US20220203418A1 - Method for manufacturing cold-forged extruded aluminum alloy rod - Google Patents
Method for manufacturing cold-forged extruded aluminum alloy rod Download PDFInfo
- Publication number
- US20220203418A1 US20220203418A1 US17/646,021 US202117646021A US2022203418A1 US 20220203418 A1 US20220203418 A1 US 20220203418A1 US 202117646021 A US202117646021 A US 202117646021A US 2022203418 A1 US2022203418 A1 US 2022203418A1
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- Prior art keywords
- cold
- preform
- aluminum alloy
- forged
- extruded aluminum
- Prior art date
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 70
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 238000000641 cold extrusion Methods 0.000 claims abstract description 42
- 239000000314 lubricant Substances 0.000 claims abstract description 16
- 239000000463 material Substances 0.000 claims abstract description 15
- 238000010273 cold forging Methods 0.000 claims abstract description 10
- 239000007787 solid Substances 0.000 claims abstract description 9
- 238000000137 annealing Methods 0.000 claims abstract description 5
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 claims abstract description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 2
- 239000004519 grease Substances 0.000 claims description 2
- 239000007788 liquid Substances 0.000 claims description 2
- 238000005242 forging Methods 0.000 description 5
- 238000001192 hot extrusion Methods 0.000 description 4
- 230000007547 defect Effects 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000001953 recrystallisation Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/04—Making uncoated products by direct extrusion
- B21C23/08—Making wire, bars, tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/18—Making uncoated products by impact extrusion
- B21C23/183—Making uncoated products by impact extrusion by forward extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/003—Selecting material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J3/00—Lubricating during forging or pressing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/55—Hardenability tests, e.g. end-quench tests
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
Definitions
- the disclosure relates to a method for manufacturing a cold-forged extruded aluminum alloy rod by cold forging and cold extrusion.
- a conventional connecting structure of a bicycle is generally made by hot forging and hot extrusion in response to the shape and structural strength requirements. Specifically, a material subjected to hot forging and hot extrusion is first heated in a furnace to a temperature above the recrystallization temperature, followed by a processing step for shaping. Hot forging and hot extrusion not only require a furnace that can withstand high temperature and a material-taking equipment, but also incur a high capital expenditure due to quick wearing of the hot forging and hot extrusion dies and large consumption of energy.
- an object of the present disclosure is to provide a method for manufacturing a cold-forged extruded aluminum alloy rod by cold forging and cold extrusion that can alleviate at least one of the drawbacks of the prior art.
- a method for manufacturing a cold-forged extruded aluminum alloy rod includes the steps of:
- (C) subjecting the preform to a homogeneous annealing which involves heating the preform in a furnace to a temperature ranging from about 410° C. to 510° C., and then removing the preform from the furnace after the furnace is cooled to a temperature ranging from about 160° C. to 200° C. at a cooling rate of 10° C. per hour;
- (G) subjecting the preform to cold forging which involves positioning the preform in the cold extrusion die, after which the cold extrusion punch is operated to strike against the preform to thereby form the cold-forged extruded aluminum alloy rod
- the cold-forged extruded aluminum alloy rod being a solid rod that extends along the axis, and having a first side surface intersecting the axis, a second side surface opposite to the first side surface along the axis, and an outer circumferential surface interconnecting outer circumferential edges of the first side surface and the second side surface
- the cold-forged extruded aluminum alloy rod having a length that extends from the first side surface to the second side surface thereof and that is longer than the length of the preform.
- FIG. 1 is a flow chart, illustrating the steps involved in a method for manufacturing a cold-forged extruded aluminum alloy rod according to an embodiment of the present disclosure
- FIG. 2 is an exploded cross-sectional view of a first cold extrusion apparatus of the embodiment, illustrating how a preform is formed into a first cold-forged extruded aluminum alloy rod having first dimensions;
- FIG. 3 is an exploded cross-sectional view of a second cold extrusion apparatus of the embodiment, illustrating how the first cold-forged extruded aluminum alloy rod is formed into a second cold-forged extruded aluminum alloy rod having second dimensions;
- FIG. 4 is an exploded cross-sectional view of a third cold extrusion apparatus of the embodiment, illustrating how the second cold-forged extruded aluminum alloy rod is formed into a third cold-forged extruded aluminum alloy rod having third dimensions;
- FIG. 5 is a schematic view, illustrating how the preform is formed into the third cold-forged extruded aluminum alloy rod of the embodiment.
- FIG. 6 is an exploded cross-sectional view of an advanced forming apparatus of the embodiment, in which a patterned cold-forged extruded aluminum alloy rod is formed.
- a method for manufacturing a cold-forged extruded aluminum alloy rod includes steps 1 to 7 .
- a primary material 1 and three cold extrusion apparatuses 2 , 2 ′, 2 ′′ are prepared.
- the primary material 1 has a block shape and is made of an aluminum alloy material, for instance, but is not limited to, AL6066 aluminum alloy and AL7050 aluminum alloy.
- Each of the cold extrusion apparatuses 2 , 2 ′, 2 ′′ includes a cold extrusion die 10 , 10 ′, 10 ′′, and a cold extrusion punch 20 , 20 ′, 20 ′′ corresponding in position to the cold extrusion die 10 , 10 ′, 10 ′′.
- the cold extrusion die 10 , 10 ′, 10 ′′ has a top surface 11 , 11 ′, 11 ′′ and a die cavity 12 , 12 ′, 12 ′′ extending inwardly and downwardly from the top surface 11 , 11 ′, 11 ′′.
- the die cavity 12 , 12 ′, 1 ′′ of each cold extrusion apparatus 2 , 2 ′, 2 ′′ has a stepped shape and tapers from top to bottom.
- the die cavity 12 has a bottom portion having a first cavity diameter (d 1 ).
- the die cavity 12 ′ has a bottom portion having a second cavity diameter. (d 2 ) smaller than the first cavity diameter (d 1 )
- the die cavity 12 ′′ has a bottom portion having a third cavity diameter (d 3 ) smaller than the second cavity diameter (d 2 ).
- the cold extrusion punch 20 , 20 ′, 20 ′′ of each cold extrusion apparatus 2 , 2 ′, 2 ′′ includes a base 21 , 21 ′, 21 ′′, and a ram 22 , 22 ′, 22 ′′ extending downwardly from the base 21 , 21 ′, 21 ′′.
- the ram 22 , 22 ′, 22 ′′ of each cold extrusion apparatus 2 , 2 ′, 2 ′′ has a rod shape with a bottom edge thereof being chamfered.
- the ram 22 has a first outer diameter (D 1 ) corresponding to the first cavity diameter (d 1 ).
- the ram 22 ′ has a second outer diameter (D 2 ) corresponding to the second cavity diameter (d 2 ) and smaller than the first outer diameter (D 1 ).
- the ram 22 ′′ has a third outer diameter (D 3 ) corresponding to the third cavity diameter (d 3 ) and smaller than the second outer diameter (D 2 ).
- the primary material 1 is processed to form a solid preform 1 ′ that extends along an axis (X) and that has a first end surface 101 intersecting the axis (X), a second end surface 102 opposite to the first end surface 101 along the axis (X), and an outer circumferential surface 103 interconnecting outer circumferential edges of the first and second end surfaces 101 , 102 .
- the preform 1 ′ has a length (L) extending from the first end surface 101 to the second end surface 102 , and an outer diameter (D 0 ) measured across the outer circumferential surface 103 .
- step 3 the preform 1 ′ is subjected to a homogeneous annealing which involves heating the preform 1 ′ in a furnace to a temperature ranging from about 410° C. to 510° C., and then removing the preform 1 ′ from the furnace after the furnace is cooled to a temperature ranging from about 160° C. to 200° C. at a cooling rate of 10° C. per hour.
- a homogeneous annealing which involves heating the preform 1 ′ in a furnace to a temperature ranging from about 410° C. to 510° C., and then removing the preform 1 ′ from the furnace after the furnace is cooled to a temperature ranging from about 160° C. to 200° C. at a cooling rate of 10° C. per hour.
- step 4 the hardness of the annealed preform 1 ′ is tested.
- the hardness of the preform 1 ′ is equal to or below 60 degrees measured on Rockwell. Hardness F scale (HRF).
- HRF Hardness F scale
- the testing of the hardness of the preform 1 ′ is performed at multiple points of the outer circumferential surface 103 of the preform 1 ′ and at equal intervals along the axis (X).
- the preform 1 ′ is immersed in a tank containing a lubricant (not shown) for a predetermined time.
- the lubricant has a free total acidity (TA) concentration ranging from 40% by weight to 50% by weight at a working temperature ranging from 80° C. to 100° C.
- the lubricant used may be boron nitride.
- the lubricant for instance, a liquid grease, has a viscosity index (VI) of equal to or above 170, a flash point of equal to or above 240° C., a pour point of equal to or above ⁇ 24° C. and a fire point of equal to or above 255° C.
- step 6 the first end surface 101 , the second end surface 102 and the outer circumferential surface 103 of the preform 1 ′ are applied with talcum powder after the preform 1 ′ is immersed in the lubricant.
- step 7 with reference to FIGS. 2 and 5 , the preform 1 ′ that has been immersed in the lubricant and applied with talcum powder is subjected to cold forging.
- the preform 1 ′ is positioned in a top opening of the die cavity 12 of the cold extrusion die 10 , after which the cold extrusion punch 20 is operated to strike the ram 22 against the preform 1 ′, thereby forming a first cold-forged extruded aluminum alloy rod 100 that has first dimensions.
- the first cold-forged extruded aluminum alloy rod 100 is a solid rod that extends along the axis (X), and has a first side surface 110 intersecting the axis (X), a second side surface 120 opposite to the first side surface 110 along the axis (X), and an outer circumferential surface 130 interconnecting outer circumferential edges of the first and second side surfaces 110 , 120 .
- the first cold-forged extruded aluminum alloy rod 100 has a length (L 1 ) that extends from the first side surface 110 to the second side surface 120 thereof and that is longer than the length (L) of the preform 1 ′, and an outer diameter (D′) smaller than the outer diameter (D 0 ) of the preform 1 ′.
- a step of subjecting the first cold-forged extruded aluminum alloy rod 100 to undergo steps 3 to 7 may be further conducted.
- the first cold-forged extruded aluminum alloy rod 100 is positioned in a top opening of the die cavity 12 ′ of the cold extrusion die 10 ′, after which the cold extrusion punch 20 ′ is operated to strike the ram 22 ′ against the first cold-forged extruded aluminum alloy rod 100 , thereby forming a second cold-forged extruded aluminum alloy rod 100 ′ that has second dimensions different from the first dimensions.
- the second cold-forged extruded aluminum alloy rod 100 ′ is also a solid rod that extends along the axis (X), and has a first side surface 110 ′ intersecting the axis (X), a second side surface 120 ′ opposite to the first side surface 110 ′ along the axis (X), and an outer circumferential surface 130 ′ interconnecting outer circumferential edges of the first and second side surfaces 110 ′, 120 ′.
- the second cold-forged extruded aluminum alloy rod 100 ′ has a length (L 2 ) that extends from the first side surface 110 ′ to the second side surface 120 ′ thereof and that is longer than the length (L 1 ) of the first cold-forged extruded aluminum alloy rod 100 , and an outer diameter (D′′) smaller than the outer diameter (D′) of the first cold-forged extruded aluminum alloy rod 100 .
- a step of subjecting the second cold-forged extruded aluminum alloy rod 100 ′ to undergo steps 3 to 7 may be further conducted.
- the second cold-forged extruded aluminum alloy rod 100 ′ is positioned in a top opening of the die cavity 12 ′′ of the cold extrusion die 10 ′′, after which the cold extrusion punch 20 ′′ is operated to strike the ram 22 ′′ against the second cold-forged extruded aluminum alloy rod 100 ′, thereby forming a third cold-forged extruded aluminum alloy rod 100 ′′ that that has third dimensions different from the second dimensions and the first dimensions.
- the third cold-forged extruded aluminum alloy rod 100 ′′ is also a solid rod that extends along the axis (X), and has a first side surface 110 ′′ intersecting the axis (X), a second side surface 120 ′′ opposite to the first side surface 110 ′′ along the axis (X), and an outer circumferential surface 130 ′′ interconnecting outer circumferential edges of the first and second side surfaces 110 ′′, 120 ′′.
- the third cold-forged extruded aluminum alloy rod 100 ′′ has a length (L 3 ) that extends from the first side surface 110 ′′ to the second side surface 120 ′′ thereof and that is longer than the length (L 2 ) of the second cold-forged extruded aluminum alloy rod 100 ′, and an outer diameter (Da) smaller than the diameter. (D′′) of the second cold-forged extruded aluminum alloy rod 100 ′.
- the outer diameter (D′) may be 45 mm
- the outer diameter (D′′) may be 22 mm
- the outer diameter (Da) may be 6 mm.
- the number of the cold extrusion apparatuses 2 , 2 ′, 2 ′′ prepared in step 1 corresponds to the number of times that steps 3 to 7 is repeated.
- the primary material 1 can be formed into the third cold-forged extruded aluminum alloy rod 100 ′′.
- the third cold-forged extruded aluminum alloy rod 100 ′′ can avoid the defects caused by metal heating, can obtain high precision and surface quality, can improve the hardness and strength of a workpiece, and has a large deformation resistance during cold forging.
- the third cold-forged extruded aluminum alloy rod 100 ′′ is not required to undergo precision machining, and the cold extrusion apparatuses 2 , 2 ′, 2 ′′ axe not easily worn out.
- the homogeneous annealing process in step 3 can improve plasticity of the preform 1 ′, the first cold-forged extruded aluminum alloy rod 100 and the second cold-forged extruded aluminum alloy rod 100 ′, so that in the cold forging process in step 7 , residual stress of the first cold-forged extruded aluminum alloy rod 100 , the second cold-forged extruded aluminum alloy rod 100 ′ and the third cold-forged extruded aluminum alloy rod 100 ′′ can be reduced, and the homogenization of the composition and structure thereof can be improved. Furthermore, both steps 5 and 6 can provide a lubricating effect to facilitate the subsequent cold forging process.
- the method for manufacturing the cold-forged extruded aluminum alloy rod 100 , 100 ′, 100 ′′ of the present disclosure does not require high temperature hot forging equipment and material-taring equipment.
- the processing of the primary material 1 into the preform 1 ′ in step 2 not only can improve precision of the cold-forged extruded aluminum alloy rod 100 , 100 ′, 100 ′′, but also can reduce wearing out of the cold extrusion dies 10 , 10 ′, 10 ′′ of the cold extrusion apparatuses 2 , 2 ′, 2 ′′ so as to prolong the service life thereof.
- an overall power consumption and the manufacturing cost can be reduced.
- a step 8 may be provided, in which, referring to FIG. 6 , an advanced forming apparatus 3 is prepared for forming the third cold-forged extruded aluminum alloy rod 100 ′′ into a patterned cold-forged extruded aluminum alloy rod ( 100 a ) according to the requirement.
- the advanced forming apparatus 3 includes a forming die 31 having a molding die cavity 311 , and a forming punch 30 corresponding in position to the forming die 31 .
- the forming punch 30 includes a forming fixing seat 34 , and a forming ram 32 extending downwardly from the forming fixing seat 34 .
- step 8 the cold-forged extruded aluminum alloy rod 100 ′′ is positioned in the molding die cavity 311 , after which the forming punch 30 is operated to strike the forming ram 32 against the third cold-forged extruded aluminum alloy rod 100 ′′ to thereby form the patterned cold-forged extruded aluminum alloy rod ( 100 a ).
- the predetermined time for immersion of the preform 1 ′ into the lubricant depends on the number of the preform 1 ′.
- the predetermined time is 4 to 5 minutes.
- the predetermined time may range from 25 to 35 minutes.
- the method for manufacturing the cold-forged extruded aluminum alloy rod 100 , 100 ′, 100 ′′ by cold forging of the present disclosure has simple processing steps and equipments, is energy-saving, can effectively reduce the capital cost, and can improve the quality of the obtained cold-forged extruded aluminum alloy rod 100 , 100 ′, 100 ′′.
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Abstract
Description
- This application claims priority of Taiwanese Invention Patent Application No. 109146653, filed on Dec. 29, 2020.
- The disclosure relates to a method for manufacturing a cold-forged extruded aluminum alloy rod by cold forging and cold extrusion.
- A conventional connecting structure of a bicycle is generally made by hot forging and hot extrusion in response to the shape and structural strength requirements. Specifically, a material subjected to hot forging and hot extrusion is first heated in a furnace to a temperature above the recrystallization temperature, followed by a processing step for shaping. Hot forging and hot extrusion not only require a furnace that can withstand high temperature and a material-taking equipment, but also incur a high capital expenditure due to quick wearing of the hot forging and hot extrusion dies and large consumption of energy.
- Therefore, an object of the present disclosure is to provide a method for manufacturing a cold-forged extruded aluminum alloy rod by cold forging and cold extrusion that can alleviate at least one of the drawbacks of the prior art.
- According to this disclosure, a method for manufacturing a cold-forged extruded aluminum alloy rod includes the steps of:
- (A) preparing a primary material having a block shape and made of an aluminum alloy material, and at least one cold extrusion apparatus including a cold extrusion die, and a cold extrusion punch corresponding in position to the cold extrusion die;
- (B) processing the primary material to form a solid preform that extends along an axis and that has a first end surface intersecting the axis, a second end surface opposite to the first end surface along the axis, and an outer circumferential surface interconnecting outer circumferential edges of the first end surface and the second end surface, the preform having a length extending from the first end surface to the second end surface, and an outer diameter measured across the outer circumferential surface;
- (C) subjecting the preform to a homogeneous annealing which involves heating the preform in a furnace to a temperature ranging from about 410° C. to 510° C., and then removing the preform from the furnace after the furnace is cooled to a temperature ranging from about 160° C. to 200° C. at a cooling rate of 10° C. per hour;
- (D) testing the hardness of the preform, the hardness being equal to or below 60 degrees measured on Rockwell Hardness F scale;
- (E) immersing the preform in a tank containing a lubricant for a predetermined time;
- (F) applying talcum powder on the first end surface, the second end surface and the outer circumferential surface of the preform after the preform is immersed in the lubricant; and
- (G) subjecting the preform to cold forging which involves positioning the preform in the cold extrusion die, after which the cold extrusion punch is operated to strike against the preform to thereby form the cold-forged extruded aluminum alloy rod, the cold-forged extruded aluminum alloy rod being a solid rod that extends along the axis, and having a first side surface intersecting the axis, a second side surface opposite to the first side surface along the axis, and an outer circumferential surface interconnecting outer circumferential edges of the first side surface and the second side surface, the cold-forged extruded aluminum alloy rod having a length that extends from the first side surface to the second side surface thereof and that is longer than the length of the preform.
- Other features and advantages of the disclosure will become apparent in the following detailed description of the embodiment with reference to the accompanying drawings, of which:
-
FIG. 1 is a flow chart, illustrating the steps involved in a method for manufacturing a cold-forged extruded aluminum alloy rod according to an embodiment of the present disclosure; -
FIG. 2 is an exploded cross-sectional view of a first cold extrusion apparatus of the embodiment, illustrating how a preform is formed into a first cold-forged extruded aluminum alloy rod having first dimensions; -
FIG. 3 is an exploded cross-sectional view of a second cold extrusion apparatus of the embodiment, illustrating how the first cold-forged extruded aluminum alloy rod is formed into a second cold-forged extruded aluminum alloy rod having second dimensions; -
FIG. 4 is an exploded cross-sectional view of a third cold extrusion apparatus of the embodiment, illustrating how the second cold-forged extruded aluminum alloy rod is formed into a third cold-forged extruded aluminum alloy rod having third dimensions; -
FIG. 5 is a schematic view, illustrating how the preform is formed into the third cold-forged extruded aluminum alloy rod of the embodiment; and -
FIG. 6 is an exploded cross-sectional view of an advanced forming apparatus of the embodiment, in which a patterned cold-forged extruded aluminum alloy rod is formed. - Referring to
FIG. 1 , a method for manufacturing a cold-forged extruded aluminum alloy rod according to an embodiment of the present disclosure includessteps 1 to 7. - In
step 1, referring toFIGS. 2 and 5 , in combination withFIG. 1 , aprimary material 1 and threecold extrusion apparatuses primary material 1 has a block shape and is made of an aluminum alloy material, for instance, but is not limited to, AL6066 aluminum alloy and AL7050 aluminum alloy. Each of thecold extrusion apparatuses cold extrusion punch top surface die cavity top surface die cavity cold extrusion apparatus cavity 12 has a bottom portion having a first cavity diameter (d1). The diecavity 12′ has a bottom portion having a second cavity diameter. (d2) smaller than the first cavity diameter (d1), and thedie cavity 12″ has a bottom portion having a third cavity diameter (d3) smaller than the second cavity diameter (d2). - The cold extrusion punch 20, 20′, 20″ of each
cold extrusion apparatus base ram base ram cold extrusion apparatus - The
ram 22 has a first outer diameter (D1) corresponding to the first cavity diameter (d1). Theram 22′ has a second outer diameter (D2) corresponding to the second cavity diameter (d2) and smaller than the first outer diameter (D1). Theram 22″ has a third outer diameter (D3) corresponding to the third cavity diameter (d3) and smaller than the second outer diameter (D2). - In
step 2, with reference toFIGS. 1 and 2 , theprimary material 1 is processed to form asolid preform 1′ that extends along an axis (X) and that has afirst end surface 101 intersecting the axis (X), asecond end surface 102 opposite to thefirst end surface 101 along the axis (X), and an outercircumferential surface 103 interconnecting outer circumferential edges of the first andsecond end surfaces preform 1′ has a length (L) extending from thefirst end surface 101 to thesecond end surface 102, and an outer diameter (D0) measured across the outercircumferential surface 103. - In
step 3, thepreform 1′ is subjected to a homogeneous annealing which involves heating thepreform 1′ in a furnace to a temperature ranging from about 410° C. to 510° C., and then removing thepreform 1′ from the furnace after the furnace is cooled to a temperature ranging from about 160° C. to 200° C. at a cooling rate of 10° C. per hour. - In
step 4, the hardness of theannealed preform 1′ is tested. The hardness of thepreform 1′ is equal to or below 60 degrees measured on Rockwell. Hardness F scale (HRF). The testing of the hardness of thepreform 1′ is performed at multiple points of the outercircumferential surface 103 of thepreform 1′ and at equal intervals along the axis (X). - In
step 5, thepreform 1′ is immersed in a tank containing a lubricant (not shown) for a predetermined time. In certain embodiments, the lubricant has a free total acidity (TA) concentration ranging from 40% by weight to 50% by weight at a working temperature ranging from 80° C. to 100° C. The lubricant used may be boron nitride. In other embodiments, the lubricant, for instance, a liquid grease, has a viscosity index (VI) of equal to or above 170, a flash point of equal to or above 240° C., a pour point of equal to or above −24° C. and a fire point of equal to or above 255° C. - In
step 6, thefirst end surface 101, thesecond end surface 102 and the outercircumferential surface 103 of thepreform 1′ are applied with talcum powder after thepreform 1′ is immersed in the lubricant. - In
step 7, with reference toFIGS. 2 and 5 , thepreform 1′ that has been immersed in the lubricant and applied with talcum powder is subjected to cold forging. Thepreform 1′ is positioned in a top opening of thedie cavity 12 of the cold extrusion die 10, after which thecold extrusion punch 20 is operated to strike theram 22 against thepreform 1′, thereby forming a first cold-forged extrudedaluminum alloy rod 100 that has first dimensions. The first cold-forged extrudedaluminum alloy rod 100 is a solid rod that extends along the axis (X), and has afirst side surface 110 intersecting the axis (X), asecond side surface 120 opposite to thefirst side surface 110 along the axis (X), and an outercircumferential surface 130 interconnecting outer circumferential edges of the first andsecond side surfaces aluminum alloy rod 100 has a length (L1) that extends from thefirst side surface 110 to thesecond side surface 120 thereof and that is longer than the length (L) of thepreform 1′, and an outer diameter (D′) smaller than the outer diameter (D0) of thepreform 1′. - In this embodiment, a step of subjecting the first cold-forged extruded
aluminum alloy rod 100 to undergosteps 3 to 7 may be further conducted. Referring toFIG. 3 , in combination withFIG. 5 , in this step, the first cold-forged extrudedaluminum alloy rod 100 is positioned in a top opening of thedie cavity 12′ of the cold extrusion die 10′, after which thecold extrusion punch 20′ is operated to strike theram 22′ against the first cold-forged extrudedaluminum alloy rod 100, thereby forming a second cold-forged extrudedaluminum alloy rod 100′ that has second dimensions different from the first dimensions. The second cold-forged extrudedaluminum alloy rod 100′ is also a solid rod that extends along the axis (X), and has afirst side surface 110′ intersecting the axis (X), asecond side surface 120′ opposite to thefirst side surface 110′ along the axis (X), and an outercircumferential surface 130′ interconnecting outer circumferential edges of the first andsecond side surfaces 110′, 120′. The second cold-forged extrudedaluminum alloy rod 100′ has a length (L2) that extends from thefirst side surface 110′ to thesecond side surface 120′ thereof and that is longer than the length (L1) of the first cold-forged extrudedaluminum alloy rod 100, and an outer diameter (D″) smaller than the outer diameter (D′) of the first cold-forged extrudedaluminum alloy rod 100. - In this embodiment, a step of subjecting the second cold-forged extruded
aluminum alloy rod 100′ to undergosteps 3 to 7 may be further conducted. Referring toFIG. 4 , in combination withFIG. 5 , in this step, the second cold-forged extrudedaluminum alloy rod 100′ is positioned in a top opening of thedie cavity 12″ of the cold extrusion die 10″, after which thecold extrusion punch 20″ is operated to strike theram 22″ against the second cold-forged extrudedaluminum alloy rod 100′, thereby forming a third cold-forged extrudedaluminum alloy rod 100″ that that has third dimensions different from the second dimensions and the first dimensions. The third cold-forged extrudedaluminum alloy rod 100″ is also a solid rod that extends along the axis (X), and has afirst side surface 110″ intersecting the axis (X), asecond side surface 120″ opposite to thefirst side surface 110″ along the axis (X), and an outercircumferential surface 130″ interconnecting outer circumferential edges of the first andsecond side surfaces 110″, 120″. The third cold-forged extrudedaluminum alloy rod 100″ has a length (L3) that extends from thefirst side surface 110″ to thesecond side surface 120″ thereof and that is longer than the length (L2) of the second cold-forged extrudedaluminum alloy rod 100′, and an outer diameter (Da) smaller than the diameter. (D″) of the second cold-forged extrudedaluminum alloy rod 100′. For example, the outer diameter (D′) may be 45 mm, the outer diameter (D″) may be 22 mm, and the outer diameter (Da) may be 6 mm. It should be noted that the number of thecold extrusion apparatuses step 1 corresponds to the number of times that steps 3 to 7 is repeated. - Thus, by utilizing the above-mentioned
consecutive steps 1 to 7 of the present disclosure and by repeatingsteps 3 to 7 twice, theprimary material 1 can be formed into the third cold-forged extrudedaluminum alloy rod 100″. The third cold-forged extrudedaluminum alloy rod 100″ can avoid the defects caused by metal heating, can obtain high precision and surface quality, can improve the hardness and strength of a workpiece, and has a large deformation resistance during cold forging. By processing theprimary material 1 into thepreform 1′ instep 2, the third cold-forged extrudedaluminum alloy rod 100″ is not required to undergo precision machining, and thecold extrusion apparatuses step 3 can improve plasticity of thepreform 1′, the first cold-forged extrudedaluminum alloy rod 100 and the second cold-forged extrudedaluminum alloy rod 100′, so that in the cold forging process instep 7, residual stress of the first cold-forged extrudedaluminum alloy rod 100, the second cold-forged extrudedaluminum alloy rod 100′ and the third cold-forged extrudedaluminum alloy rod 100″ can be reduced, and the homogenization of the composition and structure thereof can be improved. Furthermore, bothsteps - Therefore, the method for manufacturing the cold-forged extruded
aluminum alloy rod primary material 1 into thepreform 1′ instep 2 not only can improve precision of the cold-forged extrudedaluminum alloy rod cold extrusion apparatuses - It is worth mentioning that, in this disclosure, a
step 8 may be provided, in which, referring toFIG. 6 , an advanced formingapparatus 3 is prepared for forming the third cold-forged extrudedaluminum alloy rod 100″ into a patterned cold-forged extruded aluminum alloy rod (100 a) according to the requirement. The advanced formingapparatus 3 includes a formingdie 31 having amolding die cavity 311, and a formingpunch 30 corresponding in position to the formingdie 31. The formingpunch 30 includes a forming fixingseat 34, and a formingram 32 extending downwardly from the forming fixingseat 34. - In
step 8, the cold-forged extrudedaluminum alloy rod 100″ is positioned in themolding die cavity 311, after which the formingpunch 30 is operated to strike the formingram 32 against the third cold-forged extrudedaluminum alloy rod 100″ to thereby form the patterned cold-forged extruded aluminum alloy rod (100 a). - It should be noted herein that in
step 5 of this disclosure, the predetermined time for immersion of thepreform 1′ into the lubricant depends on the number of thepreform 1′. When the number of thepreform 1′ is one, the predetermined time is 4 to 5 minutes. When there are a plurality of thepreforms 1′, the predetermined time may range from 25 to 35 minutes. - In sum, the method for manufacturing the cold-forged extruded
aluminum alloy rod aluminum alloy rod - While the disclosure has been described in connection with what is considered the exemplary embodiment, it is understood that this disclosure is not limited to the disclosed embodiment but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.
Claims (11)
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TW109146653A TWI744154B (en) | 2020-12-29 | 2020-12-29 | Aluminum alloy rod forging and forming method |
TW109146653 | 2020-12-29 |
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