WO2015068757A1 - アルミニウム合金用ホットチャンバー鋳造機 - Google Patents
アルミニウム合金用ホットチャンバー鋳造機 Download PDFInfo
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- WO2015068757A1 WO2015068757A1 PCT/JP2014/079415 JP2014079415W WO2015068757A1 WO 2015068757 A1 WO2015068757 A1 WO 2015068757A1 JP 2014079415 W JP2014079415 W JP 2014079415W WO 2015068757 A1 WO2015068757 A1 WO 2015068757A1
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- molten metal
- main cylinder
- injection main
- melting furnace
- metal injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
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- the present invention relates to a hot chamber casting machine for aluminum alloy for die casting and a die casting method using the same.
- the hot chamber casting machine for aluminum alloy according to the present invention avoids the problems of the conventional hot chamber casting machine, is not suitable for the conventional hot chamber casting machine, and has been used for the cold chamber casting machine. It is a hot chamber casting machine that can also be used in the field.
- die casting is a manufacturing method in which molten metal (molten metal) is cast into a die (Die) at a predetermined pressure by a piston.
- Die-casting machines are roughly classified into hot chamber casting machines and cold chamber casting machines. In both the hot chamber casting machine and the cold chamber casting machine, a metal material for die casting is melted, and the molten metal material is injected into a molding die for casting.
- the hot chamber casting machine is called a hot chamber casting machine because the melting furnace and the casting machine are integrated, and the piston-cylinder injection part and the introduction pipe are in the molten metal of the melting furnace and heated together.
- the molten metal is pushed out from the piston-cylinder injection part sinking in the molten metal in the melting furnace, passes through the introduction pipe, reaches the mold, and is cast.
- FIG. 6 is a diagram showing a basic configuration of a conventional hot chamber casting machine.
- the hot chamber casting machine 10 has a piston-cylinder injection part 12 accommodated in a melting furnace 11, and the inside is filled with molten metal.
- the piston 13 is connected to and driven by a piston drive mechanism (not shown).
- a melt inlet 14 is provided on the side surface of the piston-cylinder injection part 12, and an injection path 15 is led from the end of the piston-cylinder injection part 12.
- a mold 17 is installed outside the melting furnace 11 via a nozzle 16 near the tip of the injection path 15. Note that the height of the tip of the nozzle 16 in the injection path 15 is provided at a position higher than the height of the molten metal surface in the melting furnace 11.
- the casting process of the conventional hot chamber casting machine 10 shown in FIG. 6 is performed according to the following procedure.
- the pressure of the piston is usually 10MP to 30MP.
- the pressure is generated by being applied to the piston by a hydraulic machine or a linear motor (not shown).
- the structure is such that the molten metal is injected from the cylinder into the injection path 15 by the pressure of the piston, and is injected into the mold 17 through the nozzle 16.
- the mold 17 is separated, and the molded product inside is taken out.
- a feature of the hot chamber casting machine 10 shown in FIG. 6 is that the hot water supply process to the piston-cylinder injection part 12 of the molten metal can be automatically performed in accordance with the piston movement of the piston-cylinder injection part 12 in the melting furnace 11. Therefore, there is a point that a casting cycle is faster than a cold chamber casting machine.
- the melting furnace and the casting machine are separate, and the molten metal is pumped from the melting furnace for one shot and is put into the casting machine outside the melting furnace, and casting is performed outside the melting furnace. Is.
- the casting machine is called a cold chamber casting machine because it is not in the melting furnace but provided outside and is not heated.
- FIG. 7 is a diagram showing a basic configuration of a conventional cold chamber casting machine 20.
- the cold chamber casting machine 20 is provided with an extrusion molding machine 24 including a sleeve 22 and a plunger 23 outside the melting furnace 21, and a pressing device 27 is connected to the plunger 23. It has a working structure.
- a mold 25 is installed at the tip of the sleeve 22.
- the casting process of the conventional cold chamber casting machine 20 shown in FIG. 7 is performed according to the following procedure.
- the molten metal in the melting furnace 21 is pumped out by the ladle 26 and the molten metal for one shot is poured into the sleeve 22.
- FIG. 7B after a predetermined amount of molten metal is poured into the sleeve 22, it is press-fitted with a plunger 23 and pushed into a mold 25 to be molded.
- the pressure of the plunger 23 is typically 60MP to 100MP.
- the pressure is generated by being applied to the plunger 23 by a hydraulic machine or a linear motor (not shown).
- a feature of the cold chamber casting machine 20 is that it can be applied to die casting using a metal material having a high melting point. Even when a metal material having a high melting point such as an aluminum alloy or a copper alloy is used, the cold chamber casting machine 20 shown in FIG. 7 has an extrusion molding machine 24 and an extrusion molding machine 24, which are separate from each other. The machine 24 does not need to be exposed to the high temperature of the melting furnace 21, and there is no risk that these parts will melt. Therefore, die casting using a material that melts the parts of the casting machine such as a metal material having a high melting point or a molten aluminum alloy is possible.
- the cold chamber casting machine 20 can easily be used for molding a large product using a large mold. Performing large molding increases the size of the casting machine itself, but the melting furnace is considerably large if the casting mechanism is housed in the melting furnace as in the hot chamber system. In this regard, in the case of cold chamber die casting, since the melting furnace and the casting machine are separated, the size of the melting furnace can be suppressed.
- the conventional cold chamber casting machine 20 has disadvantages.
- the conventional cold chamber casting machine 20 has a problem that the casting speed is relatively slow.
- the temperature of the sleeve 22 is usually lower than the melting point of the aluminum alloy, when the molten aluminum alloy is supplied to the sleeve 22 with the ladle 26, the molten aluminum alloy partially solidifies, and solids are mixed in the molten metal. Is sent to the mold, and molding is performed in a state where the solid content is scattered in the product. This is usually called a fractured chill layer and makes the product strength unstable.
- the cold chamber casting machine has disadvantages.
- the hot chamber casting machine can be said to be an excellent method if attention is paid to its high casting speed and low casting pressure.
- the conventional hot chamber casting machine 10 has a great disadvantage. That is a problem that the conventional hot chamber casting machine 10 cannot use an aluminum alloy. If the aluminum alloy is melted in the melting furnace, the melting furnace 11, the piston-cylinder injection part 12, the nozzle 16 and the like are made of an iron-based alloy, so that the aluminum alloy is melted and melted into the aluminum alloy. Function is lost. Most metals, not just iron-based alloys, are eroded by aluminum alloys, and satisfactory results cannot be obtained even if they are protected by nitriding, spraying, or the like. Therefore, there is a need for a hot chamber casting machine that can be cast even if an aluminum alloy is used by improving the hot chamber casting machine.
- FIG. 8 shows a sand-type low-pressure casting machine disclosed in Japanese Patent Application Laid-Open No. 2004-122134. Note that the numbering in the figure uses the numbering used in the figure of JP-A-2004-122134 as it is, and is not related to the other numbering in this specification. .
- this manufacturing apparatus is provided with a melting furnace 3 for storing a light metal melt 2 inside a furnace body 1.
- the furnace body 1 is provided with a heating device 8 such as a gas burner for heating the melting furnace 3.
- a mold placing table 12 on which a sand mold 11 is placed is disposed above the furnace body 1.
- the melting furnace 3 is hermetically sealed by a lid member 4, and a pressurized gas supply port 6 for supplying the pressurized gas 5 into the melting furnace 3 at a low pressure is formed in the lid member 4.
- a pressurized gas supply means 7 is connected to the pressurized gas supply port 6.
- a stalk 21 is erected in the molten metal, and a stalk 33 is further erected via an upper molten metal reservoir 29, and is connected to the sand mold 11.
- a molten metal surface sensor 34 is provided.
- the antioxidant gas or the combustion preventing gas 28 in the stalk 21 is replaced with the antioxidant gas or the combustion preventing gas 28 for the air in the cavity 16 in the sand mold 11.
- the hot metal surface of the light metal melt 2 stored in the melting furnace 3 is pressurized with a pressurized gas 5 at a low pressure, and through a stalk 21 standing in the molten metal, a chamber 29 serving as a molten metal reservoir, and further through a stalk 33.
- the molten metal 2 is pushed up into the cavity 16 of the sand mold 11.
- the pressurized gas 5 from the pressurized gas supply means 7 is used to push up the molten metal in the melting furnace 3 and push it into the mold, and does not use a mechanism system such as a piston. Yes.
- the sand-type low pressure casting machine shown in FIG. 8 is still insufficient for handling a metal material of an aluminum alloy. Most of the parts in the injection path are not in the melting furnace, so the structure is easy to radiate heat. There is no change in the exposed points, and the problem of melting damage occurs.
- the sand type low pressure casting machine shown in FIG. 8 has a problem in terms of casting speed.
- the casting cycle becomes slower than the basic shape of FIG. Therefore, it is performed while sensing the rising position of the molten metal surface by the molten metal surface sensor 34 and is performed carefully.
- a hot chamber casting machine has a problem in terms of casting speed because it can be die cast so as to be shot in one shot according to the piston cycle.
- the present invention provides a hot chamber casting machine for an aluminum alloy, which has a high casting speed by improving the hot chamber casting machine and does not cause a problem of melting even when a molten aluminum alloy is used.
- the purpose is to provide.
- a hot chamber casting machine for an aluminum alloy includes a melting furnace in which a molten metal is put, a molten metal injection main cylinder formed by ceramics standing in the melting furnace, and a molten metal injection main cylinder
- the injection path provided on the side of the injection path, the nozzle provided at the tip of the injection path, and a die for casting the molten metal into the mold, and the molten main injection cylinder are provided at a position lower than the injection path, and the melting furnace and the molten metal
- a valve body that opens and closes continuity with the internal space of the injection main cylinder part, and a pressurization part that controls application and removal of a predetermined gas pressure to the internal space of the molten metal injection main cylinder part.
- the aluminum alloy hot chamber casting machine When gas pressure is applied to the internal space of the molten metal injection main cylinder part, it works in the direction of closing the valve body, the molten metal inside the molten metal injection main cylinder part is die-cast from the injection path to the mold, and the pressurizing part is molten metal Gas pressure is removed from the internal space of the main injection cylinder
- the aluminum alloy hot chamber casting machine is characterized in that the valve body is opened and the required amount of molten metal is supplied from the melting furnace to the inside of the molten metal injection main cylinder for the next die casting.
- the member provided in the melting furnace is a molten metal injection main cylinder part made from a ceramic, it does not melt to an aluminum alloy.
- the gas pressure applied by the pressurizing part only needs to press a small molten metal surface called the molten metal injection main cylinder part, and only needs to push the molten metal.
- the control is simple and the die casting speed can be increased.
- the conventional piston-cylinder system requires high machining accuracy for the piston and cylinder wall surfaces, and its production is costly, and measures such as distortion and loss of the wall surface are required for maintenance after operation.
- pressure is applied to the cylinder by using gas pressure, distortion and error of the wall surface in the cylinder do not pose a problem, the manufacturing cost of the cylinder can be reduced, and maintenance after operation can be easily performed. The advantage is obtained.
- a wall surface structure in contact with the outer wall side surface of the molten metal injection main cylinder made of ceramic is provided in the melting furnace so that the molten metal injection main cylinder is fixed in the horizontal direction in the melting furnace, It is preferable that a flange is provided on the upper end surface of the molten metal injection main cylinder part and the molten metal injection main cylinder part is fixed in the vertical direction in the melting furnace by fixing the flange and the bottom wall surface of the molten metal injection main cylinder part.
- the valve body is a ball valve
- the lower inner surface of the molten metal injection main cylinder portion is in a mortar shape so that the ball valve is easily guided to the conduction hole, and the diameter of the ball valve is at the bottom of the mortar-shaped wall surface.
- a gas speed reduction portion for reducing the gas flow rate entering the gas injection from the pressure portion in the internal space of the molten metal injection main cylinder portion.
- the gas deceleration unit include a plate material, a labyrinth, and a damper provided at a position facing the gas introduction pipe.
- the specific gravity is smaller than the solid oxide or aluminum alloy melt that the aluminum alloy melt can come into contact with the air in order to prevent the melt surface inside the molten steel injection main cylinder from undulating and splashing when the gas pressure is applied. It is preferable that a lid-like object made of porous aluminum oxide or the like that is not melted by the molten metal is floated on the molten metal surface inside the molten metal injection main cylinder.
- the configuration of the pressurizing unit is preferably provided with a gas tank, a solenoid valve, and a gas introduction pipe. If it is a solenoid valve, the opening and closing operation is quick, and the amount of gas applied can be accurately controlled by the opening and closing operation of the solenoid valve.
- the members provided in the melting furnace are a ceramic molten metal injection main cylinder part, a nozzle and a ball valve, and the part in contact with the aluminum alloy inside the melting furnace is a ceramic paint. Since it is coated, the aluminum alloy can be used as a metal material because it does not melt into the aluminum alloy. Further, in the hot chamber casting machine for an aluminum alloy of the present invention, the gas pressure applied by the pressurizing part only needs to press a small molten metal surface called a molten metal injection main cylinder part, and only needs to be pushed downward. Pressure control is simple and the die casting speed can be increased.
- the conventional piston-cylinder system requires high machining accuracy for the piston and cylinder wall surfaces, and its production is costly, and measures such as distortion and loss of the wall surface are required for maintenance after operation.
- the present invention since pressure is applied to the cylinder by using gas pressure, distortion and error of the wall surface in the cylinder do not pose a problem, the manufacturing cost of the cylinder can be reduced, and maintenance after operation can be easily performed. The advantage is obtained.
- FIG. 1 is a diagram simply showing a configuration example of a hot chamber casting machine 100 for an aluminum alloy according to the present invention.
- each member is shown in a longitudinal section so that the internal structure can be easily understood.
- the features of the members are simply illustrated so that the features of the members can be understood. Only the members necessary for understanding the present invention are illustrated, and some other members may not be illustrated.
- the hot chamber casting machine 100 for an aluminum alloy includes a melting furnace 110, a molten metal injection main cylinder 120, an injection path 130, a nozzle 140, a valve body 150, and a gas pressurizing unit 160.
- a mold 200 is also shown.
- the melting furnace 110 is provided with a heating device 111 and a crucible 112 for storing a molten metal obtained by melting a metal material.
- a lid member 113 is provided on the upper surface of the crucible 112, and an opening 116 is formed in a part of the lid 113, and an aluminum alloy material consumed by casting is supplied from the opening 116.
- the lid member 113 is provided with an upper mounting recess 117 in which the upper part of the molten metal injection main cylinder 120 is received.
- the molten metal is a molten metal in which an aluminum alloy is dissolved. Further, in the configuration example of FIG.
- the crucible 112 of the melting furnace 110 is provided with a fixing portion 114 for fixing the molten metal injection main cylinder portion 120 in an upright state in the interior thereof.
- the lower mounting recess 118 is provided.
- a nozzle 140 for leading the injection path 130 to the mold is provided.
- the fixing portion 114 is a member for stably fixing the molten metal injection main cylinder portion 120 inside the crucible 112, and is fixed so as to be in contact with the outer wall surface or member of the molten metal injection main cylinder portion 120.
- a flange 122 is provided at the upper end of the molten metal injection main cylinder 120, and the flange 122 fits into the upper mounting recess 117 on the upper side of the molten metal injection main cylinder 120, and gas is added. Since the pressure part 160 abuts from above, the pressure part 160 is fixed so as to surround the side surface and the upper surface of the flange 122 of the molten metal injection main cylinder part 120.
- the upward movement and the horizontal movement in the vicinity of the upper portion of the molten metal injection main cylinder portion 120 can be restricted.
- a lower wall surface 126 is erected at the lower portion of the molten metal injection main cylinder portion 120, and the fixing portion 114 that fits into the lower mounting recess 118 is external to the lower wall surface 126 of the molten metal injection main cylinder portion 120. It is a member to contact.
- the downward movement and the horizontal movement in the vicinity of the lower portion of the molten metal injection main cylinder portion 120 can be restricted.
- the upper and lower portions of the molten metal injection main cylinder portion 120 are restricted from moving in the vertical direction and moving in the horizontal direction by the fixing portion 114, they are stably fixed.
- the molten metal injection main cylinder portion 120 is a ceramic cylinder erected in the crucible 112 of the melting furnace 110. It is preferable to manufacture a ceramic product having excellent heat resistance and select a molten aluminum alloy that does not melt or break.
- the shape of the molten metal injection main cylinder 120 is not limited, it is assumed here as shown in FIG. In the configuration example of FIG. 1, a flange 122 projects from the upper end of the cylindrical main cylinder portion 121.
- the internal space of the main cylinder portion 121 is 123.
- a bottom surface portion 124 formed in a mortar shape is formed on the bottom surface of the main cylinder portion 121, and a conduction hole 125 is provided at the lowermost portion thereof.
- a valve body 150 that controls opening and closing is attached to the conduction hole 125.
- a lower wall surface 126 is provided by extending an outer wall surface of the main cylinder portion 121 downward, and surrounds a bottom space 127 below the bottom surface of the main cylinder portion 121. At least a part of the lower wall surface 126 is provided with an opening 128 for introducing the molten metal into the bottom space 127. The molten metal is conducted to the bottom space 127 through the opening 128. In this way, the conduction / interruption of the internal space 123 and the bottom space 127 is controlled through the opening / closing operation of the valve body 150.
- a gas speed reduction portion 129 is provided near the upper portion of the internal space 123 of the molten metal injection main cylinder portion 120.
- the gas decelerating unit 129 is a member that decelerates the gas flow velocity that enters from the gas introduction pipe 164 by applying a gas pressure of the pressurizing unit 160 described later.
- the structure is such that the gas flow rate is weakened by hitting the gas flow, and the structure of a member such as a simple plate-like body, a damper, or a labyrinth pipe in which the passage of the conduction pipe is bent in a zigzag manner is not particularly limited.
- the injection path 130 is a path provided on the side surface of the molten metal injection main cylinder part, and is electrically connected to the internal space 123 of the molten metal injection main cylinder part 120, and the internal space 123 of the molten metal injection main cylinder part 120 is a pressurizing part.
- the molten metal pressed by the 160 gas application passes through this injection path 130 and is die-cast to the mold 200.
- the nozzle 140 is a member provided near the tip of the injection path 130 and is connected to the mold 200.
- the molten metal is die-cast from the nozzle 140 into the mold 200.
- the nozzle 140 is guided to the outside of the crucible 112 through the injection path derivation unit 115 and connected to the mold 200.
- the valve body 150 is a member that is provided at a position lower than the injection path 130 in the molten metal injection main cylinder portion 120 and opens and closes conduction between the crucible 112 of the melting furnace 110 and the internal space 123 of the molten metal injection main cylinder portion 120. is there.
- the valve body 150 is a ball valve.
- the bottom surface portion 124 of the internal space 123 of the molten metal injection main cylinder portion 120 is formed in a mortar shape so that the ball valve is easily guided to the conduction hole 125.
- the conduction hole 125 is smaller than the diameter of the ball valve, and the conduction hole 125 is closed by fitting the ball valve.
- the valve body 150 In the closed state in which the valve body 150 is pressed, the crucible 112 of the melting furnace 110 and the internal space 123 of the molten metal injection main cylinder portion 120 are shut off, and the movement of the molten metal between them is eliminated.
- the valve body 150 since the valve body 150 is provided at a position lower than the injection path 130, the conduction between the internal space 123 of the molten metal injection main cylinder portion 120 and the injection path 130 is maintained.
- the molten metal is guided toward the injection path 130.
- valve body 150 When the valve body 150 is pushed up, a gap is formed between the conduction hole 125 and the valve body 150, and the crucible 112 of the melting furnace 110 and the internal space 123 of the molten metal injection main cylinder portion 120 are electrically connected.
- the valve body 150 When the valve body 150 is opened, the molten metal is kept inside until the pressure difference between the two is eliminated, that is, until the upper surface of the molten metal in the inner space 123 of the molten metal injection main cylindrical portion 120 is substantially equal to the upper surface of the molten metal in the crucible 112. It flows into the space 123. Since the valve body 150 is heavy, it is necessary to consider the influence of the weight of the valve body 150.
- the pressurizing unit 160 is a part that controls application and removal of a predetermined gas pressure with respect to the internal space 123 of the molten metal injection main cylinder 120.
- the gas pressurization unit 160 includes a high-pressure pump 161, a gas tank 162, an electromagnetic valve 163, a gas introduction pipe 164, and a scattering prevention lid 165.
- the high-pressure pump 161 is a device that sends high-pressure gas into the gas tank 162.
- the gas tank 162 is a container that accumulates gas of a predetermined pressure in order to send high pressure gas to the internal space 123 of the molten metal injection main cylinder portion 120 at once by opening and closing the electromagnetic valve 163.
- the gas pressure accumulated in the gas tank 162 is a gas pressure that becomes 10 to 30 MP corresponding to the piston pressure generally required in a hot chamber casting machine when the electromagnetic valve 163 is opened.
- the point to be considered here is that the space in the inner space 123 of the molten metal injection main cylinder portion 120 immediately before opening the electromagnetic valve 163 is not filled with the molten metal only has an atmospheric pressure (about 0.1 MP).
- the gas pressure accumulated in the gas tank 162 is necessary for injection. It is necessary to set a larger value in consideration of a decrease in the internal space 123 due to the atmospheric pressure than a certain pressure (10MP to 30MP).
- the solenoid valve 163 has a fast valve shutter speed and can operate the valve instantaneously.
- the connection to the gas tank 162 side and the connection to the atmospheric pressure side can be switched instantaneously.
- the solenoid valve 163 is connected to the gas tank 162.
- the gas introduction pipe 164 immediately applies a gas pressure of 10MP to 30MP to the internal space 123 of the molten metal injection main cylinder portion 120. Can be applied.
- the solenoid valve 163 closes the gas tank 162 side and opens the atmospheric pressure side, the internal space 123 of the molten metal injection main cylinder part 120 can be returned to atmospheric pressure.
- the anti-scattering lid 165 is a lid-like object made of porous aluminum oxide or the like that is not melted by the molten aluminum alloy, and floats on the molten metal surface inside the molten metal injection main cylinder so that the molten metal is applied when gas pressure is applied. This is to prevent the molten metal surface inside the injection main cylinder from flowing and the molten metal from splashing.
- the oxide can be used instead of the anti-scattering lid 165.
- the gas speed reduction portion 129 is provided on the wall surface of the molten metal injection main cylinder portion to reduce the gas flow rate, thereby preventing the molten metal surface from wavy and molten metal from being scattered.
- the device is devised, it is possible to reliably prevent the molten metal surface from undulating and the molten metal from flying by preventing the scattering prevention lid 165 from floating on the molten metal surface.
- FIG. 2 is a diagram showing an initial state of the first step.
- the solenoid valve 163 is connected to the atmospheric pressure side, and in the internal space 123 of the molten metal injection main cylinder portion 120, the molten metal is high considering the density of the ball valve 150 from the height of the molten metal in the crucible 112. It is satisfied to the extent corresponding to The valve body 150 of the ball valve naturally settles on the bottom surface portion 124 of the molten metal injection main cylinder portion 120.
- the molten metal is an aluminum alloy and is heated to a predetermined temperature and is in a liquid state in a good state.
- FIG. 3 is a diagram showing a first cycle of the casting cycle.
- the solenoid valve 163 is switched to be connected to the gas tank 162 side and the gas tank 162 side is opened, the gas pressure corresponding to 10MP to 30MP necessary for die casting is immediately met through the gas introduction pipe 164.
- a high pressure gas having a high pressure is applied to the internal space 123 of the molten metal injection main cylinder portion 120.
- the valve body 150 which is a ball valve, is pressed downward, and the conduction hole 125 is closed.
- the molten metal in the internal space 123 is injected from the internal space 123 toward the injection path 130 when pressed.
- a mold 200 is installed through a nozzle 140 at the tip of the injection path 130, and a molten aluminum alloy is die-cast into the mold 200.
- FIG. 4 is a diagram showing a point in time when casting is completed. After the injection is finished and the first step is finished, the solenoid valve 163 is switched, and the internal space 123 is set to atmospheric pressure. Waiting for a predetermined time to wait until the die-cast molded product is cooled to a predetermined temperature. After cooling, the mold 200 is opened and the die-cast molded product is taken out as shown in FIG.
- FIG. 5 is a diagram showing a state where the state shown in FIG. 2 is being restored in the second step.
- the solenoid valve 163 is switched to be connected to the atmospheric pressure side, and when the connection on the gas tank 162 side is cut off, the gas valve is immediately connected via the gas introduction pipe 164.
- the internal space 123 of the molten metal injection main cylinder portion 120 becomes atmospheric pressure.
- the level of the molten metal in the internal space 123 of the molten metal injection main cylinder 120 is as shown in FIG. 3, that is, the level of the molten metal is lower than the level of the molten metal in the crucible 112.
- the pressure applied to the valve body 150 from the upper surface is a pressure generated from the height of the molten metal in the internal space 123 under atmospheric pressure
- the pressure applied to the valve body 150 from the lower surface is the pressure of the molten metal of the crucible 112. Pressure resulting from height.
- the height of the molten metal in the internal space 123 is lower than the height of the molten metal in the crucible 112, so that the pressure received from the lower surface of the valve body 150 is greater. Therefore, the valve body 150 rises, a gap is generated between the bottom surface portion 124 of the molten metal injection main cylinder 120 and the valve body 150, and the conduction hole 125 is conducted.
- the molten metal in the crucible 112 flows into the internal space 123 of the molten metal injection main cylinder portion 120.
- the valve body 150 is raised, and the molten metal is supplied to the internal space 123 of the molten metal injection main cylinder portion 120. If the weight of the valve body 150 is ignored, the supply is stopped when the molten liquid level in the internal space 123 of the molten metal injection main cylinder 120 becomes the same level as the molten liquid level in the crucible 112. Since the valve body 150 actually has a weight, the supply is stopped in a state where the molten liquid level in the internal space 123 is slightly lower than the molten liquid level in the crucible 112 due to the weight of the valve body 150. This supply amount may be the amount of molten metal necessary for the next die casting.
- the hot chamber casting machine for an aluminum alloy of the present invention there is no member that melts even when the molten aluminum alloy is filled in the melting furnace, and the hot chamber casting that can be die-cast as the molten aluminum alloy. A machine is obtained.
- the casting process of the aluminum alloy hot chamber casting machine of the present invention can be performed at the same speed as the piston-cylinder type cycle of the conventional hot chamber casting machine, and there is an advantage that the casting cycle is fast.
- the conventional piston-cylinder system requires processing accuracy of both wall surfaces and maintenance for distortion and wear due to use.
- the hot chamber casting machine for aluminum alloy of the present invention since the injection path 130 serving as a molten metal path is in the molten metal, there is no problem of air entering from the outside, and voids entering the die cast product. Less is.
- rupture chill layer seen with the cold chamber casting machine as demonstrated by the subject of the prior art can also be suppressed.
- the hot chamber casting machine for aluminum alloy of the present invention has an advantage that a transient load is not applied to the mold because the injection pressure may be relatively low.
- the present invention can be widely used as a hot chamber casting machine using an aluminum alloy as a molten metal.
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Abstract
Description
鋳造のうち、ダイカストは金型(Die)に対して、溶けた金属(溶湯)をピストンにより所定圧力で圧入射出(Cast)する製造方法である。
ダイカスト鋳造機は、大別するとホットチャンバー鋳造機とコールドチャンバー鋳造機に分類される。ホットチャンバー鋳造機、コールドチャンバー鋳造機とも、ダイカスト用の金属材料を溶融し、溶湯状態の金属材料を成形金型に射出して鋳造する。
ホットチャンバー鋳造機は、溶解炉と鋳造機が一体になっており、ピストン-シリンダ射出部および導入管が溶解炉の溶湯中にあり、一緒に加熱されているところからホットチャンバー鋳造機と呼ばれる。溶解炉の溶湯中に沈んでいるピストン-シリンダ射出部から溶湯が押し出され、導入管を通り、金型に到達して鋳造される。
図6に示すように、ホットチャンバー鋳造機10は、溶解炉11に対してピストン-シリンダ射出部12が収められており、内部は溶湯で満たされている。ピストン13はピストン駆動機構(図示せず)に接続され駆動される。ピストン-シリンダ射出部12の側面には溶湯吸入口14が設けられており、また、ピストン-シリンダ射出部12の端部から射出路15が導かれている。射出路15の先端近くにはノズル16を介して溶解炉11の外に金型17が設置されている。なお、射出路15のノズル16の先端の高さは、溶解炉11内の溶湯面の高さより高い位置に設けられている。
図6に記載したホットチャンバー鋳造機10の特徴としては、溶湯のピストン-シリンダ射出部12への給湯工程が溶解炉11中でのピストン-シリンダ射出部12のピストン運動に伴って自動的に行えるので、コールドチャンバー鋳造機に比べて鋳造サイクルが早いという点がある。
さらに、コールドチャンバー鋳造機に比べて、射出圧力が低くて良いので金型17への過渡な負荷がかからないという点もある。
図7に示すように、コールドチャンバー鋳造機20は、溶解炉21の外にスリーブ22とプランジャー23からなる押し出し成形機24が設けられており、プランジャー23には押圧装置27が接続されて稼働する構造となっている。スリーブ22の先端には金型25が設置されている。また溶解炉21から溶湯を汲み出すラドル26がある。
まず、従来のコールドチャンバー鋳造機20では鋳造速度が比較的遅いという問題がある。従来のコールドチャンバー鋳造機20では溶解炉21からラドル26で汲み出してスリーブ22に注入する作業が必要である。また、後述する空気を確実に抜くためプランジャー23の押し込みを慎重にゆっくりと行う必要がある。そのため鋳造時間が長くなってしまう問題が発生する。
上記したようにコールドチャンバー鋳造機にはデメリットがあり、特に、その鋳造速度が早いことと鋳造圧力が低いことに注目すればホットチャンバー鋳造機の方が優れた方式と言える。
それは、従来のホットチャンバー鋳造機10ではアルミニウム合金を用いることができないという問題である。もし、アルミニウム合金を溶解炉で溶解すれば溶解炉11、ピストン-シリンダ射出部12、ノズル16等が鉄系合金で出来ているため、アルミニウム合金による溶損を受け、アルミニウム合金中に溶け出し本来の機能が失われる。鉄系合金に限らず、ほとんどの金属はアルミニウム合金に侵食を受け、窒化、溶射等で保護しても満足できる結果は得られない。
そこで、ホットチャンバー鋳造機に改良を加え、アルミニウム合金を用いても鋳造できる実用に耐えるホットチャンバー鋳造機が求められている。
このように、加圧ガス供給手段7による加圧ガス5を用いて溶解炉3中の溶湯を押し上げて鋳型に押し入れるものとなっており、ピストンのような機構系を用いないものとなっている。
まず、図8に記載した砂型低圧鋳造機では、アルミニウム合金の金属材料を扱うにはまだ不十分である。射出経路の部品の大部分は溶解炉中にはないため放熱しやすい構造となっているが、溶湯は高温であり、ストーク21、溶湯溜まり29、ストーク33などの金属部品が高温のアルミニウム合金にさらされる点には変わりがなく、やはり溶損する問題が発生してしまう。
また、従来のピストン-シリンダ方式ではピストン及びシリンダの壁面には高い加工精度が求められその製作にコストがかかる上、稼動後のメンテナンスにおいても壁面の歪みや減損などの対策が必要となるが、本発明ではガス圧を利用することによりシリンダ内に圧力を掛けるため、シリンダ内の壁面の歪みや誤差などは問題とならず、シリンダの製作コストが低減できる上、稼動後のメンテナンスも簡単に済むというメリットが得られる。
ボール弁であれば上方からの圧力で確実に閉鎖することができ、上方からの圧力が負圧になれば、確実に開放することができる。ボール弁が導通孔に設置されておれば、溶解炉内の溶湯の出し入れが制御できる。また、溶湯の供給時も前回のダイカストで消費された溶湯に見合う量の溶湯を次のダイカスト用に供給することができる。
また、本発明のアルミニウム合金用ホットチャンバー鋳造機は、加圧部により印加されるガス圧は溶湯射出主筒部という小さな湯面を押圧するのみで良く、かつ下方向に押し込むだけで良いので、圧力制御が簡単であり、ダイカスト速度を速くすることができる。
また、従来のピストン-シリンダ方式ではピストン及びシリンダの壁面には高い加工精度が求められその製作にコストがかかる上、稼動後のメンテナンスにおいても壁面の歪みや減損などの対策が必要となるが、本発明ではガス圧を利用することによりシリンダ内に圧力を掛けるため、シリンダ内の壁面の歪みや誤差などは問題とならず、シリンダの製作コストが低減できる上、稼動後のメンテナンスも簡単に済むというメリットが得られる。
図1では内部の構造が分かりやすいように、各部材を縦断面において示している。図1では部材の特徴が分かるように簡単に図示しており、本発明を理解する上で必要な部材のみを図示しており、他の一部の部材については図示していない場合もある。
また、図1の構成例では、溶解炉110のルツボ112には、溶湯射出主筒部120を内部において立設状態で固定するための固定部114が設けられており、固定部114を取り付けるための下部取り付け凹部118が設けられている。
また、射出路130を金型へ導出するためのノズル140が設けられている。
溶湯射出主筒部120の形状は限定されないが、ここでは、図1に図示したようなものとする。図1の構成例では、円筒形をした主筒部分121に対して上端にフランジ122が張り出している。主筒部分121の内部空間が123である。主筒部分121の底面にはすり鉢状に成形された底面部124があり、その最下方には導通孔125が設けられている。この導通孔125には開閉を制御する弁体150が取り付けられている。
図1の構成例では、ガス加圧部160は、高圧ポンプ161、ガスタンク162、電磁弁163、ガス導入パイプ164、飛散防止蓋165を備えた構成となっている。
上記のように電磁弁163の開閉で導入されるガス圧が大きいため、溶湯射出主筒部の壁面にガス減速部129を設けてガス流速を減速させ、溶湯面の波立ちや溶湯の飛散防止の工夫を行っているが、さらに、溶湯面の上に飛散防止蓋165を浮かせておくことにより、確実に溶湯面の波立ちや溶湯の飛散を防ぐことが可能となる。
まず、鋳造サイクルの第1工程を説明する。
図2は第1工程の初期状態を示す図である。図2に示すように、電磁弁163は大気圧側に接続され、溶湯射出主筒部120の内部空間123には溶湯がルツボ112内の溶湯の高さからボール弁150の密度を考慮した高さに相当する程度満たされている。ボール弁の弁体150は自然に溶湯射出主筒部120の底面部124に落ち着いている。溶湯はアルミニウム合金であり、所定の温度にまで昇温され、良好な状態で液体状態となっている。
また、本発明のアルミニウム合金用ホットチャンバー鋳造機の鋳造工程は、従来のホットチャンバー鋳造機のピストン-シリンダ方式のサイクルと変わらない速度で行うことができ、鋳造サイクルが早いという利点がある。
また、従来のピストン-シリンダ方式ならば両者の壁面の加工精度が要求されたり使用による歪みや減耗に対するメンテナンスが要求されたりするところ、本発明のアルミニウム合金用ホットチャンバー鋳造機によれば、ガス圧を用いてシリンダ内の溶湯面を印加するので、そのような加工精度の要求やメンテナンスの要求が少ないという利点がある。
また、本発明のアルミニウム合金用ホットチャンバー鋳造機では、溶湯の経路となる射出路130が溶湯中にあるため、外部からの空気の巻き込みがなく、ダイカスト製品中に鬆が入るという不具合が生じることが少ない。
また、従来技術の課題で説明したようなコールドチャンバー鋳造機で見られる破断チル層の発生も抑えることができる。
また、本発明のアルミニウム合金用ホットチャンバー鋳造機では、比較的射出圧力が低くて良いので金型への過渡な負荷がかからないというメリットもある。
110 溶解炉
111 加熱装置
112 ルツボ
113 蓋材
114 固定部
115 射出路導出部
116 開口部
117 上部取り付け凹部
118 下部取り付け凹部
120 溶湯射出主筒部
121 主筒部分
122 フランジ
123 内部空間
124 底面部
125 導通孔
126 下方壁面
127 底部空間
128 開口
129 ガス減速部
130 射出路
140 ノズル
150 弁体
160 ガス加圧部
161 高圧ポンプ
162 ガスタンク
163 電磁弁
164 ガス導入パイプ
165 飛散防止蓋
Claims (6)
- 溶湯を入れる溶解炉と、
前記溶解炉内に立設したセラミックにより形成された溶湯射出主筒部と、
前記溶湯射出主筒部の側面に設けられた射出路と、
前記射出路の先端に設けられ、金型へ溶湯をダイカストするノズルと、
前記溶湯射出主筒部において、前記射出路よりも低い位置に設けられ、前記溶解炉内と前記溶湯射出主筒部の内部空間との導通を開閉する弁体と、
前記溶解炉の上部に配設され、前記溶湯射出主筒部の内部空間に対して所定圧力のガス圧の印加および除去を制御するガス加圧部を備え、
前記ガス加圧部が前記溶湯射出主筒部の内部空間に対して前記ガス圧を印加すると前記弁体が閉鎖される方向に働き、前記溶湯射出主筒部の内部の溶湯が前記射出路から前記金型へダイカストされ、前記ガス加圧部が前記溶湯射出主筒部の内部空間に対して前記ガス圧を除去すると前記弁体が開放される方向に働き、前記溶解炉内から次回のダイカストに必要量の溶湯が前記溶湯射出主筒部の内部に供給されるアルミニウム合金用ホットチャンバー鋳造機において、
前記溶解炉の下部に設けた固定部を介して前記溶湯射出主筒部の下方壁面を前記溶解炉に対して固定する構造と、
前記溶湯射出主筒部の上端にフランジを設け、前記溶解炉の上部に設けた上部取り付け凹部を介して前記溶湯射出主筒部上端のフランジを前記溶解炉に対して固定する構造と、
前記溶解炉の上部に配設したガス加圧部を前記溶湯射出主筒部の上端の前記フランジに当接させて下方に押し付けつつガス圧を前記溶湯射出主筒部の内部空間に対して印加する構造とを設けたアルミニウム合金用ホットチャンバー鋳造機。 - 前記弁体がボール弁であり、前記ボール弁が前記導通孔に導かれやすいように前記溶湯射出主筒部の下部内面がすり鉢状になっており、前記すり鉢状の壁面の最下部に前記ボール弁の径よりも小さな導通孔が開いて前記溶解炉内に導通した構造である請求項1に記載のアルミニウム合金用ホットチャンバー鋳造機。
- 前記溶湯射出主筒部の内部空間に、前記ガス加圧部からガス印加により突入するガス流速を減速するガス減速部を設けたことを特徴とする請求項1または2に記載のアルミニウム合金用ホットチャンバー鋳造機。
- 前記溶湯射出主筒部の内部空間の溶湯面に、前記溶湯による溶損を受けない素材で、かつ、前記溶湯面上に浮く比重にて形成された飛散防止蓋を設け、前記ガス加圧部からガス印加により突入するガスによる前記溶湯面の飛び散りを防止せしめることを特徴とする請求項1乃至3のいずれか1項に記載のアルミニウム合金用ホットチャンバー鋳造機。
- 前記ガス加圧部がガスタンクと電磁弁とガス導入パイプを備え、前記電磁弁の開閉動作により印加するガス量を制御することを特徴とする請求項1乃至4のいずれか1項に記載のアルミニウム合金用ホットチャンバー鋳造機。
- 溶湯を入れる溶解炉と、前記溶解炉内に立設したセラミックにより形成された溶湯射出主筒部と、前記溶湯射出主筒部の側面に設けられた射出路と、前記射出路の先端に設けられ、金型へ溶湯をダイカストするノズルと、前記溶湯射出主筒部において、前記射出路よりも低い位置に設けられ、前記溶解炉内と前記溶湯射出主筒部の内部空間との導通を開閉する弁体と、前記溶湯射出主筒部の内部空間に対して所定圧力のガス圧の印加および除去を制御するガス加圧部を備えた構成において、
前記ガス加圧部が前記溶湯射出主筒部の内部空間に対して前記ガス圧を印加すると前記弁体が閉鎖される方向に働き、前記溶湯射出主筒部の内部の溶湯が前記射出路から前記金型へダイカストされ、前記ガス加圧部が前記溶湯射出主筒部の内部空間に対して前記ガス圧を除去すると前記弁体が開放される方向に働き、前記溶解炉内から次回のダイカストに必要量の溶湯が前記溶湯射出主筒部の内部に供給されるようにする、アルミニウム合金を金属材料に用いたホットチャンバー鋳造方法において、
前記溶解炉の下部に設けた固定部を介して前記溶湯射出主筒部の下方壁面を前記溶解炉に対して固定する構造を設け、
前記溶湯射出主筒部の上端にフランジを設け、前記溶解炉の上部に設けた上部取り付け凹部を介して前記溶湯射出主筒部上端のフランジを前記溶解炉に対して固定する構造を設け、
前記溶解炉の上部に配設したガス加圧部を前記溶湯射出主筒部の上端の前記フランジに当接させて下方に押し付けつつガス圧を前記溶湯射出主筒部の内部空間に対して印加する構造とを設けたアルミニウム合金を金属材料に用いたホットチャンバー鋳造方法。
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JPH0910915A (ja) * | 1995-02-23 | 1997-01-14 | Howmet Corp | 鋳型空隙部中の溶融物の鋳造方法及び鋳型空隙部中の溶融物のインベストメント鋳造方法、指向性凝固鋳物の製造方法、そしてチャンバを迅速に加圧する装置 |
JPH10128517A (ja) * | 1996-09-06 | 1998-05-19 | Sanki:Kk | アルミニウム用ホットチャンバーダイカストマシン |
JP2001205425A (ja) * | 2000-01-18 | 2001-07-31 | Hiroshima Aluminum Industry Co Ltd | 自動給湯装置 |
JP2002336947A (ja) * | 2001-05-14 | 2002-11-26 | Minoru Kai | 軽金属自動給湯装置 |
JP2009148796A (ja) * | 2007-12-20 | 2009-07-09 | Gunma Univ | ホットチャンバーダイカストマシン |
JP2010247220A (ja) * | 2009-04-13 | 2010-11-04 | Ie Solution Kk | 鋳造における溶湯供給装置および溶湯供給法 |
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JP2015093286A (ja) | 2015-05-18 |
CN105339109A (zh) | 2016-02-17 |
KR101854968B1 (ko) | 2018-05-04 |
KR20160010531A (ko) | 2016-01-27 |
JP5642256B1 (ja) | 2014-12-17 |
TW201529204A (zh) | 2015-08-01 |
TWI568520B (zh) | 2017-02-01 |
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