EP1063033B1 - Method for the production of a metallic workpiece, like an element of a vehicle wheel, and corresponding wheel - Google Patents

Method for the production of a metallic workpiece, like an element of a vehicle wheel, and corresponding wheel Download PDF

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Publication number
EP1063033B1
EP1063033B1 EP00112143A EP00112143A EP1063033B1 EP 1063033 B1 EP1063033 B1 EP 1063033B1 EP 00112143 A EP00112143 A EP 00112143A EP 00112143 A EP00112143 A EP 00112143A EP 1063033 B1 EP1063033 B1 EP 1063033B1
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EP
European Patent Office
Prior art keywords
wheel
rim
stage
manufacturing process
process according
Prior art date
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EP00112143A
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German (de)
French (fr)
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EP1063033A1 (en
Inventor
Gilles Grillon
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Michelin Recherche et Technique SA Switzerland
Michelin Recherche et Technique SA France
Societe de Technologie Michelin SAS
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Michelin Recherche et Technique SA Switzerland
Michelin Recherche et Technique SA France
Societe de Technologie Michelin SAS
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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
    • B22D17/007—Semi-solid pressure die casting
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/47—Burnishing
    • Y10T29/479—Burnishing by shot peening or blasting

Definitions

  • the present invention relates to a method of manufacturing a metal part, such as that a wheel part intended for the running of a vehicle, and such a wheel.
  • the invention applies in particular to a metal wheel part such as a wheel disc, which is made of a light metal, such as aluminum, magnesium, or a metal allowing substantial lightening, such as titanium, or which is made of an alloy of one of these metals.
  • Wheel discs made of a metal alloy, such as aluminum, are usually manufactured by a forging process or by a molding process.
  • the first method cited if it usually provides discs having satisfactory mechanical and aesthetic characteristics, has the major drawback to involve a high cost of implementation.
  • This thixotropic state can be characterized by a alloy structure which comprises a non-dendritic primary phase, which consists of globules or nodules of substantially spherical shape.
  • EP-A-7 10 515 for the description of such a molding process from a thixotropic and semi-solid alloy, and of a mold for the implementation of this process.
  • thixoforming This shaping process is often referred to by the generic term of thixoforming, which includes both the principle of pressure molding (also called thixomolding) and principle of molding / forging on a vertical machine (also called thixoforgging).
  • the wheel discs shaped by this molding process have in particular the following advantages, precisely because of the aforementioned metallographic state of the alloy which can be defined by globules of reduced size (generally less than 120 ⁇ m) and distributed in a practically uniform manner.
  • These discs can have a reduced thickness and, consequently, a lightening increased, compared to discs obtained from alloys molded in another state.
  • the aim of the present invention is to propose a manufacturing process a metal wheel intended for driving a vehicle, said wheel comprising a wheel disc and a rim, or of a wheel part, said wheel part consisting of a metal disc of a wheel or a metallic rim which consists, in an initial stage, in shaping said wheel or part of a wheel by means of a metallic material having a thixotropic structure and a semi-solid state, which is such that said part has properties mechanical and lightening improved compared to those mentioned above.
  • the core temperature of said wheel or wheel part is about 450 ° C.
  • Reheating is advantageously carried out for a period of between 1 hour and 10 a.m.
  • the tempering is advantageously carried out at a temperature of 170 ° C.
  • said method consists in using, to implement said initial step forming, an alloy based on a metal belonging to the group consisting of aluminum, magnesium, titanium, iron, chromium, cobalt, nickel, copper, zinc, silver, tin, lead and antimony.
  • An aluminum-based alloy is advantageously used, such as an alloy comprising in addition between 6.5% and 7.5% of silicon, and between 0.5% and 0.6% of magnesium by weight.
  • Such an aluminum-based alloy has the advantage of minimizing the phenomenon of corrosion.
  • said initial shaping step consists into a thixoforming, which can be either a thixomoulding or a rheomolding.
  • the thixomolding process comprises a first step which consists in filling a mold with thixotropic metallic material in the semi-solid state, and a second step which consists in compacting this material under a high pressure in the mold, for example of around 100 MPa.
  • said method consists in implementing quenching followed by tempering for said structural hardening step.
  • At least one operation of said cold treatment step consists in using for said projectiles corundum grains of size between 75 and 150 ⁇ m.
  • At least one operation of said step cold treatment consists in using for said projectiles glass microbeads.
  • At least one operation of said step cold treatment consists in using for said projectiles steel shot or cast iron of size between 200 and 800 ⁇ m.
  • said initial shaping step consists in shaping a wheel intended for running a vehicle, said wheel comprising a wheel disc and a rim, so that said wheel constitutes said metal part manufactured, and said cold treatment step consists of treating by said impacts of projectiles all or part of at least one face of said disc and / or said rim.
  • said initial shaping step consists in shaping part of a wheel intended for driving a vehicle, said part of wheel being consisting of a wheel disc or rim, such that said wheel part constitutes said fabricated metal part, and said cold treatment step consists in treat by said projectile impacts all or part of at least one face of said disc or of said rim.
  • a wheel according to the invention intended for running a vehicle which comprises a rim on which is fixed, for example by welding, a metal disc, is such that said disc metallic is obtained by the manufacturing process defined in one of claims preceding.
  • a method of manufacturing a metal part according to a first embodiment of the invention consists, in a first step 10, in shaping said part by thixomolding of a metallic material having a structure thixotropic and a semi-solid state then, in an optional second step, to be submitted said shaped part to a structural hardening, then, in a third step 30, to be treated at least part of said part by projectile impacts.
  • a second embodiment of the method according to the invention consists in implementing a first step 110 identical or similar to the aforementioned step 10, to then implement a second step 120 consisting of a stamping of the part thus fashioned, to then implement a third step 130 optional structural hardening different from said step 20, then to be implemented a fourth step 140 of cold treatment by projectile impacts which is identical or similar to said step 30.
  • an aluminum-based alloy is used.
  • said alloy is then an alloy belonging to the aluminum / silicon family.
  • the metal alloy to be injected has previously been brought into a firstly, to a thixotropic metallographic structure then, secondly, to a semi-solid state.
  • said first step is implemented by submitting billets of this alloy to electromagnetic induction stirring, in accordance with method and corresponding device described in European patent document EP-A-439 981, for obtaining thixotropic billets.
  • the said billets are then heated by induction at a temperature T (° C) which is such that: T fe ⁇ T ⁇ T fe + 10, where T fe is the melting temperature of the eutectic (which is equal to 577 ° C for said alloy A-S7G0.6 preferably used).
  • the thixotropy of the alloy injected into the mold is such that the size maximum of the globules which characterize it is less than 120 ⁇ m.
  • the molded material is allowed to cool until a solid state is obtained, then immediately proceeds to demolding. This gives the metal part which is shaped according to the mold footprint.
  • step 20 (optional) of this first mode of implementation work of the process of the invention, one proceeds, preferably immediately after said demolding, to a structural hardening consisting successively of a quenching of said piece and an income from it.
  • said quenching which is carried out by means of a suitable fluid such as water and which lasts a few seconds, said fluid is maintained at a temperature between 30 and 60 ° C, preferably between 30 and 40 ° C.
  • the said income it is carried out at a temperature of 170 ° C. and for 6 hours.
  • thermo and treatment time parameters that are used for the structural hardening of a part are suitable for obtaining a torque of resistance / ductility characteristics of given values.
  • the metal part obtained following the second step 20 by cold plastic deformation in subjecting it at room temperature to projectile impacts.
  • projectile impacts are for example obtained by a device 1 for emitting projectiles 2, the structure of which is shown in a simplified manner in FIG. 2.
  • This device 1 comprises at least one inlet 3a connected upstream to a hopper 4 of storage of projectiles 2, and which comprises at least one outlet 3b for the emission of jets J.
  • the device 1 is of the suction type of the air contained in hopper 4 so as to create a depression therein, and it is known as "Giffard".
  • the device 1 shown in this exemplary embodiment includes a first flexible pipe 5a, the ends of which respectively form the inlet 3a and the outlet 3b.
  • the inlet 3a is connected to the lower part of the hopper 4, and it has an air intake P provided with a means R for adjusting the intake air flow.
  • a second compressed air supply pipe 5b (arrow A) is connected to said outlet 3b at upstream of it.
  • the air supplied by this pipe 5b is intended to project through said outlet 3b the projectiles 2 which are permanently extracted from the bottom of the hopper 4 (arrow A), by setting depression of said hopper 4.
  • a regulator 5c of the compressed air flow and, consequently, of the grain projection rate, is mounted on said pipe 5b.
  • a device 1 other than that shown could be used in Fig. 2, for example of the type creating gravity, overpressure, direct pressure at the inside of the hopper 7 or of the turbine machine type provided for mechanically projecting the projectiles 2.
  • a device 1 of the ultrasonic type or electromagnetic to accelerate the particles or to put them in intense vibration against the part to be treated, or of the explosion type or generating a laser shock.
  • projectiles 2 were used which consist of grains of brown corundum (aluminum oxide especially loaded with titanium). More specifically, the composition of the brown corundum which was used is the following, expressed in mass contents: Al 2 O 3 89% to 94% TiO 2 2% to 4% SiO 2 0.4% to 1.5% Fe 2 O 3 1.5% to 3.5% CaO + MgO 0.3% to 0.5% Na 2 O + K 2 O 0.01% to 0.02% Magnetic parts less than 4%.
  • the grains 2 had a size between 75 and 150 ⁇ m and a shape angular.
  • a compressed air pressure of 4 bar was used for the propulsion of the grains 2 via the pipe 5b and the nozzle 6a, a direction of projection substantially normal to the face 7a of the disc 7 to be treated, and a projection distance of 100 mm relative to said face 1a.
  • projectiles 2 for example grains 2 of white corundum (crystallized aluminum oxide) in place of said brown corundum or ceramic, or dry glass microbeads or wet, or steel or cast iron shot of medium size between 200 and 800 ⁇ m, preferably equal to 400 ⁇ m.
  • white corundum crystalstallized aluminum oxide
  • dry glass microbeads or wet or steel or cast iron shot of medium size between 200 and 800 ⁇ m, preferably equal to 400 ⁇ m.
  • projectiles 2 coated or not the material, mass, shape and dimensions are suitable for providing stress thermo-mechanical of the surface to be treated so as to subject it to a stress of compression to a given degree and depth, and / or to provide control over the surface condition (roughness, folds, for example), and / or to impart an aesthetic appearance determined at said treated surface (gloss, reflectance, diffusance, satin effect, color, especially).
  • this step 30 of cold treatment by projectile impact 2 can be performed in one or more operations.
  • the projection conditions such as projectile speed 2, angle of attack and coverage rate, are adapted to each operation to obtain the aforementioned results.
  • the second stamping step 120 which is implemented after molding according to step 110 is of the type which has been described in the European patent document EP-A- 119 365. More specifically, the core temperature of the molded part is approximately 450 ° C (between 400 and 500 ° C) during the stamping operation, i.e. during pressing of said molded part between the two shells of the die.
  • the third step 130 of structural hardening of the molded and stamped part consists, firstly, of a reheating which is intended to put the magnesium of said alloy A-S7G0,6 in solid substitution solution in aluminum then, in a second time, in quenching followed by tempering in the same manner as in step 20 of said first fashion.
  • This reheating is carried out for a period of between 1 hour and 10 hours, and at a temperature between 520 ° C and 540 ° C for the aforementioned solid solution.
  • the purpose of quenching in this case is to keep the magnesium in solid solution supersaturated in aluminum, while said income is intended to create a fine precipitation magnesium in aluminum, thus completing the desired structural hardening.
  • step 140 of this second mode it is analogous to said step 30 of the first mode, as indicated above.
  • a first witness D1 consists of a thixotropic structure disc molded according to the invention, but not having undergone the impact treatment of step 30 or 140.
  • a second witness D2 consists of a disc made of a wrought and forged alloy known under the name 6082T6 (European standard NF EN 573-3), that is to say comprising in particular aluminum, magnesium and silicon, this alloy having been put in solid solution, quenched and tempered. As with the first witness, this second witness did not undergone impact treatment.
  • the fatigue limit L f (in MPa) was estimated in rotary bending for a number of cycles equal to 6. 10 6 .
  • each disc was determined by taking as the reference thickness e 0 the thickness of an analog reference disc.
  • This reference disc consists of an aluminum-based alloy A-S7G0.3 Y33 according to standard NF A / 02-004, and it was obtained by a “shell molding” process, also known under the name of low-pressure molding by a person skilled in the art.
  • FIG. 3 There is shown in FIG. 3 an example of assembly on a rim 8 of a disc 7 constituting an example of a metal part manufactured by a method of the invention, for obtaining a wheel 9.
  • the rim 8 is for example made of a light metal, such as aluminum or magnesium, or an alloy of such a light metal, or any other material known to provide satisfactory lightening and endurance.
  • This rim 8 can also be made of iron or an iron-based alloy.
  • this assembly is carried out by welding known as designation MIG, i.e. with arc under inert gas, such as argon, and with contribution of metal. It will be noted that this type of welding is favored by the thixotropic structure of the disc 7.
  • wheel profiles 9 different from that shown. in Fig. 3.
  • a disc profile 7 such as that sold. under the name Full Face TM
  • a rim profile 8 such as that marketed under the name PAX TM or under the name Single TM, for example.
  • the initial shaping step 10, 110 is not limited to the molding of a wheel disc 7 only, but may also relate to the molding of the assembly of a wheel 9 constituted a disc 7 and a rim 8, so that the part finally obtained by said process is constituted by said wheel 9.
  • the cold treatment step 30, 140 consists in treating by projectile impacts 2 all or part of at least one face 7a of the disc 7 and / or of the rim 8.
  • the step initial shaping 10, 110 could consist of shaping a rim 8 (i.e. one or the other part 7, 8 of a wheel 9) in place of said disc 7, so that the part finally obtained by the process of the invention is constituted by the molded rim 8.
  • the cold treatment step 30, 140 consists in treating by projectile impacts 2 all or part of at least one face of said rim 8.
  • said face 7a can advantageously be that which is intended to be find the side of the interior of the wheel 9, because of the non-smooth appearance of this treated face 7a.

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Abstract

The component (7, 8, 9) is cast from a metallic material having a thixotropic structure and a semi-solid state. In a subsequent cold treatment stage, at least a part of the component is cold treated by impact with projectiles for plastic deformation. Preferably, after the casting stage and before the subsequent cold treatment stage, the formed component is subjected to structural hardening comprising quenching and tempering. Before structural hardening, the formed component is subjected to die-stamping. The metallic material is an alloy based on one of the following metals: aluminum, magnesium, titanium, iron, chromium, cobalt, nickel, copper, zinc, silver, tin, lead and antimony, preferably an aluminum alloy containing 6.5-7.5 weight % silicon and 0.5-0.6 weight % magnesium. Corundum particles of size 75-150 microns , glass microspheres, and steel shot of size 200-800 microns and are used in at least one operation of the cold treatment stage. Independent claims are given for: (a) fabrication of a metal component (9) for a vehicle wheel (9), the wheel (9) comprising a wheel disk (7) and a rim (8), so that the wheel comprises the fabricated metal component, and where the cold treatment stage involves subjecting the whole or at least a part of the face (7a) of the disc (7) and/or the rim (8) to impact with projectiles; (b) fabrication of a metal component (7 or 8) for a vehicle wheel (9), the component (7 or 8) comprising a wheel disk or a rim, so that the component comprises the fabricated metal component (7 or 8), and where the cold treatment stage involves subjecting the whole or at least a part of the face (7a) of the disc (7) and/or the rim (8) to impact with projectiles; and (c) a vehicle wheel (9) comprising a rim (8) on which is fixed a metallic disc (7) which is fabricated according to the above process.

Description

La présente invention concerne un procédé de fabrication d'une pièce métallique, telle qu'une partie de roue destinée au roulage d'un véhicule, et une telle roue. L'invention s'applique notamment à une partie métallique de roue telle qu'un disque de roue, qui est constituée d'un métal léger, tel que l'aluminium, le magnésium, ou un métal permettant un allègement substantiel, tel que le titane, ou encore qui est constituée d'un alliage de l'un de ces métaux.The present invention relates to a method of manufacturing a metal part, such as that a wheel part intended for the running of a vehicle, and such a wheel. The invention applies in particular to a metal wheel part such as a wheel disc, which is made of a light metal, such as aluminum, magnesium, or a metal allowing substantial lightening, such as titanium, or which is made of an alloy of one of these metals.

Les disques de roues constitués d'un alliage métallique, tel que l'aluminium, sont usuellement fabriqués par un procédé de forgeage ou par un procédé de moulage.Wheel discs made of a metal alloy, such as aluminum, are usually manufactured by a forging process or by a molding process.

Le premier procédé cité, s'il procure habituellement des disques présentant des caractéristiques mécaniques et esthétiques satisfaisantes, présente l'inconvénient majeur d'impliquer un coût de mise en oeuvre élevé.The first method cited, if it usually provides discs having satisfactory mechanical and aesthetic characteristics, has the major drawback to involve a high cost of implementation.

Depuis plusieurs années, on utilise préférentiellement, pour mettre en oeuvre le second procédé cité, une matière qui est constituée d'un alliage préalablement amené à un état métallographique thixotrope et semi-solide. Cet état thixotrope peut être caractérisé par une structure d'alliage qui comprend une phase primaire non dendritique, laquelle est constituée de globules ou nodules de forme sensiblement sphérique.For several years, we preferentially use, to implement the second cited process, a material which consists of an alloy previously brought to a state thixotropic and semi-solid metallographic. This thixotropic state can be characterized by a alloy structure which comprises a non-dendritic primary phase, which consists of globules or nodules of substantially spherical shape.

On pourra par exemple se référer au document de brevet européen EP-A-7 10 515 pour la description d'un tel procédé de moulage à partir d'un alliage thixotrope et semi-solide, et d'un moule pour la mise en oeuvre de ce procédé.We can for example refer to European patent document EP-A-7 10 515 for the description of such a molding process from a thixotropic and semi-solid alloy, and of a mold for the implementation of this process.

On pourra en outre se référer au document de brevet européen EP-A-439 981 pour la description d'une méthode d'obtention de l'état thixotrope précité.We can also refer to European patent document EP-A-439 981 for the description of a method for obtaining the aforementioned thixotropic state.

Ce procédé de façonnage est souvent désigné par le terme générique de thixoformage, qui inclut à la fois le principe de moulage sous pression (encore appelé thixomoulage) et le principe de moulage/ forgeage sur machine verticale (encore appelé thixoforgeage).This shaping process is often referred to by the generic term of thixoforming, which includes both the principle of pressure molding (also called thixomolding) and principle of molding / forging on a vertical machine (also called thixoforgging).

Les disques de roue façonnés par ce procédé de moulage présentent notamment les avantages suivants, précisément en raison de l'état métallographique précité de l'alliage qui peut être défini par des globules de taille réduite (généralement inférieure à 120 µm) et répartis d'une manière pratiquement uniforme.The wheel discs shaped by this molding process have in particular the following advantages, precisely because of the aforementioned metallographic state of the alloy which can be defined by globules of reduced size (generally less than 120 µm) and distributed in a practically uniform manner.

Ces disques peuvent présenter une épaisseur réduite et, par conséquent, un allègement accru, par rapport à des disques obtenus à partir d'alliages moulés dans un autre état. These discs can have a reduced thickness and, consequently, a lightening increased, compared to discs obtained from alloys molded in another state.

De plus, ils présentent une porosité réduite, qui se traduit par une compacité et une résistance mécanique uniformes et améliorées, et une aptitude aux traitements thermiques également améliorée.
   Ce procédé de façonnage présente d'autres avantages, notamment:

  • un large éventail de possibilités pour l'aspect esthétique des disques de roue obtenus (avec par exemple la possibilité d'obtenir des parois minces ou des variations de section importantes),
  • une grande précision dimensionnelle pour les disques obtenus, ce qui minimise les opérations d'usinage,
  • une productivité élevée en raison des temps de cycle courts et de l'automatisation des tâches, et
  • une durée de vie des moules qui est substantiellement augmentée par rapport à celle des moules qui sont utilisés dans des procédés classiques de moulage par injection sous pression de métaux liquides, tels que de l'aluminium.
In addition, they have a reduced porosity, which results in a uniform and improved compactness and mechanical strength, and also an improved ability to heat treatments.
This shaping process has other advantages, in particular:
  • a wide range of possibilities for the aesthetic appearance of the wheel discs obtained (with for example the possibility of obtaining thin walls or significant variations in section),
  • high dimensional accuracy for the discs obtained, which minimizes the machining operations,
  • high productivity due to short cycle times and task automation, and
  • a lifetime of the molds which is substantially increased compared to that of the molds which are used in conventional methods of injection molding under pressure of liquid metals, such as aluminum.

Le but de la présente invention est de proposer un procédé de fabrication d'une roue métallique destinée au roulage d'un véhicule, ladite roue comprenant un disque de roue et une jante, ou d'une partie de roue, ladite partie de roue étant constituée d'un disque métallique de roue ou d'une jante métallique qui consiste, dans une étape initiale, à façonner ladite roue ou partie de roue au moyen d'une matière métallique présentant une structure thixotrope et un état semi-solide, qui soit tel que ladite pièce présente des propriétés mécaniques et d'allègement améliorées par rapport à celles précitées.The aim of the present invention is to propose a manufacturing process a metal wheel intended for driving a vehicle, said wheel comprising a wheel disc and a rim, or of a wheel part, said wheel part consisting of a metal disc of a wheel or a metallic rim which consists, in an initial stage, in shaping said wheel or part of a wheel by means of a metallic material having a thixotropic structure and a semi-solid state, which is such that said part has properties mechanical and lightening improved compared to those mentioned above.

A cet effet, le procédé de fabrication selon l'invention est caractérisé en ce qu'il comprend en outre les étapes ultérieures suivantes:

  • (i) on soumet ladite roue ou partie de roue façonnée suite à ladite étape initiale à une étape de matricage de telle manière que la température à coeur de ladite roue ou partie de roue soit comprise entre 400° C et 500° C lors de ce matriçage, puis
  • (ii) on soumet tout ou partie d'au moins une face dudit disque et/ou de ladite jante de ladite roue ou partie de roue obtenue en (i) à des impacts de projectiles dans une étape de traitement à froid, en vue de sa déformation plastique.
    • To this end, the manufacturing method according to the invention is characterized in that it further comprises the following subsequent steps:
  • (i) subjecting said wheel or wheel part shaped following said initial step to a stamping step so that the core temperature of said wheel or wheel part is between 400 ° C and 500 ° C during this mastering, then
  • (ii) subjecting all or part of at least one face of said disc and / or said rim of said wheel or part of wheel obtained in (i) to projectile impacts in a cold treatment step, with a view to its plastic deformation.

    • Avantageusement, pendant l'étape (i) de matricage, la température à coeur de ladite roue ou partie de roue est d'environ 450°C.Advantageously, during the stamping step (i), the core temperature of said wheel or wheel part is about 450 ° C.

    Selon une variante de réalisation de l'invention, ce procédé de fabrication consiste à soumettre, dans une étape intermédiaire entre les étapes (i) et (ii), ladite roue ou partie de roue faconnée et matricée à un durcissement structural mis en oeuvre par:

    • un réchauffage effectué à une température comprise entre 520°C et 540° C, puis par
    • une trempe effectuée au moyen d'un fluide maintenu à une température comprise entre 30° C et 60° C, puis par
    • un revenu.
    According to a variant embodiment of the invention, this manufacturing process consists in subjecting, in an intermediate step between steps (i) and (ii), said shaped wheel or part of a shaped and stamped wheel to a structural hardening implemented by :
    • reheating carried out at a temperature between 520 ° C and 540 ° C, then by
    • quenching carried out by means of a fluid maintained at a temperature between 30 ° C and 60 ° C, then by
    • income.

    Le réchauffage est avantageusement effectué pendant une durée comprise entre 1 heure et 10 heures.Reheating is advantageously carried out for a period of between 1 hour and 10 a.m.

    Le revenu est avantageusement effectué à une température de 170°C. The tempering is advantageously carried out at a temperature of 170 ° C.

    De préférence, ledit procédé consiste à utiliser, pour mettre oeuvre ladite étape initiale de façonnage, un alliage à base d'un métal appartenant au groupe constitué par l'aluminium, le magnésium, le titane, le fer, le chrome, le cobalt, le nickel, le cuivre, le zinc, l'argent, l'étain, le plomb et l'antimoine.Preferably, said method consists in using, to implement said initial step forming, an alloy based on a metal belonging to the group consisting of aluminum, magnesium, titanium, iron, chromium, cobalt, nickel, copper, zinc, silver, tin, lead and antimony.

    On utilise avantageusement un alliage à base d'aluminium, tel qu'un alliage comprenant en outre entre 6,5 % et 7,5 % de silicium, et entre 0,5 % et 0,6 % de magnésium en poids.An aluminum-based alloy is advantageously used, such as an alloy comprising in addition between 6.5% and 7.5% of silicon, and between 0.5% and 0.6% of magnesium by weight.

    Un tel alliage à base d'aluminium présente l'avantage de minimiser le phénomène de corrosion.Such an aluminum-based alloy has the advantage of minimizing the phenomenon of corrosion.

    Selon une autre caractéristique de l'invention, ladite étape initiale de façonnage consiste en un thixoformage, lequel peut être soit un thixomoulage, soit un rhéomoulage.According to another characteristic of the invention, said initial shaping step consists into a thixoforming, which can be either a thixomoulding or a rheomolding.

    On notera que le procédé de thixomoulage comprend une première étape qui consiste à remplir un moule de matière métallique thixotrope à l'état semi-solide, et une seconde étape qui consiste à compacter cette matière sous une pression élevée dans le moule, par exemple de l'ordre de 100 MPa.It will be noted that the thixomolding process comprises a first step which consists in filling a mold with thixotropic metallic material in the semi-solid state, and a second step which consists in compacting this material under a high pressure in the mold, for example of around 100 MPa.

    On notera également que, d'une manière connue, le procédé connu sous le nom de « rhéomoulage» consiste essentiellement en une agitation mécanique d'un alliage liquide pour l'obtention d'un état semi-solide, puis dans un moulage direct de l'alliage semi-solide obtenu, sans qu'il n'y ait d'étape de refroidissement préalable audit moulage.It will also be noted that, in a known manner, the process known as "Rheomolding" essentially consists of mechanical agitation of a liquid alloy to obtaining a semi-solid state, then in a direct molding of the semi-solid alloy obtained, without there being a cooling step prior to said molding.

    Selon une autre caractéristique de l'invention, ledit procédé consiste à mettre en oeuvre une trempe suivie d'un revenu pour ladite étape de durcissement structural.According to another characteristic of the invention, said method consists in implementing quenching followed by tempering for said structural hardening step.

    Selon un exemple de mise en oeuvre du procédé selon l'invention, au moins une opération de ladite étape de traitement à froid consiste à utiliser pour lesdits projectiles des grains de corindon de taille comprise entre 75 et 150 µm.According to an example of implementation of the method according to the invention, at least one operation of said cold treatment step consists in using for said projectiles corundum grains of size between 75 and 150 µm.

    Selon un autre exemple conforme à l'invention, au moins une opération de ladite étape de traitement à froid consiste à utiliser pour lesdits projectiles des microbilles de verre.According to another example according to the invention, at least one operation of said step cold treatment consists in using for said projectiles glass microbeads.

    Selon un autre exemple conforme à l'invention, au moins une opération de ladite étape de traitement à froid consiste à utiliser pour lesdits projectiles de la grenaille d'acier ou de fonte de taille comprise entre 200 et 800 µm.According to another example according to the invention, at least one operation of said step cold treatment consists in using for said projectiles steel shot or cast iron of size between 200 and 800 µm.

    Selon une caractéristique avantageuse de l'invention, ladite étape initiale de façonnage consiste à façonner une roue destinée au roulage d'un véhicule, ladite roue comportant un disque de roue et une jante, de telle manière que ladite roue constitue ladite pièce métallique fabriquée, et ladite étape de traitement à froid consiste à traiter par lesdits impacts de projectiles tout ou partie d'au moins une face dudit disque et/ou de ladite jante.According to an advantageous characteristic of the invention, said initial shaping step consists in shaping a wheel intended for running a vehicle, said wheel comprising a wheel disc and a rim, so that said wheel constitutes said metal part manufactured, and said cold treatment step consists of treating by said impacts of projectiles all or part of at least one face of said disc and / or said rim.

    Selon une variante également avantageuse, ladite étape initiale de façonnage consiste à façonner une partie d'une roue destinée au roulage d'un véhicule, ladite partie de roue étant constituée d'un disque de roue ou d'une jante, de telle manière que ladite partie de roue constitue ladite pièce métallique fabriquée, et ladite étape de traitement à froid consiste à traiter par lesdits impacts de projectiles tout ou partie d'au moins une face dudit disque ou de ladite jante.According to an equally advantageous variant, said initial shaping step consists in shaping part of a wheel intended for driving a vehicle, said part of wheel being consisting of a wheel disc or rim, such that said wheel part constitutes said fabricated metal part, and said cold treatment step consists in treat by said projectile impacts all or part of at least one face of said disc or of said rim.

    Une roue selon l'invention destinée au roulage d'un véhicule, qui comporte une jante sur laquelle est fixé, par exemple par soudage, un disque métallique, est telle que ledit disque métallique est obtenu par le procédé de fabrication défini à l'une des revendications précédentes.A wheel according to the invention intended for running a vehicle, which comprises a rim on which is fixed, for example by welding, a metal disc, is such that said disc metallic is obtained by the manufacturing process defined in one of claims preceding.

    Les caractéristiques précitées de la présente invention, ainsi que d'autres, seront mieux comprises à la lecture de la description suivante d'un exemple de réalisation de l'invention, donné à titre illustratif et non limitatif, ladite description étant réalisée en relation avec les dessins joints, parmi lesquels:

  • les Figs. 1a et 1b sont des schémas à blocs illustrant un procédé de fabrication d'une pièce métallique selon deux modes de mise en oeuvre de l'invention, respectivement,
  • la Fig. 2 est une vue schématique d'un dispositif d'émission de projectiles pour la mise en oeuvre dudit procédé de fabrication selon l'invention, et
  • la Fig. 3 est une vue partielle et en section d'un disque de roue et d'une jante, dans une position d'assemblage de sorte à former une roue constituant une pièce métallique selon l'invention.
    • The aforementioned characteristics of the present invention, as well as others, will be better understood on reading the following description of an exemplary embodiment of the invention, given by way of illustration and not limitation, said description being made in relation to the accompanying drawings, among which:
  • Figs. 1a and 1b are block diagrams illustrating a process for manufacturing a metal part according to two embodiments of the invention, respectively,
  • Fig. 2 is a schematic view of a projectile emission device for the implementation of said manufacturing method according to the invention, and
  • Fig. 3 is a partial view in section of a wheel disc and a rim, in an assembly position so as to form a wheel constituting a metal part according to the invention.

    • En référence à la Fig. 1a, un procédé de fabrication d'une pièce métallique selon un premier mode de mise en oeuvre de l'invention consiste, dans une première étape 10, à façonner ladite pièce par thixomoulage d'une matière métallique présentant une structure thixotrope et un état semi-solide puis, dans une seconde étape 20 optionnelle, à soumettre ladite pièce façonnée à un durcissement structural, puis, dans une troisième étape 30, à traiter au moins une partie de ladite pièce par des impacts de projectiles.With reference to FIG. 1a, a method of manufacturing a metal part according to a first embodiment of the invention consists, in a first step 10, in shaping said part by thixomolding of a metallic material having a structure thixotropic and a semi-solid state then, in an optional second step, to be submitted said shaped part to a structural hardening, then, in a third step 30, to be treated at least part of said part by projectile impacts.

    En référence à la Fig. 1b, on voit qu'un second mode de mise en oeuvre du procédé selon l'invention consiste à mettre en oeuvre une première étape 110 identique ou similaire à l'étape 10 précitée, à mettre ensuite en oeuvre une seconde étape 120 consistant en un matriçage de la pièce ainsi façonnée, à mettre ensuite en oeuvre une troisième étape 130 optionnelle de durcissement structural différente de ladite étape 20, puis à mettre en oeuvre une quatrième étape 140 de traitement à froid par impacts de projectiles qui est identique ou similaire à ladite étape 30.With reference to FIG. 1b, it can be seen that a second embodiment of the method according to the invention consists in implementing a first step 110 identical or similar to the aforementioned step 10, to then implement a second step 120 consisting of a stamping of the part thus fashioned, to then implement a third step 130 optional structural hardening different from said step 20, then to be implemented a fourth step 140 of cold treatment by projectile impacts which is identical or similar to said step 30.

    Pour mettre en oeuvre cette première étape 10 ou 110, on injecte dans un moule (non représenté, car tel que décrit dans le document de brevet européen EP-A-710 515) des barres cylindriques de longueur prédéterminée ou lopins qui sont par exemple constituées d'un alliage à base d'un métal léger, tel que l'aluminium ou le magnésium.To implement this first step 10 or 110, we inject into a mold (not shown, as as described in European patent document EP-A-710 515) bars cylindrical of predetermined length or pieces which are for example made of an alloy based on a light metal, such as aluminum or magnesium.

    On utilise avantageusement un alliage à base d'aluminium. De préférence, ledit alliage est alors un alliage appartenant à la famille aluminium/ silicium.Advantageously, an aluminum-based alloy is used. Preferably, said alloy is then an alloy belonging to the aluminum / silicon family.

    A titre encore plus préférentiel, cet alliage répond à la dénomination A-S7G0,6 conformément à la norme NF A 02-004, de telle manière qu'il comporte en poids, outre l'aluminium, notamment:

  • entre 6,5 % et 7,5 % de silicium,
  • 0,15 % de fer,
  • 0,03 % de cuivre,
  • 0,03 % de manganèse,
  • 0,60 % de magnésium,
  • 0,03 % de nickel,
  • 0,05 % de zinc,
  • 0,03 % de plomb et d'étain,
  • 0,20 % de titane,
  • 0,05 % de strontium.
    • Even more preferably, this alloy corresponds to the name A-S7G0.6 in accordance with standard NF A 02-004, in such a way that it comprises by weight, in addition to aluminum, in particular:
  • between 6.5% and 7.5% silicon,
  • 0.15% iron,
  • 0.03% copper,
  • 0.03% manganese,
  • 0.60% magnesium,
  • 0.03% nickel,
  • 0.05% zinc,
  • 0.03% lead and tin,
  • 0.20% titanium,
  • 0.05% strontium.

    • Dans la suite de la présente description, on se réfèrera à cet alliage A-S7G0,6, d'une part, pour la description du second mode de réalisation et, d'autre part, pour les résultats de résistance mécanique et d'allègement obtenus en mettant en oeuvre ledit premier ou ledit second mode.In the remainder of this description, reference will be made to this alloy A-S7G0,6, of a on the one hand, for the description of the second embodiment and, on the other hand, for the results of mechanical strength and lightening obtained by using said first or said second mode.

    En amont dudit moule, on a préalablement amené l'alliage métallique à injecter, dans un premier temps, à une structure métallographique thixotrope puis, dans un second temps, dans un état semi-solide.Upstream of said mold, the metal alloy to be injected has previously been brought into a firstly, to a thixotropic metallographic structure then, secondly, to a semi-solid state.

    Plus précisément, on met par exemple en oeuvre ledit premier temps en soumettant des billettes de cet alliage à un brassage par induction électromagnétique, conformément au procédé et au dispositif correspondant décrits dans le document de brevet européen EP-A-439 981, pour l'obtention de billettes thixotropes.More precisely, for example, said first step is implemented by submitting billets of this alloy to electromagnetic induction stirring, in accordance with method and corresponding device described in European patent document EP-A-439 981, for obtaining thixotropic billets.

    Pour l'obtention dans ledit second temps de billettes thixotropes se trouvant en outre dans un état semi-solide, on procède ensuite à un réchauffage par induction desdites billettes à une température T (° C) qui est telle que:
    Tfe < T < Tfe + 10 , où Tfe est la température de fusion de l'eutectique (qui est égale à 577° C pour ledit alliage A-S7G0,6 utilisé préférentiellement).    In order to obtain thixotropic billets in said second time, which are also in a semi-solid state, the said billets are then heated by induction at a temperature T (° C) which is such that:
    T fe <T <T fe + 10, where T fe is the melting temperature of the eutectic (which is equal to 577 ° C for said alloy A-S7G0.6 preferably used).

    On notera que la thixotropie de l'alliage injecté dans le moule est telle que la taille maximale des globules qui le caractérisent est inférieure à 120 µm.It will be noted that the thixotropy of the alloy injected into the mold is such that the size maximum of the globules which characterize it is less than 120 µm.

    On notera que l'on pourrrait mettre en oeuvre d'autres procédés pour l'obtention d'une structure thixotrope et d'un état semi-solide. En particulier, on peut citer le procédé connu sous le nom de « rhéomoulage» par l'homme de l'art, qui consiste essentiellement en une agitation d'un alliage semi-solide, associée ou non à un procédé d'affinage chimique des grains dendritiques.Note that we could implement other methods to obtain a thixotropic structure and in a semi-solid state. In particular, mention may be made of the known method under the name of “rheomolding” by a person skilled in the art, which essentially consists of a agitation of a semi-solid alloy, whether or not combined with a chemical grain refining process dendritic.

    Lors de l'opération de moulage, qui est menée conformément audit document de brevet européen EP-A-710 515, on notera que la matière injectée dans le moule est finalement compactée avec une pression par exemple de l'ordre de 100 MPa (la valeur de la pression de compaction pouvant varier en fonction de l'alliage et du procédé utilisés).During the molding operation, which is carried out in accordance with said patent document European EP-A-710 515, it will be noted that the material injected into the mold is ultimately compacted with a pressure for example of the order of 100 MPa (the value of the pressure of compaction can vary depending on the alloy and the process used).

    On laisse refroidir la matière moulée jusqu'à l'obtention d'un état solide, puis on procède immédiatement au démoulage. On obtient ainsi la pièce métallique qui est façonnée selon l'empreinte du moule.The molded material is allowed to cool until a solid state is obtained, then immediately proceeds to demolding. This gives the metal part which is shaped according to the mold footprint.

    Conformément à ladite seconde étape 20 (optionnelle) de ce premier mode de mise en oeuvre du procédé de l'invention, on procède, de préférence immédiatement après ledit démoulage, à un durcissement structural consistant successivement en une trempe de ladite pièce et à un revenu de celle-ci.In accordance with said second step 20 (optional) of this first mode of implementation work of the process of the invention, one proceeds, preferably immediately after said demolding, to a structural hardening consisting successively of a quenching of said piece and an income from it.

    Lors de ladite trempe, qui est effectuée au moyen d'un fluide adapté tel que de l'eau et qui dure quelques secondes, ledit fluide est maintenu à une température comprise entre 30 et 60° C, de préférence entre 30 et 40° C.During said quenching, which is carried out by means of a suitable fluid such as water and which lasts a few seconds, said fluid is maintained at a temperature between 30 and 60 ° C, preferably between 30 and 40 ° C.

    Quant audit revenu, il s' effectue à une température de 170° C et pendant 6 heures.As for the said income, it is carried out at a temperature of 170 ° C. and for 6 hours.

    On notera que les paramètres de température et durée de traitement qui sont utilisés pour le durcissement structural d'une pièce sont adaptés pour l'obtention d'un couple de caractéristiques résistance/ ductilité de valeurs données.Note that the temperature and treatment time parameters that are used for the structural hardening of a part are suitable for obtaining a torque of resistance / ductility characteristics of given values.

    Conformément à la troisième étape 30 dudit premier mode selon l'invention, on traite la pièce métallique obtenue suite à la seconde étape 20 par une déformation plastique à froid, en la soumettant à la température ambiante à des impacts de projectiles.In accordance with the third step 30 of said first mode according to the invention, the metal part obtained following the second step 20 by cold plastic deformation, in subjecting it at room temperature to projectile impacts.

    Ces impacts de projectiles sont par exemple obtenus par un dispositif 1 d'émission de projectiles 2 dont la structure est représentée d'une manière simplifiée à la Fig. 2.These projectile impacts are for example obtained by a device 1 for emitting projectiles 2, the structure of which is shown in a simplified manner in FIG. 2.

    Ce dispositif 1 comporte au moins une entrée 3a reliée en amont à une trémie 4 de stockage des projectiles 2, et qui comporte au moins une sortie 3b pour l'émission de jets J.This device 1 comprises at least one inlet 3a connected upstream to a hopper 4 of storage of projectiles 2, and which comprises at least one outlet 3b for the emission of jets J.

    Dans l'exemple de la Fig. 2, le dispositif 1 est du type à aspiration de l'air contenu dans la trémie 4 de manière à créer une dépression dans celle-ci, et il est connu sous le nom de « Giffard ».In the example of FIG. 2, the device 1 is of the suction type of the air contained in hopper 4 so as to create a depression therein, and it is known as "Giffard".

    Plus précisément, le dispositif 1 représenté dans cet exemple de réalisation comporte un premier tuyau souple 5a dont les extrémités forment respectivement l'entrée 3a et la sortie 3b. L'entrée 3a est reliée à la partie inférieure de la trémie 4, et elle comporte une prise d'air P pourvue d'un moyen de réglage R du débit d'air aspiré.More specifically, the device 1 shown in this exemplary embodiment includes a first flexible pipe 5a, the ends of which respectively form the inlet 3a and the outlet 3b. The inlet 3a is connected to the lower part of the hopper 4, and it has an air intake P provided with a means R for adjusting the intake air flow.

    Un second tuyau 5b d'amenée d'air comprimé (flèche A) est relié à ladite sortie 3b en amont de celle-ci. L'air acheminé par ce tuyau 5b est destiné à projeter par ladite sortie 3b les projectiles 2 qui sont extraits en permanence du fond de la trémie 4 (flèche A), par mise en dépression de ladite trémie 4. Un régulateur 5c du débit d'air comprimé et, par conséquent, du débit de projection des grains, est monté sur ledit tuyau 5b. A second compressed air supply pipe 5b (arrow A) is connected to said outlet 3b at upstream of it. The air supplied by this pipe 5b is intended to project through said outlet 3b the projectiles 2 which are permanently extracted from the bottom of the hopper 4 (arrow A), by setting depression of said hopper 4. A regulator 5c of the compressed air flow and, consequently, of the grain projection rate, is mounted on said pipe 5b.

    La sortie 3b du tuyau 5a et l'extrémité aval dudit tuyau 5b débouchent d'une manière étanche dans un pistolet 6 se terminant par une buse de projection 6a destinée à émettre lesdits jets J.The outlet 3b of the pipe 5a and the downstream end of said pipe 5b open in a manner sealed in a gun 6 terminating in a projection nozzle 6a intended to emit said jets J.

    On notera que l'on pourrait utiliser un dispositif 1 utilisant à la place de l'air un fluide liquide, tel que de l'eau, à titre de fluide de propulsion.Note that we could use a device 1 using instead of air a fluid liquid, such as water, as propellant.

    On notera également que l'on pourrait utiliser un dispositif 1 autre que celui représenté à la Fig. 2, par exemple du type créant une gravité, une surpression, une pression directe à l'intérieur de la trémie 7 ou du type machine à turbine prévue pour projeter mécaniquement les projectiles 2. On pourrait également utiliser un dispositif 1 du type à ultrasons ou électromagnétique, pour accélérer les particules ou les mettre en vibration intense contre la pièce à traiter, ou encore du type à explosion ou générant un choc laser.It will also be noted that a device 1 other than that shown could be used in Fig. 2, for example of the type creating gravity, overpressure, direct pressure at the inside of the hopper 7 or of the turbine machine type provided for mechanically projecting the projectiles 2. One could also use a device 1 of the ultrasonic type or electromagnetic, to accelerate the particles or to put them in intense vibration against the part to be treated, or of the explosion type or generating a laser shock.

    D'une manière générale, on comprendra que l'on pourrait utiliser tout dispositif pour projeter des projectiles sur la surface à traiter, qui soit tel que les paramètres mécaniques, thermiques et balistiques soient adaptés à la nature et à l'intensité du traitement souhaité.In general, it will be understood that one could use any device for project projectiles onto the surface to be treated, which is such as the mechanical parameters, thermal and ballistic are adapted to the nature and intensity of the desired treatment.

    Exemple de mise en oeuvre de l'étape 30, 140: Example of implementation of step 30, 140 :

    On a soumis à cette étape 30, 140 de traitement à froid, au moyen dudit dispositif 1 décrit en référence à la Fig. 2, une face 7a d'un disque de roue 7 (voir Fig. 3), ledit disque 7 étant constitué dudit alliage A-S7G0,6 et constituant ladite pièce métallique qui a été préalablement façonnée conformément à l'étape de moulage 10, 110.Was subjected to this step 30, 140 of cold treatment, by means of said device 1 described with reference to FIG. 2, a face 7a of a wheel disc 7 (see Fig. 3), said disc 7 consisting of said alloy A-S7G0,6 and constituting said metal part which has been previously shaped in accordance with molding step 10, 110.

    On a utilisé dans cet exemple des projectiles 2 constitués de grains de corindon brun (oxyde d'aluminium notamment chargé en titane). Plus précisément, la composition du corindon brun qui a été utilisé est la suivante, exprimée en teneurs massiques: Al2O3 89% à 94% TiO2 2% à 4% SiO2 0,4 % à 1,5 % Fe2O3 1,5 % à 3,5 % CaO + MgO 0,3 % à 0,5 % Na2O + K2O 0,01 % à 0,02 % Parties magnétiques moins de 4 %. In this example, projectiles 2 were used which consist of grains of brown corundum (aluminum oxide especially loaded with titanium). More specifically, the composition of the brown corundum which was used is the following, expressed in mass contents: Al 2 O 3 89% to 94% TiO 2 2% to 4% SiO 2 0.4% to 1.5% Fe 2 O 3 1.5% to 3.5% CaO + MgO 0.3% to 0.5% Na 2 O + K 2 O 0.01% to 0.02% Magnetic parts less than 4%.

    De plus, les grains 2 présentaient une taille comprise entre 75 et 150 µm et une forme angulaire.In addition, the grains 2 had a size between 75 and 150 μm and a shape angular.

    De plus, on a utilisé une pression d'air comprimé égale à 4 bars pour la propulsion des grains 2 via le tuyau 5b et la buse 6a, une direction de projection sensiblement normale à la face 7a du disque 7 à traiter, et une distance de projection de 100 mm par rapport à ladite face 1a.In addition, a compressed air pressure of 4 bar was used for the propulsion of the grains 2 via the pipe 5b and the nozzle 6a, a direction of projection substantially normal to the face 7a of the disc 7 to be treated, and a projection distance of 100 mm relative to said face 1a.

    On a cherché à caractériser l'état de surface de ladite face 7a du disque 7 qui a été ainsi traitée par les impacts des grains 2, et l'on a utilisé à cet effet des critères ou paramètres de rugosité qui sont définis précisément dans la norme NF/E05-015 (témoin de rugosité viso-tactile N10b sur Rugotest n° 3 selon la norme NF/E05-051, modèle déposé): Paramètre Témoin Après traitement par impact Ra 2 µm 11 µm Rt 40 µm 120 µm Rz 24 µm 94 µm Rmax 36 µm 111 µm,

  • où Ra est l'écart moyen arithmétique du profil à caractériser,
  • Rt est la hauteur maximale dudit profil,
  • Rz est la hauteur des irrégularités sur 10 points,
  • Rmax est le maximum de la hauteur des irrégularités dudit profil.
    • We sought to characterize the surface condition of said face 7a of the disc 7 which was thus treated by the impacts of the grains 2, and we used for this purpose criteria or parameters of roughness which are defined precisely in the NF / E05-015 standard (viso-tactile roughness indicator N10b on Rugotest n ° 3 according to standard NF / E05-051, registered model): Setting Witness After impact treatment Ra 2 µm 11 µm rt 40 µm 120 µm RZ 24 µm 94 µm Rmax 36 µm 111 µm,
  • where Ra is the arithmetic mean deviation of the profile to be characterized,
  • Rt is the maximum height of said profile,
  • Rz is the height of the irregularities on 10 points,
  • Rmax is the maximum of the height of the irregularities of said profile.

    • On notera que l'on peut également utiliser d'autres matériaux et granulométries pour lesdits projectiles 2, par exemple des grains 2 de corindon blanc (oxyde d'aluminium cristallisé) à la place dudit corindon brun ou de la céramique, ou des microbilles de verre sèches ou humides, ou encore de la grenaille d'acier ou de fonte de dimension moyenne comprise entre 200 et 800 µm, de préférence égale à 400 µm.It should be noted that other materials and particle sizes can also be used to said projectiles 2, for example grains 2 of white corundum (crystallized aluminum oxide) in place of said brown corundum or ceramic, or dry glass microbeads or wet, or steel or cast iron shot of medium size between 200 and 800 µm, preferably equal to 400 µm.

    D'une manière générale, on pourrait utiliser des projectiles 2 enrobés ou non dont le matériau, la masse, la forme et les dimensions sont appropriés pour procurer une sollicitation thermo-mécanique de la surface à traiter de manière à la soumettre à une contrainte de compression selon un degré et une profondeur donnés, et/ou pour procurer une maítrise de l'état de surface (rugosité, replis, par exemple), et/ou pour conférer un aspect esthétique déterminé à ladite surface traitée (brillance, réflectance, diffusance, effet de satinage, couleur, notamment).In general, one could use projectiles 2 coated or not, the material, mass, shape and dimensions are suitable for providing stress thermo-mechanical of the surface to be treated so as to subject it to a stress of compression to a given degree and depth, and / or to provide control over the surface condition (roughness, folds, for example), and / or to impart an aesthetic appearance determined at said treated surface (gloss, reflectance, diffusance, satin effect, color, especially).

    On notera que cette étape 30 de traitement à froid par impact de projectiles 2 peut être effectuée en une ou plusieurs opérations. Dans ce dernier cas, les conditions de projection, telles que la vitesse des projectiles 2, l'angle d'incidence et le taux de recouvrement, sont adpatées à chaque opération pour procurer les résultats précités.It will be noted that this step 30 of cold treatment by projectile impact 2 can be performed in one or more operations. In the latter case, the projection conditions, such as projectile speed 2, angle of attack and coverage rate, are adapted to each operation to obtain the aforementioned results.

    Concernant le second mode du procédé de fabrication d'une pièce métallique selon l'invention, la seconde étape de matriçage 120 qui est mise en oeuvre à l'issue du moulage selon l'étape 110 est du type de celle qui a été décrite dans le document de brevet européen EP-A- 119 365. Plus précisément, la température à coeur de la pièce démoulée est d'environ 450° C (comprise entre 400 et 500° C) pendant l'opération de matriçage, c'est-à-dire lors du pressage de ladite pièce moulée entre les deux coquilles de la matrice.Regarding the second method of manufacturing a metal part according to the invention, the second stamping step 120 which is implemented after molding according to step 110 is of the type which has been described in the European patent document EP-A- 119 365. More specifically, the core temperature of the molded part is approximately 450 ° C (between 400 and 500 ° C) during the stamping operation, i.e. during pressing of said molded part between the two shells of the die.

    La troisième étape 130 de durcissement structural de la pièce moulée et matricée consiste, dans un premier temps, en un réchauffage qui est destiné à mettre le magnésium dudit alliage A-S7G0,6 en solution solide de substitution dans l'aluminium puis, dans un second temps, en une trempe suivie d'un revenu de la même manière que dans l'étape 20 dudit premier mode. The third step 130 of structural hardening of the molded and stamped part consists, firstly, of a reheating which is intended to put the magnesium of said alloy A-S7G0,6 in solid substitution solution in aluminum then, in a second time, in quenching followed by tempering in the same manner as in step 20 of said first fashion.

    Ce réchauffage est mené pendant une durée comprise entre 1 heure et 10 heures, et à une température comprise entre 520° C et 540° C pour la mise en solution solide précitée.This reheating is carried out for a period of between 1 hour and 10 hours, and at a temperature between 520 ° C and 540 ° C for the aforementioned solid solution.

    La trempe a dans ce cas pour but de maintenir le magnésium en solution solide sursaturée dans l'aluminium, alors que ledit revenu a pour but de créer une précipitation fine du magnésium dans l'aluminium, achevant ainsi le durcissement structural recherché.The purpose of quenching in this case is to keep the magnesium in solid solution supersaturated in aluminum, while said income is intended to create a fine precipitation magnesium in aluminum, thus completing the desired structural hardening.

    Quant à la quatrième étape 140 de ce second mode, elle est analogue à ladite étape 30 du premier mode, comme indiqué plus haut.As for the fourth step 140 of this second mode, it is analogous to said step 30 of the first mode, as indicated above.

    On va présenter ci-après les résultats d'essais de fatigue en flexion rotative (limite de fatigue ou d'endurance Lf et allègement relatif e) qui ont été obtenus pour un disque de roue 7 de 15 pouces de diamètre constitué dudit alliage thixotrope A-S7G0,6, qui a été fabriqué en mettant en oeuvre indifféremment ledit premier ou ledit second mode de l'invention, à la nuance près qu'un premier disque D' selon l'invention a subi le traitement par impacts de l'étape 30 ou 140 sur une seule de ses faces 7a alors qu'un second disque D'' selon l'invention a subi le même traitement par impacts sur ses deux faces.The results of rotational bending fatigue tests (fatigue limit or endurance L f and relative lightening e) which will be obtained for a wheel disc 7 15 inches in diameter made up of said thixotropic alloy will be presented below. A-S7G0,6, which was manufactured by implementing said first or said second mode of the invention interchangeably, except that a first disc D 'according to the invention has undergone the impact treatment of the step 30 or 140 on only one of its faces 7a while a second disc D '' according to the invention has undergone the same impact treatment on its two faces.

    On a considéré deux disques « témoin» pour ces expériences.Two "control" discs were considered for these experiments.

    Un premier témoin D1 est constitué d'un disque de structure thixotrope et moulé selon l'invention, mais n'ayant pas subi le traitement par impacts de l'étape 30 ou 140.A first witness D1 consists of a thixotropic structure disc molded according to the invention, but not having undergone the impact treatment of step 30 or 140.

    Un second témoin D2 est constitué d'un disque constitué d'un alliage corroyé et forgé connu sous la dénomination 6082T6 (norme européenne NF EN 573-3), c'est-à-dire comportant notamment de l'aluminium, du magnésium et du silicium, cet alliage ayant été mis en solution solide, trempé et revenu. Comme pour le premier témoin, ce second témoin n'a pas subi de traitement par impacts.A second witness D2 consists of a disc made of a wrought and forged alloy known under the name 6082T6 (European standard NF EN 573-3), that is to say comprising in particular aluminum, magnesium and silicon, this alloy having been put in solid solution, quenched and tempered. As with the first witness, this second witness did not undergone impact treatment.

    La limite de fatique Lf (en MPa) a été estimée en flexion rotative pour un nombre de cycles égal à 6. 106.The fatigue limit L f (in MPa) was estimated in rotary bending for a number of cycles equal to 6. 10 6 .

    L'allègement relatif e ( en%) a été estimé sous une charge Q à la rupture imposée pour 6. 106 cycles (en kilogramme force), suivant la relation: e (%) = 100 (1 - ((Lf1)n/(Lf2)n)),    avec, en flexion rotative, n=2/3.The relative lightening e (in%) was estimated under a load Q at rupture imposed for 6. 10 6 cycles (in kilogram force), according to the relationship: e (%) = 100 (1 - ((L f1 ) not / (L f2 ) not )), with, in rotary bending, n = 2/3.

    Tous les disques testés D', D'', D1 et D2 ont le même diamètre de 15 pouces. All discs tested D ', D' ', D1 and D2 have the same diameter of 15 inches.

    De plus, l'épaisseur de chaque disque a été déterminée en prenant comme épaisseur de référence e0 l'épaisseur d'un disque analogue de référence. Ce disque de référence est constitué d'un alliage à base d'aluminium A-S7G0,3 Y33 selon la norme NF A/02-004, et il a été obtenu par un procédé de « moulage-coquille », encore connu sous le nom de moulage basse-pression par l'homme de l'art. De plus, ledit disque de référence est caractérisé par une limite de fatigue Lf1 = 105 MPa. Résultats: Q rupture (kg.force) à 6.106 cycles Lf (Mpa) e (%) Disque D1 épaisseur=0,75e0 705 126 14,4 Disque D2 épaisseur=0,84e0 790 119 11,0 Disque D' épaisseur=0,75e0 820 147 22,6 Disque D'' épaisseur=0,75e0 1020 183 33,3 In addition, the thickness of each disc was determined by taking as the reference thickness e 0 the thickness of an analog reference disc. This reference disc consists of an aluminum-based alloy A-S7G0.3 Y33 according to standard NF A / 02-004, and it was obtained by a “shell molding” process, also known under the name of low-pressure molding by a person skilled in the art. In addition, said reference disc is characterized by a fatigue limit L f1 = 105 MPa. Results: Q rupture (kg.force) at 6.10 6 cycles L f (Mpa) e (%) Disc D1 thickness = 0.75e 0 705 126 14.4 Disc D2 thickness = 0.84e 0 790 119 11.0 Disc thickness = 0.75e 0 820 147 22.6 Disc Thickness = 0.75e 0 1020 183 33.3

    En conclusion, il apparaít que les résultats de limite de fatigue et d'allègement sont nettement améliorés pour un disque D' ou D'' selon l'invention par rapport au témoin D1 obtenu par thixomoulage et non traité par impacts et par rapport au témoin D2 forgé et également non traité par impacts, et cela d'une manière encore plus nette pour le seul disque D''.In conclusion, it appears that the fatigue limit and lightening results are markedly improved for a disc D 'or D' 'according to the invention compared to control D1 obtained by thixomolding and not treated by impacts and compared to the control D2 forged and also not treated by impacts, and this in an even sharper way for the single disc D ''.

    On a représenté à la Fig. 3 un exemple d'assemblage sur une jante 8 d'un disque 7 constituant un exemple de pièce métallique fabriquée par un procédé de l'invention, pour l'obtention d'une roue 9. La jante 8 est par exemple constituée d'un métal léger, tel que l'aluminium ou le magnésium, ou d'un alliage d'un tel métal léger, ou encore de tout autre matériau connu pour procurer un allègement et une endurance satisfaisants. Cette jante 8 peut également être constituée de fer ou d'un alliage à base de fer.There is shown in FIG. 3 an example of assembly on a rim 8 of a disc 7 constituting an example of a metal part manufactured by a method of the invention, for obtaining a wheel 9. The rim 8 is for example made of a light metal, such as aluminum or magnesium, or an alloy of such a light metal, or any other material known to provide satisfactory lightening and endurance. This rim 8 can also be made of iron or an iron-based alloy.

    Avantageusement, cet assemblage est réalisé par un soudage connu sous la dénomination MIG, c'est-à-dire à l'arc sous gaz inerte, tel que de l'argon, et avec apport de métal. On notera que ce type de soudage est favorisé par la structure thixotrope du disque 7.Advantageously, this assembly is carried out by welding known as designation MIG, i.e. with arc under inert gas, such as argon, and with contribution of metal. It will be noted that this type of welding is favored by the thixotropic structure of the disc 7.

    Cependant, on pourrait envisager tout autre mode de solidarisation du disque 7 avec la la jante 8, par exemple par fixation mécanique.However, one could consider any other method of securing the disk 7 with the the rim 8, for example by mechanical fixing.

    On notera que l'on pourrait utiliser des profils de roues 9 différents de celui représenté à la Fig. 3. En particulier, on pourrait utiliser un profil de disque 7 tel que celui commercialisé sous la dénomination Full Face™, ou un profil de jante 8 tel que celui commercialisé sous la dénomination PAX™ ou sous la dénomination Single™, par exemple.It will be noted that one could use wheel profiles 9 different from that shown. in Fig. 3. In particular, one could use a disc profile 7 such as that sold. under the name Full Face ™, or a rim profile 8 such as that marketed under the name PAX ™ or under the name Single ™, for example.

    Concernant l'application des deux modes du procédé de fabrication d'une pièce métallique selon l'invention à une roue 9 destinée au roulage d'un véhicule, on notera que l'étape initiale de façonnage 10, 110 ne se limite pas au moulage d'un disque de roue 7 seulement, mais peut également concerner le moulage de l'ensemble d'une roue 9 constituée d'un disque 7 et d'une jante 8, de sorte que la pièce finalement obtenue par ledit procédé soit constituée par ladite roue 9. Dans ce cas, l'étape de traitement à froid 30, 140 consiste à traiter par impacts de projectiles 2 tout ou partie d'au moins une face 7a du disque 7 et/ou de la jante 8.Regarding the application of the two modes of the part manufacturing process metallic according to the invention to a wheel 9 intended for running a vehicle, it will be noted that the initial shaping step 10, 110 is not limited to the molding of a wheel disc 7 only, but may also relate to the molding of the assembly of a wheel 9 constituted a disc 7 and a rim 8, so that the part finally obtained by said process is constituted by said wheel 9. In this case, the cold treatment step 30, 140 consists in treating by projectile impacts 2 all or part of at least one face 7a of the disc 7 and / or of the rim 8.

    Concernant toujours cette application à une roue 9, on notera également que l'étape initiale de façonnage 10, 110 pourrait consister à façonner une jante 8 (c'est-à-dire l'une ou l'autre partie 7, 8 d'une roue 9) à la place dudit disque 7, de sorte que la pièce finalement obtenue par le procédé de l'invention soit constituée par la jante moulée 8. Dans ce cas, comme dans le cas du disque 7, l'étape de traitement à froid 30, 140 consiste à traiter par impacts de projectiles 2 tout ou partie d'au moins une face de ladite jante 8.Still concerning this application to a wheel 9, it will also be noted that the step initial shaping 10, 110 could consist of shaping a rim 8 (i.e. one or the other part 7, 8 of a wheel 9) in place of said disc 7, so that the part finally obtained by the process of the invention is constituted by the molded rim 8. In this case, as in the case of the disc 7, the cold treatment step 30, 140 consists in treating by projectile impacts 2 all or part of at least one face of said rim 8.

    On notera par ailleurs que, dans le cas d'une étape de traitement à froid 30, 140 mise en oeuvre en une seule opération pour le traitement du disque 7 sur une seule de ses faces 7a par impacts de projectiles 2, ladite face 7a peut être avantageusement celle qui est destinée à se trouver du côté de l'intérieur de la roue 9, du fait de l'aspect non lisse de cette face 7a traitée.It will also be noted that, in the case of a cold treatment step 30, 140 work in a single operation for the treatment of the disc 7 on only one of its faces 7a by impacts of projectiles 2, said face 7a can advantageously be that which is intended to be find the side of the interior of the wheel 9, because of the non-smooth appearance of this treated face 7a.

    Claims (11)

    1. A process for manufacturing a metallic wheel (9) for the rolling system of a vehicle, said wheel comprising a wheel disk (7) and a rim (8), or a wheel part (7, 8), said wheel part (7, 8) consisting of a metallic wheel disk (7) or a metallic rim (8), said process comprising, in an initial stage (110), forming said wheel or wheel part (7, 8, 9) by means of a metallic material in a semi-solid state and having a thixotropic structure,
         characterised in that it additionally comprises the following subsequent stages:
      (i) said formed wheel (9) or wheel part (7, 8) is subjected, after said initial stage, to a die forging stage (120) in such a way that the core temperature of said wheel or wheel part (7, 8, 9) is between 400°C and 500°C during die forging, then
      (ii) all or part of at least one face (7a) of said disk and/or said rim (8) of said wheel (9) or wheel part (7, 8) obtained under (i) is blasted with projectiles (2) in a cold treatment stage (140), with a view to plastic deformation thereof.
    2. A manufacturing process according to claim 1, characterised in that, during the die forging stage (i), the core temperature of said wheel or wheel part (7, 8, 9) is approximately 450°C.
    3. A manufacturing process according to claim 1 or 2, characterised in that said formed and die-forged wheel or wheel part (7, 8, 9) is additionally subjected, in an intermediate stage (130) between stages (i) and (ii), to structural hardening implemented by:
      heating to a temperature of between 520°C and 540°C, then by
      quenching performed by means of a fluid held at a temperature of between 30°C and 60°C, then by
      annealing.
    4. A manufacturing process according to claim 3, characterised in that said heating is performed for a period of between 1 hour and 10 hours.
    5. A manufacturing process according to claim 3 or claim 4, characterised in that said annealing is performed at a temperature of 170°C.
    6. A manufacturing process according to any one of the preceding claims, characterised in that, to perform said initial forming stage (110), there is used an alloy based on a metal belonging to the group comprising aluminium, magnesium, titanium, iron, chromium, cobalt, nickel, copper, zinc, silver, tin, lead and antimony.
    7. A manufacturing process according to claim 6, characterised in that said alloy is aluminium-based.
    8. A manufacturing process according to claim 7, characterised in that said alloy additionally comprises between 6.5 % and 7.5 % by weight of silicon and between 0.5 % and 0.6 % by weight of magnesium.
    9. A manufacturing process according to any one of claims 1 to 8, characterised in that at least one operation of said cold-treatment (140) stage (ii) consists in using as said projectiles (2) corundum grains between 75 and 150 µm in size.
    10. A manufacturing process according to any one of claims 1 to 8, characterised in that at least one operation of said cold-treatment (140) stage (ii) consists in using glass microspheres as said projectiles (2).
    11. A manufacturing process according to any one of claims 1 to 8, characterised in that at least one operation of said cold-treatment (140) stage (ii) consists in using as said projectiles (2) steel or cast iron pellets between 200 and 800 µm in size.
    EP00112143A 1999-06-08 2000-06-06 Method for the production of a metallic workpiece, like an element of a vehicle wheel, and corresponding wheel Expired - Lifetime EP1063033B1 (en)

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    FR9907519 1999-06-08
    FR9907519A FR2794669A1 (en) 1999-06-08 1999-06-08 PROCESS FOR THE MANUFACTURE OF A METAL PART, SUCH AS A WHEEL PART FOR THE ROLLING OF A VEHICLE, AND SUCH A WHEEL
    CA002325786A CA2325786A1 (en) 1999-06-08 2000-11-27 Process for manufacturing a metal part, such as part of a vehicle wheel, and such a wheel

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    CA2325786A1 (en) 2002-05-27
    ATE277702T1 (en) 2004-10-15
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