KR101646528B1

KR101646528B1 - Manufacturing method of monoblock aluminium caliper body

Info

Publication number: KR101646528B1
Application number: KR1020150053019A
Authority: KR
Inventors: 김종열; 박종태
Original assignee: 델타캐스트 주식회사
Priority date: 2015-04-15
Filing date: 2015-04-15
Publication date: 2016-08-16

Abstract

The present invention relates to a caliper manufacturing method. The present invention has effects of preventing the blowing of dust and simplifying a manufacturing process by comprising: a first step of melting aluminum; a second step of holding the aluminum; a third step of inserting a core into a mold; a fourth step of heating the mold and inserting the aluminum; a fifth step of tilting the mold and coagulating the aluminum; a sixth step of disassembling the core in the aluminum; a seventh step of removing the core; an eighth step of cutting an unnecessary part of the aluminum; a ninth step of performing a heat treatment on the aluminum; and a tenth step of forming a completed caliper by finally inspecting the aluminum.

Description

{Manufacturing method of monoblock aluminum caliper body}

The present invention relates to a method of manufacturing a caliper, and more particularly, to a method of manufacturing a monolithic aluminum caliper which realizes a shape optimized for a product, .

In general, integral calipers are manufactured by machining the interior or by inserting tubes. However, such a method has a problem that the implementation of the channel hole shape is limited in the method of making the caliper, the machining is complicated and difficult, and there is a defect such as fusion bonding when the tube is inserted inside.

Korean Patent Registration No. 10-0848311 (2008.07.18)

An object of the present invention is to provide an integrated caliper using an aluminum gravity casting method and casting it into a hollow core insertion structure to solve the above problems, thereby providing a simple and high-performance caliper.

In order to accomplish the object, there are a first step of dissolving aluminum, a second step of holding aluminum, a third step of inserting a core into the mold, a fourth step of heating the mold, A fifth step of tilting the metal mold and solidifying the aluminum, a sixth step of decomposing the inner body of aluminum, a seventh step of removing the core, an eighth step of cutting off unnecessary portions of aluminum, A ninth step of heat-treating the aluminum, and a tenth step of making a caliper completed by final inspection of aluminum.

As described above, it is possible to realize a complicated flow hole shape that can not be machined, and it is possible to prevent aluminum and fusing defects when the TUBE is inserted, and the manufacturing process is simple.

1 is a representative view of a prior art disc brake caliper for a vehicle and a method for manufacturing a caliper housing.
2 is a flow chart of a method for manufacturing an integral aluminum caliper according to the present invention;
3 is a detailed flowchart of a ninth step which is a component of the method for manufacturing an integral aluminum caliper according to the present invention.
4 is a detailed flowchart of a tenth step which is a component of the method for manufacturing an integrated aluminum caliper according to the present invention.

A method of manufacturing an integral caliper using an aluminum gravity casting method, comprising the steps of: (a) a first step (S10) of dissolving aluminum (10) at a temperature of 700 to 740 ° C to form a molten aluminum (20) A second step S20 of holding the mold 100 at a temperature of 700 to 740 DEG C, a third step S30 of inserting the core 110 into the mold 100, (S40) of injecting the molten aluminum (20) into the mold (100) by heating the mold (100) at a temperature higher than the melting point of the mold A fifth step (S50) of solidifying the molten aluminum (20) injected from the molten aluminum (20) for 490 to 550 seconds to form solidified aluminum (30); and heating the solidified aluminum (30) at a temperature of 485 to 495 캜 for 8 hours and 30 minutes A sixth step S60 of burning the solidified aluminum 110 in the solidified aluminum 30 by burning the solidified aluminum 110 in the sixth step S60 for 9 hours and 30 minutes; An eighth step S80 of cutting the unnecessary portion of the unsintered aluminum 40 to produce a cut aluminum 50 and a cutting step of cutting the cut aluminum 50 (S90) of heat treating the heat-treated aluminum 60 to form a heat-treated aluminum 60, and finally, performing a final inspection of the heat-treated aluminum 60 (S100). .

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described with reference to the accompanying drawings.

FIG. 2 is a flow chart of a method for manufacturing an integrated aluminum caliper according to the present invention, wherein a first step (S10) of making aluminum (20) by dissolving aluminum (10) of A357 at a temperature of 700 to 740 ° C. is performed, A second step S20 of holding the aluminum 20 at a temperature of 700 to 740 DEG C in an electric furnace is performed. Thereafter, a third step (S30) is performed in which the core member (110) made of a synthetic resin having a particle size of 70 to 80 is molded in accordance with the shape of the caliper body and inserted into the mold (100). The core 110 is formed to conform to the internal shape of the caliper body and is configured to be broken down into particles at a temperature of 450 ° C or higher.

Thereafter, the mold 100 is heated to 330 ° C or higher and the molten aluminum 20 is injected into the mold 100 to inject the molten aluminum 20 into the mold 100. The fourth step S40 is executed.

The molten aluminum 20 is injected in the fourth step S40 in accordance with the capacity and then the metal mold 100 is tilted for 15 to 25 seconds so that the molten aluminum 20 is injected into the inside of the mold 100, And the fifth step S50 of making solidified aluminum 30 by performing solidification of the molten aluminum 20 injected in the fourth step S40 for 490 to 550 seconds is performed. A sixth step S60 of burning the solidified aluminum 30 at a temperature of 485 to 495 DEG C for 8 to 30 minutes to 9 hours and 30 minutes to decompose the core 110 in the solidified aluminum 30; And a seventh step S70 is performed in which the residual aluminum remaining in the inner channel hole and the core body 110 disassembled in the sixth step S60 are removed to form the unsiding aluminum 40. [

Thereafter, an eighth step (S80) of separating the unsiding alumina (40) from the mold (100) and cutting unnecessary portions of the unsiding alumina (40) The ninth step S90 of making the heat treated aluminum 60 is performed and the tenth step S100 of final inspection of the heat treated aluminum 60 is executed.

3 is a detailed flowchart of a ninth step which is a component of the method for manufacturing an integral aluminum caliper according to the present invention. In the ninth step (S90), the cut aluminum 50 is heated at a temperature of 525 to 535 DEG C (S91) is carried out at a temperature of 65 to 85 DEG C after the temperature is maintained for 7 to 30 minutes to 8 hours and 30 minutes, and in the 9-1 step (S91) (Step S72) in which aluminum is heated to a temperature of 525 to 535 DEG C with a temperature rise time of 40 to 60 minutes, and then maintained at a temperature of 65 to 85 DEG C for 7 to 30 minutes to 8 hours and 30 minutes ), And the aluminum that has been used in the 9-2 step (S92) is heated to a temperature of 155 to 165 ° C. and held for 7 to 30 minutes to 8 hours and 30 minutes to form a heat- Step S93 is executed.

4 is a detailed flowchart of a tenth step which is a component of the method for manufacturing an integrated aluminum caliper according to the present invention. In the tenth step (S100), the aluminum (60) is heated for 10 to 20 minutes using a shot ball Step 10-1 (S101) is performed in which the appearance of the heat-treated aluminum (60) through the 10-1 step (S101) is visually inspected to detect the defect and the defect is discarded (S102) is executed.

Due to such a structure, dust is generated due to decomposition of the core 110 inside the solidified aluminum 30 through the burning of the sixth step S60 and discharging the core 110 through the inner flow path hole And the residue of the core 110 is not left, so that the performance of the caliper is excellent.

Although the present invention has been shown and described with respect to specific embodiments and applications thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims. Anyone with knowledge will know easily.

10. Aluminum 20. Fused Aluminum
30. Solidification Aluminum 40. Alumina Aluminum
50. Cutting aluminum 60. Heat treated aluminum
100. Mold 110. Chinese character
S10. First step S20. Second step
Step S30. Third Step S40. Step 4
Step S50. Step 5 Step S60. Step 6
Step S70. Step Seventh Step S80. Step 8
Step S90. Step 9 S91. Step 9-1
S92. Step 9-2 S93. Step 9-3
S100 Step S101. Step 10-1
Step S102.

Claims

In an integrated caliper manufacturing method using an aluminum gravity casting method,
A first step (S10) of dissolving the aluminum (10) at a temperature of 700 to 740 캜 to produce a molten aluminum (20)
A second step (S20) of holding the molten aluminum (20) at a temperature of 700 to 740 캜,
A third step S30 of inserting the core 110 into the mold 100,
A fourth step (S40) of heating the mold 100 to 330 DEG C or higher and injecting the molten aluminum 20 into the mold 100;
A fifth step S50 of tilting the mold 100 for 15 to 25 seconds and solidifying the molten aluminum 20 injected in the fourth step S40 for 490 to 550 seconds to form a solidified aluminum 30; ,
A sixth step (S60) of burning the solidified aluminum (30) at a temperature of 485 to 495 DEG C for 8 hours and 30 minutes to 9 hours and 30 minutes to decompose the core (110) in the solidified aluminum (30)
A seventh step (S70) of forming the unsiding aluminum (40) by removing the disassembled core (110) in the sixth step (S60)
An eighth step (S80) of cutting unnecessary portions of the unsiding aluminum (40) to produce a cut aluminum (50)
A ninth step (S90) of forming the heat-treated aluminum (60) by heat-treating the cut aluminum (50)
(S100) a final inspection of the heat-treated aluminum (60).

The method according to claim 1,
Wherein the third step S30 is a step of forming a core 110 made of a synthetic resin having a particle size of 70 to 80 according to the shape of the caliper body and inserting the core 110 into the mold 100. [

The method according to claim 1,
In the ninth step S90, when the temperature of the cut aluminum 50 reaches the temperature of 525 to 535 DEG C for 3 to 5 hours, the temperature of the cut aluminum 50 is maintained for 7 hours to 30 minutes to 8 hours and 30 minutes, (S91) in which the temperature is raised to a temperature of 525 to 535 DEG C with the heating time being 40 to 60 minutes, (S92) in which the aluminum is maintained at a temperature of 65 to 85 DEG C after maintaining the aluminum at a temperature of 155 to 165 DEG C for a period of 5 minutes to 8 hours and 30 minutes, And a 9-3 step (S93) of holding the aluminum alloy (60) by holding it for 7 hours to 30 minutes to 8 hours and 30 minutes.

The method according to claim 1,
In the tenth step S100, S101 (S101) of removing the foreign substances on the surface of the heat-treated aluminum 60 for 10 to 20 minutes using a shot ball, and the 10-1 step (S101) And a 10-2 step (S102) of inspecting the appearance of the rough heat-treated aluminum (60) with naked eyes to detect a defect.