CN1276276A - Metal mold device, die casting method and die cast product - Google Patents
Metal mold device, die casting method and die cast product Download PDFInfo
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- CN1276276A CN1276276A CN99122854A CN99122854A CN1276276A CN 1276276 A CN1276276 A CN 1276276A CN 99122854 A CN99122854 A CN 99122854A CN 99122854 A CN99122854 A CN 99122854A CN 1276276 A CN1276276 A CN 1276276A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/32—Controlling equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
- B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
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Abstract
本发明提供一种金属模装置及采用该金属模装置的镁合金压铸方法,上述金属模装置是适用于镁合金的压铸或金属注射成型的金属模装置,其为,设数个浇口,从直浇口至各浇口设置直接流道,及将相邻浇口间的非浇口部分距离,除制品设计上不允许的情形外,设为10mm以下。本发明金属模装置的压铸方法,对于薄壁铸造有效,特别是对于1.5mm以下薄壁铸造或含硅、稀土元素,钙的合金铸造有效,特别是对该1.5mm以下薄壁铸造或含硅、稀土元素,钙的合金铸造有效能够以高品质稳定地得到没有铸件皱纹,表面裂纹,填充不良,金属模粘砂的压铸制品。The present invention provides a metal mold device and a magnesium alloy die-casting method using the metal mold device. The metal mold device is a metal mold device suitable for magnesium alloy die-casting or metal injection molding. Set up direct runners from the sprue to each gate, and set the non-gate distance between adjacent gates to be less than 10mm, except in cases where the product design does not allow it. The die-casting method of the metal mold device of the present invention is effective for thin-wall casting, especially for thin-wall casting below 1.5mm or alloy casting containing silicon, rare earth elements, and calcium, especially for thin-wall casting below 1.5mm or silicon-containing casting. , rare earth elements, and calcium alloy casting can effectively and stably obtain high-quality die-casting products without casting wrinkles, surface cracks, poor filling, and sand sticking to metal molds.
Description
本发明是关於一种适用於镁合金的压铸或摇溶模塑(thixomouldirg)制法等金属注射成形的金属模装置,采用该金属模具方案的压铸方法及压铸制品,更详细而言,是关於一种可采用於制造家电制品的框体,汽车的各种容器部件等所要求的薄壁铸造部件的金属模装置,通过采用该金属模装置的压铸方法,例如可以实现最小壁厚1.5mm以下的镁合金的压铸方法及压铸制品。The present invention relates to a metal mold device suitable for metal injection molding such as die-casting or thixomouldirg (thixomouldirg) manufacturing methods of magnesium alloys, a die-casting method and a die-cast product using the metal mold scheme, and more specifically relates to A metal mold device that can be used in the manufacture of thin-walled cast parts required for the manufacture of housings for home appliances, various container parts for automobiles, etc. By using the die-casting method using the metal mold device, for example, the minimum wall thickness can be realized below 1.5mm Die-casting method and die-casting products of magnesium alloy.
又,本发明是关於一种室温强度及高温强度优异的镁合金的压铸方法及压铸制品,更详细而言,是关於一种在汽车引擎零件等当中轻量化所要求的至523K左右的高温度也具有充分强度的镁合金的压铸方法及压铸制品。Also, the present invention relates to a die-casting method and die-cast product of a magnesium alloy excellent in room temperature strength and high-temperature strength, and more specifically, relates to a high temperature of about 523K required for weight reduction of automotive engine parts and the like. A die-casting method and a die-cast product of a magnesium alloy also having sufficient strength.
近年来,轻量材料的需求增加,逐渐使用树脂材料或轻金属材料。但是,树脂材料是一般较难反复使用而在地球环保上有问题,针对此问题,由於金属材料是一般较易再利用,因此,家电制品的框体,汽车的各种容器部件等的制造材料从树脂材料变更为镁系材料或铝系材料等的轻金属,特别是在轻薄短小的趋势中,不但具有作为金属的刚性,且在实用轻金属中密度也最小的轻量镁系材料受注目,形成以汽车或便携家电制品用材料而受注目的潮流。特别是,在笔记型个人电脑或数字摄像机、MD随身听(便携式立体声单放机)、摄像机等的便携商品的框体中,被要求壁厚1.5mm以下,特别是1.2mm以下的制品。In recent years, the demand for lightweight materials has increased, and resin materials or light metal materials have gradually been used. However, resin materials are generally difficult to reuse and have problems in environmental protection. In response to this problem, metal materials are generally easier to reuse, so they are used as manufacturing materials for housings of home appliances and various container parts for automobiles. Change from resin materials to light metals such as magnesium-based materials or aluminum-based materials. Especially in the trend of lightness, thinness and shortness, lightweight magnesium-based materials that not only have the rigidity of metals, but also have the lowest density among practical light metals are attracting attention. A trend that is attracting attention as a material for automobiles and portable home appliances. In particular, in the casings of portable products such as notebook personal computers, digital cameras, MD players (portable stereo players), and video cameras, products with a wall thickness of 1.5mm or less, especially 1.2mm or less, are required.
并且,在汽车业界,由於地球环保的意识提高,而增强提高汽车的燃料费的要求,因而强烈要求开发汽车用轻量材料。镁合金在现在被实用的金属材料中密度最低,强烈期待作为今后的汽车用轻量材料,需求正在扩大。特别是,此后开发了适用於要求能耐至约473K的耐热性、耐蠕变性的引擎零件等用途的添加硅的合金,例如AS41合金(Mg-4Al-1Si-0.2Mn),添加稀土元素的合金,例如AE42合金(Mg-4Al-2RE-0.2Mn),进而最近开发、提出了添加钙的合金(日本特开平6-25790号公报),添加钙与稀土元素的合金(日本特开平6-200348号公报,特开平7-11347号公报),相信用途会扩大。In addition, in the automobile industry, due to the increasing awareness of global environmental protection, there is a growing need to increase the fuel consumption of automobiles, so the development of lightweight materials for automobiles is strongly demanded. Magnesium alloys have the lowest density among metal materials currently in use, and are strongly expected to be used as lightweight materials for future automobiles, and demand is expanding. In particular, silicon-added alloys, such as AS41 alloy (Mg-4Al-1Si-0.2Mn), which are suitable for applications such as engine parts that require heat resistance and creep resistance up to about 473K, have been developed since then, and rare earth elements have been added. Alloys, such as AE42 alloy (Mg-4Al-2RE-0.2Mn), and then recently developed, proposed to add calcium alloys (Japanese Patent Laid-Open No. 6-25790 communique), add calcium and rare earth alloys (Japanese Patent Laid-Open Flat 6 -200348 bulletin, JP-P 7-11347 bulletin), it is believed that the use will be expanded.
然而,在镁合金的压铸或金属注射成形中存在粘砂、填充不良、热裂或缩裂、铸件皱纹、缩孔等经常发生等独特的难题。特别是,在近年来所期望的薄物铸造,或在包含硅、稀土元素或钙的合金使用等中,有扩大此等问题的趋势,相对的,在关於确保压铸等的品质上极重要的金属模装置仅是重复以往的经验延长上的尝试法,并没有建立有体系的金属模装置的设计指南。However, in the die-casting or metal injection molding of magnesium alloys, there are unique problems such as sand sticking, poor filling, hot cracks or shrinkage cracks, casting wrinkles, and shrinkage cavities. In particular, there is a tendency to increase these problems in thin castings expected in recent years, or in the use of alloys containing silicon, rare earth elements, or calcium. The mold device is only a trial method of repeating previous experience and extension, and there is no systematic design guideline for metal mold devices.
本发明是鉴于以往技术所具有的问题而完成的,本发明以提供一种在镁合金的压铸及金属注射成形中不产生粘砂、填充不良、热裂或缩裂、铸件皱纹、缩孔等的金属模装置,采用此种金属模装置的压铸方法及压铸制品,以及特别是提供一种薄壁铸造或使用包含硅、稀土元素或钙的合金时采用的金属模装置,采用此种金属模装置的压铸方法及压铸制品作为课题。The present invention is made in view of the problems of the prior art. The present invention aims to provide a magnesium alloy die-casting and metal injection molding that does not cause sand sticking, poor filling, thermal cracking or shrinkage cracking, casting wrinkles, shrinkage cavities, etc. A metal mold device, a die-casting method and a die-cast product using the metal mold device, and especially a metal mold device for thin-walled casting or using an alloy containing silicon, rare earth elements or calcium, using the metal mold The die-casting method of the device and the die-cast product are the subjects.
本发明人等为了完成上述课题反复进行了种种研究,结果发现,关於在镁合金的压铸及金属注射成形中采用的金属模装置的适当化存在几种规则。亦即,镁合金的压铸及金属注射成形时的重要点是:在模腔内,(1)使无紊乱而顺畅的金属液流,(2)不降低流速,(3)一直尽可能地等速,(4)不扰乱互相的流动,(5)应迅速填充模腔地流入,而采用实现此等条件的金属模装置,且将注射条件及/或金属模条件予以适当化,即可完全的抑制粘砂、填充不良、热裂或缩裂、铸件皱纹、缩孔等。The inventors of the present invention have conducted various studies in order to achieve the above-mentioned problems, and as a result, have found that there are several rules regarding the optimization of die devices used in die-casting and metal injection molding of magnesium alloys. In other words, the important points in the die casting and metal injection molding of magnesium alloys are: (1) to make the metal flow smoothly without disturbance, (2) not to reduce the flow rate, and (3) to wait as long as possible in the cavity. (4) do not disturb the flow of each other, (5) should quickly fill the mold cavity, and the metal mold device that realizes these conditions is used, and the injection conditions and/or metal mold conditions are appropriate, and it can be completely It can effectively inhibit sand sticking, poor filling, thermal cracking or shrinkage cracking, casting wrinkles, shrinkage cavities, etc.
亦即,本发明的金属模装置,是适用於镁合金的压铸或金属注射成形的金属模装置,其特征在于,That is, the metal mold device of the present invention is a metal mold device suitable for die casting or metal injection molding of a magnesium alloy, and is characterized in that
设定数个浇口,并从直浇口至各浇口设置直接流道,以及Set up several gates and set up direct runners from the sprue to each gate, and
将相邻接的浇口间的非浇口部分的距离,除了制品设计上不允许的情形以外,设定为10mm以下。The distance of the non-gate portion between adjacent gates is set to 10 mm or less, except for cases where the product design does not allow it.
又本发明的金属模装置,是适用於镁合金的压铸或金属注射成形的金属模装置,其特征在于,以And the metal mold device of the present invention is a metal mold device suitable for die-casting or metal injection molding of magnesium alloys, and is characterized in that:
设定数个浇口,并从直浇口至各浇口设置直接流道,及Set up several gates and set up direct runners from the sprue to each gate, and
将相邻接的浇口间的非浇口部分的距离,除了制品设计上不允许的情形以外,设定为10mm以下作为必须要件;The distance of the non-gate part between adjacent gates is set to be less than 10mm as a necessary requirement except for the case where the product design does not allow it;
进而以将直浇口至各浇口的各流道体积设定为相同,Furthermore, the volume of each runner from the sprue to each gate is set to be the same,
将各浇口的断面积设定成与从该浇口至应填充的制品体积成比例,The cross-sectional area of each gate is set to be proportional to the volume of the product to be filled from the gate,
将直浇口至各浇口的各流道的总断面积在金属熔液的流动方向维持相同或连续地减少,及maintaining the same or continuously reducing the total cross-sectional area of each runner from the sprue to each gate in the flow direction of the molten metal, and
将流道的形状尽可能设定R5以上,以使金属液流成为顺畅的液流中的至少一种作为必要条件。It is necessary to set the shape of the flow path to R5 or more as much as possible so that the molten metal flow becomes at least one of smooth flow.
本发明的镁合金的压铸方法,是从镁合金铸造没有铸件皱纹、表面裂纹、填充不良、金属模具粘砂的压铸制品的压铸方法,其特征在于,The magnesium alloy die-casting method of the present invention is a die-casting method for casting a die-casting product without casting wrinkles, surface cracks, poor filling, and sand sticking to a metal mold from a magnesium alloy, and is characterized in that,
采用上述金属模装置,Using the above-mentioned metal mold device,
将镁合金的熔液温度保持在580至750℃,Keep the melt temperature of the magnesium alloy at 580 to 750°C,
将向模腔的填充速度设定为1/100至10/100秒钟,而且Set the fill rate to the cavity from 1/100 to 10/100 of a second, and
在使用冷室式压铸机时,将填充后的增压设定为200 kgf/cm2以上。When using a cold-chamber die-casting machine, set the boost pressure after filling to 200 kgf/cm 2 or more.
本发明的镁合金的压铸方法,是从镁合金铸造没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的压铸制品的压铸方法,其特征在于,The magnesium alloy die-casting method of the present invention is a die-casting method for casting a die-casting product without casting wrinkles, surface cracks, poor filling, and metal mold sticking sand from a magnesium alloy, and is characterized in that,
采用上述金属模装置,Using the above-mentioned metal mold device,
将金属模温度保持在150至350℃,Keep the metal mold temperature at 150 to 350°C,
将在压铸铸造品上容易发生缩裂的模腔部位的金属模的表面温度较之周边部降低10K以上,The surface temperature of the metal mold in the mold cavity where shrinkage cracks are prone to occur on the die-casting casting is lowered by more than 10K compared with the peripheral part,
将压铸时的金属模内的空气压力设定为100mmHg以下,而且The air pressure in the metal mold during die casting is set to 100mmHg or less, and
作为对涂布於金属模内面的脱模剂的添加剂,使用选自由石墨、BN、水玻璃、云母、硅胶、氢氧化镁及氧化镁构成的组中的至少一种。At least one selected from the group consisting of graphite, BN, water glass, mica, silica gel, magnesium hydroxide, and magnesium oxide is used as an additive to the release agent coated on the inner surface of the mold.
较理想为,本发明的镁合金的压铸方法,是从镁合金铸造没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的压铸制品的压铸方法,其特征在于,Ideally, the magnesium alloy die-casting method of the present invention is a die-casting method for casting a die-casting product from a magnesium alloy without casting wrinkles, surface cracks, poor filling, and sand sticking to the metal mold, and is characterized in that,
采用上述金属模装置,Using the above-mentioned metal mold device,
将镁合金的熔液温度保持在580至750℃,Keep the melt temperature of the magnesium alloy at 580 to 750°C,
将向模腔的填充速度设定为1/100至10/100秒钟,Set the filling speed to the cavity from 1/100 to 10/100 of a second,
在使用冷室式压铸机时,将填充后的增压设定为200kgf/cm2以上,When using a cold chamber die-casting machine, set the pressurization after filling to 200kgf/cm2 or more ,
将金属模温度保持在150至350℃,Keep the metal mold temperature at 150 to 350°C,
将在压铸铸造品上容易发生缩裂的模腔部位的金属模的表面温度较之周边部降低10K以上,The surface temperature of the metal mold in the mold cavity where shrinkage cracks are prone to occur on the die-casting casting is lowered by more than 10K compared with the peripheral part,
将压铸时的金属模内的空气压力设定为100mmHg以下,而且The air pressure in the metal mold during die casting is set to 100mmHg or less, and
作为对涂布於金属模内面的脱模剂的添加剂,使用选自由石墨、BN、水玻璃、云母、硅胶、氢氧化镁及氧化镁构成的组中的至少一种。At least one selected from the group consisting of graphite, BN, water glass, mica, silica gel, magnesium hydroxide, and magnesium oxide is used as an additive to the release agent coated on the inner surface of the mold.
进而,在得到室温强度及高温强度优异的镁合金的压铸制品时,本发明的镁合金的压铸方法,作为镁合金是使用含有Furthermore, when obtaining a die-cast product of a magnesium alloy excellent in room temperature strength and high-temperature strength, the die-casting method of the magnesium alloy of the present invention uses a magnesium alloy containing
i)铝1至10重量%,i) 1 to 10% by weight of aluminum,
ii)选自由稀土元素0.2至5重量%,钙0.02至5重量%,及硅0.2至10重量%所构成的组中的至少一种,及ii) at least one selected from the group consisting of 0.2 to 5% by weight of rare earth elements, 0.02 to 5% by weight of calcium, and 0.2 to 10% by weight of silicon, and
iii)锰1.5重量%以下,其余由镁及不可避免的杂质所构成的镁合金。iii) Magnesium alloys consisting of 1.5% by weight or less of manganese, and the remainder consisting of magnesium and unavoidable impurities.
本发明的镁合金压铸制品,是采用上述金属模装置以上述压铸方法能制造的没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的镁合金压铸制品。The magnesium alloy die-casting product of the present invention is a magnesium alloy die-casting product without casting wrinkles, surface cracks, poor filling, and sand sticking to the metal mold, which can be produced by the above-mentioned die-casting method using the above-mentioned metal mold device.
以下详述在本发明的压铸方法中适用的镁合金组成,适用於镁合金的压铸或金属注射成形的金属模装置,采用该金属模装置的压铸方法及压铸制品等。The composition of the magnesium alloy suitable for the die-casting method of the present invention, the metal mold device suitable for die-casting or metal injection molding of magnesium alloy, the die-casting method and the die-cast product using the metal mold device will be described in detail below.
以本发明的压铸方法可铸造的镁合金,只要是可压铸的镁合金,则任何一种均可以,例如可使用MD1A、MD1B、MD1 D、MD2A、MD2B、MD3A等。The magnesium alloy that can be cast by the die-casting method of the present invention may be any as long as it is a die-castable magnesium alloy. For example, MD1A, MD1B, MD1D, MD2A, MD2B, MD3A, etc. can be used.
但是,以在汽车引擎零件等的轻量化中,即使至所要求的523K左右的高温,也具有充分强度的镁合金压铸制品作为目的时,使用含有However, for the purpose of reducing the weight of automobile engine parts and the like, magnesium alloy die-casting products with sufficient strength even at the required high temperature of about 523K are used.
i)铝1至10重量%,i) 1 to 10% by weight of aluminum,
ii)选自由稀土元素0.2至5重量%,钙0.02至5重量%,及硅0.2至10重量%所构成的组中的至少一种,及ii) at least one selected from the group consisting of 0.2 to 5% by weight of rare earth elements, 0.02 to 5% by weight of calcium, and 0.2 to 10% by weight of silicon, and
iii)锰1.5重量%以下,其余以由镁及不可避免的杂质所构成的镁合金较为理想。iii) Manganese is less than 1.5% by weight, and a magnesium alloy composed of magnesium and unavoidable impurities is more desirable.
在本发明的金属模装置中以设置数个浇口为前提条件。这样在具有数个浇口的金属模装置中,首先,为了不扰乱金属熔液的流速与金属熔液流动,必须在直浇口至各浇口设置直接流道,即直浇口至各浇口必须分别以各个流道直接连接。各流道内的金属熔液的流动成为均匀化,并同时可设定适应制品形状的浇口断面积,须设两个以上浇口,但是,最终的浇口个数与各浇口的断面积是由制品尺寸(金属熔液量)与制品形状所决定,而依金属模的尺寸、金属模成本、材料收缩率等来规定。但是,仅以金属模具来说,作成多浇口并根据制品形状将各浇口变细较为理想。In the die apparatus of the present invention, it is a prerequisite to provide a plurality of gates. In this way, in a metal mold device with several gates, first of all, in order not to disturb the flow rate of the molten metal and the flow of the molten metal, it is necessary to set a direct runner from the sprue to each gate, that is, from the sprue to each gate. The ports must be connected directly with each flow channel respectively. The flow of molten metal in each runner becomes uniform, and at the same time, the cross-sectional area of the gate can be set to suit the shape of the product. More than two gates must be set. However, the final number of gates and the cross-sectional area of each gate It is determined by the size of the product (the amount of molten metal) and the shape of the product, and is regulated by the size of the metal mold, the cost of the metal mold, and the shrinkage rate of the material. However, only for metal molds, it is ideal to make multiple gates and make each gate thinner according to the shape of the product.
如此所设定的横流道与各浇口,如上述,为了尽可能不扰乱,不抑制金属熔液的流动下能够填充於模腔,则宜将若干基本的设计条件作为必需的或较理想的条件。亦即,为了不扰乱金属熔液的流动而填充於模腔,则以将从直浇口至被分割成两个以上的各浇口的各流道的体积互相成为相同为理想,并将各浇口的断面积设计成与从浇口至欲填充的制品体积成比例,从各浇口将金属熔液一齐填充於制品中较为理想。As mentioned above, the cross runners and gates set in this way can be filled in the mold cavity without disturbance as much as possible and without inhibiting the flow of molten metal. It is advisable to take some basic design conditions as necessary or ideal. condition. That is, in order to fill the mold cavity without disturbing the flow of molten metal, it is ideal to make the volumes of the runners from the sprue to the gates divided into two or more the same as each other, and make each The cross-sectional area of the gate is designed to be proportional to the volume of the product to be filled from the gate. It is ideal to fill the product with molten metal from each gate.
又为了不降低金属熔液的流速,将从直浇口至浇口的各流道的总断面积在金属熔液的流动方向维持在相同或连续地减少较为理想。将流道的形状尽可能设定R5以上,以使金属熔液流动能顺畅。In order not to reduce the flow rate of the molten metal, it is ideal to keep the total cross-sectional area of each runner from the sprue to the gate at the same level or decrease continuously in the flow direction of the molten metal. Set the shape of the runner as much as possible above R5 so that the molten metal can flow smoothly.
如上所述,由於将金属熔液从浇口一直快速地填充於模腔,而在各浇口间容易产生冷隔,因此若采用本发明的金属模装置时,必须将相邻接的浇口间的非浇口部分的距离,除了制品设计上不允许的情形以外,设定为10mm以下。As mentioned above, since the molten metal is quickly filled from the gate to the mold cavity, cold gaps are likely to occur between the gates. Therefore, if the metal mold device of the present invention is used, the adjacent gates must be The distance between the non-gate parts, except for the case where the product design is not allowed, is set to be less than 10mm.
并且,根据流道的R,垂直於浇口面以外的向量将产生於各浇口的宽度方向。所以对浇口垂直方向的金属熔液速度,在浇口的宽度方向的速度分布中在浇口端部变慢。为了尽可能使速度分布成为一样,例如实测或金属熔液流动计算上希望达到1m/s以内。随着该速度分布中的速度差愈接近零,由於容易产生先前所述的浇口间的冷隔,因此浇口端部的金属熔液流动的趋向须充分地研究。Also, depending on the R of the runner, a vector perpendicular to the gate surface will be generated in the width direction of each gate. Therefore, the velocity of the molten metal in the direction perpendicular to the gate becomes slower at the edge of the gate in the velocity distribution in the width direction of the gate. In order to make the velocity distribution as uniform as possible, for example, it is desired to be within 1 m/s in actual measurement or calculation of molten metal flow. As the velocity difference in this velocity distribution becomes closer to zero, since the aforementioned cold shut between the gates is likely to occur, the tendency of the flow of the molten metal at the gate end must be fully studied.
采用上述金属模装置而实施本发明的压铸方法的注射条件中,有金属熔液温度。在熔化炉中的金属熔液温度不足580℃时,则流动性降低,而向金属模的填充性产生问题。另一方面,若超过750℃,则在保持金属熔液时增加着火的危险性,又会增大从金属熔液至凝固的期间的收缩率,因此容易发生热裂或缩裂。故合金的熔液温度应保持於580至750℃,较理想是须保持在650至710℃。Among the injection conditions for carrying out the die-casting method of the present invention using the above-mentioned metal mold apparatus, there is the temperature of the molten metal. When the temperature of the molten metal in the melting furnace is lower than 580° C., the fluidity decreases, and problems arise in the fillability to the mold. On the other hand, if it exceeds 750° C., the risk of ignition increases when the molten metal is held, and the shrinkage rate from the molten metal to solidification increases, so thermal cracking or shrinkage cracking tends to occur. Therefore, the melt temperature of the alloy should be kept at 580 to 750°C, ideally at 650 to 710°C.
本发明的压铸方法的注射条件中,有向模腔的填充速度。一般镁合金的凝固潜热小,因而推荐应予以提高注射速度。由於镁合金特别是在凝固相对地慢的粒部分因产生化合物而容易发生裂纹,因此在铸件全区域必须施加铸造压力。所以必须考虑铸造速度与来自金属模的冷却的平衡,经验上向金属模模腔内的填充速度设定为1/100至10/100秒钟,较理想为1/100至5/100秒钟是必要条件。为了满足此种条件,将注射速度设定为2m/s以上,较理想为3.5m/s以上,或将浇口速度设定为30m/s以上,较理想为50m/s以上。在向金属模模腔内的填充速度比10/100秒钟慢时,会在填充性(填充不良)或热裂性的任一方向产生问题。Among the injection conditions of the die casting method of the present invention, there is a filling speed into the cavity. Generally, the solidification latent heat of magnesium alloy is small, so it is recommended to increase the injection speed. Since the magnesium alloy is prone to cracks due to the generation of compounds, especially in the relatively slow-solidified grain part, casting pressure must be applied to the entire area of the casting. Therefore, the balance between the casting speed and the cooling from the metal mold must be considered. According to experience, the filling speed into the metal mold cavity is set at 1/100 to 10/100 seconds, ideally 1/100 to 5/100 seconds is a necessary condition. In order to meet this condition, the injection speed is set to be 2m/s or more, ideally 3.5m/s or more, or the gate speed is set to be 30m/s or more, preferably 50m/s or more. When the filling rate into the cavity of the metal mold is slower than 10/100 seconds, problems arise in either direction of filling property (poor filling) or thermal cracking property.
使用冷室式压铸机时,本发明的压铸方法的注射条件中有填充后的增压。向金属模模腔内的填充后须立即再施加增压,以防止填充不良,并抑制凝固或冷却时的热裂、缩裂的发生。此时的增压条件是200kgf/cm2以上,较理想为400kg/cm2以上。未施加此种增压时,会产生填充不良,或在铸件的壁厚变化部的所有区域会产生裂纹。When using a cold-chamber die-casting machine, the injection conditions of the die-casting method of the present invention include pressurization after filling. Immediately after filling into the cavity of the metal mold, pressurization must be applied to prevent poor filling and suppress thermal cracking and shrinkage cracking during solidification or cooling. The pressurized condition at this time is 200kgf/cm 2 or more, preferably 400kg/cm 2 or more. If such a pressurized pressure is not applied, poor filling occurs, or cracks occur in all regions of the casting in which the wall thickness changes.
以上的压铸注射条件互相关联,缺少此种条件中的一种条件,均无法得到镁合金的健全的薄壁铸件。相反地说,采用上述金属模装置而实施,通过满足这三种注射条件,即,The above die-casting injection conditions are related to each other, and without any one of these conditions, a sound thin-walled casting of magnesium alloy cannot be obtained. On the contrary, it is carried out by using the above-mentioned metal mold device, by satisfying the three injection conditions, namely,
将镁合金的金属熔液温度保持在580至750℃,Keep the molten metal temperature of the magnesium alloy at 580 to 750°C,
将向模腔的填充速度设定为1/100至10/100秒钟,而且Set the fill rate to the cavity from 1/100 to 10/100 of a second, and
在使用冷室式压铸机时,将填充后的增压设定为200kgf/cm2以上的条件,即可铸造没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的镁合金压铸件。When using a cold-chamber die-casting machine, set the pressurization after filling to 200kgf/cm2 or more, and you can cast magnesium alloy die-castings without casting wrinkles, surface cracks, poor filling, and sand sticking to the metal mold.
采用上述金属模装置而实施本发明的压铸方法的金属模条件中,有金属模温度。在金属模温度未满150℃时,经验上对金属熔液的填充性带来障碍,或即使可填充,也会在铸件皱纹等的表面性上造成问题。另外,在超过350℃时,由於延迟凝固速度而容易产生缩裂或热裂。因此将金属模温度保持在150至350℃,较理想为保持在180至280℃。Among the mold conditions for carrying out the die casting method of the present invention using the above-mentioned mold apparatus is the mold temperature. When the mold temperature is lower than 150° C., the fillability of the molten metal is hindered empirically, or even if the fillability is possible, problems are caused in surface properties such as casting wrinkles. In addition, when the temperature exceeds 350°C, shrinkage cracking or thermal cracking tends to occur due to the delayed solidification rate. Therefore, the temperature of the metal mold is kept at 150 to 350°C, preferably at 180 to 280°C.
本发明的压铸方法的金属模具条件中,有局部冷却。依据铸件的形状,在厚度急变部等形状上有容易发生裂痕的部位。在此等情形下,除了上述的整体的金属模温度的控制以外,还必须作局部的温度控制。为了该温度控制,则可采取在金属模的必要部位设置致冷剂用通路,而在该通路中流动水、油、空气等的致冷剂进行局部冷却的方法,或者在打开金属模时通过吹喷脱模剂或空气而进行局部冷却的方法等。总之均须将金属模需要局部冷却的部位的表面温度比周边的表面温度冷却10K以上,较理想为冷却20K以上,使容易发生缩裂的部位优先凝固以防止缩裂。Partial cooling is included in the mold conditions of the die casting method of the present invention. Depending on the shape of the casting, there are parts where cracks are likely to occur in the shape such as the abrupt thickness change part. In such cases, in addition to the above-mentioned overall mold temperature control, local temperature control is also necessary. In order to control the temperature, it is possible to install passages for refrigerants in necessary parts of the metal mold, and to flow refrigerants such as water, oil, and air in the passages for local cooling, or to pass through the passages when the molds are opened. A method of locally cooling by spraying a release agent or air, etc. In short, the surface temperature of the part of the metal mold that needs local cooling must be cooled by 10K or more than the surrounding surface temperature, and ideally it should be cooled by 20K or more, so that the parts that are prone to shrinkage cracks are preferentially solidified to prevent shrinkage cracks.
本发明的压铸方法的金属模具条件中,有金属模内的减压。为了帮助金属熔液向模腔内填充,同时为了防止由金属模内的空气所产生的金属熔液流动的紊乱,金属模内的减压是必要的。为了达到该目的,须将金属熔液的注射时的金属模内的空气压力设定为100mmHg以下,较理想为50mmHg以下。In the die conditions of the die casting method of the present invention, there is decompression in the die. In order to help the molten metal to fill the mold cavity, and to prevent the disturbance of the flow of the molten metal caused by the air in the metal mold, decompression in the metal mold is necessary. In order to achieve this purpose, the air pressure in the mold must be set to 100 mmHg or less, preferably 50 mmHg or less, during injection of the molten metal.
本发明的压铸方法的金属模具条件中,有涂布於金属模内面的脱模剂。关於用以凝固的冷却条件,不仅是金属模的温度条件,而且可籍脱模剂的保温效果来延迟凝固而使铸造压力起作用。为了达到该目的,作为脱模剂的添加剂,使用选自由石墨、BN、水玻璃、云母、硅胶、氢氧化镁及氧化镁所构成的组中的至少一种是有效的。In the die conditions of the die casting method of the present invention, there is a mold release agent coated on the inner surface of the die. Regarding the cooling conditions for solidification, not only the temperature conditions of the metal mold, but also the heat preservation effect of the release agent can delay the solidification and make the casting pressure work. In order to achieve this purpose, it is effective to use at least one selected from the group consisting of graphite, BN, water glass, mica, silica gel, magnesium hydroxide, and magnesium oxide as an additive for the release agent.
以上的金属模条件互相关联,但是金属模温度特别重要。在压铸铸造品上容易发生缩裂的模腔部位不存在时,并不需要局部冷却,此时局部冷却可由本发明的构成必要条件中予以删除。根据模腔形状及压铸制品形状,虽然金属模内的减压及脱模剂的添加剂并不一定是必要的必要条件,但并用此种构成必要条件可得到更良好的结果,故较理想。The above mold conditions are related to each other, but the mold temperature is particularly important. When there is no mold cavity where shrinkage cracks are likely to occur on the die-casting casting, local cooling is not required. In this case, local cooling can be eliminated from the constitutional requirements of the present invention. Depending on the shape of the mold cavity and the shape of the die-casting product, although the pressure reduction in the metal mold and the additive of the release agent are not necessarily necessary conditions, it is more desirable to use these conditions together to obtain better results.
在本发明中,采用上述金属模装置而加以实施,通过满足此等四种金属模条件,即In the present invention, it is carried out by adopting the above-mentioned metal mold device, by satisfying these four kinds of metal mold conditions, namely
将金属模温度保持在150至350℃,Keep the metal mold temperature at 150 to 350°C,
将在压铸铸造品上容易发生缩裂的模腔部位的金属模的表面温度,较之周边部降低10K以上,The surface temperature of the metal mold in the mold cavity where shrinkage cracks are likely to occur on the die-casting casting is lowered by more than 10K compared with the peripheral part,
将压铸铸造时的金属模内的空气压力设定为100mmHg以下,而且The air pressure in the metal mold during die casting is set to 100mmHg or less, and
作为对涂布於金属模内面的脱模剂的添加剂,使用选自由石墨、BN、水玻璃、云母、硅胶、氢氧化镁及氧化镁所构成的组中的至少一种,就能够铸造没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的镁合金压铸件。As an additive to the release agent coated on the inner surface of the metal mold, at least one selected from the group consisting of graphite, BN, water glass, mica, silica gel, magnesium hydroxide and magnesium oxide can be used to cast without casting Magnesium alloy die castings with wrinkles, surface cracks, poor filling, and metal mold sticking sand.
上述的本发明的金属模装置,采用该金属模装置的压铸方法,对於薄壁铸造,特别是,在1.5mm以下的薄壁铸造或含有硅、稀土元素、钙的合金的铸造是有效的,可得到没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的压铸制品。The metal mold device of the present invention described above, and the die-casting method using the metal mold device are effective for thin-wall casting, especially thin-wall casting of 1.5 mm or less or casting of alloys containing silicon, rare earth elements, and calcium. , Die-casting products without casting wrinkles, surface cracks, poor filling, and sand sticking to metal molds can be obtained.
以下依据实施例及比较例具体地说明本发明。Hereinafter, the present invention will be specifically described based on examples and comparative examples.
实施例1和比较例1至6Example 1 and Comparative Examples 1 to 6
金属模装置是采用:The metal mold device is adopted:
设定四个浇口,并从直浇口到各浇口设置直接流道,Set four gates, and set up direct runners from the sprue to each gate,
将邻接的浇口间的非浇口部分的距离设定为5mm,Set the non-gate distance between adjacent gates to 5mm,
将直浇口至各浇口的各流道体积设定为相同,Set the volume of each runner from the sprue to each gate to be the same,
将各浇口的断面积设定成与从其浇口至应该填充的制品体积成比例,The cross-sectional area of each gate is set to be proportional to the volume of the product that should be filled from the gate,
将直浇口至各浇口的各流道的总断面积在金属熔液的流动方向维持相同,The total cross-sectional area of each runner from the sprue to each gate is kept the same in the flow direction of the molten metal,
将流道的形状设定为R15以上。Set the shape of the runner to R15 or higher.
采用上述金属模装置,使用AZ91(Mg-9Al-0.7Zn-0.2Mn)合金,冷室式压铸机使用日本宇部公司制的650吨机,将合金熔液温度设定为680℃,将向模腔的填充速度设定为5/100秒钟,将填充后的增压设定为300kgf/cm2,将金属模温度设定为250℃,将压铸时的金属模内的空气压力设定为100mmHg,并且在金属模内面涂布滑石系脱模剂,而实施A4尺寸的笔记型个人电脑壳体(制品厚度0.8mm)的试制品的铸造。铸造结果如表1中所示。将金属模装置如表1所示地变化(未记载於表1的金属模装置仍维持上述而未变化)实施比较例1至6。这些铸造结果如表1中所示。Using the above-mentioned metal mold device, using AZ91 (Mg-9Al-0.7Zn-0.2Mn) alloy, the cold chamber die-casting machine uses a 650-ton machine made by Ube Corporation of Japan, and the temperature of the alloy melt is set at 680 ° C. The filling speed of the cavity is set to 5/100 second, the boost pressure after filling is set to 300kgf/cm 2 , the mold temperature is set to 250°C, and the air pressure in the mold during die casting is set to 100mmHg, and a talc-based mold release agent was coated on the inner surface of the metal mold, and the casting of a trial product of an A4 size notebook personal computer case (product thickness 0.8mm) was implemented. Casting results are shown in Table 1. Comparative Examples 1 to 6 were carried out with the mold apparatus changed as shown in Table 1 (the mold apparatus not described in Table 1 was kept unchanged as above). These casting results are shown in Table 1.
表1
实施例2Example 2
使用热室式压铸机,将金属熔液温度设定为610℃,除未实施填充后的增压外,其余则与实施例1同样地实施铸造。铸造的结果如表1中所示。实施例3Casting was performed in the same manner as in Example 1 except that the temperature of the molten metal was set to 610° C. using a hot-chamber die-casting machine, and pressurization after filling was not performed. The results of the casting are shown in Table 1. Example 3
采用在实施例1所采用的金属模装置,使用热裂敏感性高的Mg-5Al-3Ca-0.2Mn合金,Mg-5Al-4RE-0.2Mn-0.05Ca合金,Mg-5Al-2Si-0.5RE-0.2Mn合金,或Mg-9Al-2Ca-2RE-1Si-0.2Mn合金,冷室式压铸机使用日本宇部公司制的650吨机,将合金熔液温度设定为700℃,将向模腔的填充速度设定为5/100秒钟,将填充后的增压设定为500kgf/cm2,将金属模温度设定为200℃,将压铸时的金属模内的空气压力设定为40mmHg,而以模仿汽车零件的300mm×300mm×180mm的尺寸,实施壁厚3mm的盒型试制品的铸造。在所有四种压铸品中并未看到热裂。实施例4Adopt the metal mold device that adopts in embodiment 1, use the high Mg-5Al-3Ca-0.2Mn alloy of thermal cracking sensitivity, Mg-5Al-4RE-0.2Mn-0.05Ca alloy, Mg-5Al-2Si-0.5RE -0.2Mn alloy, or Mg-9Al-2Ca-2RE-1Si-0.2Mn alloy, the cold chamber die-casting machine uses a 650-ton machine made by Ube Corporation of Japan, and the temperature of the alloy melt is set at 700 ° C, and the mold cavity The filling speed is set to 5/100 seconds, the boost pressure after filling is set to 500kgf/cm 2 , the mold temperature is set to 200°C, and the air pressure in the mold during die casting is set to 40mmHg , and with the size of 300mm × 300mm × 180mm imitating the size of auto parts, the casting of a box-type trial product with a wall thickness of 3mm is implemented. No hot cracking was seen in all four die castings. Example 4
为使压铸制品成为容易发生缩裂的形状,在实施例3的盒型试制品的四角隅设置壁厚从300mm变化成10mm的部分。使用Mg-5Al-4Ca-1RE-0.2Mn合金,在和实施例3相同条件下铸造该形状的试制品,结果则在壁厚变化部位的边缘部以约10%概率发生缩裂,并且在浇口进入压铸制品的部分每隔100至300次注射发生粘砂。In order to make the die-cast product into a shape that is prone to shrinkage cracking, a portion where the wall thickness is changed from 300 mm to 10 mm is provided at the four corners of the box-shaped trial product in Example 3. Using the Mg-5Al-4Ca-1RE-0.2Mn alloy, casting a trial product of this shape under the same conditions as in Example 3 resulted in shrinkage cracks occurring at a probability of about 10% at the edge of the wall thickness change portion, and after casting Sand sticking occurs every 100 to 300 shots at the part where the mouth enters the die-casting product.
因此,作为缩裂的对策,将壁厚变化部的金属模部分冷却至230℃(令与周围的金属模温度的差为20K)时,可抑制缩裂的发生。Therefore, as a countermeasure against shrinkage cracking, the occurrence of shrinkage cracking can be suppressed when the mold part of the wall thickness changing part is cooled to 230°C (the temperature difference from the surrounding mold temperature is 20K).
作为粘砂的对策,将添加BN的脱模剂涂布於在上述产生粘砂的部分而进行铸造时,可抑制粘砂的发生。并且,代替BN,使用石墨、水玻璃、云母、硅胶、氢氧化镁或氧化镁时也可得到同等的效果。As a countermeasure against sand sticking, when casting is performed by applying a release agent added with BN to the above-mentioned part where sand sticking occurs, the occurrence of sand sticking can be suppressed. In addition, equivalent effects can be obtained when graphite, water glass, mica, silica gel, magnesium hydroxide, or magnesium oxide is used instead of BN.
采用本发明的金属模装置的压铸方法,在薄壁铸造,特别是1.5mm以下的薄壁铸造或含有硅、稀土元素、钙的合金铸造上是有效的,以高品质而稳定地可得到没有铸件皱纹、表面裂纹、填充不良、金属模粘砂的压铸制品。The die casting method using the metal mold device of the present invention is effective in thin-wall casting, especially thin-wall casting of 1.5mm or less or alloy casting containing silicon, rare earth elements, and calcium, and can obtain high-quality and stable Die-casting products with casting wrinkles, surface cracks, poor filling, and metal mold sticking sand.
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| JP161334/1999 | 1999-06-08 | ||
| JP16133499A JP3534650B2 (en) | 1999-06-08 | 1999-06-08 | Die, die casting and die casting products |
| JP161334/99 | 1999-06-08 |
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| CN1276276A true CN1276276A (en) | 2000-12-13 |
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| CN99122854A Expired - Fee Related CN1096906C (en) | 1999-06-08 | 1999-11-30 | Metal die device, die-casting method and die-cast articles |
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| JP (1) | JP3534650B2 (en) |
| KR (1) | KR100412071B1 (en) |
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- 1999-08-06 KR KR10-1999-0032271A patent/KR100412071B1/en not_active Expired - Fee Related
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Also Published As
| Publication number | Publication date |
|---|---|
| JP3534650B2 (en) | 2004-06-07 |
| CN1096906C (en) | 2002-12-25 |
| JP2000343199A (en) | 2000-12-12 |
| KR100412071B1 (en) | 2003-12-31 |
| TW407078B (en) | 2000-10-01 |
| KR20010005428A (en) | 2001-01-15 |
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