JPH11179523A - Production of round-shaped member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a producing method for a round-shaped member, with which an insert product can be produced without stripping off an aluminum alloy from an annular insert material at the time of cooling after inserting the ferro annular material to be inserted with the aluminum alloy. SOLUTION: This producing method of the cylindrical member is executed, by which at the time of inserting the aluminized annular material 1 to be inserted with the aluminum alloy in a mold, the molten aluminum alloy is made to flow not only to the insert peripheral surface 1b side of annular material 1 to be inserted, but also to the outer peripheral surface 1a side, and the alloy portions 3A and 3B, 3C are integrally and the inner peripheral surface 1b and the inner peripheral surface 1b and the outer peripheral surface 1a of the annular material are integrally inserted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a circular member, and more particularly, to a method of manufacturing a circular member in which an annular cast insert made of iron-based metal and an aluminum alloy are integrated.

[0002]

2. Description of the Related Art Conventionally, when constructing various parts and members, a plurality of materials are combined and integrated, and the characteristics of each material are brought out to exhibit composite excellent characteristics that cannot be obtained with a single material. Was to be done. For example, an annular cast towel made of an iron-based metal has been cast with an aluminum alloy, and casting to integrate the annular cast towel with the aluminum alloy has been performed.

[0003] A conventional method for producing a circular member by means of cast-in is a so-called alumina in which a ring-shaped cast-to-be-stuffed material is immersed in molten aluminum or aluminum alloy to cause a diffusion reaction between the surface of the cast-to-be-stuffed material and aluminum. An ising process is performed to hold the annular cast towel in the mold, and the molten aluminum alloy is filled into the mold to fuse and bond the aluminum alloy and the annular towel.

[0004]

In this case, an annular cast stuffed material is formed by using an iron-based annular cast stuffed material as the outer peripheral surface of a circular member, and filling the inner peripheral surface of the annular cast stuffed material with an aluminum alloy. When the circular member is manufactured by integrating the inner peripheral surface of the aluminum alloy with the aluminum alloy, the heat shrinkage of the aluminum alloy is higher than that of the iron-based metal. A phenomenon in which the aluminum alloy tends to separate from the inner peripheral surface of the material occurs, and as a result, the aluminum alloy may peel off from the annular cast-in-place material.

In the case of manufacturing a pulley as a circular member, the ring-shaped cast material is made of an iron-based material to form a belt hook portion. It is preferable to integrate with the aluminum alloy, but in addition to the problem of separation due to the difference in heat shrinkage as described above, the ring-shaped to-be-stuffed member becomes hot due to frictional heat generated by sliding with the belt in the belt hooking portion. There was a problem.

Accordingly, the present invention provides a method for manufacturing a circular member formed by integrally forming an annular cast material made of an iron-based metal and an aluminum alloy, wherein the aluminum alloy does not peel off from the annular cast material. It is another object of the present invention to provide a method for manufacturing a circular member in which generated heat is efficiently dissipated when the circular member is a pulley.

[0007]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention relates to a method of immersing an annular cast stuffed material 1 made of an iron-based metal into molten aluminum or an aluminum alloy, By taking out, the surface of the ring-shaped cast material 1 is subjected to aluminizing treatment, the aluminized ring-shaped cast material 1 is held in a mold, and the molten aluminum alloy 3 is filled in the mold. Then, the annular cast object 1 is cast into the aluminum alloy 3 and the annular cast object 1 and the aluminum alloy 3 are joined to each other to form an integrated circular member. When the aluminum alloy 3 is filled in the mold, the inner peripheral surface 1b and the outer peripheral surface 1a of the annular cast-in-place material 1 are encapsulated with the aluminum alloy 3. Inner peripheral surface 1b side of the aluminum alloy 3B and outer peripheral surface 1a of the aluminum alloy 3C, 3C '
Provide a method for manufacturing a circular member formed integrally with 3A and 3D.

Here, the circular member is a pulley, and a communication hole 1c communicating between the inner peripheral surface 1b side and the outer peripheral surface 1a side is formed in the annular cast-in-place material 1, and the aluminum alloy When the mold 3 is filled in the mold, the aluminum alloy 3B on the inner peripheral surface 1b side and the aluminum alloy 3C 'on the outer peripheral surface 1a side are integrally formed through the communication hole, and the annular cast-in-place material is formed. 1 of the outer peripheral surface 1a side of the outer peripheral surface 1a
It is preferable that at least a portion of the pulley is exposed to form a belt hooking portion of the pulley.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a circular member according to a first embodiment of the present invention will be described with reference to FIG. The circular member 10 has a center hole 10a formed therein, and an annular groove 10b formed in the outer peripheral surface. And the circular member 10
Is composed of a composite material in which an annular cast-insulated material 1 of an iron-based metal and an aluminum alloy 3 are combined.

The annular cast-in-place material 1 has a substantially Y-shaped cross section, and when viewed in cross section, the groove side (inside) of the V portion of the Y-shaped head.
Becomes the outer peripheral surface 1a of the annular to-be-stuffed material 1, and the V portion outer surface and the I portion of the foot become the inner peripheral surface 1b. Further, a communication hole 1 communicating the outer peripheral surface 1a side and the inner peripheral surface 1b side with a V portion of the head.
c is formed.

The annular cast-in-place material 1 is previously subjected to an aluminizing treatment before being held in a mold (not shown). This aluminizing treatment is performed by immersing the ring-shaped to-be-stuffed material 1 held by a holder (not shown) for 120 seconds in an alloy of aluminum and silicon (aluminum alloy) held at 740 ° C. Thereafter, the annular cast material 1 is removed from the molten aluminum alloy. By performing this aluminizing process,
Since a diffusion layer of iron and aluminum is formed on the surface of the annular cast-in-mold material, which is an iron-based metal, the annular cast-in-mold material 1 is cast with an aluminum alloy later as compared with the case without aluminizing treatment. When the annular cast-stuffed material 1
And the aluminum alloy can increase the bonding force.

The annular cast material 1 subjected to the aluminizing treatment is set in a mold (not shown), and an aluminum alloy 3 such as JIS-AC4C is filled in the mold by gravity casting. Inner peripheral surface 1b of annular cast material 1
Most of the molten aluminum alloy is supplied to the inner surface 1b and is integrated with the inner peripheral surface 1b, and along the outer inclined surface of the V portion of the annular to-be-stuffed material 1 and through the communication hole 1c, the outer peripheral surface 1a side The molten aluminum spreads all over. That is, the inner peripheral surface 1b and the outer peripheral surface 1a of the annular cast-in-place material 1 are encapsulated with an aluminum alloy, and the aluminum alloy on the inner peripheral surface 1b side and the aluminum alloy 3 on the outer peripheral surface 1b side are integrally formed. The to-be-filled material 1 and the aluminum alloy 3 are fused and bonded, and a circular member as a to-be-filled product is cast.

[0013] When the cast as-cast product is subsequently cooled, the aluminum alloy 3 generates a force to shrink inward in the radial direction of the circular member due to the heat shrinkage of the aluminum alloy 3. However, since the aluminum alloy 3A is integrated on the inner peripheral surface side and the outer peripheral surface side of the annular cast-molded material 1, the aluminum alloy 3A faces the maximum radius portion 1a 'on the outer peripheral surface 1a of the annular cast-molded material 1. Aluminum alloy 3A
The presence of the portion prevents the aluminum alloy 3 from shrinking inward in the radial direction, and prevents the aluminum alloy 3 from peeling off from the annular cast insert 1.

The aluminum alloy portion 3 which is the inner peripheral surface 1b of the annular cast-in-place material 1 and faces the V-part inclined surface
B is the structure that is most easily separated from the V portion of the inner peripheral surface 1b due to the generated contraction force.
Aluminum alloy is also foreskin on the outer peripheral surface 1a side,
In particular, the aluminum alloy portion 3C facing the V portion inclined surface of the outer peripheral surface 1a is the aluminum alloy portion 3 in the communication hole 1c.
Since the alloy portion 3B is integrated with the alloy portion 3B by D, shrinkage of the alloy portion 3B in the radial direction can be prevented by the alloy portions 3C and 3D.

As described above, according to the method for manufacturing a circular member according to the first embodiment, the aluminum alloy 3 does not peel off from the annular cast-in-mold material 1 during cooling of the product after the cast-in process. This eliminates the need for strict product inspections, recovery of defective cast-in products that have been peeled off, and the regeneration of materials used in casting of defective cast-in products, which is necessary in the past, and the consumption of power fuel for casting of cast-in products. Can also be significantly reduced. Further, the labor due to the reduction in the number of processes can be greatly reduced. Thus, it becomes possible to manufacture a circular member by using an inexpensive insert as a whole.

Next, a method of manufacturing a circular member 10 'according to a second embodiment of the present invention will be described with reference to FIG.
The second embodiment is applied when a circular member is used as a pulley.

The aluminizing process of the annular to-be-stuffed material 1 and the as-casting process of the annular to-be-stuffed material 1 are the same as in the first embodiment. It differs from the first embodiment in that a cutting process is performed.

The as-cast product cast according to the first embodiment is subjected to a heat treatment for the purpose of removing the residual stress of the aluminum alloy. This heat treatment is performed by heating the cast product at 180 ° C. for 5 hours.
After the heat treatment, the outermost peripheral portion of the annular cast-molded material 1 and the aluminum alloy located on the outer side thereof are removed, and the V-shaped groove of the aluminum alloy located on the outer peripheral surface 1a side of the annular cast-molded material 1 is removed. An aluminum alloy portion near the tip is removed by cutting to expose at least a part of the outer peripheral surface of the annular cast-in-place material 1 to form an exposed portion 1d.
This exposed portion 1d forms a belt hooking portion of the pulley.
In this cutting, the aluminum alloy portion 3C 'at the bottom of the V-shaped groove remains without being removed, and is still integrated with the aluminum alloy portion 3B via the aluminum alloy portion 3D.

In the second embodiment, since the aluminum alloy portion near the tip of the V-shaped groove is removed in the cutting step, the aluminum alloy portion 3A at the forefront is present as in the first embodiment. Therefore, the tendency of the aluminum alloy portion 3B located on the inner peripheral surface 1b side of the annular to-be-stuffed material 1 to be peeled off due to shrinking inward in the radial direction is greater than that in the first embodiment. Therefore, a heat treatment is performed to remove the residual stress of the aluminum alloy so as to prevent peeling as much as possible. As described above, the presence of the aluminum alloy portion 3C ′ on the outer peripheral surface 1a side can prevent the alloy portion 3B from peeling off from the inner peripheral surface 1b.

According to the second embodiment, when the manufactured circular member is used as a pulley, a belt (not shown) is hung on the exposed portion 1d. A strong force is applied to the belt hanging portion 1d for power transmission, and the temperature rise due to friction with the belt during the rotation operation is remarkable. Here, the belt hanging portion is the exposed portion 1d, and since the exposed portion 1d is made of an iron-based metal that can withstand severe conditions, a durable and heat-resistant pulley can be provided.

Further, since the pulley is a composite of iron and an aluminum alloy, it is much lighter than the case where the whole is made of iron, and in addition, unnecessary aluminum alloy portions are removed by cutting. Therefore, it is possible to further reduce the weight of the pulley as a whole, and to obtain high power transmission efficiency.

Further, the annular cast material 1 is exposed only at the portion in contact with the belt, and the aluminum alloy portion 3C 'is still casting the annular cast material 1 on the other outer peripheral surface side. Since the portion 3C 'is integrated with the aluminum alloy portion 3B on the inner peripheral surface 1b side via the aluminum alloy portion 3D in the communication hole 1c, in addition to the above-described effect of preventing the peeling, the friction with the belt is caused. The generated heat can be efficiently conducted to the aluminum alloy portion 3B on the inner peripheral surface 1b side to promote heat radiation. Aluminum alloys have better thermal conductivity than ferrous metals, so the temperature rise of the pulley as a whole can be suppressed efficiently, and the surrounding parts do not become hot, and as a result, products of the entire equipment including the pulley The service life can be improved.

FIG. 3 is a metallographic micrograph of a circular member manufactured according to the second embodiment, at a magnification of 200 times, showing the vicinity of the interface between the annular cast insert 1 and the aluminum alloy 3. FIG. 4 is a metallographic micrograph (magnification: 200) showing the vicinity of the interface between an annular cast-stuffed material and an aluminum alloy of a circular member manufactured based on a conventional method for manufacturing a circular member.

As shown in FIG. 4, a striped diffusion-bonded reaction layer 1X is formed in the vicinity of the interface with the aluminum alloy portion 3B of the annular cast-insulating material 1 made of an iron-based metal by aluminizing. The bonding between the aluminum alloy and the iron-based metal is achieved by the reaction layer 1X, but since the shrinkage of the aluminum alloy is not prevented at all in the conventional method, the aluminum alloy portion 3B peels off from the reaction layer 1X after the bonding, It is recognized that a gap G (black portion) has occurred. On the other hand, as shown in FIG. 3, according to the second embodiment, no gap is found between the reaction layer 1X and the aluminum alloy portion 3B, and it has been found that the problem caused by the shrinkage of the aluminum alloy has been solved. did. In addition,
3 and 4, the black linear portions in the aluminum alloy 3B are crystallized substances and precipitates in the alloy.

The method for forming a circular member according to the present invention is not limited to the above-described embodiment, and various modifications and improvements can be made within the scope described in the claims. For example, the cross-sectional shape of the annular to-be-stuffed material is not limited to the substantially Y-shape described in the embodiment, but may be a substantially V-shape, a substantially rectangular shape, or another shape.

[0026]

According to the method for manufacturing a circular member according to the first aspect, the outer peripheral surface and the inner peripheral surface of the annular to-be-stuffed material are integrally cast with an aluminum alloy. It is possible to avoid peeling of the aluminum alloy from the annular cast-insulating material, which is caused when the cast-receiving material is cooled after being cast in the mold. As a result, it is possible to reduce the labor required for the process of detecting and recovering a defective cast-in product, and to manufacture a low-cost circular member in total.

According to the method for manufacturing a circular member according to the second aspect, only the aluminum alloy covering the part of the pulley, which is the circular member, which is in contact with the belt, is removed, and the circular cast insert made of an iron-based metal is removed. By exposing a part of the material to be in contact with the belt, a pulley having strength and heat resistance can be obtained, and the weight of the circular member can be reduced. Furthermore, the power transmission efficiency at the time of rotation can be made extremely high with the weight reduction of the circular member.
Also, the aluminum alloy portion remaining on the outer peripheral surface side of the annular cast-in-place material is integrated with the aluminum alloy portion located on the inner peripheral surface side of the annular cast-in-place material, so that the belt on the outer peripheral surface of the annular cast-in-place insert material The heat generated in the portion in contact with the aluminum alloy is transmitted to the inner peripheral surface through the residual aluminum alloy portion, and the heat can be efficiently released in combination with the good thermal conductivity of aluminum itself. Further, since the temperature rise around the circular member can be prevented by this, the product life of the whole device incorporating the circular member can be extended.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a circular member obtained by a method for manufacturing a circular member according to a first embodiment of the present invention.

FIG. 2 is a sectional view showing a circular member obtained by a method of manufacturing a circular member according to a second embodiment of the present invention.

FIG. 3 is a metallographic micrograph showing the vicinity of an interface between an annular cast-stuffed material and an aluminum alloy of a circular member manufactured according to a method for manufacturing a circular member according to a second embodiment of the present invention.

FIG. 4 is a metallographic micrograph showing the vicinity of an interface between an annular cast-stuffed material and an aluminum alloy of a circular member manufactured according to a conventional method for manufacturing a circular member.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Annular cast-stuffed material 1a Outer peripheral surface 1b Inner peripheral surface 1c Communication hole 3 Aluminum alloy

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Norihito Iwata 3-25-1 Tonomachi, Kawasaki-ku, Kawasaki-shi, Kanagawa Prefecture Isuzu Motors, Inc. Kawasaki Plant (72) Inventor Suguru Liu Eighth shelf, Fujisawa-shi, Kanagawa Prefecture Isuzu Motors Co., Ltd. Fujisawa Plant (72) Inventor Nobuaki Shinya 3-25-1 Tonomachi, Kawasaki-ku, Kawasaki City, Kanagawa Prefecture Isuzu Motors Co., Ltd. Kawasaki Plant (72) Inventor Masami Ueno 3 Tonomachi, Kawasaki-ku, Kawasaki City, Kanagawa Prefecture -25-1 Isuzu Motors Corporation Kawasaki Plant (72) Inventor Makoto Nitta 3-15-1 Sotokanda, Chiyoda-ku, Tokyo Ryobi Corporation Tokyo Head Office (72) Inventor Naomi Nishi Outside Chiyoda-ku, Tokyo 3-15-1 Kanda Ryobi Co., Ltd. Tokyo Head Office

Claims (2)

[Claims] An aluminizing treatment is performed on a surface of the ring-shaped stuffed material made of an iron-based metal by immersing the ring-shaped stuffed material in molten aluminum or an aluminum alloy and then taking out the molten aluminum or aluminum alloy, Holding the aluminizing-treated annular cast material in a mold, filling the mold with an aluminum alloy melt, and casting the annular cast material into the aluminum alloy to form the annular cast material. In a method for manufacturing a circular member, in which a wrapped material and the aluminum alloy are joined to each other to form an integrated circular member, the inner periphery of the annular stuffed material is filled when the aluminum alloy is filled in the mold. The surface and the outer peripheral surface are covered with the aluminum alloy, and the aluminum alloy on the inner peripheral surface side and the aluminum alloy on the outer peripheral surface side are integrally formed. A method for producing a circular member, characterized in that: 2. The circular member is a pulley, and a communication hole communicating between the inner peripheral surface side and the outer peripheral surface side is formed in the annular to-be-cast material, and the aluminum alloy is inserted into the mold. The aluminum alloy on the inner peripheral surface side and the aluminum alloy on the outer peripheral surface side are integrally formed through the communication hole when filling the aluminum alloy. A method of manufacturing a circular member, wherein a portion is cut off to expose at least a part of an outer peripheral surface of the annular to-be-stuffed material to form a belt hooking portion of the pulley.