The specific embodiment
Fig. 1 (a) shows the ideograph of the cold chamber die casting mode casting system of the embodiment of the invention.But metal mould device 10 has dynamic model 11, the fixed die 12 that can freely move back and forth, but dynamic model 11 can move at joint and detaching direction by relative fixed mould 12.But fixed die 12 contacts with the tight of dynamic model 11, has formed the hollow space with shape opposite with goods, i.e. die cavity D.
In fixed die 12 1 sides, be provided with the cast gate A that is used for molten metal is imported die cavity D.Having the cylindrical body that can make the passage that molten metal flows through is that sleeve 13 relative gravity directions flatly connect in the earthing mutually with this cast gate A, in this sleeve 13, the plunger 14 that is connected with the not shown injector that goes out can be installed with freely advancing and retreat.Also be provided with in this sleeve 13 and molten metal can be injected inner opening, ie in solution inlet 15.In addition, the bottom of this sleeve 13 also is provided with as the combustion furnace of the heater that is difficult for making the molten metal cooling etc. sometimes.Sleeve 13 heated to make molten metal insulation, and can improve the molten metal flowability of molten metal in metal mould device 10.
Next, with Fig. 1 (a), 1 (b) illustrates the action of this casting system.But at the recess coating remover of the die cavity that constitutes dynamic model 11 and fixed die 12, but drive dynamic model 11, but dynamic model 11 is closely contacted with fixed die 12, form the die cavity D (step 1) that is communicated with cast gate A.Then, the magnesium alloy that will be dissolved state by feeder 16 takes out from heating furnace, and by the solution inlet 15 that is arranged on the sleeve 13, molten metal 17 is infeeded sleeve 13 (step 2).
Then, by plunger 14 being inserted into fixed die 12 1 sides fast, the molten metal that injects sleeve 13 is pressed into metal mould device 10 (step 3) by the cast gate A that is arranged on the metal mould device 10 by the not shown injector that goes out.Afterwards, in the process of relative metal mould device 10 distribute heats of the molten metal in being pressed into metal mould device 10 and cooling curing, plunger 14 is got back to home position (step 4) shown in Fig. 1 (b).
Then, but retract dynamic model 11, separate with fixed die 12.At this moment, but the magnesium alloy component of cooling curing is attached to dynamic model 11 1 sides.But this magnesium alloy component is extruded by the not shown ejection pin that goes out that is arranged in the dynamic model 11, but and from dynamic model 11 demoulding (step 5).Thus, casting circulation finishes.
The foundry goods that obtains like this carries out disjunction by punch press, shown in Fig. 2 (a), takes out the goods X at the position that only is equivalent to die cavity D, and rest parts is as utilizing resource to reclaim again.Goods X deburrs where necessary and applies after the processing, shown in Fig. 2 (b), is used for the casing building block as the notebook computer Y of electric product.When being used for the portable electric goods of notebook computer and portable phone etc., can improve the Portability of these electric products.
Below, describe the situation of advancing of the molten metal of metal mould device 10 inside with reference to the accompanying drawings in detail.In Fig. 3 (a) and (b), but show the profile of the flow passage that is formed at the interior molten metal of metal mould device 10 when the dynamic model of cutting open along the main flow direction of the length direction of cast gate A and molten metal 11 closely contact with fixed die 12.
Be pressed into the molten metal of cast gate A by plunger 14, flow into the first flow part B that is communicated with cast gate A.First flow part B is thinner than the cross section of cast gate A, and its sectional area ratio is 0.1.The molten metal that has improved flow velocity by first flow part B flows into the second runner section C.The second runner section C is arranged on and flows through with extending the direction of main flow direction quadrature of the molten metal of first flow part B.Molten metal is by the width shunting of this second runner section C along article shape.(choked flow cast gate (ゲ-ト) 21) is connected throttle clearance by high 1 millimeter that is provided with along the second flow channel length direction of the second runner section C and cavity section D communicatively.Behind this choked flow cast gate 21, molten metal flows into die cavity D.But die cavity D is the cavity with shape opposite with casing that is between the protuberance of the recess on dynamic model 11 surfaces and fixed die 12.With regard to the molten metal that one side loading mould cavity D advances on one side, carrying the molten metal of bubble secretly and invading the pore E that is arranged on die cavity D periphery.In the terminal of die cavity D, also be provided with pore E, charge into the gas in the die cavity D, E carries out exhaust by this pore.
When flow front arrived the terminal of die cavity D, molten metal was invaded and through air passing hole E.At this moment, what the pore E that is located at die cavity D terminal had a molten metal accumulates part 22, this part is formed with the flow passage wideer than other parts, this molten metal accumulates part 22 makes flow tendency invade chilling hole F damply, in order to form long flow passage, the cross sectional shape that the direct of travel in the moving forward position of chilling hole F longshore current is cut open is a zigzag.When the flow front of molten metal was solidified, this solidifying body played stopper, so that molten metal can not be ejected into the outside of metal pattern.
Utilize the molten metal with pore E of chilling hole F one side to accumulate the effect of part 22, the reaction minimum that the solidifying body in the chilling hole is caused.Therefore, when shaping thin-walled shape, the molten metal that is positioned at pore E accumulates part 22 makes the shaping of die cavity D stable easily.Molten metal flows into up to the time of solidifying at chilling hole F from cast gate A approximately needs 2 milliseconds.Therebetween, relative metal mould device nature heat release of the heat of molten metal and cooling.Molten metal in other parts solidifies similarly.
Particularly when carrying out the injection moulding of cold chamber die casting mode, being pressed into of plunger 14 can produce in sleeve 13 and carry bubble secretly, before injecting die cavity D, sneaks into bubble in the molten metal easily.Such bubble is included near the flow front of molten metal mostly, therefore by pore is set, can get rid of such bubble from design surface.In addition, in pore that the chilling hole links to each other,, can in pore, form the part of accumulating of molten metal by enlarging flow passage midway, make high speed impact molten metal the pressure transmission slowly and utilize the reaction reduction impacted influence to design surface.
Below, with reference to accompanying drawing the cast gate A in the above-mentioned flow passage structure, first flow part B, the second runner section C are at length described.Among Fig. 4, show the ideograph of the intercepting first flow B and the second runner C.When the area of the cross section of the chain-dotted line O of the cast gate A shown in Fig. 3 (a) and (b) is L, and the area of the cross section of the chain-dotted line P of the first flow part B shown in Fig. 4 (a) is M, then sets M/L=0.1 in the above-described embodiment for.In addition, when the area of the cross section of the chain-dotted line Q of the second runner section C shown in Fig. 4 (a) is N, set M=2N for.
Chain-dotted line O, P, Q represent the cross section perpendicular to the main direct of travel of the molten metal of each flow passage that flows into vacant state respectively.Be roughly the A4 size (length direction of the die cavity D of the negative shape of the box part of 296mm * 210mm) is connected the flow passage of above-mentioned design and carried out forming test, can obtain not have the molded article of bad part with regard to having.
Relation with regard to area of section M and N, be not more than the area of section of leading portion part by the area of section of setting the back segment part for, can make the loss of injection pressure less, in addition, be similar to M=2N by making the back segment part partly be unlikely to too small setting for as far as possible, can avoid flow velocity to increase sharp than leading portion.Thus, can make flow front stable, and can in controllable scope, carry out filling at a high speed.From the viewpoint that the pressure loss reduces flow velocity, with regard to the relation between area of section L and the area of section M, think that its difference is preferably less, and the value of M/L is preferably set for more than 0.05.In addition, think that also the value of 2N/L preferably sets for more than 0.05 equally.
That is, during electric product casing below making general family expenses size,, set 2N/L as far as possible near 1 with regard to the relation between the area of section L of the area of section 2N of the second runner section C and cast gate A.In addition, the area of section of runner section in the past is that M/L is 0.02~0.03, and does not possess second runner section of the effect of storing.
Second runner section has cavity, and this cavity has the choked flow cast gate 21 in the gap that highly is about 1mm relatively, has the comparatively depth capacity of sufficient 20mm of relative its short transverse.That is, an end of the depth direction of cavity is the flow passage that is made of the choked flow cast gate 21 that disposes throttling.On the wall that the second runner section C constitutes, be formed with side wall portion W and extend the wall (inhibition face WL) that ground is provided with in the vertical direction of the direct of travel of relative flow front, this side wall portion W is provided with communicatively along the long side direction of die cavity D and extends the choked flow cast gate 21 that ground is provided with, with regard to the flow front of major part, the inflow towards die cavity D is played a part interim obstruction from the molten metal of first flow part B inflow.
This inhibition can make the flow front that is flowed into by first flow part B postpone towards the time (period) that die cavity D flows into.Promptly, cast gate one side towards in the past not only has the flow passage structure of the component that constitutes sharp keen projection, with the perpendicular direction of the direction of advance of flow front, or by means of the such component of recess with die cavity D one side, the wall of component can make the flow front that pours produce delay to advancing of die cavity D one side.
In addition, the second runner section C has the space that can temporarily store molten metal, therefore, can control the flow front that flows into the molten metal in the die cavity D at an easy rate.In structure in the past, owing to can not limit the decay of the flow velocity of flow front, and towards the direction of choked flow cast gate, be enough to make the flow passage that molten metal advances removing, rich space is not set, nor possesses the space that obstruction stores effect.In structure in the past, molten metal is invaded die cavity D with the feed pressure inflow velocity that is adapted to the first flow part, and produced this situation, promptly, near the extended line of the length direction of runner section, supply with molten metal in large quantities, and molten metal almost can not supply to peripheral part in addition.
Utilize the structure of runner section of the present invention, molten metal from cast gate A inflow, by impact to inhibition face W, hindered inflow provisionally towards die cavity D, simultaneously, also, mate synchronously with width at die cavity D by storing the effect in the cavity of the second runner section C provisionally.When molten metal was filled the second runner section C, based on Pascal's principle, the transmission of pressure made molten metal inject die cavity D from the second runner section C again.
Along the cross section of the width intercepting of the die cavity D of the above-mentioned second runner section C, its long limit is communicated with the long limit of die cavity D, and extends concurrently with respect to the long limit of die cavity D and to be provided with.Thus, can shorten the time that flows through die cavity D, make molten metal be difficult to cooling curing, and can suppress to impair the phenomenon of molten metal flowability.
At the main flow direction of the molten metal of the above-mentioned second runner section C, on the surface of the opposition side that is positioned at choked flow cast gate 21, disposing ejection pin 31 symmetrically along the direction line of die cavity D.The surface configuration of this bottom surface is plane.The wall portion (inhibition face W) that forms being connected with choked flow cast gate 21 is provided with the conical surface, and therefore, the cross section of the second runner section C roughly is the platform shape.Compare with being configured in die cavity D inside, the influence to article shape preferably can be reduced in the inside that ejection pin 31 is configured in the second runner section C.
With regard to the shape in the cross section, bottom surface of the second runner section C, can be various distortion.The cross section is the discontinuous shape of polygonal etc. preferably, but from being easy to the viewpoint that molten metal flows, preferably forms circle semicircle free curve shape etc.
The second runner section C that Fig. 4 (b) illustrates at the width of die cavity D, has step part 32 in its bottom surface.Impact the flow vector of the molten metal generation of this step part 32 towards choked flow cast gate 21.Thereby, the position by adjusting this step part, shape, highly, quantity etc., can flow into the amount of the molten metal in the die cavity in width control.
In addition, in the runner shown in Fig. 4, has the inclined bottom that shoals gradually at width.Because the flow velocity of molten metal is very fast, therefore have this situation, that is, even do not form clear and definite step part, can control flow tendency yet.In addition, such situation is arranged also, that is, by using shape, can adjust the influx of molten metal, thereby can generate the fluid forward position of the multiple shape of coincideing with the cavity shape of whole die cavity D at the width of die cavity D as the bottom surface with free curve.
With regard to the length of choked flow cast gate 21, can widely set for apart from the length of die cavity D by in the past 1mm (runner terminal part) to 30mm (runner branch point), but think that molten metal is below the 10mm by the ultimate range of choked flow cast gate 21.Consider because molten metal makes mobile variation because of being cooled during by choked flow cast gate 21, to molded article generation harmful effect.At last, the part of solidifying in the part of solidifying in die cavity D and the second runner section C is separated by means of pressure, and therefore, because the residual part that its cutting-out is arranged, the length of choked flow cast gate is preferably more than the 1mm.In addition, shown in Fig. 3 (a) and (b), the open amount of choked flow cast gate 21 preferably is not one, as a plurality of pore E that link to each other with chilling hole F, can be divided into a plurality of by isolation.In addition, with respect to the length of the width of the die cavity D of the second runner section C, the width of setting relative die cavity D in the above-described embodiments for is 0.8 times, but unqualified to this, can suitably set.
In the above-described embodiments at being illustrated, but be not limited to this, also be applicable to for example aluminium, zinc, copper and their alloy with the situation of magnesium alloy as molten metal.
In the above-described embodiments, the injecting systems of cold chamber die casting mode is illustrated, but is not limited to this, the metal mould device of hot chamber diecasting mode and thixotroping pattern mode also is suitable for.
In the above-described embodiments, manufacture method with the box part of notebook computer is illustrated, but be used for external packing casings such as portable audio-device, portable phone and case and bag etc., constitute the box part of design shape with regard to itself and had special effect, but in addition, also can be used for other purposes as required.
In the above-described embodiment, constitute the superhard alloy that the metal pattern surface of die cavity D has used nitriding to handle, but consider the durability of metal pattern, preferably implement various coatings processing.Embodiment to effective especially coated layer describes with reference to the accompanying drawings.
In order to obtain the cast product of thin-walled, must promptly be full of die cavity, lower and produce fluid and flow and descend to be unlikely generation by the molten metal temperature.Therefore, when adopting cold chamber die casting, injecting the molten metal required time is 2 milliseconds.Consider hot chamber die casting and thixotroping type method etc., during other casting method, estimate that the inflow velocity scope of the molten metal of choked flow cast gate is 50m/s to 200m/s.
But, at high temperature fluid during, make the occurrence frequency of the damage of body surface and microfissure comparatively remarkable with the high-speed impact object plane.When the appearance of metal pattern surface is damaged, make mobile the reduction, and damaged shape copying constitutes the bad main cause that is shaped to the surface of molded article.In addition, the bump of damaged part and heat stagnation are returned and can be caused stress to be concentrated, and metal pattern is cracked.
Therefore, when considering the life-span of shaping Products Quality and metal pattern, preferably provide the structure that is difficult for producing cavitation erosion.
Among Fig. 5, show the ideograph of sleeve surface of the die cavity D of the metal mould device that constitutes the embodiment of the invention.
Lining 40 comprises: parent metal part 41, and this parent metal part is by constituting with identical in the past hot rolling mould steel (SKD61); Intermediate layer 42, this intermediate layer are formed on these parent metal part 41 surfaces and are made of stainless steel (SUS304), and thickness is 2mm; Cobalt alloy layer 43, this cobalt alloy layer are formed on these 42 surfaces, intermediate layer and become the metal pattern surface that constitutes die cavity D, and thickness is 2mm.In order to improve surface roughness, carry out fine finishining to the surface of cobalt alloy layer 43.
The design in intermediate layer 42 is to be used for preventing that the lining 40 from the cobalt alloy layer from peeling off.Cobalt alloy layer 43 forms by spraying plating or welding cobalt alloy, at this moment, produces thermal stress between hot rolling mould steel and cobalt alloy, can not engage well.Even can engage,, also can occur peeling off because the heat stagnation in residual stress and the casting process is returned.Therefore, by forming intermediate layer 42, can make cobalt alloy layer 43 unlikely generation stripping damage by the parts that relax thermal stress.
The cobalt alloy that constitutes cobalt alloy layer 43 is chosen the alloy of this component ratio, that is, weight ratio is Co:64%, Cr:28%, W:4%, Fe:3%, C:1%.Compare with the hot rolling mould steel that hot rolling mould steel, nitrogen treatment are crossed, use the metal pattern of this cobalt alloy can obtain the endurance quality of 8 times and 4 times respectively.But the thickness of nitrogen treatment layer that is formed on the surface of hot rolling mould steel is 0.1mm, but the cobalt alloy layer that welding or spraying plating form can reach the thickness of 2mm, is expected to obtain the longer life-span.
In addition, when metal pattern being implemented coating with cobalt alloy, in common metal pattern, preferably only on the surface of choked flow gate portions and formation die cavity, carry out, but have so that the flow front of the molten metal that flows into slows down when for purpose the inhibition face being set, as second runner section, preferably also this inhibition face is implemented coating.
As what above be described in detail, the manufacture method of metal mould device of the present invention and structural member can be made the thin-wall box body member with high rate of finished products.