the extrusion press, the die clamping speed of the extrusion press is greater than 100mm/s, so as to ensure that the rapid extrusion molding under the non-isothermal condition is smoothly performed, and in addition, the hardness of the extrusion punch 103 is greater than 50HRC.
The length of the front channel 302 is 720mm, the length of the rear channel 303 is 100mm, the radius of the front channel 302 is 10mm larger than that of the annular working belt 203, the radius of the rear channel 303 is 30mm larger than that of the front channel 302, and the annular channel 301 needs to be lubricated with graphite powder in advance so as to prevent the surface of an extruded large thin-wall member from being scratched or even blocked.
Example two
The method for semi-solid extrusion forming of the thin-wall component provided by the embodiment is used for forming a large-sized ribbed thin-wall component shown in fig. 8, wherein the wall thickness of the large-sized ribbed thin-wall component is 1.5mm, the rib height is 15mm, and the required female die 202 and male die 201 of the large-sized ribbed thin-wall component are shown in fig. 7, and the specific steps are as follows:
s1, as shown in FIG. 4, preparing 7075 aluminum alloy semi-solid blank 105 by using a strain-induced melting activation method, and performing machining and cutting after descaling the semi-solid blank 105 to prepare cylindrical 7075 aluminum alloy semi-solid blank 105 with the radius of 50mm and the length of 200 mm; after machining, the outer diameter of the semi-solid blank 105 is the same as the outer diameter of the extrusion cylinder 104, and the semi-solid blank and the extrusion cylinder are in clearance fit; the semi-solid billet 105 has a length less than the length of the extrusion barrel 104;
s2, performing gradient heating treatment on the extrusion barrel 104 and the semi-solid blank 105 by using a first gradient heating temperature control device 106, so that the temperature of the extrusion barrel 104 near the male die 201 is 560 ℃ and the temperature of the extrusion barrel 104 near the extrusion punch 103 is 420 ℃; carrying out gradient heating treatment on the male die 201 and the female die 202 by using a second gradient heating temperature control device 206, wherein the temperature of the main body parts of the male die 201 and the female die 202 is 500 ℃, and the temperature of the annular working belt 203 is 420 ℃; heating the annular channel 301 by using a third gradient heating temperature control device 304, wherein the heating temperature of the annular channel 301 is 420 ℃;
S3, uniformly spraying grease graphite on the working surfaces of the extrusion cylinder 104, the male die 201, the female die 202 and the annular channel 301 by adopting a high-pressure air pump;
s4, remelting and heating the semi-solid blank 105 by adopting a resistance furnace, when the furnace temperature reaches 540 ℃, putting the processed cylindrical alloy blank into the resistance furnace, and starting timing when the furnace temperature reaches the set temperature again; when the remelting heat preservation time of the blank reaches a preset value, preserving heat for 5min;
s5, rapidly taking the semi-solid blank 105 out of the hearth and clamping the semi-solid blank 105 into the extrusion barrel 104, extruding the semi-solid blank 105 into the male die 201 and the female die 202 by the extrusion punch 103, and extruding a large thin-wall member from the annular working belt 203, wherein the wall thickness is 1.5mm, the rib height is 15mm, and the radius is 200mm.
The speed of the extrusion bar is 1mm/s;
s6, the extruded large thin-wall member enters the annular channel 301 and slowly moves along the annular channel 301, and heat treatment is carried out to adjust the performance of the large thin-wall member;
s7, after the semi-solid blank 105 is extruded, the extrusion punch 103 is retracted;
s8, circularly carrying out S1-S7, and continuously carrying out semi-solid extrusion molding on the thin-wall component.
The principles and embodiments of the present invention have been described in detail with reference to specific examples, which are provided to facilitate understanding of the method and core ideas of the present invention; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (10)
1. A device for semi-solid extrusion forming of thin-walled components, which is characterized in that: comprises a pretreatment unit, an extrusion unit and a heat treatment unit;
the pretreatment unit comprises a first gradient heating temperature control device and a pretreatment die, the pretreatment die comprises an extrusion barrel, an extrusion punch, a connecting rod and a die frame, two ends of the extrusion barrel are opened, the inside of the extrusion barrel is used for accommodating semi-solid blanks, one end of the extrusion punch is fixedly connected with the die frame through the connecting rod, the extrusion punch can extend into the extrusion barrel from one end opening of the extrusion barrel, which is close to the die frame, a gap is reserved between the outer side wall of the extrusion punch and the inner side wall of the extrusion barrel, the extrusion punch can reciprocate in the axis direction of the extrusion barrel, one end, which is far away from the extrusion punch, of the die frame is used for being connected with a pressurizing shaft of an extruder, the first gradient heating temperature control device is fixedly arranged outside the extrusion barrel, and the first gradient heating temperature control device can heat the extrusion barrel;
the extrusion unit comprises a second gradient heating temperature control device and an extrusion die, the extrusion die comprises a male die and a female die, the female die is fixedly arranged at one end of the extrusion barrel far away from the die carrier, the male die is fixedly arranged between the female die and the extrusion barrel, one end of the extrusion barrel far away from the die carrier can be plugged by the male die through opening, an annular welding chamber and an annular working belt are formed by combining the male die with the female die, one end of the annular working belt is communicated with the welding chamber, a plurality of portholes are formed in the male die, the portholes can enable the welding chamber to be communicated with the inside of the extrusion barrel, so that semi-solid blanks enter the welding chamber through the portholes, the second gradient heating temperature control device is fixedly arranged outside the extrusion die, and the second gradient heating temperature control device can heat the extrusion die;
The heat treatment unit comprises a third gradient heating temperature control device and a heat treatment supporting body, an annular channel is formed in the heat treatment supporting body, one end of the annular channel is communicated with one end, far away from the welding chamber, of the annular working belt, the third gradient heating temperature control device is fixedly arranged outside the heat treatment supporting body, and the third gradient heating temperature control device heats the heat treatment supporting body.
2. The apparatus for semi-solid extrusion forming of thin-walled members as claimed in claim 1 wherein: the first gradient heating temperature control device is fixedly sleeved on the outer wall of the extrusion cylinder, the second gradient heating temperature control device is fixedly sleeved on the outer wall of the extrusion die, and the third gradient heating temperature control device is fixedly sleeved on the outer wall of the heat treatment carrier; the outer walls of the first gradient heating temperature control device, the second gradient heating temperature control device and the third gradient heating temperature control device are fixedly sleeved with heat preservation and insulation layers; and heat insulation connecting plates are fixedly arranged between the die frame and the pressurizing shaft of the extruding machine, between the extruding cylinder and the male die, and between the female die and the heat treatment supporting body.
3. The apparatus for semi-solid extrusion of thin-walled structures as claimed in claim 2 wherein: the extrusion die is characterized in that a first temperature measuring channel is formed in the extrusion cylinder, a first temperature measuring element is fixedly arranged in the first temperature measuring channel, a second temperature measuring channel is formed in the extrusion die, a second temperature measuring element is fixedly arranged in the second temperature measuring channel, a third temperature measuring channel is formed in the heat treatment supporting body, and a third temperature measuring element is fixedly arranged in the third temperature measuring channel; the first gradient heating temperature control device and the first temperature measuring element are connected with the heating temperature control system, the second gradient heating temperature control device and the second temperature measuring element are connected with the heating temperature control system, and the third gradient heating temperature control device and the third temperature measuring element are connected with the heating temperature control system.
4. A device for semi-solid extrusion of thin-walled structures as claimed in claim 3 wherein: the outer wall of the first gradient heating temperature control device is fixedly sleeved with a prestress ring.
5. The apparatus for semi-solid extrusion forming of thin-walled members as claimed in claim 1 wherein: the annular channel comprises a front channel and a rear channel which are sequentially connected and communicated, the front channel is arranged between the annular working belt and the rear channel, the length of the front channel is larger than 500mm, the length of the rear channel is larger than 100mm, the radius of the front channel is 5-10mm larger than that of the annular working belt, and the radius of the rear channel is 20-30mm larger than that of the front channel.
6. A method of semi-solid extrusion forming a thin-walled member using the apparatus for semi-solid extrusion forming a thin-walled member as claimed in any of claims 1 to 5, characterized in that: the method comprises the following steps:
s1, preparing a semi-solid blank, performing crane cutting on the semi-solid blank to remove oxide skin, and then performing machining and cutting to obtain a cylindrical semi-solid blank;
s2, preheating the extrusion cylinder by using a first gradient heating temperature control device; preheating the extrusion die by using a second gradient heating temperature control device; preheating the heat treatment carrier by using a third gradient heating temperature control device;
s3, uniformly spraying the lubricant on the working surfaces of the extrusion cylinder, the male die, the female die and the annular channel;
s4, remelting and heating the semi-solid blank by adopting a resistance furnace, and placing the cylindrical semi-solid blank obtained in the S1 into the resistance furnace, heating and preserving heat;
s5, taking the heated and insulated semi-solid blank out of the resistance furnace, clamping the semi-solid blank into an extrusion cylinder, driving an extrusion punch to extrude the semi-solid blank in the extrusion cylinder to enter an extrusion die by the operation of the extruder, and extruding a thin-wall member from an annular working belt;
s6, the thin-wall component extruded from the annular working belt enters the annular channel and slowly moves along the annular channel, and heat treatment is carried out to adjust the performance;
S7, after the semi-solid blank in the extrusion cylinder is extruded, the extruder works to drive the extrusion punch to exit the extrusion cylinder;
s8, circularly carrying out S1-S7, and continuously carrying out semi-solid extrusion molding on the thin-wall component.
7. The method of semi-solid extrusion forming a thin-walled member in accordance with claim 6 wherein: in S4, the remelting heating temperature is 300-700 ℃, and the remelting heating heat preservation time is 5-40min.
8. The method of semi-solid extrusion forming a thin-walled member in accordance with claim 6 wherein: in S2, preheating the extrusion cylinder by using a first gradient heating temperature control device, and enabling the temperature of the semi-solid blank close to the male die to be 400-700 ℃, namely, enabling the semi-solid blank close to the male die to have 10-60% of liquid blank, and enabling the temperature of the semi-solid blank close to the extrusion punch to be 200-450 ℃, namely, enabling the semi-solid blank close to the extrusion punch to be completely solid.
9. The method of semi-solid extrusion forming a thin-walled member in accordance with claim 6 wherein: in S2, preheating an extrusion die by using a second gradient heating temperature control device, so that the temperatures of a male die and a female die are 200-650 ℃, and the temperature at an annular working belt is 200-450 ℃; and preheating the heat treatment carrier by using a third gradient heating temperature control device to ensure that the temperature in the annular channel is 250-550 ℃.
10. The method of semi-solid extrusion forming a thin-walled member in accordance with claim 6 wherein: in S5, the extrusion speed of the extrusion punch is 1-20mm/S.
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