JPH0663677A - Method and device for manufacturing aluminum parts - Google Patents

Abstract

PURPOSE:To provide a method and a device for manufacturing a parts having deformed and complicate shape, which saves the processes and has good yield and little forged defect and uses a device in a comparatively low cost. CONSTITUTION:An aluminum alloy bar blank is charged into a cavity 6 and the lower surface of the blank is stopped at the position abutted on the cavity surface. An upper punch 7 is lowered by using a cylinder 10 for driving the upper punch, and while shifting the blank downward, the blank is pressed with an upper die 5 to be bent. The lower surface of the blank is stopped at the position abutted on a lower punch surface, and by working a cylinder 11 for driving the lower punch, as well, the blank is pressurize-compressed and plastic- deformed with the upper punch and the lower punch. A preformed material having vol. allocation and shape being suitable to a finish product is manufactured, and successively, die forging is executed to manufacture the parts having deformed and complicate shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to a method for forging aluminum or aluminum alloy (hereinafter referred to as "aluminum") parts having irregular cross sections.

[0002]

2. Description of the Related Art Aluminum is not only lightweight, has high specific strength, excellent impact resistance, fatigue strength, corrosion resistance, etc., but is also easily machined compared to other metal materials. , Has been used in aircraft and ships for a long time, and recently is used in automobiles, electronic devices and precision instruments. For example, aluminum alloys have begun to be used as a material for upper arms and the like, which are suspension parts of automobiles, in consideration of light weight, strength, corrosion resistance and the like. Aluminum forging has many advantageous conditions such as less scale generation than iron-based metal forging and low forging temperature.For this reason, it is relatively applicable to members with more complicated shapes than steel die forging. Easy to say. By the way, as a generally used forging method, a melt-cast billet or a billet formed by free forging or extruding into a certain shape (for example, a round bar) is used as a material, and the die is forged. , Predetermined shape
It is known how to obtain sized forged products.

In the above description, for example, a case where a round bar material obtained by extrusion is used as a material will be described. First, the round bar is cut into a required length, and then the cut round bar is finally manufactured. Bending is performed in advance to a shape that roughly follows the overall shape of the suspension component (primary preliminary processing). Next, the pre-processed material is heated to a predetermined temperature and pre-forged. This process is called a buster and is used to form a rough shape of the final suspension member, such as an arm portion, which corresponds to a characteristically protruding portion. After this buster, the material is cooled and deburred, that is, trimmed (secondary pre-processing). After the above steps, the secondary pre-processed material is heated again, and further pre-forging is performed using a die closer to the final product than the pre-forging. This process is called a blocker.
After this blocker, the material is cooled and trimmed as in the case of the secondary pre-processing (third pre-processing). The stage where this third preliminary processing is completed is the completion of the so-called preforming step. Then, the material preformed as described above is heated again, finally put into a finishing die for forging (finisher process), and after the finisher, a final trim is performed to obtain a required forged component, that is, a suspension. Parts are completed.

However, in the case of the above forging method, the number of steps required for forging is inevitably increased.
If the product has a thick part, the cross-sectional shape and dimensions of the material must be selected accordingly, or the material weight must be adjusted to prevent flashing (burrs) to some extent in order to prevent the forging from running out of thickness. Since it is necessary to set more than the weight of the forged product in advance, waste of the material occurs, the yield of the material deteriorates, the productivity is poor such as the step of trimming and removing the flash, and the manufacturing cost is low. There is the problem of becoming expensive.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and it is possible to improve productivity and material yield by omitting the number of forging steps, and to reduce manufacturing cost. An object is to provide a method of manufacturing a component.

[0006]

The invention according to claim 1 is
“In an aluminum part and a preformed material, the part and the molded material are divided into a plurality of parts along the longitudinal direction so that the respective divided parts correspond to each other, and each divided part of the part and the corresponding molded material The material has a volume ratio of 1.2 to 1.5 with respect to each of the divided parts, and the material is preformed so that that of the molding material is similar to or similar to the shape of the central axis of the component, and then forged. Aluminum part manufacturing method characterized by obtaining an aluminum part "
Is. The number of divided parts in the longitudinal direction of the aluminum part, that is, the as-forged part or the preform, needs to be changed depending on the shape and size of the aluminum part, and is selected in the range of 3 to 6. One segment of the aluminum part has a close correspondence with one segment of the preform. That is, the ratio of the volume of each divided portion of the component to the corresponding volume of each divided portion of the preformed material is in the range of 1.2 to 1.4, preferably 1.25 to 1.30. is there. In addition, the preformed material or the corresponding preformed material is approximated or similar to the shape of the respective central axes obtained by continuously connecting the barycentric positions of the longitudinal cross sections of the parts or the respective divided parts in the longitudinal direction. Molded into the shape of the central axis of each of the divided parts.

According to a second aspect of the present invention, there is provided a "base, a frame assembled in a substantially gate shape on the base, and a punch driving cylinder provided on a horizontal member of the frame. An upper punch that is suspended and supported and plastically deforms the charged material by pressing or compression, and a universal joint portion provided at the tip of the upper punch and a lower portion of any vertical member of the frame. And a punch device that is supported by a punch driving cylinder and plastically deforms the charged material by pressure and compression, and a die device that is provided so as to be movable back and forth in the vertical direction and that includes a pressing means. It is a preforming device characterized by that.

According to a third aspect of the present invention, "the tip of the upper punch has a universal joint structure and / or the tip of the lower punch has a universal joint structure.
The described preforming device ”. The universal joint structure may be of any type as long as it can make fine movements in the front, rear, left and right in the cavity of the mold and can transmit the force without waste.

According to a fourth aspect of the present invention, "a material is charged into a penetrating cavity formed by an upper die and a lower die of a die apparatus using the preforging apparatus according to the second or third aspect. Of the preform, which is obtained by bending and shaping so as to approximate or resemble the shape of the center axis of an as-forged aluminum part, and then obtaining a formed material by plastically deforming it by applying strong pressure compression. Manufacturing method ”. The bend-formed material is strongly pressed and compressed by the upper punch and the lower punch, and is plastically deformed so as to fill the inside of the cavity.Therefore, unlike general forging, there is no fogging on the surface or near the surface. A major feature is that there are almost no forging defects. At least as far as the upper punch or the lower punch is loaded, the cavity needs to be formed so that the upper punch or the lower punch can move slightly to the left or to the right.

According to a fifth aspect of the present invention, "Using the preforming apparatus according to the second or third aspect, the material charged into the cavity formed by the upper die and the lower die of the die apparatus is loaded. ,
A method of manufacturing an aluminum part, characterized by bending a material that has been plastically deformed by being strongly pressed and compressed so as to approximate or resemble the shape of the central axis of the aluminum part, and then forging to obtain the aluminum part " Is. Bending of a plastic material that has been plastically deformed using a preforming apparatus is performed by a known method such as a die bending apparatus or a roll bender.

[0011]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an example of a lower arm which is one of suspension components according to the present invention. This suspension component is used as a part of a suspension mechanism of an automobile (not shown) and is made of aluminum. FIG. 2 shows an example of a suspension component as it is forged. Mounting portions 12a, 12b, 12c for mounting the suspension components at predetermined positions on the chassis of the automobile are formed on this. The suspension component in this case is used as a final suspension component by machining the mounting portion and further mounting a bush or the like. The above-mentioned suspension component is finally obtained by die forging a preform material molded by the method according to the present invention described below. Examples will be described.

FIG. 3 shows a preforming apparatus 1 used for carrying out the forming method according to the present invention. In the preforming apparatus 1, reference numeral 2 is a base, and 3 is a frame assembled on the base 2 in a substantially gate shape. A lower die 4 is installed in the center of the upper surface of the base 2. An upper die 5 is suspended from and supported by an upper die driving cylinder 9 on the upper side of the lower die 4 so as to be vertically movable. The upper die driving cylinder 9 is the first horizontal member 3 of the frame 3.
It is provided in a. The lower die 4 and the upper die 5 form a cavity 6 having a predetermined shape penetrating therethrough. The upper punch driving cylinder 10 is provided in this cavity.
The upper punch 7 having a universal joint structure is fitted and inserted at the tip end thereof which is driven in the vertical direction by. The upper punch driving cylinder 10 is provided on a second horizontal member 3b located above the first horizontal support member 3a.
Further, a lower punch 8 supported by a lower punch driving cylinder 11 provided at a lower portion of the frame 3 and driven leftward or rightward is fitted into a cavity and held at a predetermined position.

Next, a method of forming a preform for the suspension component by using the above preformer will be described. First, as shown in FIG. 3, the upper mold is driven downward by the mold driving cylinder to bring the upper mold and the lower mold into close contact with each other to define a cavity. Then, a rod-shaped material made of an aluminum alloy (for example, JIS-A6061) having a diameter of 63 mm and a length of 350 mm is charged into the cavity. The charged rod-shaped material remains at the position where the lower surface of the rod-shaped material contacts the cavity surface. From this state, the upper punch driving cylinder lowers the upper punch, the charged rod-shaped material is pushed in, and the upper die is driven by the upper die cylinder and pressed to move downward while bending. Then, the lower surface of the rod-shaped material remains at the position where it abuts the lower punch that is held in place. In this state, bending of the rod-shaped material is completed.

After that, the descending operation of the upper punch is continued until it reaches a predetermined position, and the lower punch driving cylinder is moved rightward (or leftward) by the lower punch driving cylinder until it reaches a predetermined position. Then, the bent rod-shaped material is compressed under pressure, and the bent material is plastically deformed so that the material fills the predetermined space of the cavity shown by the diagonal lines in FIG. Due to the above action, a preformed material is obtained as shown in FIG. After that, the preformed material is hot-forged by a known method using a predetermined forging die (not shown) and then finish-formed to obtain the suspension component shown in FIG. The suspension component as shown in FIG. 1 is completed by machining this suspension component after heat treatment.

As described above, according to the present invention, it is possible to obtain a preformed material having a volume distribution suitable for the suspension component shown in FIG. 2 and a shape of a central axis line which is extremely close to that with a low load. Also has a low load,
In addition, it can be formed by one heat and one blow process, and can be achieved without defects such as cracks, scratches, flesh and sinks, which are peculiar to hot forging, which are likely to occur on the surface or inside. Therefore, molding can be performed with a small molding device, and the work is efficient.

Table 1 shows a comparison of the necessary steps and the conditions corresponding to each step when the above-mentioned conventional method and the method according to the present invention described above are used to form the suspension component from a round bar-shaped material. Show. As shown in Table 1,
According to the method of the present invention, one time of preforming and one time of heating are repeated, whereas the conventional method requires one preforming and two heating and repeating steps of molding and trimming steps. It can be obtained by molding only once. Moreover, in the conventional method,
2,600t and 2,40 respectively in two moldings
While a large load of 0t is required, in the method according to the present invention, the preforming load is 280t, and the subsequent molding load is as low as 1,600t.

As can be seen from the top of Table 1, the amount of material required is much less with the method of the present invention, with a material yield of about 58% with the conventional method. That is extremely high, about 71%. Further, in the case of the conventional method, since the number of steps is large, it is inevitable that a forging defect such as a lack of wall or a crack easily occurs,
The number of man-hours for inspection and rework increases.

[0018]

[Table 1]

[0019]

As described above, the preformed material according to the present invention is suitable for the volume distribution of the as-forged as-prepared parts.
Since the volume distribution is such that proper material is not likely to be wasted and the shape of the central axis of the component is extremely close to it, even if only one heat is applied in the subsequent forging, the surface or inner surface such as lacking or cracking will not be affected. It is possible to obtain a good forged product with a relatively low load without causing the forging-specific defects that occur. As described above, according to the present invention, compared with the conventional method, it is possible to manufacture a forged product having a deformed and complicated shape in which the steps can be omitted, the yield is good, and the forging defects are few.

[Brief description of drawings]

FIG. 1 shows an example of the shape of an automobile suspension component.

FIG. 2 shows an example of the shape of an automobile suspension component as it is forged.

FIG. 3 is a partially sectional elevational view showing an example of a preforming apparatus used to complete the present invention.

FIG. 4 shows an example of the shape of a preformed material.

[Explanation of symbols]

 1 Preforming Device 2 Base 3 Frame 3a First Horizontal Member of Frame 3b Second Horizontal Member of Frame 4 Lower Die 5 Upper Die 6 Cavity 7 Upper Punch 8 Lower Punch 9 Upper Die Driving Cylinder 10 Upper Punch Drive cylinder 11 Lower punch drive cylinder 12a Suspension component mounting part 12a Suspension component mounting part 12c Suspension component mounting part

Claims (5)

[Claims] 1. In an aluminum part and a preformed material, the part and the shaped material are divided into a plurality of parts along the longitudinal direction so that each divided part corresponds to each divided part of the part and the corresponding part. The volume ratio to each divided portion of the molding material is 1.2 to 1.5, and the material is preformed so that that of the molding material approximates or is similar to the shape of the central axis of the component, Then, forging is performed to obtain an aluminum part, which is a method for manufacturing an aluminum part. 2. A base, a frame assembled in a substantially gate shape on the base, a punch driving cylinder provided on a horizontal member of the frame, and suspended and supported. The punched material is plastically deformed by pressure and compression, and the punch driving cylinder provided at the bottom of either vertical member of the frame is supported, and the charged material is plastically deformed by pressure and compression. A preforming apparatus comprising substantially a lower punch and a mold apparatus provided with a pressing means and provided so as to be movable back and forth in the vertical direction. 3. The preforming apparatus according to claim 2, wherein the tip of the upper punch has a universal joint structure and / or the tip of the lower punch has a universal joint structure. 4. Using the preforming apparatus according to claim 2 or 3, the material charged into a cavity formed by an upper die and a lower die of a die device is shaped into a shape of a central axis line of an aluminum part. After bending to approximate or resemble
A method for producing a preformed material, which comprises compressing strongly and plastically deforming to obtain a molded material. 5. Using the preforming apparatus according to claim 2 or 3, the material charged into the cavity formed by the upper die and the lower die of the die apparatus is strongly pressed and compressed. A method for manufacturing an aluminum part, which comprises forming a plastically deformed forming material, bending the same so as to approximate or resemble the shape of the central axis of the aluminum part, and then forging to obtain the aluminum part.