JP4055223B2 - Plastic working method using casting material for plastic working made of high ductility aluminum alloy - Google Patents

Description

【００８０】
次いで、上記各合金の鋳造割れ性を調べるために、図２８に示すように、合金例１，２、ＡＤＣ６及びＡＤＣ７の各合金でリング状の試験片を鋳造した。このとき、各試験片の鋳造時の金型温度は常温とした。そして、鋳造した各試験片の表面に生じた割れの個数と割れ長さを調べ、各合金について試験片１つ当たりの平均総割れ個数と平均総割れ長さを算出して鋳造割れ性を比較した。
【００８１】
この鋳造割れ性の結果を図２７に示す。この結果、合金例１の合金で鋳造した試験片には、Ｍｇ成分を少なくしてＦｅ成分をある程度含有させることによる鋳造割れ性向上の効果が顕著に現れており、内部の状態もＡＤＣ６やＡＤＣ７で鋳造したものに比べて良好であり、ひけ巣等は殆ど発生していない。また、合金例２の合金で鋳造したものは、鋳造割れ性としては劣るものの、内部の状態は良好であり、鋳造性は向上されているといえる。
【００８２】
さらに、合金例３〜１４の合金についても、上記と同様の試験を行い、内部の状態を含めて鋳造性の評価を行った。この評価の結果を表１に合せて示す。尚、表１中の記号は、ｄ、ｃ、ｂ及びａの順に鋳造性が良くなることを示す。この結果、合金例１〜１４の合金で鋳造したものは、いずれも鋳造性がＡＤＣ６やＡＤＣ７よりも良好であり、全般に、Ｆｅ成分の含有量が多いと鋳造性はより一層良好となることが判る。
【００８３】
したがって、合金例１〜１４の合金は、強度をある程度確保していて、しかも、伸び及び鋳造性が優れている。特に、合金例１，１１の合金は、伸び及び鋳造性が共に非常に良好である。また、合金例２，１４の合金のように、強度をさらに向上させようとすると、鋳造性が若干低下するが、それでも従来のものよりは優れていることが判る。
【００８４】
次に、鋳造素材の塑性加工性を調べるために、Ｍｎ成分、Ｆｅ成分及びＭｇ成分の含有量をそれぞれ異ならせて合金例Ａ〜Ｆの６種類のアルミニウム合金で円柱状の鋳造素材を鋳造した（各合金における各成分含有量については表２参照）。これら合金例Ａ〜Ｆのうち合金例Ａ，Ｂが本発明の実施例に相当し、その他の合金例は上記参考形態で説明したものに相当する。また、比較のために上記ＪＩＳ規格のＡＣ４ＣＨで同様の鋳造素材を鋳造した（比較例）。このＡＣ４ＣＨとしては、Ｍｇ成分が０．３重量％、Ｓｉ成分が７．０重量％それぞれ含有された（Ｍｎ成分及びＦｅ成分は含有されていない）合金を使用した。
【００８５】
上記合金例Ａ〜Ｆ及び比較例の各鋳造素材についてその各鋳造素材の軸心方向にすえ込み加工を行って限界すえ込み率を調べた。すなわち、鋳造素材に割れが生じた時点で加工を中止し、その時点のすえ込み率（圧下率）を求めた。尚、このすえ込み加工は、各鋳造素材の端面と該端面を押圧する治具との間にはすべりが生じないようにして行った。
【００８６】
上記各鋳造素材についての限界すえ込み率を表２に示す。また、すえ込み加工前の各鋳造素材の伸びと限界すえ込み率との関係を図２９に示す。この結果、合金例Ａ〜Ｆの鋳造素材の限界すえ込み率は、比較例のものよりもかなり大きくて塑性加工性が良好であることが判る。また、限界すえ込み率は、すえ込み加工前の各鋳造素材の伸びと関連しており、その伸びが大きいほど大きくなることが判る。
【００８７】
【表２】

【００８８】
続いて、上記合金例Ａ〜Ｄ，Ｆの各鋳造素材について圧下率と硬さとの関係を調べた。この結果を図３０に示す。このことより、硬さは、圧下率が約２０％よりも小さい範囲では圧下率の増加に対して大きく上昇するが、２０％以上の範囲では殆ど上昇せず、略一定となる。したがって、圧下率（塑性加工率）を２０％以上となるように加工すれば、硬さは加工前に比べて向上しかつ安定することが判る。
【００８９】
さらに、図３１は、上記合金例Ｂについて圧下率に対する引張強度及び０．２％耐力の変化を調べた結果を示し、図３２は、同じく合金例Ｂについて圧下率に対する伸びの変化を調べた結果を示す。このことで、圧下率を２０％以上とすれば、上記硬さと同様に、引張強度及び耐力を安定的に向上させることができる。一方、伸びは、圧下率の増加に伴って減少するが、圧下率が２０％以上であれば、約５％で安定していることが判る。尚、伸びが５％程度であれば、従来のもの（通常、約１％）よりも高い値を維持している。
【００９０】
したがって、本発明のアルミニウム合金で鋳造素材を鋳造することにより鋳造素材全体の強度や伸びを確保しつつ、さらに強度や硬さ等を必要とする部位のみに対して塑性加工率が２０％以上となるように塑性加工を行うことにより、その部位の部分的な強化を図ることができる。
【００９１】
【発明の効果】
以上説明したように、請求項１の発明では、０．５〜２．５重量％のＭｎ成分、０．４〜１．５重量％のＦｅ成分及び０．０１〜０．５重量％のＭｇ成分が含有されかつ残部が不可避不純物を含むアルミニウムからなる高延性アルミニウム合金で鋳造された高延性アルミニウム合金製塑性加工用鋳造素材を鋳造した後、鋳放しのままの鋳造素材に対して、機械的特性を変える部位の塑性加工後の塑性加工率が２０％以上となるように常温下で塑性加工を行うようにした。したがって、この発明によると、アルミニウム合金の強度を維持しつつ、鋳造性及び伸びの両方を同時に向上させることができ、この合金で鋳造した鋳造素材に対して鋳放しのままでも常温下で塑性加工を行うことができるようになると共に、塑性加工部位の機械的特性の安定化を図ることができる。
【００９２】
請求項２の発明によると、Ｍｎ成分の含有量を１．０〜２．０重量％とし、Ｆｅ成分の含有量を０．４〜１．５重量％とし、Ｍｇ成分の含有量を０．０１〜０．５重量％としたことにより、鋳造素材の強度を維持しつつ、請求項１の発明よりも伸びを向上させることができる。
【００９３】
請求項３の発明によると、Ｍｎ成分の含有量を１．２〜１．６重量％とし、Ｆｅ成分の含有量を０．４〜０．７重量％とし、Ｍｇ成分の含有量を０．０１〜０．５重量％としたことにより、鋳造素材の強度を維持しつつ、請求項２の発明よりもさらに伸びの改善を図ることができる。
【００９４】
請求項４の発明によると、高延性アルミニウム合金に、０．１〜０．２重量％のＴｉ成分、０．０１〜０．１重量％のＢ成分及び０．０１〜０．２重量％のＢｅ成分のうちの少なくとも１つを添加したことにより、鋳造素材の伸びのより一層の向上化を図ることができる。
【図面の簡単な説明】
【図１】 本発明の参考形態１に係る高延性アルミニウム合金製塑性加工用鋳造素材を用いた塑性加工方法により製造された自動車用のインストルメントパネルの裏側要部を示す斜視図である。
【図２】 インストルメントパネルの表側を示す斜視図である。
【図３】 鋳造素材において固定部近傍を示す拡大斜視図である。
【図４】 図３のIV方向矢視図である。
【図５】 ダイカストマシンを示す断面図である。
【図６】 曲げ加工金型で鋳造素材に対して曲げ加工を施している状態を示す図１のVI−VI線に相当する断面斜視図である。
【図７】 プレス成型金型を示す断面図である。
【図８】 鋳造素材に対して絞り・張出し加工を施している状態を示す図７相当図である。
【図９】 実施形態１に係るＡＴドラムを示す断面図である。
【図１０】 鋳造素材を示す斜視図である。
【図１１】 鋳造素材の歯部を示す部分平面図である。
【図１２】 鋳造素材の底部のすえ込み加工を模式的に示す説明図である。
【図１３】 参考形態２に係るシフトレバーを示す断面図である。
【図１４】 鋳造素材の下端部のしごき加工を示す説明図である。
【図１５】 実施形態２に係るベルト用プーリを示す断面図である。
【図１６】 鋳造素材を示す断面図である。
【図１７】 ギヤ付きプーリを示す断面図である。
【図１８】 実施形態３に係るオイルパンを示す斜視図である。
【図１９】 鋳造素材の要部を示す断面図である。
【図２０】 実施形態４に係るロードホイールを示す断面図である。
【図２１】 実施形態５に係るアッパーアームを示す斜視図である。
【図２２】 図２１のXXII−XXII線断面図である。
【図２３】 鋳造素材が引張変形する場合を模式的に示す説明図である。
【図２４】 合金の種類と伸びとの関係を示すグラフである。
【図２５】 合金の種類と引張強さとの関係を示すグラフである。
【図２６】 合金の種類と０．２％耐力との関係を示すグラフである。
【図２７】 鋳造した試験片の合金の種類と平均総割れ個数及び平均総割れ長さとの関係を示すグラフである。
【図２８】 鋳造した試験片を示す斜視図である。
【図２９】 すえ込み加工前の鋳造素材の伸びと限界すえ込み率との関係を示すグラフである。
【図３０】 鋳造素材の圧下率と硬さとの関係を示すグラフである。
【図３１】 合金例Ｂの鋳造素材における圧下率と引張強度及び０．２％耐力との関係を示すグラフである。
【図３２】 合金例Ｂの鋳造素材における圧下率と伸びの関係を示すグラフである。
【図３３】 アルミニウム合金におけるＭｎ成分の含有量と引張強さとの関係を示すグラフである。
【図３４】 アルミニウム合金におけるＭｎ成分の含有量と伸びとの関係を示すグラフである。
【図３５】 アルミニウム合金におけるＦｅ成分の含有量と伸びとの関係を示すグラフである。
【図３６】 アルミニウム合金におけるＭｇ成分の含有量と引張強さとの関係を示すグラフである。
【図３７】 アルミニウム合金におけるＭｇ成分の含有量と伸びとの関係を示すグラフである。
【図３８】 アルミニウム合金におけるＭｇ成分及びＦｅ成分の含有量とその合金で鋳造した鋳造素材の鋳造割れ発生率との関係を示すグラフである。
【符号の説明】
４′ 基端部（機械的特性を変える部位）
５，１１，１８，２８，５５ 高延性アルミニウム合金製塑性加工用鋳造素材
８′ 底部（機械的特性を変える部位）
１０′ 歯部（機械的特性を変える部位）
１６′ 下端部（機械的特性を変える部位）
２５′ 外周部（機械的特性を変える部位）
２７′ リブ部（機械的特性を変える部位）
５２′ 突出部（機械的特性を変える部位）[0001]
BACKGROUND OF THE INVENTION
  The present invention belongs to a technical field related to a casting material for plastic working made of a high ductility aluminum alloy and a plastic working method using the raw material.
[0002]
[Prior art]
  Generally, as an aluminum alloy, for example, “aluminum alloy die casting” defined in JIS standard H5302 and “aluminum alloy casting” defined in the standard H5202 are known.
[0003]
  On the other hand, in recent years, in parts related to automobiles and the like, from the viewpoint of cost reduction and weight reduction, it has been studied to integrally form parts that have conventionally been composed of a plurality of parts by casting with an aluminum alloy.
[0004]
  However, when the part to be cast has a part that cannot be directly shaped by casting because of die cutting, the above parts cannot be integrally formed. In addition, after casting a cast material in a shape that can be cast, it is conceivable that the cast material is subjected to plastic processing such as forging and bending to obtain a predetermined shape. However, it is difficult to integrally mold such parts because it is cracked or broken when plastic working is performed.
[0005]
  Therefore, an aluminum alloy having good elongation characteristics is required so that it does not crack or break even if plastic working is performed, and is disclosed in, for example, Japanese Patent Laid-Open Nos. 3-122242 and 6-330202. As described above, it has been proposed to improve the strength, elongation or toughness by changing the components of aluminum alloys and their ratios.
[0006]
  On the other hand, for example, as disclosed in JP-A-62-149839 and JP-A-7-252616, it has been proposed to improve wear resistance and strength by containing a relatively large amount of Si component. ing.
[0007]
[Problems to be solved by the invention]
  However, when a relatively large amount of Mg component is contained, the strength is increased, but there is a difficulty that defects such as a sinkhole are likely to occur inside the casting material. In addition, the casting cracking property indicating the degree of cracking on the surface of the casting material may be deteriorated, and therefore an alloy having a high content of Mg component generally has poor casting property. For this reason, the elongation of the product actually cast with the alloy is lower than the elongation of the alloy itself. In fact, the elongation of what is actually cast with an alloy such as ADC5 or ADC6 specified in the JIS standard H5302 is considerably lower than the elongation of the alloy itself. Therefore, the alloy of the former proposal example (Japanese Patent Laid-Open No. 3-122242 and Japanese Patent Laid-Open No. 6-330202) also contains a large amount of Mg component in the same manner as the above-described alloys such as ADC5 and ADC6. The cast material cast cannot be expected to grow.
[0008]
  Further, the alloy of the latter proposed example (Japanese Patent Laid-Open No. Sho 62-149839 and Japanese Patent Laid-Open No. Hei 7-252616) is the ADC7 (November 1, 1976) defined in the old JIS standard. Similar to alloys such as AC4CH specified in the JIS standard H5202, the castability is slightly improved because the alloy contains a relatively large amount of Si components as in the case of alloys such as AC4CH specified in JIS standard H5202). However, the elongation of the alloy itself is lowered, and the elongation is lower than that of the above-mentioned alloys such as ADC5 and ADC6.
[0009]
  Thus, in general, the elongation of the alloy itself and the castability are in a contradictory relationship, and when trying to improve the castability, the elongation of the alloy itself decreases. Will deteriorate, so the elongation of the cast material will decrease. Therefore, it is impossible to obtain an aluminum alloy having good cast material elongation characteristics, and as a result, it has been difficult to perform plastic working on the cast material. Although it is possible to improve the elongation by subjecting the cast product to heat treatment or to facilitate the processing by performing plastic processing at a high temperature, there is a certain limit, and the manufacturing cost increases on the contrary. There is a problem.
[0010]
  The present invention has been made in view of such various points. The object of the present invention is to improve the components of the aluminum alloy and the content of the components, while maintaining the strength of the alloy, For both as-cast materials that have both improved elongation and are cast with the alloy.AlwaysAn object is to enable plastic working under temperature, and to stabilize by changing mechanical properties such as tensile strength, proof stress, hardness, and elongation of the part subjected to the plastic working.
[0011]
[Means for Solving the Problems]
  In order to achieve the above object, in the present invention, a high ductility aluminum alloy comprising aluminum in which an Mn component, an Fe component, and an Mg component are contained within a predetermined range and other components such as an Si component are inevitable impurities. A cast material was cast, and the thickness before plastic processing was set so that the plastic processing rate after plastic processing of the portion of the cast material whose mechanical characteristics were changed was 20% or more.
[0012]
  Specifically, in the invention of claim 1,As a plastic working method using a casting material for plastic working made of high ductility aluminum alloy,0.5 to 2.5% by weight of Mn component,0.4~ 1.5 wt% Fe component and 0.01 ~0.5Cast with high ductility aluminum alloy consisting of aluminum containing Mg component by weight and the balance containing inevitable impuritiesThen, plastic processing is performed at room temperature so that the plastic processing rate after plastic processing of the portion that changes the mechanical characteristics is 20% or more with respect to the cast material as-cast.Shall.
[0013]
  That is, when the content of the Mn component is less than 0.5% by weight, the effect of strengthening the Mn component by dissolving in aluminum is reduced, and the tensile strength becomes insufficient. If the amount is more than the above, it is easy to generate a compound in combination with other elements, the tensile strength is lowered, and the elongation is also reduced to be lower than that of the conventional alloy, so the range is 0.5 to 2.5% by weight.
[0014]
  In addition, the content of the Fe component is0.4If less than% by weight, seizure with moldCannot be effectively prevented, and casting cracking is not sufficiently improved.On the other hand, if it is more than 1.5% by weight, a compound is likely to be formed like the Mn component, and the elongation is reduced below that of the conventional alloy.0.4The range is ˜1.5% by weight.
[0015]
  Furthermore, if the content of the Mg component is less than 0.01% by weight, the effect of increasing the tensile strength by dissolving in aluminum as in the case of the Mn component is small,0.5If the amount is more than% by weight, the oxidation of the molten aluminum alloy is promoted, and the quality of the cast material deteriorates due to the inclusion of the oxidized layer inside the cast material. In addition, the compound tends to be generated and the elongation is greatly reduced.0.5The range is% by weight.Further, the content of the Fe component reduces the elongation as compared with the case where the content of the Fe component is less than 0.4% by weight, but the content of the Mg component is more than 0.5% by weight. Then, the elongation is further reduced, so the upper limit of the content of the Mg component is set to 0.5% by weight.
[0016]
  As a result, the castability and elongation can be improved while securing the strength of the alloy to some extent by setting the content of the Mg component in a predetermined range that is smaller than the conventional range. And although content of Mg component decreases and intensity | strength falls, it reinforces with Mn component. Further, the cast cracking property is improved by the Fe component. For this reason, it is possible to improve both castability and elongation, which are conflicting properties, while maintaining the strength of the aluminum alloy.
[0017]
  Therefore, even if the casting material is cast with the above-mentioned aluminum alloy, there is no decrease in elongation due to deterioration of castability, and the elongation of the alloy itself is at a high level. Therefore, the casting material has a high elongation even without being heat-treated. The plastic working can be easily performed on the cast material. And in the site | part which made the plastic working rate 20% or more, the tensile strength of a mechanical characteristic, yield strength, hardness, etc. improve and stabilize from before plastic working. Further, the elongation is lower than that before plastic working, but is stable at a higher value than that obtained by casting with a conventional alloy. For this reason, for example, by setting the thickness before plastic working of the part that is desired to be stronger than the casting material by changing the strength so that the plastic working rate is 20% or more, the part of the part after plastic working is set. The strength can be improved stably. Therefore, while maintaining the strength of the aluminum alloy, it is possible to improve both the castability and the elongation at the same time.AlwaysPlastic working can be performed at a low temperature, and mechanical characteristics of the plastic working portion can be stabilized, and in particular, strength and hardness can be improved.
[0018]
  Claim2In the invention of claim1In the invention, the content of the Mn component is 1.0 to 2.0% by weight.
[0019]
  That is, when the content of the Mn component is less than 1.0% by weight, the strength is greatly decreased. On the other hand, when the content is more than 2.0% by weight, it is impossible to improve the elongation. The range is 0 to 2.0% by weight. Therefore, while maintaining the strength of the casting material, the claim1Elongation can be improved as compared with the invention.
[0020]
  Claim3In the invention of claim2In the invention, the content of the Mn component is 1.2 to 1.6% by weight, and the content of the Fe component is 0.4 to 0.7% by weight.
[0021]
  That is, if the content of Fe component is more than 0.7% by weight, the elongation cannot be further improved. On the other hand, if the content is less than 0.4% by weight, as described above, the cast cracking property Is not sufficiently improved, the range is 0.4 to 0.7% by weight. The content of the Mn component is 1.2 to 1.6% by weight,2It is for making it into a still more preferable range than this invention. Therefore, while maintaining the strength of the casting material, the claim2Elongation can be further improved as compared with the present invention.
[0022]
  Claim4In the invention of claim 1,3One ofOneIn the invention ofHigh ductility aluminum alloyAt least one of 0.1 to 0.2 wt% Ti component, 0.01 to 0.1 wt% B component and 0.01 to 0.2 wt% Be componentTheAdditionDoShall.
[0023]
  That is, the Ti component, the B component, and the Be component can improve the casting cracking property by improving the characteristics by refining the crystal grains of the casting material, but each addition amount is 0.1% by weight. When the content is less than 0.01% by weight and 0.01% by weight, the effect is small and the casting cracking property cannot be sufficiently improved. On the other hand, the respective addition amounts are 0.2% by weight and 0.1% by weight. If the amount is more than 0.1% and 0.2% by weight, a coarse compound is produced and elongation is lowered, and in the Ti component, the fluidity of the molten metal is also lowered. The range is 01 to 0.1% by weight and 0.01 to 0.2% by weight. Therefore, the cast cracking property can be further improved while preventing the elongation of the alloy from decreasing, and as a result, the elongation of the cast material can be further improved.
[0024]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, first, a reference form similar to the embodiment of the present invention will be described, and thereafter, the difference of the embodiment of the present invention from the reference form will be described.
[0025]
  (referenceForm 1)
  1 and 2 show the present invention.reference1 shows an automotive instrument panel A manufactured by a plastic working method using a cast material for plastic working made of high ductility aluminum alloy according to Embodiment 1. This panel A has a substantially rectangular box shape having an opening on the back side (rear side), and on the back side there are substantially rectangular fixing portions 1, 1... For mounting and fixing the panel A to the front part of the vehicle interior. Provided at a plurality of locations, each fixing portion 1 is provided with a bolt insertion hole 2 at a substantially central portion thereof. In addition, each fixed portion 1 is formed by being bent at a substantially right angle from the upper, lower, left and right portions of the panel A to the center side, and the inner radius of each bent portion 4 is set to each bent portion 4 before bending (plastic processing). The thickness is equal to or greater than the thickness t0 (see FIG. 4) of the corresponding portion (the base end portion 4 ′ of each fixed portion 1 in the casting material 5 described later). In FIGS. 1 and 2, reference numeral 3 denotes a glove box opening.
[0026]
  The instrument panel A is made of a highly ductile aluminum alloy having an elongation of 10% or more. Specifically, this aluminum alloy contains 0.5 to 2.5% by weight of Mn component, 0.1 to 1.5% by weight of Fe component and 0.01 to 1.2% by weight of Mg component. The balance is made of aluminum containing inevitable impurities.
[0027]
  That is, when the content of the Mn component is less than 0.5% by weight, the effect of strengthening the Mn component by dissolving in aluminum is reduced, and the tensile strength is excessively lowered, whereas the content of 2.5% by weight or less. If the amount is too large, a compound is likely to be generated in combination with other elements, the tensile strength is lowered, and the elongation is also lowered below that of a conventional alloy, so the range is 0.5 to 2.5% by weight.
[0028]
  On the other hand, if the Fe component content is less than 0.1% by weight, seizure with the mold tends to occur. On the other hand, if the Fe component content is more than 1.5% by weight, a compound is generated in the same manner as the Mn component. Since it becomes easy and elongation falls below the conventional alloy, it is set as the range of 0.1 to 1.5 weight%.
[0029]
  Furthermore, if the content of the Mg component is less than 0.01% by weight, the effect of increasing the tensile strength by solid solution in aluminum is small as in the case of the Mn component, while if more than 1.2% by weight, Oxidation of the molten aluminum alloy is promoted, and the oxidized layer is mixed into the casting material 5 to cause deterioration of the quality of the casting material 5, and the fluidity and replenishment of the molten metal are also lowered, resulting in poor castability. In addition, since the compound tends to be generated, the elongation is too low, so the range is 0.01 to 1.2% by weight.
[0030]
  In addition, without changing the content of the Mn component of the aluminum alloy, the content of the Fe component is 0.4 to 1.5% by weight, and the content of the Mg component is 0.01 to 0.5% by weight. Good. That is, if the content of the Fe component is less than 0.4% by weight, seizure with the mold cannot be effectively suppressed, and the casting cracking property is insufficient, but 1.5% by weight. If it exceeds the upper limit, the elongation falls below that of the conventional alloy as described above, so the range is 0.4 to 1.5% by weight. For this reason, the elongation is reduced as compared with the case where the Fe component content is less than 0.4% by weight. However, when the Mg component content is more than 0.5% by weight, the elongation is further reduced. On the other hand, if it is less than 0.01% by weight, the effect of increasing the tensile strength is small as described above, so the content of the Mg component is in the range of 0.01 to 0.5% by weight.
[0031]
  Further, the content of the Mn component is 0.5 to 2.5% by weight, the content of the Fe component is 0.1 to 0.3% by weight, and the content of the Mg component is 0.7 to 1.2% by weight. % May be used. That is, if the content of the Mg component is less than 0.7% by weight, a sufficiently high tensile strength cannot be maintained. On the other hand, if the content is more than 1.2% by weight, the castability deteriorates as described above. In addition, since the elongation is remarkably reduced, the range is 0.7 to 1.2% by weight. For this reason, the elongation is reduced as compared with the case where the content of the Mg component is less than 0.7% by weight, but the elongation is further reduced when the content of the Fe component is more than 0.3% by weight. On the other hand, if the amount is less than 0.1% by weight, seizure with the mold is likely to occur as described above, so the content of the Fe component is in the range of 0.1 to 0.3% by weight. .
[0032]
  In order to manufacture the instrument panel A having the above configuration, first, as shown in FIG. 3, a casting material 5 for plastic working is cast with an aluminum alloy having the above components. At this time, as will be described later, two casting molds are arranged on the front side and the back side of the instrument panel A for casting, but the casting mold on the back side is die-cut due to the presence of the fixing portions 1, 1,. Therefore, each fixed part 1 cannot be directly shaped by casting. Therefore, the casting material 5 is cast in a shape that extends straight in the back direction in which each fixed portion 1 is not bent, and as a result, is substantially equal to the shape of the panel A, but each bent portion 4 is not formed. Is different. That is, the base end portion 4 ′ of each fixed portion 1 in the casting material 5 is a portion corresponding to each bending portion 4 of the casting material 5 and a portion that changes mechanical characteristics by bending (mechanical property changing portion). Has been.
[0033]
  And the thickness of the base end part 4 'of each fixed part 1 in the casting material 5 is set so that the plastic working rate after plastic working is 20% or more. That is, as shown in FIG. 4, assuming that the thickness of each bent portion 4 after plastic working is t and the thickness of the base end portion 4 ′ before plastic working is t0, (t0−t) / t0 × 100. The thickness t0 of the base end portion 4 ′ is set so as to satisfy ≧ 20. Note that t0 is set so that the distortion amount is 0.22 or more. That is, t0 is set so as to satisfy ln (t0 / t) ≧ 0.22. In FIG. 4, the thickness of each fixed portion 1 of the casting material 5 is constant from the base end portion 4 ′ to the tip end portion.
[0034]
  Here, FIG. 5 shows a die casting machine for casting the casting material 5, and the casting material 5 is cast in a space 33 formed between the fixed mold 31 and the movable mold 32 of the die casting machine. It has come to be. The fixed mold 31 is attached and fixed to a die plate 35 having an injection sleeve 34, and has a connection hole 31a for connecting one end of a through hole 34a provided in the injection sleeve 34 and the space 33. . A piston 36 is slidably fitted to the other end portion of the injection sleeve 34, and a pouring hole 34b for pouring the molten aluminum 38 of the aluminum alloy into the through hole 34a by a handle rod 37 at the upper portion in the vicinity thereof. Is formed. Then, the molten metal 38 poured into the through hole 34a from the pouring hole 34b is fed into the space 33 by the slide of the piston 36, and the casting material 5 is cast into a predetermined shape. The casting of the casting material 5 is not limited to the method using the die casting machine, but may be any casting method such as a high pressure casting method, a die casting method, a continuous casting method, or the like.
[0035]
  After casting the casting material 5, bending is performed on the base end portion 4 ′ of each fixing portion 1 that extends straight of the as-cast casting material 5, so that each fixing portion 1 is about 90 °. Panel A is completed when it is bent to a predetermined shape. At this time, the bending processAlwaysThe test is performed under heat, and the inner radius of each bent portion 4 is set to be equal to or greater than the thickness t0 of the base end portion 4 ′. Further, since the wall thickness t0 of the base end portion 4 'is set so that the plastic working rate is 20% or more, the bending process is performed so that the wall thickness t of each bending portion 4 becomes a predetermined thickness. For example, the plastic working rate after plastic working is 20% or more.
[0036]
  The bending process is performed by a bending mold as shown in FIG. This bending die includes a plurality of punches 43, 43,... Which are supported by upper and lower holders 41 and 42 which hold the front portion of the panel A in the up and down direction and slidable in the up and down direction. It consists of. Each punch 43 is provided at a position corresponding to each of the fixing portions 1. By sliding the punch 43 downward, the fixing portions 1 are made substantially perpendicular to the lower surface of the punch 43. It is designed to bend.
[0037]
  In the case where the casting material 5 is drawn and stretched by a press molding die, as shown in FIGS. 7 and 8, the periphery of the processing portion 5a (the mechanical property changing portion) of the casting material 5 is as follows. Is sandwiched between the die 46 and the holder 47, and the processed portion 5 a is processed into a predetermined shape by the punch 48. At that time, the thickness t0 before processing in the processing portion 5a of the casting material 5 is (t0−t) / t0 × 100 ≧ 20 (plastic processing rate is 20% or more), where t is the thickness after processing. It is set to satisfy ln (t0 / t) ≧ 0.22 (distortion amount is 0.22 or more). Then, the processing is performed so that the die shoulder radius R1 and the punch shoulder radius R2 are not less than five times the thickness t0 of the cast material 5 before processing at the processing site 5a.
[0038]
  Therefore, abovereferenceIn Form 1, the aluminum alloy contains 0.5 to 2.5% by weight of Mn component, 0.1 to 1.5% by weight of Fe component and 0.01 to 1.2% by weight of Mg component. Therefore, while maintaining the strength of the alloy, it is possible to improve both the castability and elongation, which are conflicting properties, and the cast material 5 cast with this alloy has no decrease in elongation due to deterioration of castability, Even in an as-cast state without heat treatment, it has the same high elongation of about 10% or more as the alloy itself. Therefore, for each fixed part 1 of the casting material 5AlwaysEven if the bending process is performed at a low temperature, the bent portions 4 are not cracked or broken and can be easily formed into a predetermined shape.
[0039]
  Then, the thickness t0 of the base end portion 4 'of each fixed portion 1 in the casting material 5 is set so that the plastic working rate after plastic working is 20% or more, and the base end portion 4' is bent. Since the processing is performed, the tensile strength, the yield strength, the hardness, etc., among the mechanical properties of each bending portion 4 can be improved and stabilized as compared with those before the processing. Moreover, although the elongation of each bending part 4 falls compared with before a process, it can improve and stabilize from the conventional alloy, and can fix panel A reliably. Furthermore, since the panel A as a whole has good elongation, the panel A can be stretched without breaking when the vehicle collides, and the collision energy can be absorbed, while reducing the cost and weight of the panel A. Impact characteristics can be improved.
[0040]
  And, without changing the content of the Mn component of the aluminum alloy, the content of the Fe component is set to 0.4 to 1.5% by weight, and the content of the Mg component is set to 0.01 to 0.5% by weight. Thus, it is possible to further improve the cast cracking property while preventing the elongation and strength of the alloy from being lowered, and as a result, the cast material 5 that has been cast is further improved in elongation, and plastic processing can be performed more easily. Will be able to.
[0041]
  Furthermore, if the content of the Fe component is 0.1 to 0.3% by weight and the content of the Mg component is 0.7 to 1.2% by weight, while preventing a decrease in the elongation of the casting material 5, The strength can be increased, and as a result, the strength of the panel A can be improved.
[0042]
  The effects of the Mn component content on the tensile strength and elongation, the Fe component content on the elongation, and the Mg component content on the tensile strength and elongation in the aluminum alloy are shown in FIGS. As shown in FIG. FIG. 38 shows the relationship between the contents of the Mg component and Fe component in the aluminum alloy and the rate of occurrence of casting cracks in the casting material cast with the alloy. From this, the elongation decreases with increasing content of any element, and the tensile strength becomes maximum at about 2.0% by weight for the Mn component, but proportionally increases with increasing content for the Mg component. Increase. Moreover, it turns out that casting cracking property is so favorable that there is much content of Fe component. Therefore, as described above, appropriate ranges for the contents of the Mn component, the Fe component, and the Mg component are determined.
[0043]
  (Embodiment1)
  Next, an embodiment of the present invention will be described.
[0044]
  FIG. 9 shows an embodiment of the present invention.1This is applied to the AT drum B in an automatic transmission of an automobile. This AT drum BreferenceIn the same manner as in the first embodiment, the cast material 11 (see FIG. 10) is cast with a high ductility aluminum alloy, and then the cast material 11 is subjected to plastic working. However, the abovereferenceIt does not have the site | part which cannot be directly shape | molded by casting like the form 1.
[0045]
  The AT drum B has a bottomed cylindrical shape with one end opened, and has a through hole 9 through which the shaft passes at a substantially central portion of the bottom portion 8, and a plurality of tooth portions 10 on the outer peripheral portion on the opening side. Are formed at equal intervals in the circumferential direction.
[0046]
  The aluminum alloy contains 1.0 to 2.0% by weight of Mn component, 0.4 to 1.5% by weight of Fe component and 0.01 to 0.5% by weight of Mg component, and the remainder is inevitable. It is made of aluminum containing impurities and emphasizes elongation. That is, when the content of the Mn component is less than 1.0% by weight, the strength becomes insufficient. On the other hand, when the content is more than 2.0% by weight, a sufficiently high elongation cannot be maintained. The range is 1.0 to 2.0% by weight. In addition, about the range of content of Fe component and Mg component, the abovereferenceThis is set as described above for the same reason described in the first embodiment.
[0047]
  Furthermore, in the above aluminum alloy, without changing the content of the Mg component, the content of the Mn component is set to 1.2 to 1.6% by weight, and the content of the Fe component is set to 0.4 to 0.7% by weight. It is even more desirable to do so. That is, if the content of Fe component is more than 0.7% by weight, the elongation cannot be further improved. On the other hand, if the content is less than 0.4% by weight, as described above, the cast cracking property Is in the range of 0.4 to 0.7% by weight. The reason why the content of the Mn component is set to 1.2 to 1.6% by weight is to make the strength and elongation more appropriate ranges.
[0048]
  In order to manufacture the AT drum B, first, a casting material 11 is cast as shown in FIGS. The cast material 11 has a bottomed cylindrical shape like the AT drum B, but the thickness of the bottom 8 '(the mechanical property changing portion) of the cast material 11 is larger than the thickness of the bottom 8 of the AT drum B. The plastic working rate (upsetting rate or rolling reduction) after plastic working is set to 20% or more. That is, as schematically shown in FIG. 12, the thickness h0 of the bottom 8 'of the casting material 11 before plastic working is defined as h, and the thickness of the bottom 8 of the AT drum B is defined as h. (H0-h) / h0 × It is set so as to satisfy 100 ≧ 20. The abovereferenceAs in the first embodiment, the thickness h0 of the bottom 8 ′ is set so that the distortion amount is 0.22 or more, that is, ln (h0 / h) ≧ 0.22.
[0049]
  Further, the thickness of each tooth portion 10 ′ (mechanical characteristic changing portion) of the casting material 11 is set in the same manner as the bottom portion 8 ′, and the tooth profile thereof is similar to each tooth portion 10 of the AT drum B. In addition, the projecting amount is not increased and is not squared, and the draft is increased to make it easy to form by casting.
[0050]
  Then, the bottom portion 8 'and each tooth portion of the AT drum B are subjected to forging, that is, upsetting (plastic working) in the axial direction of the casting material 11 with respect to the bottom portion 8' and each tooth portion 10 'of the casting material 11. 10 is formed. At this time, the upsetting process of each tooth portion 10 ′ of the casting material 11 is performed in a mold having the same tooth profile as each tooth portion 10 of the AT drum B. That is, each tooth portion 10 'has its tip portion bulged outward in the radial direction by swaging, so that the bulge is constrained by a mold so as to have a predetermined shape.
[0051]
  Therefore, the above embodiment1Is cast with a high ductility aluminum alloy containing 1.0 to 2.0% by weight of Mn component, 0.4 to 1.5% by weight of Fe component and 0.01 to 0.5% by weight of Mg component. Since the material 11 was cast, the elongation of the cast material 11referenceThis can be further improved as compared with the first mode, and the plastic working rate can be further increased. For this reason, in the AT drum B, it is possible to more effectively improve and stabilize the tensile strength, proof stress, and the like of the bottom portion 8 and each tooth portion 10 that particularly require bending strength. In addition, casting of the casting material 11 can be facilitated, and the tooth profile accuracy of each tooth portion 10 can be improved as compared with the case of forming directly by casting.
[0052]
  Further, the quality of the AT drum B is further stabilized by setting the content of the Mn component to 1.2 to 1.6% by weight and the content of the Fe component to 0.4 to 0.7% by weight. be able to.
[0053]
  The casting material 11 is not limited to the shape described above, and may be formed in a substantially ring shape. In this way, the casting material 11 can be cast more easily and there are many parts to be subjected to plastic working. In addition, since the plastic working rate is increased, the strength of the casting material 11 can be increased overall rather than partially..
[0054]
  (referenceForm2)
  Although this embodiment is different from the embodiment of the present invention, it will be described as a reference embodiment.
[0055]
  FIG. 13 shows the present invention.referenceForm2And is applied to a shift lever C for automobiles. The shift lever C has an elongated shape extending in the vertical direction, and a screw portion 15 into which a shift knob is screwed is provided at an upper end portion thereof, and an outer diameter of the lower end portion is larger than that of the upper end portion and The connecting portion 16 is connected to a connecting shaft extending upward from the transmission, and a shaft insertion hole 17 into which the tip end portion of the connecting shaft is inserted is formed on the lower end surface thereof.
[0056]
  The shift lever C has a high ductility containing 1.5 to 2.5% by weight of Mn component, 0.1 to 0.3% by weight of Fe component and 0.7 to 1.2% by weight of Mg component. It is made of an aluminum alloy and emphasizes strength. That is, when the content of the Mn component is less than 1.5% by weight, a sufficiently high strength cannot be maintained. On the other hand, when the content is more than 2.5% by weight, the elongation is excessively lowered as described above. Therefore, the range is 1.5 to 2.5% by weight. In addition, about the range of content of Fe component and Mg component, the abovereferenceThis is set as described above for the same reason described in the first embodiment.
[0057]
  Furthermore, in the above aluminum alloy, it is more preferable for securing the strength that the content of the Mn component is 1.8 to 2.2% by weight without changing the content of the Fe component and the Mg component. can do.
[0058]
  To manufacture the shift lever C, first, a casting material 18 is cast as shown in FIG. The casting material 18 has the same shape as the shift lever C, but the upper end portion 15 '(located on the right side in FIG. 14) is not formed with the threaded portion 15, and is formed in a cylindrical shape. Yes. On the other hand, the outer diameter of the lower end portion 16 ′ (mechanical characteristic changing portion) of the casting material 18 is larger than that of the connecting portion 16, but the length is shortened. A tool insertion hole 17 'having the same inner diameter as the shaft insertion hole 17 is formed on the end surface of the lower end portion 16' of the casting material 18. The depth of the tool insertion hole 17 'is the length of the lower end portion 16'. It is smaller than the shaft insertion hole 17 by the amount that is shortened.
[0059]
  The thickness h0 of the lower end portion 16 'of the casting material 18 is the same as that of the above embodiment.1Similarly, the thickness of the connecting portion 16 is set to h, and is set so as to satisfy (h0−h) / h0 × 100 ≧ 20 (plastic working rate is 20% or more).
[0060]
  Then, the tool shaft 20 is fitted into the tool insertion hole 17 ′ of the casting material 18, and the casting material 18 is rotated around the axis center with the axis direction being horizontal. At this time, the threaded portion 15 is formed by rolling the upper end portion 15 ′ of the casting material 18, while the ironing is performed while sliding the tool 21 in the axial direction with respect to the lower end portion 16 ′. Thus, the connecting portion 16 is formed.
[0061]
  Therefore, abovereferenceForm2Cast with a highly ductile aluminum alloy containing 1.5 to 2.5 wt% Mn component, 0.1 to 0.3 wt% Fe component and 0.7 to 1.2 wt% Mg component By casting the material 18, while maintaining the elongation of the casting material 18,referenceThe strength can be made higher than that of the first embodiment, and as a result, the overall strength of the shift lever C can be made higher. And especially in the connection part 16 which requires bending strength, a tensile strength, a yield strength, etc. can be improved more stably by performing the ironing process from which a plastic working rate will be 20% or more. Further, since the threaded portion 15 is not formed on the casting material 18 and the depth of the shaft insertion hole 17 'is small, the casting can be easily performed. Furthermore, the screw accuracy of the threaded portion 15 is better than that formed directly by casting. Therefore, the reliability of the shift lever C can be improved while facilitating casting of the casting material 18.
[0062]
  Moreover, the intensity | strength of the shift lever C whole and the intensity | strength of the connection part 16 can be improved further by making content of a Mn component into 1.8 to 2.2 weight%.
[0063]
  The abovereferenceForm2The content of each component of the aluminum alloy inreferenceForm 1 orEmbodiment 1It may be within the range described in.If the content of each component of the aluminum alloy is in the range described in the first embodiment, an embodiment of the present invention is obtained.
[0064]
  (Embodiment2)
  FIG. 15 shows an embodiment of the present invention.2And applied to the belt pulley D. A plurality of V-shaped grooves 25, 25,... Around which a V-ribbed belt is wound are formed on the outer peripheral portion of the belt pulley D, and a fitting hole penetrating in the axial direction for fitting to the shaft is formed at the center. 26 is formed. Further, the outer peripheral portion and the central portion are integrally coupled by a rib portion 27. This pulley D is the above embodiment.1Explained inHighMade of ductile aluminum alloy.
[0065]
  In order to manufacture such a pulley D, first, as shown in FIG. 16, a casting material 28 is cast with the aluminum alloy. The grooves 25 are not formed in the outer peripheral portion 25 ′ (mechanical characteristic changing portion) of the casting material 28, and the outer diameter of the outer peripheral portion 25 ′ is larger than the outermost diameter of the groove portions 25 of the pulley D. On the other hand, it is small in the axial direction. Further, the thickness (axial direction) of the rib portion 27 ′ (the mechanical property changing portion) of the casting material 28 is formed larger than that of the rib portion 27 of the pulley D. The thickness of the outer peripheral portion 25 ′ (the thickness in the radial direction from the outer peripheral edge portion to the boundary portion with the rib portion 27 ′) and the thickness of the rib portion 27 ′ are as described above.Reference form andEmbodiment1Similarly, the plastic working rate after plastic working is set to be 20% or more. The central portion of the casting material 28 is formed in the same shape as the pulley D, and the fitting hole 26 is already formed in the central portion.
[0066]
  Then, the outer circumferential portion 25 ′ of the casting material 28 is subjected to roll processing (plastic processing) in the radial direction to form each groove portion 25, and the rib portion 27 ′ is swept in the axial direction. The rib portion 27 of the pulley D is formed. Thereby, the hardness of each groove part 25 can be improved and the abrasion resistance with respect to a belt can be improved. In addition, the strength of the rib portion 27 that requires strength can be improved more than other portions.
[0067]
  As shown in FIG. 17, in the case of the geared pulley E having the gear 29, the groove portions 25 and the rib portions 27 are formed in the same manner as the pulley D, and the embodiment described above is used.1By forming the gear 29 in the same manner as each tooth portion 10 of the AT drum B, the tooth profile accuracy of the gear 29 can be improved.
[0068]
  (Embodiment3)
  FIG. 18 shows an embodiment of the present invention.3And is applied to an oil pan F for automobiles. The oil pan F has a bottomed shape with an upper end opened, and has a flange portion 51 that extends outward on the entire circumference of the opening edge. The flange portion 51 is formed with a plurality of coupling portions 52, 52,... For coupling with an upper member that closes the opening of the oil pan F. As shown by a two-dot chain line in FIG. 19, the lower portion of each coupling portion 52 protrudes downward from the lower surface of the flange portion 51, and a bolt insertion hole 53 is provided at the center of each coupling portion 52. . That is, the lower surface of each connecting portion 52 is a seating surface against which the bolt head at the time of bolt tightening comes into contact. Further, two baffle plates 54 and 54 are integrally formed at the bottom of the oil pan F to prevent the liquid level from shaking. In addition, this oil pan F is also the above embodiment.1Explained inHighMade of ductile aluminum alloy.
[0069]
  In order to manufacture such an oil pan F, a casting material 55 in which only the shape of the lower part of each connecting portion 52 is changed is cast. That is, as shown in FIG. 19, the casting material 55 is formed with a protruding portion 52 ′ (mechanical characteristic changing portion) protruding downward from the lower surface of the flange portion 51 at a position corresponding to each connecting portion 52. The thickness (projection amount) of the protrusion 52 'Each reference form andSimilarly to each embodiment, the plastic working rate is set to be 20% or more. And each coupling | bond part 52 is formed by giving a swaging process with respect to said protrusion part 52 '.
[0070]
  Therefore, the above embodiment3Then, since the strength and hardness of each coupling part 52 can be improved, when the oil pan F is coupled by fastening the upper member and the bolt, the sag of each coupling part 52 due to the contact of the bolt head is fixed. Can be prevented and the coupling can be ensured. Further, since the impact characteristics of the entire oil pan F can be improved, even if stones on the road surface jump and come into contact with the bottom of the oil pan F, it is possible to prevent the bottom from cracking. . For this reason, it is not necessary to use an iron plate at the bottom as in the prior art, and the baffle plates 54 and 54 can be integrally formed. Therefore, the weight reduction and cost reduction of the oil pan F can be achieved.
[0071]
  (Embodiment4,5)
  FIG. 20 shows an embodiment of the present invention.4And is applied to a road wheel G of an automobile tire. The road wheel G includes a rim portion 57 on the outer peripheral portion and a spoke portion 58 that connects the rim portion 57 and the center portion. The rim portion 57 is formed by subjecting a casting material (not shown) cast in a substantially disc shape to ironing such as spinning, thereby ensuring the pressure resistance of the rim portion 57. Further, the spoke portion 58 is formed by applying a rolling reduction at a high reduction rate, and improves the strength of the spoke portion 58.
[0072]
  FIG. 21 shows an embodiment of the present invention.5This is applied to the upper arm H of the automobile suspension. The upper arm H has two support portions 60, 60 that are joined at one end to form a substantially V-shape, and the upper and lower surfaces of each support portion 60 are shown in FIG. It is formed in a concave shape along the longitudinal direction of the portion 60. Each support portion 60 is formed by upsetting the portion corresponding to each support portion 60 having a substantially rectangular cross section in a casting material (not shown) in the vertical direction. The strength of the part 60 is improved.
[0073]
  The aboveEach reference form andIn each embodiment, an aluminum alloy containing an Mn component, an Fe component, and an Mg component was used, but a 0.1 to 0.2 wt% Ti component and a 0.01 to 0.1 wt% B component were also used. And at least one of 0.01 to 0.2% by weight of the Be component may be added. That is, the Ti component, the B component, and the Be component have a function to improve the casting cracking property by improving the characteristics by refining the crystal grains of the casting material. If less than 0.01% by weight, less than 0.01% by weight, the effect is small and the improvement in casting cracking properties is insufficient, while the addition amount is 0.2% by weight, 0.1% by weight, When the amount is more than 0.2% by weight, a coarse compound is generated and elongation is lowered, and in the Ti component, the fluidity of the molten metal is also deteriorated. The range is 0.1% by weight and 0.01 to 0.2% by weight. Therefore, by adding these, it is possible to further improve the cast cracking property while preventing a decrease in the elongation of the alloy, and to further improve the elongation of the casting material.
[0074]
  The present invention also provides the aboveEach reference form andNot only the parts in each embodiment, but also by applying to brackets such as engines and their auxiliary equipment, it is possible to prevent the bolt seat surface from sagging at the mounting part of these parts, and the overall strength of the parts While maintaining, the impact characteristics can be made favorable. And by applying to hydraulic system parts, such as a brake master cinder and a fuel distributor pipe, the pressure resistance can be secured.
[0075]
  In addition, the aboveEach reference form andIn each embodiment, the case where the casting material is compressively deformed in the direction in which the force acts is shown. However, when the casting material is subjected to tensile deformation, the plastic working rate is (L-L0) as shown in FIG. / L × 100, and plastic processing may be performed so that this value is 20% or more. The distortion amount is ln (L / L0), and this value may be 0.22 or more.
[0076]
【Example】
  Next, specific examples will be described. Different contents of Mn, Fe and Mg componentsalloyFourteen types of aluminum alloys of Examples 1 to 14 were prepared (see Table 1 for each component content in each alloy).Among these alloy examples 1 to 14, alloy examples 1, 8, 9, and 11 to 13 correspond to examples of the present invention, and the other alloy examples correspond to those described in the above reference embodiment.In any alloy, the balance contains 0.04 to 0.06% by weight of Si component and a small amount of other elements as inevitable impurities.
[0077]
  Elongation, tensile strength, and 0.2% proof stress were measured for the 14 types of alloys and ADC 6 in the JIS standard and ADC 7 in the old JIS standard as comparative examples. As the ADC 6, an alloy containing 0.50% by weight of the Mn component, 0.10% by weight of the Fe component, 4.00% by weight of the Mg component, and 0.10% by weight of the Si component, As the old JIS standard ADC7, an alloy containing 0.56% by weight of Fe component and 4.9% by weight of Si component (not containing Mn component and Mg component) was used.
[0078]
  Table 1 and FIGS. 24 to 26 show the mechanical properties of casting materials manufactured by these molds using a high pressure mold casting method. From this,Alloy Examples 1-14Each of these alloys has improved elongation compared to ADC6 and ADC7, and in most of the alloys, the elongation exceeds 10%. Further, it can be seen that the tensile strength and the 0.2% proof strength are comparable in any alloy.
[0079]
[Table 1]

[0080]
  Next, in order to investigate the cast cracking property of each of the above alloys, as shown in FIG.alloyRing-shaped specimens were cast from the alloys of Examples 1 and 2, ADC6 and ADC7. At this time, the mold temperature at the time of casting each test piece was normal temperature. Then, the number of cracks generated on the surface of each cast specimen and the crack length were investigated, and the average total number of cracks per specimen and the average total crack length were calculated for each alloy and the cast cracking properties were compared. did.
[0081]
  The result of this cast cracking property is shown in FIG. As a result,alloyThe test piece cast with the alloy of Example 1 has a remarkable effect of improving the casting cracking property by reducing the Mg component and containing the Fe component to some extent, and the inner state is also cast with ADC6 or ADC7. Compared to the above, the shrinkage nest and the like hardly occur. Also,alloyAlthough the cast of the alloy of Example 2 is inferior in terms of cast cracking property, it can be said that the internal state is good and the castability is improved.
[0082]
  further,Alloy Examples 3-14For these alloys, the same test as described above was performed, and the castability was evaluated including the internal state. The results of this evaluation are shown in Table 1. The symbols in Table 1 indicate that the castability is improved in the order of d, c, b, and a. As a result,Alloy Examples 1-14It can be seen that those casted with these alloys have better castability than ADC6 and ADC7, and in general, the castability becomes even better when the content of Fe component is large.
[0083]
  Therefore,Alloy Examples 1-14This alloy has a certain level of strength and is excellent in elongation and castability. In particular,alloyThe alloys of Examples 1 and 11 are very good in both elongation and castability. Also,alloyAs in the alloys of Examples 2 and 14, when the strength is further improved, the castability is slightly lowered, but it is still better than the conventional one.
[0084]
  Next, in order to investigate the plastic workability of the casting material, the contents of Mn component, Fe component and Mg component are varied.alloyA cylindrical casting material was cast with the six types of aluminum alloys of Examples A to F (see Table 2 for each component content in each alloy).Among these alloy examples A to F, alloy examples A and B correspond to the examples of the present invention, and the other alloy examples correspond to those described in the reference embodiment.For comparison, a similar casting material was cast with the above JIS standard AC4CH (comparative example). As this AC4CH, an alloy containing 0.3 wt% Mg component and 7.0 wt% Si component (not containing Mn component and Fe component) was used.
[0085]
  the abovealloyFor each casting material of Examples A to F and the comparative example, the upsetting process was performed in the axial direction of each casting material, and the limit upsetting rate was examined. That is, the processing was stopped when a crack occurred in the casting material, and the upsetting rate (rolling rate) at that time was obtained. This upsetting process was performed so that no slip occurred between the end face of each casting material and the jig pressing the end face.
[0086]
  Table 2 shows the limit upsetting ratio for each of the above casting materials. Further, FIG. 29 shows the relationship between the elongation of each casting material before the upsetting and the limit upsetting rate. As a result,Alloy examples A to FIt can be seen that the limit upsetting rate of the cast material is considerably larger than that of the comparative example and the plastic workability is good. Further, it is understood that the limit upsetting rate is related to the elongation of each casting material before the upsetting process, and the larger the elongation is, the larger the upsetting rate is.
[0087]
[Table 2]

[0088]
  Then, abovealloyFor each of the casting materials of Examples A to D and F, the relationship between the rolling reduction and the hardness was examined. The result is shown in FIG. From this, the hardness rises greatly with respect to the increase of the rolling reduction in the range where the rolling reduction is less than about 20%, but hardly increases in the range of 20% or more and becomes substantially constant. Therefore, it can be seen that if the reduction ratio (plastic working rate) is 20% or more, the hardness is improved and stabilized as compared with that before the processing.
[0089]
  Furthermore, FIG.alloyFIG. 32 shows the result of examining the change in tensile strength and 0.2% proof stress with respect to the rolling reduction for Example B.alloyThe result of having investigated the change of the elongation with respect to the rolling reduction about example B is shown. Thus, if the rolling reduction is 20% or more, the tensile strength and the proof stress can be stably improved as in the case of the hardness. On the other hand, the elongation decreases as the rolling reduction increases, but it can be seen that if the rolling reduction is 20% or more, it is stable at about 5%. If the elongation is about 5%, a value higher than the conventional one (usually about 1%) is maintained.
[0090]
  So bookInventionBy casting the cast material with an aluminum alloy, while ensuring the strength and elongation of the entire cast material, plastic processing is performed so that the plastic processing rate is 20% or more only for parts that require strength, hardness, etc. By performing the above, it is possible to partially strengthen the part.
[0091]
【The invention's effect】
  As explained above, in the invention of claim 1, 0.5 to 2.5 wt% of Mn component,0.4~ 1.5 wt% Fe component and 0.01 ~0.5Casting element for plastic working made of high ductility aluminum alloy cast by high ductility aluminum alloy consisting of aluminum containing weight percent Mg component and the balance containing inevitable impuritiesMaterialAfter casting, for the as-cast material, the plastic working rate after plastic working of the part that changes the mechanical properties will be 20% or moreAlwaysPlastic working was performed under temperature. Therefore,thisAccording to the invention, while maintaining the strength of the aluminum alloy, both castability and elongation can be improved at the same time, and the cast material cast with this alloy remains as cast.AlwaysThe plastic working can be performed at a low temperature, and the mechanical properties of the plastic working portion can be stabilized.
[0092]
  Claim2According to the invention, the content of the Mn component is 1.0 to 2.0% by weight, the content of the Fe component is 0.4 to 1.5% by weight, and the content of the Mg component is 0.01 to 0%. .5% by weight, while maintaining the strength of the casting material,1Elongation can be improved as compared with the invention.
[0093]
  Claim3According to the invention, the content of the Mn component is 1.2 to 1.6% by weight, the content of the Fe component is 0.4 to 0.7% by weight, and the content of the Mg component is 0.01 to 0%. .5% by weight, while maintaining the strength of the casting material,2The elongation can be further improved as compared with the present invention.
[0094]
  Claim4According to the inventionHigh ductility aluminum alloyBy adding at least one of 0.1 to 0.2 wt% Ti component, 0.01 to 0.1 wt% B component and 0.01 to 0.2 wt% Be component, It is possible to further improve the elongation of the casting material.
[Brief description of the drawings]
FIG. 1 of the present inventionreferenceIt is a perspective view which shows the back side principal part of the instrument panel for motor vehicles manufactured by the plastic working method using the casting material for plastic working made from a highly ductile aluminum alloy which concerns on form 1. FIG.
FIG. 2 is a perspective view showing a front side of an instrument panel.
FIG. 3 is an enlarged perspective view showing the vicinity of a fixed part in a casting material.
4 is a view taken in the direction of the arrow IV in FIG. 3;
FIG. 5 is a cross-sectional view showing a die casting machine.
6 is a cross-sectional perspective view corresponding to the line VI-VI in FIG. 1 showing a state in which the casting material is bent with a bending die.
FIG. 7 is a cross-sectional view showing a press mold.
FIG. 8 is a view corresponding to FIG. 7 and showing a state where the casting material is drawn and stretched.
FIG. 91It is sectional drawing which shows the AT drum which concerns on.
FIG. 10 is a perspective view showing a casting material.
FIG. 11 is a partial plan view showing a tooth portion of a casting material.
FIG. 12 is an explanatory view schematically showing the upsetting process of the bottom of the casting material.
FIG. 13referenceForm2It is sectional drawing which shows the shift lever which concerns on.
FIG. 14 is an explanatory view showing ironing of a lower end portion of a casting material.
FIG. 15 is an embodiment.2It is sectional drawing which shows the pulley for belts which concerns on this.
FIG. 16 is a cross-sectional view showing a casting material.
FIG. 17 is a sectional view showing a pulley with gears.
FIG. 18 shows an embodiment.3It is a perspective view which shows the oil pan concerning.
FIG. 19 is a cross-sectional view showing a main part of a casting material.
FIG. 20 shows an embodiment.4It is sectional drawing which shows the road wheel which concerns on.
FIG. 21 Embodiment5It is a perspective view which shows the upper arm which concerns on.
22 is a cross-sectional view taken along line XXII-XXII in FIG.
FIG. 23 is an explanatory view schematically showing a case where a casting material undergoes tensile deformation.
FIG. 24 is a graph showing the relationship between alloy type and elongation.
FIG. 25 is a graph showing the relationship between alloy type and tensile strength.
FIG. 26 is a graph showing the relationship between alloy type and 0.2% yield strength.
FIG. 27 is a graph showing the relationship between the type of alloy of a cast test piece, the average total number of cracks, and the average total crack length.
FIG. 28 is a perspective view showing a cast test piece.
FIG. 29 is a graph showing the relationship between the elongation of the cast material before upsetting and the limit upsetting rate.
FIG. 30 is a graph showing the relationship between the reduction ratio and hardness of a casting material.
FIG. 31alloyIt is a graph which shows the relationship between the rolling reduction in the casting raw material of Example B, tensile strength, and 0.2% yield strength.
FIG. 32alloyIt is a graph which shows the relationship between the rolling reduction and elongation in the casting raw material of Example B.
FIG. 33 is a graph showing the relationship between the content of Mn component and tensile strength in an aluminum alloy.
FIG. 34 is a graph showing the relationship between the content of Mn component and elongation in an aluminum alloy.
FIG. 35 is a graph showing the relationship between the content of Fe component and elongation in an aluminum alloy.
FIG. 36 is a graph showing the relationship between the content of Mg component and tensile strength in an aluminum alloy.
FIG. 37 is a graph showing the relationship between the content of Mg component and elongation in an aluminum alloy.
FIG. 38 is a graph showing the relationship between the contents of Mg and Fe components in an aluminum alloy and the rate of occurrence of casting cracks in a casting material cast with that alloy.
[Explanation of symbols]
  4 'base end (site that changes mechanical properties)
  5, 11, 18, 28, 55 High ductility aluminum alloy casting material for plastic working
  8 'bottom (the part that changes the mechanical properties)
  10 'tooth (part that changes mechanical properties)
  16 'Lower end (the part that changes the mechanical properties)
  25 'Peripheral part (part that changes the mechanical properties)
  27 'Rib (parts that change the mechanical properties)
  52 'Protrusion (site that changes mechanical properties)

Claims (4)

From aluminum containing 0.5 to 2.5% by weight of Mn component, 0.4 to 1.5% by weight of Fe component and 0.01 to 0.5 % by weight of Mg component with the balance containing inevitable impurities After casting a high ductility aluminum alloy casting material for plastic working with a high ductility aluminum alloy ,
A high ductility aluminum alloy characterized by performing plastic working at room temperature so that a plastic working rate after plastic working of a portion where mechanical properties are changed is 20% or more with respect to the cast material as-cast. A plastic working method using a casting material for plastic working. In the plastic working method using the casting material for plastic working made of high ductility aluminum alloy according to claim 1,
A plastic working method using a cast material for plastic working made of a high ductility aluminum alloy , wherein the content of the Mn component is 1.0 to 2.0% by weight . In the plastic working method using the casting material for plastic working made of high ductility aluminum alloy according to claim 2,
The content of Mn component Ri 1.2-1.6 wt% der, the content of Fe component casting high-ductility aluminum alloy plastic working, which is a 0.4 to 0.7 wt% Plastic working method using raw materials. In the plastic working method using the casting material for plastic working made of high ductility aluminum alloy according to any one of claims 1 to 3 ,
At least one of 0.1 to 0.2 wt% Ti component, 0.01 to 0.1 wt% B component and 0.01 to 0.2 wt% Be component is added to the high ductility aluminum alloy. A plastic working method using a cast material for plastic working made of high ductility aluminum alloy, characterized by adding

Images