JP2004243364A - Method and apparatus for producing die cast product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and an apparatus for producing a die cast product which can obtain the product at lower cost of a facility and with a smaller number of processes than those in the conventional method. <P>SOLUTION: In a first and a second dies 10, 20, the producing apparatus in which shaping parts with pressing (12, 22) for plastically deforming a platy metal 3 by utilizing the die clamping movement of both dies and casting spaces (13, 23) demarcated with the die clamping of both dies are arranged, is prepared. To the first die 10, the platy metal 3 is disposed so as to extend over the shaping parts with pressing and the casting spaces, and the platy metal 3 is plastically deformed into the prescribed shape in the shaping parts with pressing by die clamping movement of both dies. Thereafter, molten metal is supplied into the casting spaces and a part of the platy metal 3 is included to produce the die cast product containing the platy metal 3. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a die casting, and an apparatus for producing a die casting used for carrying out the method.
[0002]
[Prior art]
For example, some mechanical parts for vehicles are manufactured by casting a part of a semi-finished product with metal. For example, in a method of manufacturing a rocker cover for an engine disclosed in Patent Document 1, an aluminum plate material having a predetermined thickness is formed into a semi-finished product having a predetermined shape by shaping such as hydraulic molding, and a predetermined product of the semi-finished product is formed. After applying a shot blast to the part to roughen the surface, the semi-finished product is set in a casting mold, and the roughened part is cast with a molten metal made of aluminum or its alloy.
[0003]
[Patent Document 1] Japanese Patent Application Laid-Open No. 2001-314955
However, in the above-mentioned conventional manufacturing method, a shaping device (and a shaping process) for shaping such as hydraulic forming, and a predetermined portion of a shaped semi-finished product (a portion subjected to a rough surface treatment by shot blast). Since a casting apparatus (and a casting process) for casting the steel was separately required, cost burden on equipment was large. Further, by performing the rough surface treatment by shot blast, the cost is increased due to an increase in the number of steps.
[0005]
[Problems to be solved by the invention]
An object of the present invention is to provide a method of manufacturing a die casting, which has a lower cost burden on equipment than in the past, and can obtain a product with a small number of steps, and a manufacturing apparatus of a die casting used to implement the method. To provide.
[0006]
[Means for Solving the Problems]
The invention according to claim 1 includes first and second molds that can be joined to each other, and the first and second molds plastically deform the plate-shaped metal material using the mold clamping operation of both molds. Using a device provided with a press forming part for molding and a casting space defined by the mold clamping of both dies, wherein the die is formed by any one of the first and second dies. On the other hand, a plate-shaped metal material is disposed so as to straddle the press-formed portion and the casting space, and the plate-shaped metal material is pressed by the press-formed portion by the first and second mold clamping operations. Is plastically deformed into a predetermined shape, and thereafter, a molten metal is supplied into the casting space to cast at least a part of the plate-shaped metal material.
[0007]
According to this manufacturing method, by using the apparatus having the first and second molds in which the press-formed portion and the casting space are provided side by side, the plate-shaped metal is formed by the press-formed portion synchronized with the mold clamping operation. The plastic deformation of the material and the subsequent cast-in forming by supplying the molten metal into the casting space can be performed as a series of steps. In other words, the plastic deformation (press forming) of the sheet metal material and the cast-in forming (casting) of the sheet metal material can be continuously performed by one apparatus, so that the equipment cost is lower than before. A product (die casting) can be obtained with a small burden and a small number of steps.
[0008]
According to a second aspect of the present invention, in the method of manufacturing a die casting according to the first aspect, a plate-shaped metal material is formed on one of the first and second molds by using the press-formed portion, the casting space, When arranging so as to straddle, the plate-shaped metal material is suction-fixed to one of the molds by using a vacuum suction force.
[0009]
According to this method, the plate-like metal material is suction-fixed to one of the first and second molds by using the vacuum suction force, whereby the positioning of the plate-like metal material with respect to the mold is ensured, and plastic deformation is performed. The processing accuracy at the time and the processing accuracy after the insert molding are improved.
[0010]
According to a third aspect of the present invention, there are provided first and second molds that can be joined to each other, and the first and second molds plastically deform the plate-shaped metal material using the mold clamping operation of both molds. And a casting space defined by the clamping of the two dies.
[0011]
This manufacturing apparatus is an apparatus used for carrying out the above-mentioned manufacturing method, and its technical significance conforms to the method inventions described in claims 1 and 2.
[0012]
According to a fourth aspect of the present invention, in the apparatus for manufacturing a die casting according to the third aspect, at least one of the first and second dies is provided with the press-formed portion before at least clamping of both dies. A fixing means for temporarily fixing the plate-shaped metal material to be plastically deformed to the mold is provided.
[0013]
Fixing means is provided in one of the first and second molds, and the plate-shaped metal material that is plastically deformed in the press shaping portion is temporarily fixed to the mold, thereby positioning the plate-shaped metal material with respect to the mold. And the processing accuracy at the time of plastic deformation and the processing accuracy after cast-in molding are improved.
[0014]
In claim 4, it is preferable that the fixing means is a suction fixing mechanism using a vacuum suction force.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the present invention will be described with reference to the drawings. As shown in FIGS. 1 to 4, the apparatus for manufacturing a die casting according to the present embodiment includes a fixed platen 1 and a movable platen 2, and the fixed platen 1 has a fixed mold 10 as a first die, The movable platen 2 is provided with a movable mold 20 as a second mold. The movable platen 2 and the movable mold 20 can be approached to and separated from the fixed platen 1 and the fixed mold 10, and the fixed mold 10 and the movable mold 20 can be joined by mutual approach of both molds. Has become.
[0016]
The upper half part of the joint surface of the fixed mold 10 facing the movable mold 20 has a shallow holding recess 11 for mounting and holding the sheet metal 3 as a sheet metal material, and is involved in plastic deformation of the sheet metal 3. A shaping recess 12 is formed. The depth of the holding recess 11 is set to half the thickness of the sheet metal 3 mounted thereon. A casting recess 13 is formed in the middle of the joint surface of the fixed mold 10. On the other hand, a shallow holding recess 21 for mounting and holding the sheet metal 3 corresponding to the holding recess 11 of the fixed mold is provided in the upper half portion of the joint surface of the movable mold 20 facing the fixed mold 10. A shaping projection 22 corresponding to the shaping recess 12 of the fixed mold is formed. The depth of the holding recess 21 is set to half the thickness of the sheet metal 3 mounted thereon. Further, a casting recess 23 is formed in the middle of the joint surface of the movable mold 20.
[0017]
The shaping concave portion 12 of the fixed mold and the shaping convex portion 22 of the movable mold form a press shaping portion for plastically deforming the sheet metal 3 by using the mold clamping operation of the two dies 10 and 20. . The casting recesses 13 and 23 of the fixed mold and the movable mold form a casting space when the molds 10 and 20 are clamped.
[0018]
Inside the fixed mold 10, a suction passage 15 for communicating the holding recess 11 with the vacuum pump P outside the mold, and a valve mechanism 16 capable of opening and closing the suction passage 15 are provided. The valve mechanism 16 includes a valve body 16a that can be moved into and out of the suction passage 15. By disposing the valve body 16a at the valve closing position (see FIGS. 2 to 4) that closes the suction passage 15, communication between the holding recess 11 and the vacuum pump P is cut off, and the valve body 16a is retracted from the suction passage 15. The communication between the holding recess 11 and the vacuum pump P is ensured by being arranged at the valve opening position (see FIG. 1). The suction passage 15, the valve mechanism 16, and the vacuum pump P are suction-fixing mechanisms serving as fixing means for temporarily fixing the sheet metal 3 to (the holding recess 11 of) the fixing die 10 by using a vacuum suction force. Is composed.
[0019]
Further, a cylindrical spool 4 is provided in the lower half of the fixed mold. The spool 4 is connected to a sleeve 5 supported by the fixed platen 1, and a plunger tip 6 driven by a piston can slide in a cylinder formed by the spool 4 and the sleeve 5. The sleeve 5 has a pouring opening 5 a for introducing the molten metal prepared in the ladle 7 into the sleeve 5. The spool 4, the sleeve 5, and the plunger tip 6 constitute a mechanism for injecting and supplying the molten metal into the casting space.
[0020]
Next, a method of manufacturing a cast casting using the above manufacturing apparatus will be described.
During standby, as shown in FIG. 1, the fixed mold 10 and the movable mold 20 are in the mold open state. Here, by operating the vacuum pump P and arranging the valve element 16a of the valve mechanism at the valve opening position, a vacuum suction force is exerted on the holding recess 11 of the fixed mold via the suction passage 15. Under this condition, the sheet metal 3 is mounted on the holding recess 11. In addition, the sheet metal 3 is a plate-shaped metal material to be cast-in, for example, a metal material made of an aluminum alloy or a magnesium alloy. When the sheet metal 3 is attached to the holding recess 11, the sheet metal 3 is suction-fixed to the holding recess 11 based on the suction action from the suction passage 15. As a result, in a state where the middle of the sheet metal 3 covers the shaping recess 12 and the lower end of the sheet metal 3 enters the region of the casting recess 13 (that is, a state in which the sheet metal 3 straddles the shaping recess and the casting space). The sheet metal 3 is arranged on the fixed mold 10.
[0021]
Subsequently, as shown in FIG. 2, the movable platen 2 and the movable mold 20 are moved, and the movable mold 20 is joined to the fixed mold 10 (so-called mold clamping). In synchronization with this mold clamping operation, the shaping projections 22 of the movable mold enter the shaping recesses 12 of the fixed mold while pressing the back surface of the sheet metal 3. Then, a part of the sheet metal 3 sandwiched between the shaping concave portion 12 and the shaping convex portion 22 is plastically deformed into a shape corresponding to the uneven shape, and the press forming for the sheet metal 3 is completed. In addition, a mold space (the inner shape corresponds to the shape of the main body of the final product) formed by the concave portions 13 and 23 is secured between the two dies 10 and 20 by the mold clamping. Then, the lower end of the sheet metal 3 is disposed in the casting space. Simultaneously with completion of mold clamping (ie, completion of press molding), the valve body 16a of the valve mechanism is switched from the valve opening position shown in FIG. 1 to the valve closing position shown in FIG. 2 and the like, and the suction passage 15 is closed.
[0022]
A molten metal M (for example, a molten aluminum alloy or magnesium alloy) is supplied to the ladle 7 from a melting furnace (not shown) in advance. As shown in FIG. 2, immediately after the mold clamping, the molten metal M in the ladle 7 is poured into the spool 4 and the sleeve 5 through the pouring port 5a. Then, as shown in FIG. 3, by moving the plunger tip 6 forward, the molten metal M is forcibly filled into the casting space (13, 23) secured between the two dies, and the injection molding is completed. . At this time, the lower end of the sheet metal 3 that has entered the casting space is cast by the molten metal M.
[0023]
When the molten metal M solidifies, as shown in FIG. 4, the movable mold 20 is separated from the fixed mold 10 (so-called mold opening), so that a part of the sheet metal 3 is cast with the metal M. As a result, a die casting 30 is obtained. Note that the die casting 30 immediately after the mold opening is accompanied by a plan 30a, and a final product can be obtained by separating the plan 30a.
[0024]
As described above, according to the present embodiment, the mold is formed by using the manufacturing apparatus including the fixed mold 10 and the movable mold 20 provided with the press forming portions (12, 22) and the casting spaces (13, 23). As a series of steps, plastic deformation of the sheet metal 3 by the press forming portions (12, 22) synchronized with the tightening operation, and subsequent cast-in forming by pouring the molten metal M into the casting space (13, 23). Can be implemented. That is, the plastic deformation (press forming) of the sheet metal 3 and the cast-in forming (casting) of the sheet metal 3 can be continuously performed by one apparatus, so that the cost burden on equipment is less than in the conventional case, Moreover, the die casting 30 can be obtained with a small number of steps.
[0025]
Specific examples of the die castings that can be manufactured according to the present invention include vehicle parts such as a center pillar member in a body frame and a rocker cover of an engine, but are limited to such mechanical parts for vehicles. Not something.
[0026]
(Modification) The above embodiment may be modified as follows.
As shown in FIG. 5, it is also possible to provide a piercing pin 41 and a cylinder 42 for driving the piercing pin 41 in the fixed mold 10 and to provide a piercing support 43 and a cylinder 44 for driving the same in the movable mold 20. Good. The piercing pin 41 and the support 43 are opposed to each other with the lower end of the sheet metal 3 entering the casting space (13, 23) interposed therebetween. When the molds 10 and 20 are clamped, the support 43 is projected into the casting space to abut the left side of the sheet metal 3 and the sheet metal 3 is punched from the right side to the left side by the piercing pin 41. Let After the completion of the punching and before pouring of the molten metal M, the drilling pin 41 and the support 43 are retracted into the respective dies, and the hole penetrated in the horizontal direction through the lower end of the sheet metal 3 as shown in FIG. 32 are formed. Then, as shown in FIG. 6B, the entire lower end of the sheet metal 3 including the inside of the through hole 32 is cast with the metal M by pouring the molten metal M into the casting space. In the product thus obtained, the metal solidified in the through hole 32 extending in the horizontal direction constitutes a horizontal locking portion integrated with the metal M around the metal plate 3. Since the horizontal locking portion resists the pulling load Y that tends to pull the sheet metal 3 vertically upward, the sheet metal 3 is less likely to be pulled out of the product main body, and the integrated strength of the sheet metal 3 and the product main body is improved.
[0027]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to the manufacturing method of the die casting of this invention, plastic deformation (press molding) of the plate-shaped metal material and cast-in molding (casting) of the plate-shaped metal material can be continuously performed by one apparatus. For this reason, a product (die-casting product) can be obtained with less cost burden on equipment and a smaller number of steps than in the past. Further, if the apparatus for manufacturing a die casting according to the present invention is used, the above manufacturing method can be reliably performed.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a die casting manufacturing apparatus during standby.
FIG. 2 is a cross-sectional view of the apparatus for manufacturing a die casting at the time of mold clamping.
FIG. 3 is a cross-sectional view of the apparatus for manufacturing a die casting at the time of injection molding.
FIG. 4 is a cross-sectional view of the die casting manufacturing apparatus when the mold is opened.
FIG. 5 is a sectional view of a main part showing a modified example of the apparatus for manufacturing a die casting.
6A and 6B are cross-sectional views of a main part of a semi-finished product or the like in a modified example.
[Explanation of symbols]
3 ... sheet metal (plate-like metal material), 10 ... fixed mold (first mold), 11 ... holding recess, 12 ... shaping recess, 13 ... casting recess, 15 ... suction passage, 16 ... valve mechanism , 20 ... movable mold (second mold), 21 ... holding recess, 22 ... shaping convex (12 and 22 constitute a press shaping), 23 ... casting recess (13 and 23 M: molten metal or metal, P: vacuum pump (15, 16 and P constitute a suction fixing mechanism as fixing means).

Claims (4)

It has first and second molds that can be joined to each other, and the first and second molds each have a press-formed part for plastically deforming a plate-shaped metal material by using a mold clamping operation of both molds. A method for manufacturing a die casting using an apparatus provided with a casting space defined by both molds, and
Placing a plate-shaped metal material on one of the first and second molds so as to straddle the press-formed portion and the casting space,
The plate-shaped metal material is plastically deformed to a predetermined shape in the press forming part by the mold clamping operation of the first and second molds,
Thereafter, a method for producing a die casting is characterized in that a molten metal is supplied into the casting space and at least a part of the plate-shaped metal material is cast. When arranging a plate-shaped metal material in one of the first and second molds so as to straddle the press-formed portion and the casting space, use a vacuum suction force to make the plate-shaped metal material 2. The method for producing a die casting according to claim 1, wherein the die is fixed by suction to one of the molds. It has first and second molds that can be joined to each other, and the first and second molds each have a press-formed part for plastically deforming a plate-shaped metal material by using a mold clamping operation of both molds. And a casting space defined by the mold clamping of both dies. At least one of the first and second dies is provided with a fixing for temporarily fixing a plate-shaped metal material that is plastically deformed by the press forming part to at least the two dies before clamping. The apparatus for producing a die casting according to claim 3, wherein a means is provided.

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