WO2005107974A1 - Processus de coulée et de forgeage de roue en aluminium - Google Patents

Processus de coulée et de forgeage de roue en aluminium Download PDF

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Publication number
WO2005107974A1
WO2005107974A1 PCT/CN2005/000638 CN2005000638W WO2005107974A1 WO 2005107974 A1 WO2005107974 A1 WO 2005107974A1 CN 2005000638 W CN2005000638 W CN 2005000638W WO 2005107974 A1 WO2005107974 A1 WO 2005107974A1
Authority
WO
WIPO (PCT)
Prior art keywords
casting
forging
aluminum
forging process
spokes
Prior art date
Application number
PCT/CN2005/000638
Other languages
English (en)
Chinese (zh)
Inventor
Xinying Zhang
Zengyuan Pan
Original Assignee
Xinying Zhang
Zengyuan Pan
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Xinying Zhang, Zengyuan Pan filed Critical Xinying Zhang
Publication of WO2005107974A1 publication Critical patent/WO2005107974A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/005—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of rolls, wheels or the like
    • 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
    • B21J5/004—Thixotropic process, i.e. forging at semi-solid state
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/28—Making machine elements wheels; discs
    • B21K1/38—Making machine elements wheels; discs rims; tyres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
    • B22D31/002—Cleaning, working on castings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49496—Disc type wheel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49496—Disc type wheel
    • Y10T29/49504—Disc shaping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting

Definitions

  • the present invention relates to the technical field of manufacturing aluminum alloy wheels for automobiles and other types of motor vehicles, and particularly to a casting and forging process for replacing traditional "forging slab forging” aluminum wheels with “forging slab forging”.
  • the manufacturing of automotive aluminum wheels generally includes casting, forging, spinning rims, (plate) spinning and rolling technologies.
  • the traditional casting process of aluminum wheels includes gravity casting and squeeze casting.
  • the former is usually a method of using gravity (without any additional pressure) to make the molten metal flow and fill the cavity.
  • This casting method is widely used due to its advantages such as lower production cost, greater freedom of appearance and modeling, lighter weight than cast slabs, and reliable strength. But because this process only uses gravity to fill the cavity with aluminum liquid, compared with other pressure casting and forging methods, the density of the billet formed after the injection of aluminum liquid into the mold is lower; at the same time, the large wall thickness required to meet the strength of the wheel , Increased the weight of aluminum wheels.
  • extrusion casting uses high pressure to quickly fill the cavity with aluminum liquid to obtain higher density products.
  • the production cost of extrusion casting of aluminum wheels is higher than the cost of gravity casting. The reason is that its performance depends on the pressure (that is, the higher the pressure, the higher the cost of the machine). It is usually sold in OEM and afterniarket. Aluminium wheels are generally "pressure field" cast products.
  • the forming process of aluminum wheels manufactured by this method is: firstly casting the slab with low pressure, spinning the slab with a special machine tool, then heating the outside of the slab, and then rolling the rim into the final width and shape by hot rolling. .
  • the rim portion thus obtained has the same strength as the forged wheel without the need for higher costs.
  • Forging technology uses solid pressure to form a solid aluminum billet in the forging die cavity.
  • the final billet is undoubtedly very dense and strong, so the product can also be very light.
  • Forging methods of traditional aluminum wheels need to go through the following steps: (1) smelting, (2) casting into round billets, (3) homogenizing materials, (4) extruding billets, (5) cutting, (6) heating, (7) Forging billets, (8) heating, (9) preliminary forging, ( ⁇ ) heating, (11) precision forging, (12) removing flash, (13) heat treatment, (14) fluorescent inspection, (15) Machining.
  • the purpose of the present invention is to solve the deficiencies in the prior art mentioned above, and provide a casting and forging process for aluminum wheels.
  • the process is simple to operate, the overall cost is significantly reduced, and the product performance of aluminum wheels is comparable to or even higher than that of the forging wheel.
  • the process is easy to repeat production and easy to promote.
  • the casting and forging process of an aluminum wheel includes the casting and forging process of a wheel spoke, and includes the following steps: First, a low pressure casting or gravity casting spoke is produced, and the spoke is heated to the plastic deformation temperature of the material Then, put the heated spokes into a forging die for high-pressure forging, then check whether the forged spokes are defective, and then machine the forged spokes into semi-finished spokes. Finally, combine it with the corresponding rim to form a complete wheel.
  • the high pressure forging is to compress a heated spoke casting by about 5 to 20 mm; the pressure of the low pressure casting is about 0.1 to 1 kg / cm 2 , and the pressure of the high pressure forging is about 500 to 1000 kg / cm 2 ; the forged spokes Defect detection uses fluorescent flaw detection, or other known flaw detection techniques; the machined spokes refer to processing the spokes to the required spoke size, and also include the dimensions of the processing and assembly accessories, such as center holes, valve holes, etc .; The machined spokes and the rim are connected by bolts or welded into a wheel; the spoke material is mainly composed of aluminum, and generally includes the following constituent elements: In terms of mass percentage, Si is about 6 ⁇ 8%, Mg is about 0.25 ⁇ 0.45%, Ti about 0.1 ⁇ 0.2%, Sr about 0.01 ⁇ 0.02%, Fe about 0.1 ⁇ 0.2%, the rest is A1; it can also be about 6 ⁇ 8% Si, Mg about 0.25-0.45%, Ti about 0.1 ⁇ 0.
  • the present invention has obvious advantages and beneficial effects.
  • the required production steps are: (1) smelting, (2) casting into a round billet, (3) material Homogenization, (4) extruded billet, (5) cut, (6) heating, (7) forging billet, (8) heating,
  • the present invention reduces the number of production steps compared to the above method, so Significantly reduced processing time, increased use of metallic materials, reduced overall manufacturing processes and reduced final product costs by almost 40%. Since the present invention uses a cast slab as a forged billet, it provides an unlimited free design for the spokes.
  • the wheels produced are rarely defective, such as pinholes, and the aluminum wheels manufactured at the same time even in the center hole region can reach 10% elongation and have higher than 250N / mm 2 tensile strength, the most attractive is preserved a large degree of freedom in modeling casting wheel great advantage of the method. This ensures that a variety of high-end aluminum wheels can be provided for today's automotive industry.
  • Figure 1 is a flowchart of the corresponding process of the traditional forging method
  • FIG. 3 are schematic diagrams of each step of connecting a spoke to a spinning rim in the present invention.
  • FIGS. 3 to c are sectional views of an assembly connecting the spoke and the rim by bolts;
  • FIG. 4 is a schematic diagram of each manufacturing process of the casting and forging manufacturing method of the present invention, including a process from a casting slab to a forging slab.
  • Figures 2 to 4 are schematic illustrations of the different manufacturing steps and their charts of the casting and forging method of the present invention.
  • Figure 1 is a traditional aluminum wheel forging method, which specifically includes the following steps: (1) 10 smelting, (2) 12 casting into a round billet, (3) 14 material homogenization, (4) 16 extruded billet, (5 ) 18 cuts, (6) 20 heating, (7) 22 forging billets, (8) 24 heating, (9) 26 preliminary forging, (10) 28 heating, (11) 30 fine forging, (12) 32 removing fly Edge, (13) 3 "4 heat treatment, (14) 36 fluorescent flaw detection, (15) 38 machining.
  • the present invention aims to simplify and combine the first 8 steps of the above-mentioned aluminum wheel manufacturing process (ie, from (1) to (8)), directly heating and forging with a cast slab, and then processing the forged wheel into The required dimensions of the product. It is proved through experiments that the aluminum wheels manufactured by the casting and forging process in the present invention and their mechanical properties are superior to the conventional cast or forged aluminum wheels.
  • the casting and forging process of the present invention first uses low pressure casting to produce a The spokes 40 of the rim 42.
  • low-pressure casting uses air pressure technology, and the air pressure ranges from about 0.1 to 1 kg / cm 2 .
  • the spoke 40 is heated to its plastic temperature, and the temperature thereof is a commonly known plastic deformation temperature of the aluminum material. Once the plastic temperature is reached, the spokes 40 are put into a forging die 45, and the heated spokes are forged under high pressure into a finished shape.
  • a screw press of about 8,000 tons is used for forging and casting the spokes 40 under high pressure.
  • the deformable compression amount after high pressure is 5-20 mm, as shown by the X mark in FIG. 4.
  • the screw press used for high-pressure castings produces a pressure of about 500 to 1000 kg / cm 2 .
  • the forged spokes 46 can be ejected from the mold by the ejector mechanism of the forging press.
  • the forged spokes 46 are inspected by fluoroscopy for defects in the interior, including inspection of the forged spokes using known X-rays.
  • the inspection of the forged spokes can also be performed by other common detection techniques without departing from the scope of the present invention.
  • the mechanical properties of the material can then be improved by heat treatment according to the properties of the material.
  • the heat-treated spokes are then machined to the required size.
  • This machining process also includes the dimensions required when processing and assembling accessories such as: center hole, valve hole and bead seat.
  • parameters such as offset and center diameter of bolt hole (PCD) should be considered to meet the requirements of automobiles and tires. Assembly requirements.
  • the rim 48 may be manufactured by a conventional spinning forming process, that is, an aluminum plate is spin-formed in a spinning mold, and the rim may be manufactured by other methods without departing from the scope of the present invention. For example: simply cut the aluminum pipe into a rim, or roll the aluminum plate first and then join it into a rim. Obviously, the objective of the present invention can still be achieved by using gravity casting instead of the low-pressure casting process.
  • the forged spokes 46 and the spun rim 48 can be connected by bolts 50 to ensure the balanced performance of the wheel assembly, such as well-known methods (see a ⁇ c).
  • bolts 50 to ensure the balanced performance of the wheel assembly, such as well-known methods (see a ⁇ c).
  • there are other mature processes to connect the forged spokes 46 and the spinning rims 48 such as welding the forged spokes 46 and the spinning rims 48 by welding to produce lightweight wheels.
  • forged spokes and spun rims can also be connected by conventional sealants (such as 49 sealing adhesive) to prevent air leakage between the spokes and the rim after the tire is mounted.
  • sealants such as 49 sealing adhesive
  • the aluminum material used in the casting and forging process in the present invention is one A special chemical composition of materials to facilitate the casting process and produce wheels that meet the requirements of forging performance.
  • This alloy material is composed of A1-Si-Mg and other elemental components.
  • the elemental components can have the following solutions: (1) Si about 6%, Mg about 0.25%, Ti about 0.1%, Sr about 0.01%, Fe about 0.1 %, The rest is A1; (2) Si is about 8%, Mg is about 0.45%, Ti is about 0.2%, Sr is about 0.02%, Fe is about 0.2%, and the rest is A1; (3) Si is about 6.58%, Mg is about 0.3% , Ti is about 0.2%, Sr is about 0.18%, Fe is about 0.16%, L is about 0.2%, C is about 0.2%, and the rest is Al.
  • a product produced by a material using such a component through a casting and forging method can meet or even surpass the requirements of the strength, weight, and performance of today's forged wheels.
  • the forged spokes are described as including a partial rim or connected to a spinning rim, it is easy to think that the forged spokes can be produced with or without a partial rim and can be connected to a rim. In addition, it is easy to judge that the invention produces

Abstract

La présente invention concerne un processus de coulée et de forgeage de roue en aluminium qui comprend des rayons. Ce processus consiste à produire un rayon de roue par coulée en basse pression, à chauffer ce rayon à la température de déformation du plastique, puis à mettre ce rayon dans un moule de forgeage en vue d'une coulée de haute pression. Ce processus consiste aussi à détecter un défaut de rayon de roue, à usiner ce rayon à la dimension souhaitée à la machine, puis à assembler ce rayon et une jante de roue correspondante en vue de former une roue complète. Cette invention réduit les étapes de production, raccourcit le temps de production, augmente la disponibilité du matériau métallique et réduit les coûts du produit final de 40 %. Un autre avantage réside dans le fait que la route terminée possède une élongation de 10 % et une résistance en tension >250N/mm dans la partie du trou central.
PCT/CN2005/000638 2004-05-10 2005-05-09 Processus de coulée et de forgeage de roue en aluminium WO2005107974A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US56978704P 2004-05-10 2004-05-10
US60/569,787 2004-05-10

Publications (1)

Publication Number Publication Date
WO2005107974A1 true WO2005107974A1 (fr) 2005-11-17

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Application Number Title Priority Date Filing Date
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Country Status (3)

Country Link
US (1) US20050262693A1 (fr)
CN (1) CN100396400C (fr)
WO (1) WO2005107974A1 (fr)

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CN103212693A (zh) * 2013-03-27 2013-07-24 金相龙 新型溶汤锻造机
CN103418771A (zh) * 2012-05-16 2013-12-04 华硕电脑股份有限公司 金属件的铸锻成型方法及铸锻成型设备

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CN102179469B (zh) * 2011-01-04 2012-09-05 安徽工业大学 一种减小锻压力的火车车轮预成形方法
CN102228951B (zh) * 2011-04-26 2012-11-14 哈尔滨哈飞工业有限责任公司 一种复杂结构铝合金轮毂锻扩成形方法及其模具
FR2981605B1 (fr) * 2011-10-25 2013-11-01 Saint Jean Ind Procede de fabrication d'une roue hybride en deux parties en alliage leger notamment aluminium
GB2503936B (en) * 2012-07-13 2020-03-04 Gkn Wheels Ltd Manufacture of wheels
CN103624235A (zh) * 2012-08-28 2014-03-12 昆山拓卡自动化设备制造有限公司 采用液态锻造和旋压工艺组合制造轮毂的方法
CN103084560B (zh) * 2013-02-18 2015-05-13 天津那诺机械制造有限公司 熔汤锻造方法及其模具
TWI586453B (zh) * 2014-04-11 2017-06-11 Method of manufacturing near - round forging of rims
CN105014304A (zh) * 2014-04-18 2015-11-04 瑞鸿电通有限公司 轮圈的近形锻旋制造方法
CN105127399A (zh) * 2015-08-25 2015-12-09 来安县科来兴实业有限责任公司 一种动车组制动系统安装管座低压铸造工艺
CN106141589A (zh) * 2016-08-04 2016-11-23 浙江保康轮毂制造有限公司 一种重型卡车超大轮毂锻造工艺
CN106078118A (zh) * 2016-08-04 2016-11-09 浙江保康轮毂制造有限公司 一种高强度铝合金轮毂制造工艺
CN109158519B (zh) * 2018-10-31 2020-01-14 扬州易达利机械科技有限公司 一种铝合金轮毂铸锻设备
KR20200089544A (ko) * 2019-01-17 2020-07-27 현대자동차주식회사 더블레이어 타입 변속기 유성 기어 캐리어의 제조방법 및 이로부터 제조된 유성 기어 캐리어
CN111283173B (zh) * 2020-03-26 2021-12-10 安徽拓普勒汽车科技有限公司 一种大尺寸汽车铝合金轮毂的制造方法

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CN103418771A (zh) * 2012-05-16 2013-12-04 华硕电脑股份有限公司 金属件的铸锻成型方法及铸锻成型设备
CN103212693A (zh) * 2013-03-27 2013-07-24 金相龙 新型溶汤锻造机
CN103212693B (zh) * 2013-03-27 2015-08-19 金相龙 新型溶汤锻造机

Also Published As

Publication number Publication date
CN1946497A (zh) 2007-04-11
CN100396400C (zh) 2008-06-25
US20050262693A1 (en) 2005-12-01

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