JP2002001488A - Manufacturing method for aluminum foil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for aluminum foil capable of reducing the manufacturing period from decision of a design to mass production. SOLUTION: In the manufacturing method for aluminum foil at least including a process deciding a design, a process investigating the shape of a product, a process studying the casting method, a process for designing a mold, and a process working the mold, three-dimensional computerized information is used in at least one process from the process investigating the shape of a product to the process working the mold.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an aluminum wheel using a mold used for low pressure casting, gravity casting, forging, molten metal forging, and the like. The present invention relates to a method for determining a mold shape and the like.

[0002]

2. Description of the Related Art Aluminum wheels greatly contribute to energy saving from the viewpoint of their lightness, and the mounting rate on automobiles is increasing year by year. Further, in recent years, demand for high-design, large-diameter aluminum wheels has been increasing due to their fashionability. Furthermore, aluminum wheels are also required to have various designs to differentiate themselves from others, and the mass production of small varieties has been replaced by the small production of many varieties. Aluminum wheels are usually manufactured using molds, and it is necessary to make separate molds for each product,
Many man-hours were required to design the shape and the casting plan for each product. Therefore, when making a general new aluminum wheel, after the design is completed,
It took a long time of about 5 months to shift to mass production.

A general process from the design of a conventional aluminum wheel as shown in FIG. 2 to mass production will be described. First, a customer presents a wheel design picture to a wheel manufacturer. The mold maker requested by the wheel maker performs modeling based on the design image and manufactures a wheel model. The customer confirms the model, and when OK is given, the wheel maker starts two-dimensional shape design using drawings. With the recent development of digitized information, there are cases where design data is supplied from customers instead of design drawings, in which case there is no need to perform modeling work at the mold maker,
Perform direct shape design. The shape design is based on paper design materials such as drawings of aluminum wheels of similar shape manufactured in the past. Next, based on the shape determined by the shape design, a two-dimensional plan design for determining the flow of the molten metal during casting, the shape of the product cavity, the cooling method, and the like is performed. The design data of aluminum wheels of similar shape in the past is used for this plan design. At the time of this shape design and plan design, the use of a three-dimensional model to perform strength calculation and solidification calculation by CAE was also studied. However, there is a problem that modeling takes time and it cannot be completed in advance. Was not used. Further, the design drawing of the mold in the subsequent process is two-dimensional, and at this stage, a large number of man-hours have not been taken to create a three-dimensional model.

Next, based on the result of the plan design, a two-dimensional mold design, that is, a mold design drawing is created. Based on the design drawing of this mold, the mold is manufactured, casting is performed using the mold, and a prototype is manufactured.Furthermore, using the prototype, appearance inspection, internal defect investigation, strength test, etc. The prototype is evaluated, and if it meets the specifications, mass production of the product is started.

[0005] However, although product design and plan design are performed using the design data of similar products in the past, the shape is slightly different for each product, so the strength of the prototype is insufficient, and problems such as casting defects are caused. Evaluation of the first prototype of the product made it difficult to meet customer product specifications. Therefore, it is necessary to modify the mold at least once for the purpose of changing the product shape.If casting defects etc. cannot be eliminated, it is necessary to reconsider the plan design, and the construction Was causing the prolongation. The work of repairing the mold only requires machining when carving the cavity surface, but to build up the cavity surface, perform the build-up work,
Heat treatment and further processing must be performed, and the construction period has been prolonged. Specifically, it took at least 3.5 months, on average, 5 months from the time the customer provided the aluminum wheel design drawings.

[0006]

As described above, aluminum wheels usually require a long period of time from the completion of design to the start of mass production, and a new design of aluminum wheels that matches the latest aluminum wheel design trends is required. There was a problem that the market could not be supplied in a short time. In addition, in the case of genuine aluminum wheels that are mounted on a car from the start of a new car, the development period of a new car by an automobile manufacturer has been shortened to reduce costs, and naturally such a short delivery time is required for aluminum wheel manufacturers. It was necessary to respond to new products that could be used, but as described above, it took a long time from the completion of the design to the start of mass production, and the production of genuine aluminum wheels for new cars by automobile companies was There was also a problem that the schedule was not met.

[0007] An object of the present invention is to provide a method for manufacturing an aluminum wheel which can shorten the work period from design decision to mass production.

[0008]

According to the present invention, there is provided a method for manufacturing an aluminum wheel, comprising: a step of determining a design; a step of examining a shape of a product; and a step of examining a casting plan.
In a method for manufacturing an aluminum wheel including at least a step of performing a mold design and a step of performing a mold processing, in at least one step from a step of examining a shape of a product to a step of performing a mold processing, a three-dimensional electronic device is used. Characterization information is used.

In the present invention, the digitized information does not simply mean that the information is digitized and transmitted / received.
Analysis data of stress, structure, hot water flow, solidification, etc. (CA
E), a database or the like in which past characteristics, experimental data, quality information, etc. of past products are collected and stored. This digitized information is used for analysis, manufacturing, review, change, correction, etc. in the aluminum wheel manufacturing process.

In the method for manufacturing an aluminum wheel according to the present invention, it is preferable to use three-dimensional digitized information for examining the product shape and plan, and to study the shape and plan based on the three-dimensional digitized information used for design decision. It is preferable to perform mold design and mold processing. In other words, the present invention simulates, for example, three-dimensional digitized information using CAE analysis, which has been considered to be less effective in spite of man-hours and time, thereby eliminating the need for trial production using real objects. In both cases, it was found that a product having an optimal shape can be produced with high accuracy, and that the total construction period can be shortened compared to actually producing a prototype.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing an aluminum wheel according to the present invention as shown in FIG. 1 will be described while following the steps. First, the handling of designs between customers and manufacturers of aluminum wheels is explained. at first,
A case in which a customer designs an aluminum wheel will be described. After finishing the design of the aluminum wheel, the customer requests each aluminum wheel manufacturer to make a prototype. Then, the customer provides the aluminum wheel manufacturer with a paper design picture of the aluminum wheel whose design has been completed. Three-dimensional modeling is performed based on the design image of the customer. On the basis of the three-dimensional computerized information, a three-dimensional model is manufactured by using an NC machine or a stereolithography method. Since the subsequent work is performed using this three-dimensional model, the approval of the customer is first obtained for this three-dimensional model. The approval of the three-dimensional model means that the three-dimensional digitized information used in the production of the three-dimensional model has also been approved by the customer, so the next work uses the three-dimensional digitized information. Done.

On the other hand, when the design is provided by the customer as three-dimensional digitized information, the three-dimensional digitized information is used as it is without performing such modeling. In this case, it is preferable to use digital transmission means for exchanging information. For example, it is preferable to go through a prototype order window provided on a customer homepage on the Internet. In order to protect the security of such windows, a security code etc. is assigned to the aluminum wheel manufacturer that the customer recognizes as a business partner, and there is a mechanism that only the manufacturer with the security number can access the window. It has been subjected. When the customer presents the design, required specifications and required quantity of the aluminum wheels through the window of the homepage, the manufacturer informs the customer of the price, delivery time until mass production, etc. You can select a product and place an order for prototype or mass production. Alternatively, transmission may be performed between the customer and the manufacturer using a dedicated line, or a recording medium such as an FD may be simply used.

Next, a case where a wheel maker designs an aluminum wheel will be described. The most effective way to promote aluminum wheels designed by wheel manufacturers to customers is to show how the new design of aluminum wheels fits the design of each model of the car manufacturer. is there.

Next, the shape of the product is designed. Performs stress analysis, etc. by CAE based on three-dimensional digitized information,
The shape design is performed while taking the results into account. Usually, in the process, a model for analysis divided into small elements is created based on the three-dimensional computerized information, and strength analysis is performed using the analysis model. After examining the results of the strength analysis, if the specifications required by the customer are satisfied, proceed to the next step. If the specifications are not satisfied, change the shape of the three-dimensional model again, perform element division and strength analysis again. Repeat the loop,
Perform shape design until specifications are satisfied.

Next, a plan design is performed to determine a casting shape, a mold structure, and a cooling structure for manufacturing a product. In this case as well, a three-dimensional modeling is similarly performed on the rough casting, the mold shape, and the cooling structure based on the three-dimensional computerized information obtained in the shape design obtained earlier, and elements are formed based on the three-dimensional computerized information. A model for analysis is created by division, and coagulation analysis is performed. Investigate the results of the solidification analysis and proceed to the next step if there is no underfill on the surface of the casting coarse material or no internal casting defects, or if it does meet the product specifications. , If there is any problem, casting rough material shape, mold structure,
The loop of changing the cooling structure, performing element division and solidification analysis again is repeated, and a plan design is performed until there is no problem as a product.

Next, a mold is designed. The die design creates a die design drawing based on the three-dimensional data of the die structure used in the plan design. At the time of designing the mold, the mold may be formed integrally, but it is preferable to create a built-in standard part in consideration of the easiness of manufacturing and the like, and combine them.
Next, in the actual manufacture of the mold, the machining of the mold is preferably performed by creating machining data from the three-dimensional CAD data for design or the three-dimensional data of the mold structure using a CAM. The transmission of the three-dimensional CAD data to the CAM may use a transmission medium or a recording medium such as an FD. The processing of the mold may be formed as an integrated mold.However, in the case of manufacturing by cutting from a material, there are many parts that become Dalai powder, and the proportion of the mold material cost increases, In some cases, the cost was increased. For this purpose, the parts of the structure common to the dies for each product can be standardized as main parts of the dies, and can be incorporated into the dies structure to save dies material costs.

Next, in the case of a prototype, in the case of the present invention, a detailed simulation is performed on the basis of three-dimensional data at the stage of shape design and plan design before the prototype, so that the prototype of the entity is first produced. Even if it is performed once, there is a high probability that a product satisfying the specifications is obtained. Even if the product does not satisfy the specifications, the CA at the plan design stage or shape design stage
By performing the E analysis, it is possible to easily correct it.

As described above, in the method for manufacturing an aluminum wheel of the present invention, prior examination can be sufficiently performed by CAE or the like using electronic information in the process. Compared to the study, the construction period up to mass production can be significantly reduced. Specifically, it can be shortened to at least 2 months and an average of 2.5 months.

[0019]

As described above, by using the method of manufacturing an aluminum wheel according to the present invention, the period from the design decision of the aluminum wheel to the start of mass production can be greatly reduced as compared with the conventional manufacturing method. Was.

[Brief description of the drawings]

FIG. 1 is a flowchart showing the steps of the present invention.

FIG. 2 is a flowchart showing a conventional process.

 ──────────────────────────────────────────────────の Continuing on the front page (72) Inventor Ryoji Iijima 5200 Sankajiri, Kumagaya-shi, Saitama F-term in Kumagaya Light Alloy Factory, Hitachi Metals Co., Ltd. 4E093 FC10 NA01 NA02 NA04 NB10 VA01 VA04 5B046 AA04 AA05 DA08 KA05

Claims (4)

[Claims] 1. An aluminum wheel including at least a step of determining a design, a step of examining a shape of a product, a step of examining a casting plan, a step of designing a mold, and a step of performing mold processing. A method for manufacturing an aluminum wheel, wherein three-dimensional digitized information is used in at least one step from a step of examining a shape of a product to a step of performing die machining. 2. The method for manufacturing an aluminum wheel according to claim 1, wherein three-dimensional digitized information is used for examining the shape of the product. 3. The method for manufacturing an aluminum wheel according to claim 1, wherein three-dimensional computerized information is used for studying a casting plan. 4. The method for manufacturing an aluminum wheel according to claim 1, wherein three-dimensional digitized information is obtained in all steps from a step of examining the shape of the product to a step of performing die machining. The method of manufacturing the aluminum wheels to be used.