KR100981742B1 - A complex forming apparatus and method for aluminium wheel manufacturing - Google Patents

Abstract

PURPOSE: An apparatus and a method for manufacturing an aluminum wheel using a combined process of thixoforging and flow forming are provided to enable recycling of aluminum and improve the tensile strength and elongation ratio of products. CONSTITUTION: A method for manufacturing an aluminum wheel comprises the steps of: injecting molten metal into a cavity formed by upper, lower, and side molds to form a semi-product of an aluminum wheel(400), attaching the aluminum wheel semi-product to a flow forming chuck and allowing it to rotate, pressing the exterior surface of a rim part(404) of the fixed aluminum wheel to be extended in the radial direction, pushing a hub part(406) inward with a flow forming roller(304), and forming a center hole(402) in the center of the aluminum wheel.

Description

Apparatus and method for manufacturing aluminum wheels using complex process of reaction high forging and flow molding {A COMPLEX FORMING APPARATUS AND METHOD FOR ALUMINIUM WHEEL MANUFACTURING}

The present invention relates to an apparatus and method for manufacturing an aluminum wheel using a combined process of reaction high forging and flow molding, and more particularly, a reaction high forging process for forming a preform using a whole body aluminum alloy material, and flow forming. The present invention relates to an apparatus and method for manufacturing an aluminum wheel using a combined process of reaction solid forging and flow forming, which is performed by a flow forming process through forming.

The casting process for manufacturing an aluminum wheel is a method of melting an aluminum material and pouring it into a mold to produce a shape close to the final product. The casting process is performed by plastic working after casting or cutting into a predetermined dimension.

Aluminum castings can be broadly classified into castings that fill the molten metal using a mold to form a shape, and die casting that pressurizes a closed mold.In the case of die casting, the flow of the molten metal flows rapidly when the molten metal is injected into the mold. A small amount of Fe component is added to improve the properties because the Fe component is a harmful impurity element in the casting but an effective element in die casting.

For this reason, parts of structural materials that require safety and reliability, including aluminum disk wheels or wheel hubs, are difficult to manufacture with the above method, so that low pressure casting, differential pressure casting, vacuum suction casting, high pressure casting (die casting), molten metal Squeeze casting method is applied, and various pressurization methods and molten metal filling methods are adopted to secure the soundness of castings, and among these methods, most of the aluminum disk wheel companies have low pressure as shown in FIG. The casting method is adopted.

However, the low pressure casting method is suitable for mass production of aluminum wheels and the manufacture of small parts, and has excellent mass production, but is weak in securing reliability due to the limitation of strength and toughness. There are disadvantages.

As a result, some companies use a melt casting method or a vacuum pressure casting method to realize a 15% lighter weight than a low pressure casting method, but the quality thereof is lower than that of the forging method.

Therefore, the manufacturing method of the aluminum wheel is a trend that has been converted to a forging method having a relatively high quality but relatively high quality, and an aluminum disc wheel is manufactured using the hot forging method.

The hot forging is a plastic working method for producing a roughly shaped material by pressing a billet with a large press. The metal tissue is stretched by pressing, and the small micropores in the inside are pressed to minimize defects, thereby reducing strength and toughness. There is an advantage that can be increased.

The hot forging method is largely divided into free forging and die forging. Mold forging is a process of forming a desired shape by applying a compressive stress by inserting a material into a mold. As the product is formed through various steps in a repetitive process that cannot be manufactured, there is a disadvantage that the manufacturing cost increases, the size of the facility and the initial investment must be increased, and the size of the facility and the recycling of the use billet are difficult, and It is very high, there is a problem that shows the limits of mass production and cost competitiveness of automotive parts.

The method developed to compensate for the shortcomings of the hot forging is the rotation forging method, this rotation forging process is divided into two step (Step) process for the final shape.

That is, the first pre-forming step of the two-step process is a stress-intensive rotary forging step utilizing a relatively small pressing force, and has a basic shape, and thereafter, flow forming a detailed part as a second step. The spinning process is performed.

However, this rotation forging and spinning method also has a limit in the reduction of the material cost, which accounts for more than 70% of the cost of the parts because it is impossible to recycle the material.

In view of this, a reaction solid forging method has been proposed that makes good use of the advantages of casting and forging. After the material is melted and put into the mold, solidification and pressurization are carried out by an appropriate mechanism, thereby forming a complex shape in a solid liquid coexistence state. It is a method of forming and producing products at once.

The reaction solidification forging method has high material adhesion rate due to pressurization, high solidification rate, fast production speed, and can fundamentally solve shrinkage defects occurring during material solidification, allowing mass production of large products, and also directly applying high pressure directly to the material. By adding, it is possible to control the spheroidization of the tissue, and there is an advantage that the product weight can be realized by increasing the strength.

However, there is a disadvantage in securing mass productivity of the whole body material in terms of proper temperature and pressure control in the solid-liquid coexistence section, and it is difficult to see further progress in weight reduction due to the limitation of cast material properties.

The present invention has been made in view of the above, it is possible to manufacture the product using the aluminum alloy material for the whole body material, due to the high strength, high toughness, stagnant lightweight development and mass production system of various structural material parts is possible. In addition, after preforming the reaction and forging by using the aluminum alloy material for the whole material to enable the recycling of the material, the reaction product forging and flow forming of the reaction high for forming the final product by flow forming through the flow forming (Flow Forming) An object of the present invention is to provide an apparatus and method for manufacturing an aluminum wheel using a composite process.

One embodiment of the present invention for achieving the above object is: the upper mold and the take-out punch mounted to the upper plate, the lower mold disposed directly below the upper mold, the side is connected back and forth to the side of the lower mold Comprising a mold and a side holder whose lower end is fastened to a lower plate while supporting the outer peripheral surface of the side mold, forms a predetermined cavity for forming a preform of an aluminum wheel, and is filled with aluminum 6000-based whole body material filled in the cavity A preform part for reacting and forging the molten metal of the raw material; A center hole processing unit for processing a center hole in the center of the aluminum wheel preformed in the preform part using aluminum 6000 system material; A pair of flow forming chucks that hold the front and rear surfaces of the centered aluminum wheels and rotatably fix them, a flow forming plate integrally fixed to one end of one flow forming chuck, and the rim of the aluminum wheels are pressed against the surface of the flow forming plate. A first flow forming part having a predetermined thickness while pressurizing the hub portion of the aluminum wheel toward the center hole, and a flow forming part including a plurality of flow forming rolls for performing secondary flow molding to a predetermined thickness; It provides an aluminum wheel manufacturing apparatus using a composite process of reaction high forging and flow molding, characterized in that configured to include.

According to a preferred embodiment of the present invention, the hub hole processing unit for processing the hub hole in the center of the hub of the aluminum wheel molded in the flow-forming portion; The lathe processing unit for processing the inner and outer surfaces of the aluminum wheel, the hub hole processing is completed, the bolt hole and the vent hole in the hub; It characterized in that it further comprises.

Another embodiment of the present invention for achieving the above object is: a preform for an aluminum wheel by injecting a molten aluminum 6000 system material material into the cavity formed by the upper mold, the lower mold, and the side mold A reaction solid forging step of forming; After the aluminum wheel, a preform manufactured by reaction forging, was rotatably fixed to one side of the flow molding chuck and the other side of the flow molding chuck having the flow molding plate, the outer surface of the fixed rim of the aluminum wheel was fixed to the flow molding roller. A primary flow forming step of being pressed onto the flow-forming plate and being pressed radially in the rotational direction, the thickness of the rim being reduced to a predetermined thickness and the width of the rim being increased to a predetermined width; A step of thinning the thickness of the hub portion of the aluminum wheel, which is a preform, to a predetermined thickness, the second flow molding step of pressing the hub portion of the aluminum wheel from the outside to the inside with the flow-forming roller; It provides an aluminum wheel manufacturing method using a composite process of reaction high forging and flow molding, characterized in that consisting of.

In another preferred embodiment of the present invention, before the first flow molding step, further processing the center hole in the center of the aluminum wheel, which is a preform, so that the hub portion of the preform in the second flow molding step from the outside to the inside When pressed, the pressed material is characterized in that the flow in the direction of the center hole.

The method may further include a T6 heat treatment or a solution heat treatment step for processing the center hole on the preform after the reaction forging step, and an aging heat treatment step after the second flow molding step.

Through the above problem solving means, the present invention provides the following effects.

According to the present invention, an aluminum 6000 series material having high physical properties can be easily manufactured into an ultralight high strength aluminum wheel through a reaction high forging process and a flow molding process.

In particular, by using the aluminum 6000-based whole body material can be recycled, it is possible to realize a light weight by reducing the weight, and can significantly improve the properties such as tensile strength and elongation compared to the existing cast material.

1A to 1D are schematic views showing a reaction solid forging process as an apparatus and method for manufacturing an aluminum wheel according to the present invention;
2a to 2d is a schematic view showing the reaction high forging process, the aluminum wheel manufacturing apparatus and method according to the present invention,
3 is a schematic view showing a center hole machining process as an apparatus and method for manufacturing an aluminum wheel according to the present invention;
4A to 4D are schematic diagrams showing a flow forming process as an apparatus and method for manufacturing an aluminum wheel according to the present invention;
5 is a schematic view showing a hub hole manufacturing process as an apparatus and method for manufacturing an aluminum wheel according to the present invention;
6A to 6D are schematic views showing a lathe machining process as an apparatus and method for manufacturing an aluminum wheel according to the present invention;
7 is a process chart for explaining a conventional low pressure casting disk wheel manufacturing process,

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

The present invention has a main point in that it is possible to produce an ultra-light high strength aluminum wheel through a composite process in which the reaction high forging process and the flow molding process are sequentially performed.

First, a reaction solid forging apparatus and method for manufacturing an aluminum wheel according to the present invention will be described.

1A to 1D are schematic diagrams showing an apparatus for producing an aluminum wheel according to the present invention and a reaction solid forging process.

Reaction solid forging apparatus of the present invention is a pre-formed part 100 for preforming the shape of the aluminum wheel using aluminum 6000-based whole body material, the upper side of the upper mold 104 and the take-out is mounted on the upper plate 102 Punch 106 is disposed.

More specifically, the hydraulic cylinder (not shown) is coupled to the upper surface of the upper plate 102, the upper mold 104 for the reaction high forging of the aluminum wheel integrally to the bottom edge of the upper plate 102. It is assembled, and the blowout punch 106 is mounted to the center of the upper plate 102 so that the upper punch cylinder 107 can be moved up and down.

The lower mold 108 having a molten metal filling space is assembled on the lower plate 112 at the lower side of the upper mold 104, and the lower working shaft 109 is formed at the center of the lower mold 108. The lower ejection cylinder 111, which is positioned to be capable of raising and lowering and is a lowering driving means of the lower operation shaft 109, is disposed at the bottom of the lower plate 112.

In addition, a rail-shaped guide 113 is mounted on an outer circumferential lower plate 112 of the lower mold 108, and a side holder 114 is disposed on the rail-shaped guide 113 so as to be able to move forward and backward.

At this time, the side mold 110 is integrally assembled on the front surface of the side holder 114, and the hydraulic cylinder 115 that is the forward and backward driving means is disposed on the rear surface.

Looking at the reaction forging process proceeded by the reaction forging forging preform 100 configured as follows.

First, the side holder 114 and the side mold 110 are advanced along the rail guide 113 by the driving of the hydraulic cylinder 115 to be in close contact with the side of the lower mold 108 to form a preform of an aluminum wheel. A cavity 116 is formed for shaping the mold.

Subsequently, the molten metal in which the aluminum 6000 system material is melted is injected into the cavity 116.

Next, the upper mold 104 is lowered and the reaction solid forging process of pressurizing the molten metal in the cavity 116 is performed, thereby completing the preform of the aluminum wheel.

Subsequently, the upper mold 104 is raised to its original position and the lower working shaft 109 pushes up the bottom surface of the preform in the lower mold 108 by driving the lower eject cylinder 111, thereby preforming The chain aluminum wheel 400 is lifted with the upper mold 104.

Subsequently, in the state in which the upper mold 104 is stopped, the extraction plate 118 is disposed under the movement by a transfer robot (not shown), and at the same time, the lower mold 104 is lowered by driving the upper eject cylinder 107. As the blowout punch 106 pushes down the aluminum wheel 400 which is a preform, the aluminum wheel 400 is seated on the takeout plate 118.

The aluminum wheel 400 preliminarily formed by the reaction forging and seated on the takeout plate 118 is transferred to a center hole processing line, which is the next process.

Thus, as shown in Figure 3 attached to the center of the hub portion 406 of the aluminum wheel 400 mounted on the work target of the center hole processing line using a predetermined processing means such as a drill center hole of a predetermined size ( 402 is formed through.

On the other hand, as shown in Figures 2a to 2d attached, the side mold 110 can be assembled by lifting up and down using the link members (119a, 119b).

That is, the side mold 110 is disposed between the side holder 114 and the lower plate 112 in a state in which the side holder 114 is fixed to the lower plate 112, and the top and side of the side mold 110 are disposed. The upper end of the holder 114 is hinged by the first link member 119a, and at the same time, the lower end of the side mold 110 and the lower plate 112 are connected by the second link member 119b.

Therefore, the lower working shaft 109 pushes up the bottom surface of the preform that was in the lower mold 108 by driving the lower ejection cylinder 111, whereby the aluminum wheel 400, which is a preform, becomes the lower mold 108. And ascending and descending, and at the same time, the side mold 110 is lifted and lifted by the rotation of the first and second link members 119a and 119b, and the ejection of the aluminum wheel 400 preformed by reaction forging is performed. This is done.

Here, the flow forming part and the flow forming process of the aluminum wheel manufacturing apparatus according to the present invention will be described.

4A to 4D are schematic diagrams showing an apparatus and a method for manufacturing an aluminum wheel according to the present invention, showing a flow molding part and a flow molding process.

Flow molding unit 300 of the present invention is a device for forming the aluminum wheel 400, the center hole 402 is processed to a predetermined thickness over the first and second, the flow molding chuck for holding the aluminum wheel 400 302a and 302b, and a flow-forming roller 304 for flowing the rim portion 404 and the hub portion 406 of the aluminum wheel 400 to a predetermined thickness.

The flow forming chuck 302a is adopted as a small diameter chuck in close contact with the center of the hub portion 406 of the aluminum wheel 400, and the flow forming chuck 302b located on the opposite side is an edge of the hub portion 406. Adopted in the 'c' cross-sectional structure in close contact with the part, in particular, the end of the flow forming chuck 302b is integrally assembled with a flow forming plate 310 having the shape of an aluminum wheel.

The rotation shaft 305 is integrally connected to the center of the flow-forming roller 304, the rotation shaft 305 is rotatably assembled through the bearing 307 in the hollow support shaft 306, and also supported The upper end of the shaft 306 is connected to the transfer robot 308 for the X-axis and Y-axis transfer of the flow-forming roller 304.

The aluminum wheel 400 is fixed to the flow-forming chuck 302a for flow-forming by the flow-forming part 300 having such a configuration.

That is, the fluid forming chuck 302a is brought into close contact with the center of the outer diameter portion of the hub 406 of the aluminum wheel 400, and the flow forming chuck 302b is brought into close contact with the inner diameter portion of the aluminum wheel 400, thereby fixing the aluminum wheel 400. This is done.

At this time, the flow forming plate 310 having the surface shape of the aluminum wheel is integrally fixed to the end of the flow forming chuck 302b, so that the inner diameter of the hub portion 406 of the aluminum wheel 400 is substantially the flow forming plate ( It is in a state of being in close contact with the front of the 310.

The rim portion 404 is molded to a predetermined thickness (dimension of the rim portion of the designed target product) while the aluminum wheel 400, which is a reaction molded in a radial or cylindrical shape, is fixed using the chucks 302a and 302b. The first flow molding step is performed.

More specifically, when the outer surface of the rim portion 404 of the aluminum wheel 400 is pressed and pressed by the flow forming roller 304 moving in the X-axis or Y-axis direction, the rim portion 404 is the flow-forming plate 310 At the same time, it is pressed in the rotational radial direction, and eventually the thickness of the rim portion 404 is made thin by a predetermined thickness by the flow forming roller 304, and at the same time the width of the rim portion 404 is increased to a predetermined width. This completes the first flow molding step.

Next, the thickness of the hub portion 406 of the aluminum wheel 400 which is the preform, that is, the flow forming process for the hub portion 406 of the aluminum wheel 400, that is, the thickness is reduced to a predetermined thickness. The secondary flow forming step is performed.

To this end, the primary flow molded aluminum wheel 400 is turned 180 ° and fixed to the chucks 302a and 302b in opposite directions.

Subsequently, the outer surface of the hub portion 406 of the aluminum wheel 400 is pressurized by the flow-forming roller 304 moving in the X-axis or Y-axis direction, and flow molding is performed to a predetermined thickness.

That is, the flow forming roller 304 presses the hub portion 406 of the aluminum wheel 400 from the outside to the inside to perform the flow molding to a predetermined thickness.

More specifically, when the fluid forming roller 304 presses the hub portion 406 of the aluminum wheel 400, which is a preform, from the outside to the inside, the amount of material to be pressed is easily flowed toward the center hole 402. Thus, the thickness of the hub portion 406 can be easily molded to a predetermined thickness.

When the hub portion 406 of the aluminum wheel 400 is pressed from the outside to the inside in the absence of the center hole 402, the amount of material to be pressed is concentrated in the center of the hub portion 406 and the hub portion 406 is provided. Although the thickness of the central portion of the may increase, the amount of material to be pressed easily flows into the center hole 402 as the center hole 402 is formed, so that the overall thickness of the hub portion 406 may be easily controlled.

According to the present invention, as shown in the accompanying FIG. 5, the aluminum wheel 400 finally formed in the flow forming part 300 is transferred to the hub hole processing part 500 to be the actual hub in the center of the hub part 406. The machining of the hole 408 is further performed. Then, as shown in FIGS. 6A to 6D, CNC machining of the inner and outer surfaces of the aluminum wheel 400 where the hub hole processing is completed is performed in the lathe machining part 600. After the process, the step of machining the bolt hole and the vent hole in the hub portion 406 is further progressed to complete the final aluminum wheel product.

On the other hand, the heat treatment process according to the United States ASTM American Metal Standards for the aluminum wheel manufactured as described above is further progressed, through the heat treatment to maintain the target properties, ie tensile strength, yield strength, elongation, etc. Can be.

That is, the T6 heat treatment (solvent-> water bath quenching-> aging) or solution heat treatment step performed to process the center hole 402 for the aluminum wheel 400, which is a preform after the reaction high forging step, and the secondary heat treatment step; As the aging heat treatment step performed after the flow forming step proceeds, it can be maintained at a level satisfying tensile strength, yield strength, elongation, and the like.

By the solution process, the aluminum wheel is kept at 535 degrees lower than the solidification start point for 5 hours to soften the tissue by receiving heat up to the core, and then immersed in water rapidly to refine the tissue while quenching the tissue and then at an aging temperature of about 155 degrees. After maintaining for 5 hours, it is cooled in air and finished heat treatment.

In this case, the flow molding process may be carried out after the heat treatment of the solution, and may be performed after the completion of the solution and the time-effect tablet.

As such, the aluminum 6000 series material having high physical properties can be easily manufactured as an ultra-high strength aluminum wheel that can be recycled through a reaction high forging process and a flow molding process.

100: preform 102: the upper plate
104: upper mold 106: take-out punch
107: upper eject cylinder 108: lower mold
109: lower working shaft 110: side mold
111: lower eject cylinder 112: lower plate
113: rail guide 114: side holder
115: hydraulic cylinder 116: cavity
118: blowout plate 200: center hole processing unit
300: flow molding part 302a, 302b: flow molding chuck
304: roller for flow molding 305: rotating shaft
306: support shaft 307: bearing
308: transfer robot 310: flow molding plate
400: aluminum wheel 402: center hole
404: rim portion 406: hub portion
408: hub hole 500: hub hole machining
600: lathe machining

Claims (6)

delete delete delete delete Reaction of forming a preform for an aluminum wheel by injecting a molten aluminum 6000 system material into the cavity 116 formed by the upper mold 104, the lower mold 108, and the side mold 110. High forging step;
The aluminum wheel 400, which is a preform manufactured by reaction forging, is rotatably fixed to the other side of the fluid forming chuck 302a and the other side of the fluid forming chuck 302b having the fluid forming plate 310. After that, the outer surface of the rim portion 404 of the fixed aluminum wheel 400 is pressed on the flow forming plate 310 by the flow forming roller 304 and pressed in the rotational radial direction, thereby increasing the thickness of the rim portion 404. A first flow molding step of thinning to a predetermined thickness and simultaneously increasing the width of the rim portion 404 to a predetermined width;
The thickness of the hub portion 406 of the aluminum wheel 400, which is a preform, is reduced to a predetermined thickness, and the hub portion 406 of the aluminum wheel 400 is moved from the outside to the inside by the flow-forming roller 304. Pressurized into a second flow molding step;
Further processing the center hole 402 in the center of the pre-formed aluminum wheel 400 before the first flow molding step, the hub portion of the pre-formed aluminum wheel 400 in the second flow molding step ( When pressing the 406 from the outside to the inside, the pressed material can flow in the direction of the center hole (402) characterized in that the aluminum wheel manufacturing method using a combined process of reaction high forging and flow molding. delete

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