EP0710515B1 - Procédé thixotropique pour la fabrication de roues en alliage à l'état de mélange liquide-solide - Google Patents

Procédé thixotropique pour la fabrication de roues en alliage à l'état de mélange liquide-solide Download PDF

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Publication number
EP0710515B1
EP0710515B1 EP95830240A EP95830240A EP0710515B1 EP 0710515 B1 EP0710515 B1 EP 0710515B1 EP 95830240 A EP95830240 A EP 95830240A EP 95830240 A EP95830240 A EP 95830240A EP 0710515 B1 EP0710515 B1 EP 0710515B1
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EP
European Patent Office
Prior art keywords
cavity
die
sections
wheel
ingot
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95830240A
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German (de)
English (en)
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EP0710515A1 (fr
Inventor
Valter Baldi
Gianni Benni
Giorgio Muneratti
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Reynolds Wheels International Ltd
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Reynolds Wheels International Ltd
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Publication date
Application filed by Reynolds Wheels International Ltd filed Critical Reynolds Wheels International Ltd
Priority to US08/549,094 priority Critical patent/US5900080A/en
Priority to CA002161923A priority patent/CA2161923A1/fr
Publication of EP0710515A1 publication Critical patent/EP0710515A1/fr
Application granted granted Critical
Publication of EP0710515B1 publication Critical patent/EP0710515B1/fr
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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
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/005—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of rolls, wheels or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/004—Thixotropic process, i.e. forging at semi-solid state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/38—Making machine elements wheels; discs rims; tyres
    • 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
    • B22D17/007—Semi-solid pressure die casting

Definitions

  • the present invention relates to a thixotropic forming process suitable for wheels fashioned from rheocast metal alloy in the semisolid state, and in particular for the manufacture of aluminium alloy road wheels fitted ultimately with pneumatic tyres (see also GB-A-2026363).
  • the shaping processes employed conventionally in the manufacture of road wheels for pneumatic tyres are essentially those of forging, and casting in permanent moulds, both of which well known in the wider field of mechanical engineering.
  • Forging is the familiar process by which a metal alloy can be shaped in the solid state.
  • this is a facility which allows the realization of products with superior mechanical properties, but which at the same time gives rise to a number of drawbacks, namely, the need to use alloys suitable for plastic working, the impossibility of producing articles with geometrically complex shapes, and the fact that the end product will be arrived at only after implementing a series of consecutive steps, especially a product characterized by significant variations in thickness such as are evident in the typical geometry of a road wheel.
  • the high cost of the forging process represents a further drawback.
  • the lower mechanical quality of the cast wheel is attributable to the structural characteristics of casting alloys, as well as to the porosity and discontinuity which are generated within the fabric of the wheel and derive from the particular type of casting process.
  • both of the processes mentioned above are characterized in that the forged or cast piece requires generous allowances of material, dictating the need for extensive additional machining steps before the piece can be considered an end product.
  • the end product is obtained from an ingot or billet exhibiting a particular structure that appears physically homogeneous on macroscopic inspection, but when viewed microscopically appears as a plurality of solid globular granules immersed in a liquid phase.
  • the ingot can take on different characteristics according to the percentages, by weight, of the solid and liquid fractions: in the case of a semisolid, the material can behave in the manner of a solid, for example when conveyed from a heating station to a work station or thixotropic injection forming station, but in the manner of a liquid when injected under pressure.
  • the object of the present invention is to overcome the drawbacks of each such method while combining the advantages.
  • the process disclosed can be applied in manufacturing metal alloy wheels even of complex geometry, including slender sections and much broader sections alternating substantially in unlimited manner, and thus incorporates a feature characteristic of the permanent mould type casting techniques mentioned above.
  • the invention relates to a process for the manufacture of wheels in rheocast metal alloy, typically road wheels fitted subsequently with pneumatic tyres, which utilizes billets of rheocast aluminium alloy obtained in conventional manner by recasting from pigs of raw stock having a dendritic structure.
  • the liquid alloy is directed through a filter and into a casting device equipped with an agitator and a chill, whereupon the cooling material solidifies and is formed into billets exhibiting a rheocast microstructure.
  • the billets are then divided into ingots 1 of predetermined weight, which undergo controlled heating at a temperature within the solidification range of the alloy and are brought to a thixotropic semisolid state characterized by a microstructure (indicated in fig 1a) that comprises a liquid phase 14, resulting from the components of the alloy having a lower melting point, and a mass of substantially rounded solid granules 15 immersed in the liquid.
  • a microstructure indicated in fig 1a
  • the ingots 1 are uplifted in this same semisolid state, for example by automatic handling means 23 (as indicated in fig 2) and introduced singly into the injection chamber 3 of a thixotropic injection forming machine 4 (figs 1, 2 and 3) operating in conjunction with a closed die or mould 5 by which the wheel 2 is effectively given its shape.
  • automatic handling means 23 as indicated in fig 2
  • figs 1, 2 and 3 operating in conjunction with a closed die or mould 5 by which the wheel 2 is effectively given its shape.
  • the die 5 affords a cavity 7 of shape substantially matching that of the wheel 2 and is provided with thermoregulating circuits 6 carrying a hot fluid, oil for example, supplied by a unit not shown in the drawings.
  • the injection chamber accommodates a ram 22 that can be reciprocated at a variable rate by the thixotropic injection forming machine 4 (described more fully in due course).
  • thermoregulating circuits 6, which run adjacent to the die cavity 7, are mutually independent and arranged in such a way that sections A' of greater width exhibited by the cavity 7 can be cooled, or more exactly heated to a lower temperature, whilst sections B' of lesser width are heated to higher temperature.
  • width is used to indicate the transverse dimensions of the space afforded by the relative passage of the cavity 7.
  • the operation of filling the die 5 with the alloy in its semisolid state is a particularly critical one.
  • a complete fill is in fact made possible only by ensuring that the liquid phase of the semisolid alloy (which in any event is proportionally less than the solid) does not solidify within the sections B' of lesser width and thus block the passage afforded to the semisolid material entering the cavity 7, forced in by the ram 22, before the part of the die 5 beyond the blockage has been filled to capacity.
  • it is essential that the interface between the solidifying alloy and the liquid phase of the injected semisolid mass should progress regularly, advancing internally of the die cavity 7 from the peripheral parts of the wheel 2 back to the areas nearer the injection chamber 3.
  • wheels for pneumatic tyres are manufactured from rheocast metal alloy employing a thixotropic forming process in which use is made of ingots 1 already preheated to the point of bringing the alloy to the uniform semisolid state described above.
  • sections A of greater thickness exhibited by the typical wheel 2 consist in a central disc 9 incorporating a hub 9a, and a plurality of spoke ribs 10 radiating from the hub in alternation with respective voids 11.
  • sections B of lesser thickness consisting in a lateral cylindrical surface 12 or rim composed of an inner portion 13 and an outer portion 16. The two portions are compassed in turn by an inside flange 17 and an outside flange 18.
  • the process comprises a step of injecting the metal alloy ingot 1, in the semisolid thixotropic state, into the cavity 7 of the die 5.
  • the width Zi at least of the narrower section B' of the cavity 7, which corresponds to the inner portion 13 of the rim 12, is greater than the width Zd that will determine the definitive or final shape of the inner portion 13. Accordingly, the thickness Si of this same portion 13 on completion of the injection step will be greater than the final thickness Sd to be obtained on completion of the process overall.
  • thermoregulating the die 5 is implemented by way of the relative circuits 6 which, to reiterate, are able to maintain a relatively higher temperature in the cavity 7 at the sections B' of lesser width and at the same time a relatively lower temperature at the sections A' of greater width.
  • the velocity at which the ingot 1 is forced into the die will be monitored and varied by monitoring and varying the linear velocity of the ram 22, and thus controlling the rate at which the front of metal alloy advances in the semisolid state internally of the cavity 7.
  • the injection rate is a function of the dissimilar flow passages afforded by the wider and narrower sections A' and B' of the cavity 7, and continues to be controlled until the die has filled, thereby allowing a faster advance of the front of semisolid alloy through the wider areas A' of the cavity 7 and a slower advance through the narrower areas B'.
  • the material is subjected to an additional pressure force, applied through the ram 22 by the thixotropic injection forming machine 4, compounding and therefore much greater than the injection pressure force applied previously.
  • Solidification is followed by the steps of removing the wheel 2 from the die 5 and then hot-drawing the inner portion 13 of the rim 12 by compression.
  • the purpose of the drawing operation is to reduce the inner portion 13 from the initial injection forming thickness Si, indicated in fig 1c by phantom lines, down to the definitive or final thickness Sd.
  • this step has the effect of achieving increased mechanical strength, at least across the inner portion 13 of the rim 12, and of compacting the metal alloy still further so as to avoid the eventuality, should the finishing steps of manufacture involve the removal of material by machining, that interstices could then appear in the structure and jeopardize the airtightness of the wheel when fitted ultimately with a pneumatic tyre.
  • both of the narrow sections B' exhibited by the die cavity 7, which generate the lateral surface 12 of the wheel 2 are proportioned to a width Zi greater than the definitive or final width Zd, as described already with reference to fig 1c.
  • the selfsame thixotropic forming process is implemented using a closed die 5 with a cavity 7 of geometry, sectional profile and dimensions identical to the final geometry, sectional profile and dimensions of the wheel 2. In this instance, no drawing operation is performed on the wheel 2 once removed from the die 5.
  • the process allows for the application of a heat treatment whereby the ingots 1, initially in the solid state, are immersed in convectional flows of hot air for a period of time and at a temperature sufficient to bring the alloy to the thixotropic semisolid state.
  • the step of injecting the semisolid ingots 1 is implemented generally at low velocity so that laminar flow can be induced in the thixotropic alloy; in addition, the velocity is varied cyclically so as to ensure a uniform progression of the solidification interface aforementioned.
  • the ingot 1 is advanced by the ram 22 of the injection forming machine 4 from a first position X of introduction into the injection chamber 3, to a second position Y from which the material is forced into the die 5.
  • the ingot 1 In passing from position X to position Y, the ingot 1 is forced at minimal velocity so that air will not be trapped between the ingot 1 and the wall 21 of the chamber 3 and allowed thus to find its way into the die cavity 7 at the next injection.
  • Solidification of the liquid phase in the semisolid alloy represents a critical aspect of the process disclosed, as already explained. Nonetheless, as long the rheocast alloy introduced into the die cavity 7 has a solid content of some 50 or 60%, this ensures advantageously that contractions and thermal shocks will be of a limited order.
  • the ingots 1 utilized are of a predetermined weight. More exactly, the weight of the ingot is selected to ensure a quantity of the alloy greater than can be contained within the die cavity 7, so that on completion of the step in which the ingot 1 is injected into the cavity 7, a residual portion 8 of semisolid material is left to solidify externally of the die 5, between the die and the injection chamber 3 (see fig 3).
  • This deliberately generated residual portion 8 of the ingot is instrumental in achieving homogeneity and quality of the wheel. More exactly, the inlet of the die 5 presents a restricted section 25 to the ingot 1 passing from the injection chamber 3 to the cavity 7, of which the effect is to gather up the skin 20 of the ingot, physically and chemically distressed by the intense oxidizing action of the air especially on the liquid phase of the rheocast material, when forced from the injection chamber 3 (see fig 4).
  • the process includes a shearing step effected by a blade 19, which will be operated after the injection chamber 3 is distanced from the die 5.
  • a wheel of the type described above can be obtained substantially in a single operation, and, unlike other comparable cast alloy road wheels, betrays no problems of porosity thanks to the viscosity of the semisolid alloy, the variable rate of injection and the advantages of the subsequent hot-drawing step; the wheel described and illustrated also benefits from closer dimensional tolerances due to the fact that solid contractions, affecting only the liquid fraction of the semisolid alloy, are compensated by the application of high pressure forces within the solid-liquid interface, with the result that fewer machining operations are required.
  • the process disclosed might comprise the further step of heat treating the wheel 2 after its removal from the die 5, and after the step of hot-drawing the rim 12 by compression, if included. This would be a heat treatment designed to induce solid solution in the thixotropic metal alloy from which the wheel is fashioned.
  • the wheel 2 will be age hardened to the end of preventing precipitation in the alloy. Thereafter, the wheel can be machined to remove surface material from the rim 12, and more exactly, to remove the machining allowance left by the earlier compression hot-drawing step performed on the inner portion 13, and possibly on the outer portion 16, of the lateral surface 12.
  • a wheel produced by the process according to the present invention possesses the premium mechanical properties typical of the forged product, and is also superior in quality to the cast product, thus further improving the resistance to fatigue and the tenacity of the alloy road wheel, and enhancing its appearance.
  • a further characteristic of any wheel obtained by means of the process disclosed is the especially homogeneous structure of the material from which the wheel itself is fashioned.

Claims (10)

  1. Un procédé de formage thixotropique pour la fabrication de roues en alliage à l'état de mélange liquide-solide et munies de pneumatiques, utilisant des lingots (1) qui sont initialement soumis à une phase de préchauffage de façon à porter la microstructure métallique globulaire de l'alliage, à l'état de mélange liquide-solide, à un état semi-solide uniforme sur tout le lingot (1), et produisant des roues (2) qui présentent typiquement des sections de plus grande épaisseur (A) consistant en un disque (9) et, irradiant de ce disque, en une pluralité de rayons (10) alternés avec des vides respectifs (11), ainsi que des sections de plus petite épaisseur (B) consistant en une surface latérale en substance cylindrique (12) ou jante définie par une portion interne (13) et une portion externe (16) délimitées par un bord interne (17) et un bord externe (18), caractérisé en ce qu'il comprend les phases suivantes :
    injection du lingot (1) en alliage, à l'état thixotropique semi-solide, dans une matrice fermée (5) dont la cavité (7) de formage de la roue (2) présente des sections de plus grande largeur (A') correspondant aux sections de plus grande épaisseur (A) présentées par la roue (2), et des sections de plus petite largeur (B') correspondant aux sections de plus petite épaisseur (B) présentées par la roue (2), proportionnées de façon à ce qu'au moins la largeur (Zi) de la section de plus petite largeur (B') correspondant à la portion interne (13) de la surface latérale (12) soit supérieure à la largeur (Zd) qui définira l'épaisseur définitive ou finale de cette même portion interne (13) ;
    thermorégulation de la matrice (5) en maintenant simultanément une température relativement supérieure au niveau des sections de plus petite largeur (B') présentées par la cavité (7) et une température relativement inférieure au niveau des sections de plus grande largeur (A') présentées par la cavité (7) ;
    contrôle et modification simultanés de la vitesse à laquelle le lingot (1) est injecté, de façon à établir et à contrôler une variation du débit auquel le front d'alliage à l'état semi-solide avance à l'intérieur de la cavité (7) par les différentes ouvertures de passage présentées par les sections de plus grande largeur (A') et les sections de plus petite largeur (B'), jusqu'au plein remplissage de la cavité, et de façon à ce que le front semi-solide avance à un débit plus rapide par les sections de plus grande largeur (A') ;
    puis application, sur l'alliage se solidifiant à l'intérieur de la cavité (7), d'une force de pression supérieure à la force de pression d'injection, compressant ainsi encore plus le matériau dans la matrice ;
    retrait de la roue formée (2) de la matrice (5) et emboutissage à chaud de la portion interne (13) de la surface latérale (12) par compression, réduisant ainsi l'épaisseur initiale (Si) de cette même portion interne (13) pour lui donner une épaisseur définitive ou finale (Sd).
  2. Procédé selon la revendication 1, selon lequel le volume et la masse du lingot (1) sont supérieurs au volume et à la masse de la quantité d'alliage pouvant être contenue dans la cavité (7) de la matrice, de sorte que la phase d'injection se termine avant que la masse totale du lingot puisse pénétrer dans la cavité, et qu'une portion résiduelle (8) contenant la dépouille (20) du lingot (1), rassemblée et retenue à l'intérieur d'une chambre (3) à partir de laquelle le matériau est injecté, se solidifie dans une position intermédiaire entre l'entrée (25) de la matrice (5) et la chambre d'injection (3), puis la portion résiduelle solidifiée (8) est coupée avant que la roue formée soit retirée de la cavité (7) de la matrice (5).
  3. Procédé selon la revendication 1, utilisant une matrice fermée (5) dont la cavité (7) est proportionnée de façon à ce que la largeur (Zi) des sections de plus petite largeur (B') correspondant à la surface latérale (12) de la roue (2) soit supérieure à la largeur (Zd) qui définira l'épaisseur définitive ou finale des deux portions, interne (13) et externe (16), de cette même surface latérale (12), selon lequel la phase de retrait de la roue formée (2) de la matrice est suivie de la phase d'emboutissage à chaud de la surface latérale (12) par compression de façon à réduire l'épaisseur initiale (Si) de la portion interne (13) et de la portion externe (16) pour leur donner leur épaisseur définitive ou finale (Sd).
  4. Procédé selon la revendication 1, selon lequel le lingot (1) est injecté dans une matrice (5) dont la cavité (7) présente une forme, un profil en coupe et des dimensions identiques à la forme, au profil en coupe et aux dimensions qu'aura la roue (2) finie, rendant donc superflue la phase d'emboutissage à chaud de la surface latérale (12) par compression.
  5. Procédé selon la revendication 1, selon lequel la phase de thermorégulation de la matrice (5) est effectuée par l'intermédiaire d'un fluide chauffant circulant dans une pluralité de circuits thermorégulateurs (6), réciproquement indépendants, placés périphériquement par rapport à la cavité (7) de la matrice et à une chambre d'injection (3) à partir de laquelle les lingots (1) sont poussés dans la cavité.
  6. Procédé selon la revendication 1, selon lequel la phase de préchauffage consiste en un traitement thermique où les lingots en alliage (1) à l'état solide sont soumis à des flux d'air chaud convectifs pendant une période de temps et à une température devant suffire pour porter l'alliage à l'état thixotropique semi-solide.
  7. Procédé selon la revendication 1, selon lequel les lingots (1) en alliage thixotropique se composent, quand ils sont à l'état semi-solide, d'une phase solide devant représenter entre 50 et 60 % et d'une phase liquide constituant les 50 ou 40 % restant.
  8. Procédé selon la revendication 1, selon lequel la phase d'emboutissage à chaud d'au moins la portion interne (13) de la surface latérale (12) par compression est suivie d'une phase de traitement thermique de la roue (2) pour induire une solution solide dans l'alliage thixotropique.
  9. Procédé selon la revendication 8, selon lequel la phase de traitement thermique de la solution est suivie d'une phase de durcissement.
  10. Procédé selon la revendication 8 ou 9, selon lequel la phase d'emboutissage à chaud d'au moins la portion interne (13) de la surface latérale (12) est suivie d'une phase d'usinage destinée à éliminer la surépaisseur laissée pendant les phases de formage précédentes du procédé.
EP95830240A 1994-11-07 1995-06-08 Procédé thixotropique pour la fabrication de roues en alliage à l'état de mélange liquide-solide Expired - Lifetime EP0710515B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US08/549,094 US5900080A (en) 1994-11-07 1995-10-27 Thixotropic forming process for wheels fashioned in rheocast metal alloy and fitted with pneumatic tires
CA002161923A CA2161923A1 (fr) 1994-11-07 1995-11-01 Procede thixotrope pour l'obtention de roues en alliage metallique rheocast munies de pneumatiques

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITBO940484A IT1274094B (it) 1994-11-07 1994-11-07 Procedimento di formatura tixotropica di cerchi per pneumatici in lega metallica reocolata.
ITBO940484 1994-11-07

Publications (2)

Publication Number Publication Date
EP0710515A1 EP0710515A1 (fr) 1996-05-08
EP0710515B1 true EP0710515B1 (fr) 1998-11-18

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EP (1) EP0710515B1 (fr)
AT (1) ATE173419T1 (fr)
DE (1) DE69506075T2 (fr)
IT (1) IT1274094B (fr)

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RU2443494C1 (ru) * 2010-07-22 2012-02-27 Открытое акционерное общество Акционерная холдинговая компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (ОАО АХК "ВНИИМЕТМАШ") Штамп и способ изготовления корпуса буксы из цилиндрической заготовки с глобулярной структурой
CN105705271A (zh) * 2013-09-05 2016-06-22 通用汽车环球科技运作有限责任公司 生产高性能轴对称部件的方法和设备
RU2709079C2 (ru) * 2017-11-08 2019-12-13 Акционерное общество Акционерная холдинговая Компания "Всероссийский научно-исследовательский и проектно-конструкторский институт металлургического машиностроения имени академика Целикова" (АО АХК "ВНИИМЕТМАШ") Способ изготовления поршня с упрочняющим нирезистовым кольцом методом твёрдожидкого формования
RU2724235C2 (ru) * 2018-07-10 2020-06-22 Федеральное государственное бюджетное образовательное учреждение высшего образования "Московский государственный технологический университет "СТАНКИН" (ФГБОУ ВО "МГТУ "СТАНКИН") Способ формообразования тонкополотной поковки

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US4579604A (en) * 1982-07-08 1986-04-01 Ni Industries, Inc. Method of spin forging a finished article
FR2641721B1 (fr) * 1989-01-19 1992-02-21 Pechiney Aluminium Procede d'obtention par moulage sous pression de pieces metalliques presentant des masses isolees compactes
CA2053990A1 (fr) * 1990-11-30 1992-05-31 Gordon W. Breuker Appareil utilise pour produire des articles faconnes a partir de preformes de metal semi-solides et procede connexe

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EP0710515A1 (fr) 1996-05-08
ITBO940484A0 (it) 1994-11-07
ATE173419T1 (de) 1998-12-15
DE69506075D1 (de) 1998-12-24
DE69506075T2 (de) 1999-04-15
IT1274094B (it) 1997-07-15
ITBO940484A1 (it) 1996-05-07

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