KR101846747B1 - Method of Aluminum Injection Mold using magnetization and Magnetic Force type Die Casting Mold System thereof - Google Patents

Abstract

A die casting mold system of the present invention comprises: a mold composed of a movable mold (10) and a stationary mold (20) that are combined to and separated from each other; an electromagnet (70) for attracting Fe component of a molten metal filled in a cavity (11) by an electromagnetic force in a state where the mold is in a combined state; and a PLC controller (90) for supplying and blocking an electric current to the electromagnet (70). When a control arm (300-2) is casted by using an ADC 10 or ADC 12 which is a secondary material, the Fe content of an internal structure is significantly lowered to impart a high elongation characteristic. In particular, by collecting the Fe component on the surface of the control arm (300-2), the manufacturing process can be more easily performed by improving a blocking effect of the movable mold (10) and the stationary mold (20), thereby capable of easily controlling the Fe content.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing an aluminum injection molded article and a die casting mold system,

The present invention relates to the production of aluminum extrusions, and more particularly to a process for producing aluminum extrusions using a magnetizing die casting mold system in which low elongation properties due to Fe are solved.

In general, an aluminum injection molded article which contributes to the improvement of fuel economy by reducing the weight of the vehicle should be manufactured so as not to have a low elongation which is easily broken together with a low manufacturing cost. Examples of such aluminum extrusions include control arms (or lower arms, upper arms) of the suspension.

For this purpose, automotive aluminum extrusions are manufactured by die casting method with secondary alloy of ADC 10 or ADC 12, which is not primary alloy, so high mass production and cheap price are met.

Domestic Special 10-2010-0008304 (January 25, 2010)

However, the ADC 10 or ADC 12 materials contain high amounts of Fe, which prevents the seizure between the aluminum material and the mold and enables effective extraction, which causes difficulties in controlling the effective Fe content by lowering the elongation of the aluminum injection material.

Especially, when Fe needle-shaped structure is present inside the structure of aluminum injection molding, it is inevitably required to have a low elongation characteristic which is easily broken by the characteristic of brittleness. Such low elongation characteristic increases the risk of field breakage when the vehicle is applied, . ≪ / RTI >

Accordingly, the present invention, which has been made in view of the above, can produce an aluminum extrudate having high elongation characteristics by significantly reducing the Fe content after the manufacturing while maintaining the merits of the secondary alloy and the die casting method. And to provide a die-casting mold system and a method of manufacturing a magnetism-based aluminum injection molding capable of improving the adhesion-blocking effect between an aluminum material and a mold by moving the mold to the surface of the molding.

According to an aspect of the present invention, there is provided a die casting mold system comprising: a mold having a cavity filled with a molten metal and including a movable mold and a fixed mold, An electromagnet provided in each of the movable mold and the stationary mold to generate an electromagnetic force for attracting the Fe component contained in the molten metal; A position sensor for generating a sensor signal for forming the electromagnetic force; A spray in which cooling water and release agent are sprayed; And a PLC controller for supplying and disconnecting a current of the electromagnet with a sensor signal of the position sensor.

In a preferred embodiment, the electromagnet has a rectangular cross section or a hat cross section.

In a preferred embodiment, the sensor signal of the position sensor includes a sleeve current supply signal generated at a position where the plunger pushing the molten metal of the runner provided in the stationary mold passes through the sleeve of the runner, Is a gate current supply signal which is generated at a position where the gate voltage is reached. The sleeve current supply signal is generated at the sleeves sensor located at the sleeve portion in the runner and the gate current supply signal is generated at a gate passage sensor located at the gate portion in the runner.

According to another aspect of the present invention, there is provided a method of manufacturing an aluminum injection molded product, comprising the steps of: (A) preparing a casting condition of a product produced by injecting into a cavity in a combined state of a movable mold and a fixed mold; (B) a casting start process step in which the movable mold is moved and merged with the stationary mold, and a molten metal injected into a sleeve formed in a runner of the stationary mold is pushed by a plunger to be injected into the cavity through a gate formed in the runner; (C) a magnetic force applying step of supplying a current to the electromagnet of the movable mold to form a movable mold electromagnetic force, supplying a current to the electromagnet of the stationary mold to form a fixed mold electromagnetic force, and injecting the molten metal into the cavity ; (D) After the current supply of the electromagnet is stopped, the solidified molten metal of the cavity is formed as an aluminum molding, the aluminum molding is taken out by the mold of the movable mold and the stationary mold, and the cooling water and the mold release agent are injected into the aluminum molding And a product finishing step of finishing the product with an aluminum extruded product.

As a preferred embodiment, the movement position of the plunger is detected by a sensor signal of a sleeve passage sensor provided at a sleeve position of the runner and a gate passage sensor provided at a gate position of the runner, Lt; / RTI >

In a preferred embodiment, the movable mold electromagnetic force is first stopped and then stopped before the fixed mold electromagnetic force at 70 to 90% of the low speed section where the melt is completely filled into the sleeve and into the cavity along the runner, The mold electromagnetic force is formed from the start point of the high-speed section where the molten metal flows into the cavity through the quick molten flow in the runner to the completion of the filling of the molten metal in the cavity and is formed later than the movable mold electromagnetic force.

The present invention realizes the following advantages and effects by manufacturing the aluminum injection molding by the magnetizing die casting mold system.

First, aluminum injection molding is manufactured with high elongation required for automotive parts while using secondary alloy of ADC 10 and ADC 12 with high Fe content. Second, it is very easy to control the Fe content by using the magnetic force for collecting Fe components in the molten metal. Third, by collecting Fe onto the surface of the injection molding, the robustness of the product is strengthened, and the workability of taking out the product becomes more smooth. Fourth, it improves the physical properties (strength and elongation) of the product itself, thereby preventing damage caused in the field, thereby eliminating the cost of the claim and various quality problems. Fifth, by eliminating the field breakage phenomenon, it is possible to expand the vehicle parts to which the die casting method is applied, in which high mass productivity and low price are satisfied. Sixth, it is possible to improve the performance of die casting mold system by forming stronger mechanical fastening force by fixed and movable molds.

FIG. 1 is a configuration diagram of a magnetizing die-casting mold system according to the present invention, FIG. 2 is a flowchart of a method of manufacturing an aluminum extruded product according to the present invention, FIG. 3 is a casting- FIG. 4 is a timing diagram of a step of applying a magnetic force during the manufacturing process of aluminum extrusions according to the present invention, FIG. 5 is a state in which a movable mold is electromagnetically formed in a magnetic force applying process step according to the present invention, FIG. 7 shows a product completion process in the process of manufacturing an aluminum extrudate according to the present invention, and FIG. 8 shows an example of a final product completed in the process of manufacturing an aluminum extrudate according to the present invention .

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings, which illustrate exemplary embodiments of the present invention. The present invention is not limited to these embodiments.

1, a magnetizing die-casting mold system 1 includes a movable mold 10, a stationary mold 20, a runner 30, a plunger 40, a position sensor 50, a spray 60, an electromagnet 70, a PLC controller 90, a power 100, and a ladle 200.

Specifically, the movable mold 10 includes a movable mold nozzle 60-1 and a movable rectangular electromagnet 70-1 or a movable-side cap-shaped electromagnet 80- 1), forms a cavity 11 of a product shape, and has a mold core. The stationary mold 20 includes a runner 30 for injecting molten metal, a plunger 40 for pushing the molten metal, a position sensor 50 for determining a power supply time point for the electromagnet 70, Side rectangular electromagnet 70-2 or the fixed-side cap-shaped electromagnet 80-2 which constitute the fixed mold nozzle 60-2 and the electromagnet 70. The movable mold 10 And a pressing portion 21 inserted into the cavity 11. Therefore, the movable mold 10 and the stationary mold 20 are formed of a mold for producing a pair of products.

Specifically, the runner 30 is divided into a sleeve forming an inlet through which the molten metal is injected and a gate forming a molten metal outlet through which the molten metal pushed by the plunger 40 enters the cavity 11. Therefore, the runner 30 has the same configuration as a conventional runner.

Specifically, the plunger 40 is coupled with the runner 30 and linearly moved forward and backward in the longitudinal direction of the runner 30. For example, the backward linear movement of the plunger 40 is the sleeve position and the forward linear movement is the gate position.

Specifically, the position sensor 50 is provided in the runner 30 and is divided into a sleeve passage sensor 50-1 provided at a sleeve position and a gate passage sensor 50-2 provided at a gate position. For example, the sleeve passage sensor 50-1 detects the sleeve passing position of the plunger 40 and transmits it to the PLC controller 90 so that the PLC controller 90 can supply the power source 100 to the movable mold 10 To the movable side rectangular electromagnet 70-1 or the movable side head type electromagnet 80-1. The gate passage sensor 50-2 detects the gate arrival position of the plunger 40 and transmits the detected position to the PLC controller 90 so that the PLC controller 90 controls the power source 100 to the fixed side Side rectangular electromagnet 70-1 or the movable side hat-shaped electromagnet 80-2 provided in the movable mold 10 so as to be supplied to the rectangular electromagnet 70-2 or the fixed- 1). Therefore, the sensor signal of the position sensor 50 is used for the current supply control and the sensor signal of the sleeve passage sensor 50-1 is transmitted to the plunger 40 at the position where the plunger 40 pushing the molten metal passes through the sleeve of the runner 30 And the sensor signal of the gate passage sensor 50-2 is a gate current supply signal generated at a position where the plunger 40 pushing the molten metal reaches the gate of the runner 30. [

More specifically, the spray 60 is composed of a movable mold nozzle 60-1 and a fixed mold nozzle 60-2 provided in the movable mold 10 and the stationary mold 20, respectively. For example, when the product is taken out from the movable mold 10 and the stationary mold 20, the movable mold nozzle 60-1 is moved from the movable mold 10 side to the product by simultaneous control by the PLC controller 90 and / And the stationary mold nozzle 60-2 injects cooling water and / or releasing agent into the product from the stationary mold 20 side.

Specifically, the electromagnet 70 is provided in the movable mold 10 and the stationary mold 20, respectively, and is shaped differently for the purpose of efficient generation of electromagnetic force.

The electromagnet 70 illustrated in Fig. 1 (A) has a rectangular cross section. Therefore, the movable-side rectangular electromagnet 70-1 is embedded in the movable mold 10 and is located long in the cavity 11 of the movable mold 10, and the fixed-side rectangular electromagnet 70-2 is placed in the fixed mold 20 And is located long in the pressing portion 21 of the stationary mold 20. The electromagnet 70 illustrated in Fig. 1 (B) has a hat-shaped cross section. Therefore, the movable-side head-shaped electromagnet 80-1 is embedded in the movable mold 10 so as to surround the cavity 11 of the movable mold 10, and the fixed-side head-shaped electromagnet 80-2 is fixed to the stationary mold 20 so as to be directly inserted into the pressing portion 21 of the stationary mold 20. [

As a result, the magnetic force of the electromagnetic force of the electromagnet 70 attracting the Fe component in the molten metal is higher than the movable / fixed side rectangular electromagnets 70-1, 70-2, 2) is relatively superior.

In particular, the power supply 100 supplies all the necessary power from the components of the magnetically assisted die casting mold system 1. The PLC controller 90 controls the movement of the movable mold 10, the movement of the plunger 40, the detection of the position sensor 50, the ON and OFF operations of the spray 60, And controls the magnetically assisted die casting mold system 1 with logic (e.g., ladder logic) tailored to the product production process. The ladle (200) moves and injects the molten metal injected into the sleeve of the runner (30).

Referring to FIG. 2, a method of manufacturing an aluminum injection molded product is characterized in that a molten metal is filled in a sleeve during a die casting process, a magnetic force is applied to the movable / stationary mold side from the moment the plunger moves at a high speed, So that the Fe components in the Al melt are solidified while being moved to the surface of the molten metal due to the magnetic force of the mold. As a result, the final coagulated product can be easily separated from the movable / fixed mold by releasing the Fe and Fe intermetallic compound on the surface, and the removed product moves the needle-like Fe and Fe intermetallic compound to the surface Brittle property and elongation deterioration property deterioration disappear. Further, the force generated by the magnetic force during the diecasting, which is a secondary action and effect, induces the rise of the mold pressure (fastening force) of the stationary mold and the movable mold, thereby securing a robust mechanical fastening force. In particular, it improves the physical properties (strength and elongation) of the product itself, thereby reducing the damage caused in the field, and it is possible to eliminate the cost of the claim and various quality problems in advance.

Hereinafter, the method of manufacturing the magnetized aluminum extrudate of FIG. 1 will be described in detail with reference to FIGS. 3 to 8. FIG. The control subject is the PLC controller 90 and the controlled object is the movable mold 10, the stationary mold 20, the runner 30, the plunger 40, the position sensor 50, the spray 60, And ladle (200).

The casting preparation process step is performed in steps S10 and S20. The PLC controller setting of S10 means that the PLC controller 90 is activated. The setting of the casting condition of S20 can be carried out in various manners such as speed (eg, injection and movement of molten metal), pressure (eg, pressure at the time of assembling the movable and stationary molds) , Product formation time), spraying of coolant or release agent of spray 60, and the like. At this time, the diecasting conditions set in the PLC controller 90 are applied as they are.

 The casting starting process step is performed in the steps of S30 to S50.

Referring to FIG. 3, the mold assembly of S30 means that the movable mold 10 is moved to the stationary mold 20 by the PLC controller 90 and coupled to each other. The molten metal injection (ladle movement) in S40 means that the ladle 200 containing the molten metal is moved to the runner 30 and then injected into the runner 30 through the sleeve. At this time, the plunger 40 is moved back to the sleeve position by the PLC controller 90 and then stopped by the PLC controller 90 with the sleeve reaching position detection of the plunger 40 by the sleeve passing sensor 50-1. The PLC controller 90 causes the plunger 40 to move forward in the sleeve position so that the molten metal is injected into the cavity 11 in the state where the movable mold 10 and the stationary mold 20 are joined together, Is injected. At this time, the PLC controller 90 stops the detection of the gate arrival position of the plunger 40 by the gate passage sensor 50-2.

Therefore, the aluminum moldings 300 are filled in the cavities 11 of the movable mold 10 and the stationary mold 20, which are assembled in the casting start step.

The magnetic force applying process step is performed in steps S60 to S100. Particularly, in the magnetic force applying process step, the electromagnets are sequentially turned ON / OFF on the power supply of the movable side and the fixed side in consideration of the characteristic having a kind of N-S pole like the N-S pole of the permanent magnet. That is, the electric power supply to the movable rectangular electromagnet 70-1 (or the movable side hat-shaped electromagnet 80-1 and the fixed side rectangular electromagnet 70-2 (or the fixed side hat-shaped electromagnet 80-2) By sequentially turning on / off, Fe moving due to an electromagnetic force can be uniformly moved without being tilted toward a larger magnetic force.

Referring to the control timing diagram of FIG. 4, current supply conditions of the movable mold 10 and the current supply conditions of the stationary mold 20 for efficiently adsorbing Fe components on the mold surface are as follows.

Control timing In the casting condition of the lead line, the speed of movement of the plunger 40 according to the casting time is displayed as a low speed section and a high speed section in the case of the control variable as shown in the left figure. At this time, in the low speed section, the sleeve of the runner 30 is completely filled with the molten metal and the molten metal moves along the runner 30 and enters the cavity 11. At the start of the high speed section, It is a condition that limit exists. However, at this time, the control of the gate passage time is when the volume of the total flow of the molten metal is equal to the volume of the sleeve and the runner. If the speed is maintained at a low speed, the molten metal after the passage of the gate is low speed. .

Therefore, the moment of magnetic force generation starts at a low speed section just before the start of the gate passage time of the molten metal occurring before the start of the high-speed section so that the adsorption of Fe elements to the surface of the mold can be effectively progressed. For example, the timing of the magnetic force application timing is set such that the movable rectangular electromagnet 70-1 (or the movable-side head-shaped electromagnet 80-1) of the movable mold 10 is positioned at a position 70 to 90% And the current is cut off after the holding of the electromagnetic force by the supply of the current within at least 1 to 2 seconds or 4 seconds, and the current flows through the fixed-side rectangular electromagnet 70-2 (or the fixed- (80-2) is started immediately after the high-speed change, and the current is cut off after the electromagnetic force is maintained by the current supply until the completion of the melt filling (for example, 1 to 2 seconds before the product is taken out). In order to reflect the difference in conditions between products, it is considered that the holding time of the electromagnetic force is set within 1 to 2 seconds or 4 seconds, considering the difficult point of the solidification of Fe.

5, when the movable-side rectangular electromagnet 70-1 (or movable (movable) side) of the movable mold 10 is operated in the step of supplying the movable mold current and the electromagnetic force in S60 and the current interruption after elapse of the movable mold electromagnetic force holding time in S60-1 Side-head-shaped electromagnet 80-1). The electromagnetic force is generated at a point of time before the molten metal of the runner 30 passes through the gate (for example, 70 to 90% of the low-speed section of FIG. 4), is maintained for about 1 to 2 seconds or 4 seconds and then disappears. As a result, the Fe intermetallic compound layer contained in the internal structure of the aluminum mold 300 of the cavity 11 is collected on the surface positioned by the movable mold 10. This action enhances the strength of the product by smoothly taking out the product due to the completion of the aluminum molded product 300 and enhancing the fastening force in the combined state by increasing the coupling force between the movable mold 10 and the stationary mold 20 while maintaining the electromagnetic force. Lt; / RTI >

Referring to FIG. 6, in the step S80, the fixed mold current supply and the electromagnetic force supply of S80 and the current supply interruption of the stationary mold electromagnetic force holding time of S90, Electromagnetic force is formed in the fixed-side rectangular electromagnet 70-2 (or the fixed-side head-shaped electromagnet 80-2) The electromagnetic force is generated until the molten metal filling of the cavity 11 is completed after the molten metal of the runner 30 has passed through the gate (for example, the start point of the high speed section of FIG. 4) Disappear. As a result, the Fe intermetallic compound layer contained in the internal structure of the aluminum formed product 300 of the cavity 11 is collected on the surface positioned by the stationary metal mold 20. Such an operation can smoothly take out the product due to the completion of the aluminum molded product 300 and smooth the product. In addition, while the electromagnetic force is maintained, the joining force of the movable mold 10 and the stationary mold 20 is increased to improve the joining force.

The product finishing process is performed in steps S110 to S140.

7, in the solidification step of S110, the aluminum moldings 300 in the cavity 11 are formed such that the Fe component is distributed to the left surface (e.g., the surface located in the movable mold 10) of the aluminum moldings 300 and the aluminum moldings (For example, the surface located in the stationary mold 20) of the first and second molds 300 and 300. The movable mold 10 is released from the stationary mold 20 in the mold opening step of S120 and the extractor 400 takes the aluminum molded product 300 under the control of the PLC controller 90 in the product take- ). The control of the PLC controller 90 in the spraying step of S140 causes the movable mold nozzle 60-1 of the movable mold 10 and the fixed mold nozzle 60-2 of the stationary mold 20 to cool water and / So that the aluminum mold 300 is completed with the aluminum mold 300-1.

S150 is an operation interruption step, and the operation interruption means the casting initiation process, the magnetic force application process, and the end of the product completion process.

Referring to FIG. 8, it can be seen that the aluminum injection mold 300-1 is made of a control arm 300-2 applied to a suspension of a vehicle.

The control arm 300-2 constitutes a lower arm or an upper arm. Especially, although the control arm 300-2 is made of a secondary material (ADC12), the fatigue life of the aluminum alloy is lowered and the control arm 300-2 has a needle-like structure of the process silicon and the Fe compound Type) is not generated.

As described above, in the die casting mold system according to the present embodiment, the mold composed of the movable mold 10 and the stationary mold 20 which are merged and released together, and the Fe component of the molten metal filled in the cavity 11, An electromagnet 70 for attracting the electromagnet 70 to the electromagnet 70 and a PLC controller 90 for supplying and interrupting the current to the electromagnet 70 so that the control arm 300-2 using the ADC 10 or ADC12, It is possible to improve the effect of preventing the sticking of the movable mold 10 and the stationary mold 20 by reducing the Fe content of the internal structure significantly during casting to give a high elongation characteristic and collecting the Fe component on the surface of the control arm 300-2. A more easy manufacturing process is possible.

1: die casting mold system
10: movable mold 11: cavity
20: stationary mold 21:
30: Runner 40: Plunger
50: Position sensor 50-1: Sleeve passing sensor
50-2: gate passage sensor 60: spray
60-1: movable mold nozzle 60-2: stationary mold nozzle
70: electromagnet 70-1: movable side rectangular electromagnet
70-2: Fixed side rectangular electromagnet
80-1: movable-side hat-shaped electromagnet
80-2: Fixed side head type electromagnet
90: PLC controller 100: power (power)
200: Ladle 300: Aluminum molding
300-1: Aluminum Injection
300-2: control arm
400: extractor

Claims (13)

A mold comprising a movable mold and a stationary mold which form a cavity filled with a molten metal and which are assembled and united with each other;
An electromagnet which is provided in the mold and generates an electromagnetic force to attract the Fe component contained in the molten metal;
A die casting mold system,
The die casting mold system according to claim 1, wherein the electromagnets are provided in the movable mold and the stationary mold, respectively,
The die casting mold system according to claim 2, wherein the electromagnet is a rectangular cross section or a hat cross section,
The die casting mold system according to claim 1, wherein the electromagnet is supplied with current and shut off by a PLC controller,
[Claim 4] The method of claim 4, wherein the PLC controller supplies the current with a sensor signal of a position sensor, and the sensor signal is generated at a position where a plunger pushing the molten metal of the runner provided in the stationary mold passes through the sleeve of the runner A sleeve current supply signal and a gate current supply signal generated at a position where the plunger reaches the gate of the runner,
6. The method of claim 5, wherein the sleeve current supply signal is generated in a sleeve passage sensor located at the sleeve portion in the runner and the gate current supply signal is generated in a gate passage sensor located at the gate portion in the runner Die casting mold system,
[6] The die casting mold system according to claim 5, wherein the PLC controller injects cooling water with a spray, and the spray is provided as each of the movable mold and the stationary mold,
(A) a casting preparation step of setting a casting condition of a product which is injected into a cavity in a state where a movable mold and a fixed mold are combined;
(B) a casting initiation process step in which the movable mold is moved and merged with the stationary mold, and a molten metal injected into a sleeve formed in the runner of the stationary mold is pushed by a plunger to be injected into the cavity through a gate formed in the runner;
(C) a magnetic force applying step of supplying a current to the electromagnet of the movable mold to form a movable mold electromagnetic force, supplying a current to the electromagnet of the stationary mold to form a fixed mold electromagnetic force, and injecting the molten metal into the cavity ;
(D) After the ceasing of current supply of the electromagnet, the solidified molten metal of the cavity is formed as an aluminum molding, the aluminum moldings are taken out by the molds of the movable mold and the stationary mold, and cooling water is sprayed on the aluminum moldings, A product finishing process step is completed,
The movable mold electromagnetic force is formed earlier than the fixed mold electromagnetic force and is stopped before the fixed mold electromagnetic force
Wherein the aluminum foil is made of aluminum.
[8] The method of claim 8, wherein the movement position of the plunger is detected by a sensor signal of a sleeve passage sensor provided at a sleeve position of the runner and a gate passage sensor provided at a gate position of the runner, To the aluminum foil.
delete 9. The method of claim 8, wherein the formation of the movable mold electromagnetic force is at a point 70 to 90% of the low speed section where the melt is completely filled in the sleeve and enters the cavity along the runner, Wherein the high-speed section starts from a high-speed section starting from the runner into the cavity through a rapid flow of molten metal until the completion of the filling of the molten metal in the cavity.
12. The method according to claim 11, wherein the holding time of the movable mold electromagnetic force is within 4 seconds.
12. The method according to claim 11, wherein the holding time of the fixed mold electromagnetic force is 1 to 2 seconds before the molten metal of the cavity is taken out of the product.

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