CN107866546B - Hollow frame design and differential pressure casting method - Google Patents
Hollow frame design and differential pressure casting method Download PDFInfo
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- CN107866546B CN107866546B CN201711368764.6A CN201711368764A CN107866546B CN 107866546 B CN107866546 B CN 107866546B CN 201711368764 A CN201711368764 A CN 201711368764A CN 107866546 B CN107866546 B CN 107866546B
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- 238000005266 casting Methods 0.000 title claims abstract description 65
- 238000000034 method Methods 0.000 title claims abstract description 23
- 238000013461 design Methods 0.000 title claims abstract description 15
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 38
- 239000007788 liquid Substances 0.000 claims abstract description 35
- 239000000047 product Substances 0.000 claims abstract description 23
- 238000010438 heat treatment Methods 0.000 claims abstract description 19
- 239000011265 semifinished product Substances 0.000 claims abstract description 14
- 238000003754 machining Methods 0.000 claims abstract description 13
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000004512 die casting Methods 0.000 claims abstract description 6
- 238000004891 communication Methods 0.000 claims description 11
- 238000011049 filling Methods 0.000 claims description 9
- 239000004576 sand Substances 0.000 claims description 9
- 239000007789 gas Substances 0.000 claims description 8
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- 238000002425 crystallisation Methods 0.000 claims description 6
- 230000008025 crystallization Effects 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 238000010791 quenching Methods 0.000 claims description 6
- 230000000171 quenching effect Effects 0.000 claims description 6
- 230000001360 synchronised effect Effects 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- YNDGDLJDSBUSEI-UHFFFAOYSA-N aluminum strontium Chemical compound [Al].[Sr] YNDGDLJDSBUSEI-UHFFFAOYSA-N 0.000 claims description 5
- 238000004321 preservation Methods 0.000 claims description 5
- 238000007670 refining Methods 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 4
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 4
- 230000032683 aging Effects 0.000 claims description 3
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 3
- 238000007872 degassing Methods 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 239000006104 solid solution Substances 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- 230000035882 stress Effects 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 238000010924 continuous production Methods 0.000 abstract description 2
- 230000007547 defect Effects 0.000 description 3
- 230000000630 rising effect Effects 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 238000003917 TEM image Methods 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000005485 electric heating Methods 0.000 description 2
- 210000001503 joint Anatomy 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 235000015073 liquid stocks Nutrition 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000011550 stock solution Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
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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
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/023—Alloys based on nickel
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
-
- 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
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- Chemical & Material Sciences (AREA)
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- Mechanical Engineering (AREA)
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- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a hollow frame design and counter-pressure casting method, which comprises the following steps: s1, designing a hollow structure with wall thickness of 4mm, which meets the safety requirement of 1.5 times of CAE; s2, aluminum alloy double-phase treatment; s3, casting a sand core in the sand core mould, then placing the cast sand core into a negative pressure difference die casting mould, forming the modified aluminum alloy liquid through a negative pressure difference die casting process, and removing the sand core after forming to obtain a semi-finished product of the hollow frame; s4, heating the semi-finished product at the T6 stage; and S5, machining by a large four-axis machining center. The hollow frame design and counter-pressure casting method provided by the invention has the advantages that the prepared product is light in weight, high in safety, excellent in tensile strength, yield strength and extensibility, wide in application range and capable of realizing batch continuous production.
Description
Technical Field
The invention relates to the technical field of counter-pressure casting, in particular to a hollow frame design and counter-pressure casting method.
Background
Aluminum alloy castings are produced by adopting resin sand mold, metal mold or die casting and other methods, but the defects of inclusion, shrinkage, looseness and the like which are difficult to solve always exist. The casting method has the problems that the speed, pressure, temperature and the like in the casting process are difficult to control accurately, the mold filling is not stable, the alloy splashes and the like, so that the casting is poor and the technical requirement on high performance cannot be met. Counter-pressure casting is an antigravity special casting technology, and realizes the filling, solidification and crystallization of alloy liquid under pressure and final forming. On the basis of low-pressure casting, a sealing cover is added outside a casting mould, compressed air with controllable pressure is introduced into a crucible and the cover, the pressure in the crucible is controlled to be higher than the pressure in the cover, so that aluminum alloy liquid in the crucible is stably filled into the casting mould through a liquid lifting pipe under the action of pressure difference, the casting mould is solidified and crystallized under the pressure, and the 'controllable speed filling type' and 'controllable pressure crystallization' are combined, so that the ideal filling type speed and optimal quality of the filled aluminum alloy liquid can be obtained, inclusion is effectively prevented from entering the casting mould, and the density of casting structures is greatly improved due to the crystallization under the pressure. The metal mold is combined with a differential pressure casting machine, so that a casting with compact structure, no casting defect and excellent performance can be obtained, and continuous batch production can be realized. Therefore, the invention provides a hollow frame design and a counter-pressure casting method.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a hollow frame design and a differential pressure casting method.
A hollow frame design and counter-pressure casting method comprises the following steps:
s1, designing a hollow structure: obtaining a 3D digital model of a product with a steel structure, modifying the 3D digital model of the product by UG (Unigraphics) to enable the structure of the product to meet the casting production requirement, then carrying out loading stress and fatigue life simulation, analyzing the result, adjusting parameters, determining product data, and carrying out production;
s2, aluminum alloy double-phase treatment: preparing an aluminum alloy liquid, detecting, adjusting the proportion of Cu and Mg alloy elements, heating the aluminum alloy liquid, adding 100-150 g of a deslagging agent, introducing argon for refining, degassing, slagging off, adding an aluminum strontium refiner for grain refinement, stirring, and standing to obtain a modified aluminum alloy liquid;
s3, carrying out negative differential pressure casting and sand core casting, and using: casting a sand core in a sand core mould, wherein the specific process flow comprises the steps of front sand shooting, exhausting, crusting, mould overturning, vibration sand pouring, curing, mould opening and ejection, and sand core taking; placing the well cast sand core into a negative pressure differential pressure casting die, forming the modified aluminum alloy liquid obtained in the step S2 through a negative pressure differential pressure casting process, and removing the sand core after forming to obtain a semi-finished product of the hollow frame;
heating and heat treating at S4 and T6 stages: feeding the semi-finished product obtained in the step S3 into a solid solution furnace, heating to 530-540 ℃, preserving heat for 350-370 min, putting the semi-finished product subjected to heat preservation into water at the temperature of 55-65 ℃ for quenching treatment, wherein the quenching time is not more than 10S, feeding the quenched semi-finished product into an aging furnace, heating to 165-175 ℃, preserving heat for 350-370 min, taking out the product, standing in air, and cooling to room temperature to complete the T6-stage heating treatment;
s5, machining by a large four-axis machining center: and (4) performing hole machining on the lifting lug on the product processed in the step S4 by using a rotary cutter and a high-precision clamp, machining other parts needing machining by using other cutters, and finishing the hollow frame design and differential pressure casting after the machining is finished.
Preferably, the heating temperature of the aluminum alloy liquid is 710-720 ℃, the refining time is 7-12 min, and the adding amount of the aluminum strontium refiner is 0.1-0.2%.
Preferably, the apparatus used in the negative pressure differential casting includes: the aluminum alloy bin comprises a rack, a movable plate, an upper die, a middle plate, a lower die, a die closing device, a die temperature control device and an air pressure control device, wherein the movable plate is connected with the rack, can move up and down and is provided with an upper tank body, the upper die is installed on the movable plate, the middle plate is fixed on the rack and is provided with a lower tank body, the lower die is installed on the middle plate, the die closing device, the die temperature control device and the air pressure control device are used for controlling the upper die and the lower die to open and close, the die temperature control device and the air pressure control.
Preferably, the air pressure control device comprises a first mutual valve, a second mutual valve, a third mutual valve, an air inlet valve, a first micro exhaust valve, a second micro exhaust valve, a first exhaust valve and a second exhaust valve, one end of the air inlet valve is connected with a high-pressure air source, the other end of the air inlet valve is respectively connected with the first mutual valve, the second mutual valve and the third mutual valve through air pipes, the first mutual valve is connected with the upper tank body through an air pipe, the second mutual valve is connected with the lower tank body through an air pipe, the third mutual valve is connected with the cabin body through an air pipe, the first micro exhaust valve is installed on the upper tank body, the second micro exhaust valve is installed on the lower tank body and directly exhausts air, the first exhaust valve is installed on the upper tank body, and the second exhaust valve is installed on the lower tank body and directly exhausts air outwards.
Preferably, the locking device comprises a die opening movable plate locking device, a die closing movable plate locking device and a chute clamp on the frame, the die opening movable plate locking device comprises a first lateral oil cylinder, a first wedge block and a first guide rod, and the first lateral oil cylinder: fixed mounting is connected with first guide bar through connecting, first guide bar: one end is connected with first lateral cylinder, and the other end is connected with first tight piece of carving through the screw thread, first tight piece of carving: one end of the locking device is connected with the first guide rod, the other end of the locking device is clamped with the inclined groove on the rack, the locking device of the mold closing movable plate is the same as the locking device of the mold opening movable plate in structure, and the locking device of the mold closing movable plate comprises a second lateral oil cylinder, a second wedge block and a second guide rod.
Preferably, the negative differential pressure die casting is performed by the following method: the upper tank body and the lower tank body can discharge internal gas controllably through the micro exhaust valve, so that pressure difference is generated between the upper tank body, the lower tank body and the bin body, the liquid-raising pressure difference is 0.01-0.03 MPa, the mold-filling pressure difference is 0.03-0.04 MPa, the deteriorated aluminum alloy liquid is filled into a mold cavity through the pressure difference, the incrustation pressurizing pressure is 0.01-0.015 MPa, the incrustation pressurizing time is 5-10 s, the crystallization pressurizing pressure difference is 0.07-0.10 MPa, and when the pressure difference between the upper tank body, the lower tank body and the bin body reaches 0.1MPa, pressure maintaining is carried out for 90-100 s.
The hollow frame design and the differential pressure casting method provided by the invention can obtain a reliable product which is 30-50% lighter than the conventional steel chassis auxiliary frame and has 0.3 higher performance safety coefficient, the tensile strength is more than or equal to 290MPa, the yield strength is more than or equal to 220MPa, and the extension is more than or equal to 8%, the reliable product can be widely used for the front and rear auxiliary frames of the automobile chassis, swing arms, connecting rods, steering knuckles, brake calipers, left and right connecting plates of a front beam and a rear beam of a top cover of the automobile body, left and right A/B columns, left and right side wall C/D column inner plates, left and right front longitudinal beams of a rear floor, left and right front suspension impact towers, left and right longitudinal beams of an engine room, automobile doors, automobile door brackets and other all-aluminum automobile body parts, the proportion of Cu and Mg alloy elements is properly adjusted and rare earth elements are added, The requirement of industries such as military industry, ships and the like on the quality of high-performance aluminum alloy castings can be met, batch continuous production can be realized, the two products can be accurately positioned and butted in a mode of combining negative pressure differential pressure casting and sand core casting, and the wall thickness and the mechanical property of the products are ensured to reach the standard.
Drawings
FIG. 1 is a TEM image of an aluminum alloy liquid stock solution in examples;
FIG. 2 is a TEM image of aluminum alloy liquid in examples after being denatured;
FIG. 3 is a schematic diagram showing a structure of a mold clamping state of an apparatus used in the differential pressure casting in the embodiment;
FIG. 4 is a view showing the construction of the apparatus used in the negative differential pressure casting in the embodiment in the open state.
The device comprises a die body, an upper die, a die cavity, a lower die, a die cavity, a die, a movable plate, a middle plate, a die cavity, a die assembly device, a die cavity, a movable plate, a die cavity, a control cabinet, a mutual valve, a first mutual valve, a second mutual valve, a third mutual valve, a fourth mutual valve, 4-6-2 parts of an electric heating rod, 4-6-3 parts of an electric thermocouple, 4-6-3 parts of a temperature controller for control, 5 parts of a bin body, 5-1 parts of a bin body, 5-2 parts of a heat preservation furnace, 5-3 parts of a liquid lifting pipe, 5-4 parts of an aluminum alloy liquid, 6 parts of a lifting device, 7-1 parts of a mould opening movable plate locking device, 7-1-1 parts of a first lateral oil cylinder, 7-1-2 parts of a mould opening movable plate locking device, 7-1-1 parts of a first wedge block, 7-1-3 parts of a first guide rod, 7-2 parts of a mould closing movable plate locking device, 7-2-1 parts of a second lateral oil cylinder, 7-2-2 parts of a second wedge block, 7-2-3 parts of a second guide rod, 7-3 parts of a chute.
Detailed Description
The invention will be further illustrated with reference to specific embodiments, with reference to fig. 1-4.
The embodiment of the invention provides a hollow frame design and counter-pressure casting method, which comprises the following steps:
s1, designing a hollow structure: obtaining a 3D digital model of a steel structure product, modifying the 3D digital model of the product by UG (Unigraphics) to enable the structure of the product to meet the requirement of CAE (computer aided engineering) 1.5 times of safety on 4mm of wall thickness, then carrying out loading stress and fatigue life simulation, analyzing the result, adjusting parameters, determining product data, and carrying out production of a chassis auxiliary frame;
s2, aluminum alloy double-phase treatment: preparing aluminum alloy liquid, detecting, adjusting the proportion of Cu and Mg alloy elements, heating the aluminum alloy liquid to 715 ℃, adding 125g of slag removing agent, introducing argon for refining for 10min, degassing, slagging off, adding 0.15% of aluminum strontium refiner for grain refinement, stirring and standing to obtain modified aluminum alloy liquid;
s3, carrying out negative differential pressure casting and sand core casting, and using: casting a sand core in a sand core mould, wherein the specific process flow comprises the steps of front sand shooting, exhausting, crusting, mould overturning, vibration sand pouring, curing, mould opening and ejection, and sand core taking; placing the cast sand core into a negative pressure differential pressure casting die, forming the modified aluminum alloy liquid through a negative pressure differential pressure casting process, removing the sand core after forming to obtain a semi-finished product of the hollow frame, wherein the die temperature is 230 ℃, the sand shooting time is 20s, the exhaust time is 5s, the crusting time is 20s, the vibration time is 15s, and the curing time is 50s in the sand core casting process;
heating and heat treating at S4 and T6 stages: feeding the semi-finished product obtained in the step S3 into a solid solution furnace, heating to 535 ℃, preserving heat for 360min, putting the semi-finished product subjected to heat preservation into water at the temperature of 60 ℃ for quenching treatment, wherein the quenching time is not more than 10S, feeding the quenched semi-finished product into an aging furnace, heating to 170 ℃, preserving heat for 360min, taking out the product, standing in the air, and cooling to room temperature to finish the temperature rise heat treatment in the T6 stage;
s5, machining by a large four-axis machining center: and (4) carrying out hole machining on the lifting lug on the product processed in the step S4 by using a rotary cutter and a high-precision clamp, and finishing the design of the hollow frame and the differential pressure casting after the machining is finished.
In the present invention, an apparatus used in negative differential pressure casting includes: the aluminum alloy production device comprises a rack, a movable plate 2-1 which is connected with the rack, can move up and down and is provided with an upper tank body 2-1-1, an upper mold 1-1 which is arranged on the movable plate 2-1, a middle plate 2-2 which is fixed on the rack and is provided with a lower tank body 2-2-1, a lower mold 1-2 which is arranged on the middle plate, a mold closing device 3 which controls the upper mold 1-1 and the lower mold 1-2 to open and close, a mold temperature control device 4-6 and an air pressure control device 4, wherein the mold temperature control device 4-6 and the air pressure control device 4 are respectively connected with a control cabinet 4-1, working parameters are set by the control cabinet 4-1, and a bin body 5 for storing aluminum alloy liquid and a lifting device 6 for;
the air pressure control device 4 comprises a first mutual-communication valve 4-2-1, a second mutual-communication valve 4-2-2, a third mutual-communication valve 4-2-3, an air inlet valve 4-3, a first micro exhaust valve 4-4-1, a second micro exhaust valve 4-4-2, a first exhaust valve 4-5-1 and a second exhaust valve 4-5-2, one end of the air inlet valve 4-3 is connected with a high-pressure air source, the other end of the air inlet valve is respectively connected with the first mutual-communication valve 4-2-1, the second mutual-communication valve 4-2-2 and the third mutual-communication valve 4-2-3 through air pipes, the first mutual-communication valve 4-2-1 is connected with the upper tank body 2-1-1 through an air pipe, the second mutual-communication valve 4-2-2 is connected with the lower tank body 2-2-1 through an air pipe, The third mutual valve 4-2-3 is connected with the bin body through an air pipe, the first micro exhaust valve 4-4-1 is arranged on the upper tank body 2-1-1, the second micro exhaust valve 4-4-2 is arranged on the lower tank body 2-2-1 and directly exhausts air outwards, the first exhaust valve 4-5-1 is arranged on the upper tank body 2-1-1, and the second exhaust valve 4-5-2 is arranged on the lower tank body 2-2-1 and directly exhausts air outwards;
the locking device comprises an open die movable plate locking device 7-1, a closed die movable plate locking device 7-2 and a chute clamp 7-3 on a rack, wherein the open die movable plate locking device 7-1 comprises a first lateral oil cylinder 7-1-1, a first wedging block 7-1-2 and a first guide rod 7-1-3, and the first lateral oil cylinder 7-1-1: fixedly installed and connected with a first guide rod 7-1-3 through a joint, wherein the first guide rod 7-1-3: one end of the first lateral oil cylinder is connected with the first lateral oil cylinder 7-1-1, the other end of the first lateral oil cylinder is connected with the first wedging block 7-1-2 through threads, and the first wedging block 7-1-2: one end of the locking device is connected with a first guide rod 7-1-3, the other end of the locking device is connected with a chute clamp 7-3 on the rack, a locking device 7-2 of the mold closing movable plate has the same structure as that of a locking device 7-1 of the mold opening movable plate, and the locking device 7-2 of the mold closing movable plate comprises a second lateral oil cylinder 7-2-1, a second wedge block 7-2-2 and a second guide rod 7-2-3;
the mold temperature control device 4-6 comprises an electric heating rod 4-6-1 for heating, an electric thermocouple 4-6-2 for detection, a temperature control instrument 4-6-3 for control, an upper mold 1-1 and a lower mold 1-2, the temperature control is realized through the mold temperature control device 4-6, the temperatures of the upper mold 1-1 and the lower mold 1-2 are set to be 200-220 ℃, the upper mold 1-1 and the lower mold 1-2 are matched through a mold matching device 3, and meanwhile, the butt joint, sealing and locking of the upper tank body 2-1-1 and the lower tank body 2-2-1 are realized;
the bin body 5 comprises a bin body 5-1, a heat preservation furnace 5-2, a liquor lift pipe 5-3 and aluminum alloy liquid 5-4, the bin body 5 is lifted by a lifting device 6 to realize sealing and locking with the middle plate 2-2, so that the aluminum alloy liquid 5-4 can enter a die cavity through the liquor lift pipe 5-3;
the upper tank body 2-1-1, the lower tank body 2-2-1 and the bin body 5 are communicated with each other by opening the intercommunication valve 4-2, and high-pressure gas is introduced by opening the gas inlet valve 4-3 to realize synchronous gas inlet and synchronous pressure building, after the upper tank body 2-1-1, the lower tank body 2-2-1 and the bin body 5 reach the set working pressure of 0.55-0.65 MPa, the intercommunication valve 4-2 is closed, and the upper tank body 2-1-1, the lower tank body 2-2-1 and the bin body 5 are isolated from each other.
The negative pressure difference die casting is formed by adopting the following method:
A. an upper die 1-1 is arranged on a movable plate 2-1 with an upper tank body 2-1-1 of a differential pressure casting device, a lower die 1-2 is arranged on a middle plate 2-2 with a lower tank body 2-2-1 and is respectively connected with a differential pressure device and a die temperature control device 4-6 to realize temperature control;
B. the upper die 1-1 and the lower die 1-2 are matched through the die matching device 3, meanwhile, the upper tank body 2-1-1 and the lower tank body 2-2-1 are in butt joint, sealed and locked, the movable plate 2-1 drives the second wedge block 7-2-2 to lock the second guide rod 7-1-3 to clamp the chute clamp 7-3 to lock the movable plate 2-1 through the second lateral oil cylinder 7-2-1;
C. the bin body 5 is lifted by the lifting device 6 to be sealed with the middle plate 2-2, so that the aluminum alloy liquid 5-4 can enter the die cavity 1-3 through the liquid lifting pipe 5-3;
D. opening the mutual-communicating valve 4-2 to enable the upper tank body 2-1-1 and the lower tank body 2-2-1 to be communicated with the bin body 5, and simultaneously opening the air inlet valve 4-3 to introduce dried gas to realize synchronous air inlet and synchronous pressure build-up, wherein the working pressure is 0.60 MPa;
E. the intercommunication valve 4-2 is closed to isolate the upper tank body 2-1-1, the lower tank body 2-2-1 and the bin body 5;
F. opening a micro exhaust valve 4-4, slowly exhausting gas in the upper tank body 2-1-1 and the lower tank body 2-2-1, and controlling the liquid rising pressure to be 0.02MPa, the filling pressure difference to be 0.035MPa, the liquid rising speed to be 65mm/S and the filling speed to be 55 mm/S;
G. the aluminum alloy liquid 5-4 is smoothly filled into a mold cavity 1-3 under the accurately controlled pressure difference, the incrustation pressurizing pressure difference is 0.015MPa, the incrustation time is 8s, the crystallization pressurizing pressure difference is 0.08MPa, the pressure difference of an upper tank body 2-1-1, a lower tank body 2-2-1 and a bin body 5 reaches 0.10MPa, the pressure is maintained for 95s, and the aluminum alloy liquid is solidified and crystallized under the action of the pressure difference to form a casting;
H. opening an exhaust valve 4-5 to exhaust and release pressure, opening the upper die 1-1 and the lower die 1-2 through a die closing device 3, driving a first wedge block 7-1-2 to lock a first guide rod 7-1-3 to clamp a chute clamp 7-3 of 4 large columns to lock the movable plate 2-1 by the movable plate 2-1 through a first lateral oil cylinder 7-1-1;
I. and taking out the casting, namely completing the whole processes of liquid rising, mold filling, pressure maintaining and pressure relief of the differential pressure casting to obtain the qualified high-performance aluminum alloy casting.
The performance test of the auxiliary frame of the chassis produced in the embodiment shows that the auxiliary frame of the chassis produced in the embodiment has the mass 46 percent lighter than that of the auxiliary frame of the conventional steel chassis, the performance safety coefficient is 0.3 percent higher, the tensile strength is 295MPa, the yield strength is 224MPa, and the elongation is 8.6 percent.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (3)
1. A method for designing a hollow frame and casting a hollow frame by counter pressure is characterized by comprising the following steps:
s1, designing a hollow structure: obtaining a 3D digital model of a product with a steel structure, modifying the 3D digital model of the product by UG (Unigraphics) to enable the structure of the product to meet the casting production requirement, then carrying out loading stress and fatigue life simulation, analyzing the result, adjusting parameters, determining product data, and carrying out production;
s2, aluminum alloy double-phase treatment: preparing an aluminum alloy liquid, detecting, adjusting the proportion of Cu and Mg alloy elements, heating the aluminum alloy liquid, adding 100-150 g of a deslagging agent, introducing argon for refining, degassing, slagging off, adding an aluminum strontium refiner for grain refinement, stirring, and standing to obtain a modified aluminum alloy liquid;
s3, carrying out negative differential pressure casting and sand core casting, and using: casting a sand core in a sand core mould, wherein the specific process flow comprises the steps of front sand shooting, exhausting, crusting, mould overturning, vibration sand pouring, curing, mould opening and ejection, and sand core taking; placing the cast sand core into a negative pressure differential pressure casting die, forming the modified aluminum alloy liquid obtained in the step S2 through a negative pressure differential pressure casting process, and removing the sand core after forming to obtain a semi-finished product of the hollow frame;
heating and heat treating at S4 and T6 stages: feeding the semi-finished product obtained in the step S3 into a solid solution furnace, heating to 530-540 ℃, preserving heat for 350-370 min, putting the semi-finished product subjected to heat preservation into water at the temperature of 55-65 ℃ for quenching treatment, wherein the quenching time is not more than 10S, feeding the quenched semi-finished product into an aging furnace, heating to 165-175 ℃, preserving heat for 350-370 min, taking out the product, standing in air, and cooling to room temperature to complete the T6-stage heating treatment;
s5, machining by a large four-axis machining center: using a turning tool and a high-precision clamp to perform hole machining on the lifting lug on the product processed in the step S4, using other tools to machine other parts needing machining, and finishing the design of the hollow frame and differential pressure casting after the machining is finished;
the device used in the negative pressure differential pressure casting comprises: a frame and a locking device, a movable plate (2-1) which is connected with the frame and can move up and down and is provided with an upper tank body (2-1-1), an upper mold (1-1) which is arranged on the movable plate (2-1), a middle plate (2-2) which is fixed on the frame and is provided with a lower tank body (2-2-1), a lower mold (1-2) which is arranged on the middle plate (2-2), a mold closing device (3) which controls the upper mold (1-1) and the lower mold (1-2) to open and close, a mold temperature control device (4-6) and an air pressure control device (4), the mould temperature control device (4-6) and the air pressure control device (4) are respectively connected with the control cabinet (4-1), the control cabinet (4-1) sets working parameters, a bin body (5) for storing aluminum alloy liquid and a lifting device (6) for lifting and fixing the bin body (5) at the bottom of the frame;
the air pressure control device (4) comprises a first mutual-communicating valve (4-2-1), a second mutual-communicating valve (4-2-2), a third mutual-communicating valve (4-2-3), an air inlet valve (4-3), a first micro exhaust valve (4-4-1), a second micro exhaust valve (4-4-2), a first exhaust valve (4-5-1) and a second exhaust valve (4-5-2), one end of the air inlet valve (4-3) is connected with a high-pressure air source, the other end of the air inlet valve is respectively connected with the first mutual-communicating valve (4-2-1), the second mutual-communicating valve (4-2-2) and the third mutual-communicating valve (4-2-3) through air pipes, and the first mutual-communicating valve (4-2-1) is connected with the upper tank body (2-1-1) through the air pipes, The second mutual-communicating valve (4-2-2) is connected with the lower tank body (2-2-1) through an air pipe, the third mutual-communicating valve (4-2-3) is connected with the bin body through an air pipe, the first micro exhaust valve (4-4-1) is installed on the upper tank body (2-1-1), the second micro exhaust valve (4-4-2) is installed on the lower tank body (2-2-1) and directly exhausts air outwards, the first exhaust valve (4-5-1) is installed on the upper tank body (2-1-1), and the second exhaust valve (4-5-2) is installed on the lower tank body (2-2-1) and directly exhausts air outwards;
the negative pressure difference die casting is formed by adopting the following method: the upper tank body (2-1-1), the lower tank body (2-2-1) and the bin body (5) are communicated by opening a first mutual communication valve (4-2-1), a second mutual communication valve (4-2-2) and a third mutual communication valve (4-2-3), simultaneously, the air inlet valve (4-3) is opened to introduce high-pressure gas, so as to realize synchronous air inlet and synchronous pressure build-up, after the upper tank body (2-1-1), the lower tank body (2-2-1) and the bin body (5) reach the set working pressure of 0.55-0.65 MPa, the first mutual-communicating valve (4-2-1), the second mutual-communicating valve (4-2-2) and the third mutual-communicating valve (4-2-3) are closed, and the upper tank body (2-1-1), the lower tank body (2-2-1) and the bin body (5) are isolated; then the upper tank body (2-1-1) and the lower tank body (2-2-1) respectively discharge the internal gas in a controllable way through a first micro exhaust valve 4-4-2 and a second micro exhaust valve 4-5-1, pressure difference is generated among the upper tank body (2-1-1), the lower tank body (2-2-1) and the bin body (5), the liquid-raising pressure difference is 0.01-0.03 MPa, the mold-filling pressure difference is 0.03-0.04 MPa, the deteriorated aluminum alloy liquid is filled into a mold cavity through the pressure difference, the incrustation pressurizing pressure is 0.01-0.015 MPa, the incrustation pressurizing time is 5-10 s, the crystallization pressurizing pressure difference is 0.07-0.10 MPa, and when the pressure difference among the upper tank body (2-1-1), the lower tank body (2-2-1) and the bin body (5) reaches 0.1MPa, pressure maintaining is carried out for 90-100 s.
2. The hollow frame design and counter-pressure casting method according to claim 1, characterized in that the heating temperature of the aluminum alloy liquid is 710-720 ℃, the refining time is 7-12 min, and the addition amount of the aluminum strontium refiner is 0.1-0.2%.
3. The hollow frame design and differential pressure casting method according to claim 1, characterized in that the mold temperature in the sand core casting process is 220-240 ℃, the sand shooting time is 15-25 s, the exhaust time is 3-8 s, the crusting time is 15-25 s, the vibration time is 10-20 s, and the curing time is 45-55 s.
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| DE102020205545A1 (en) * | 2020-04-30 | 2021-11-04 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein | Method for manufacturing a material cartridge, container for use in a corresponding method, material cartridge and method for manufacturing a cast product using the material cartridge, and a corresponding cast product |
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| JPS55136555A (en) * | 1979-04-11 | 1980-10-24 | Hitachi Ltd | Low-pressure casting method |
| IN170880B (en) * | 1987-05-07 | 1992-06-06 | Metal Casting Tech | |
| JPS6453755A (en) * | 1987-08-21 | 1989-03-01 | Honda Motor Co Ltd | Low pressure casting method for light alloy casting |
| FR2705044B1 (en) * | 1993-05-10 | 1995-08-04 | Merrien Pierre | LOW PRESSURE PILOT CASTING PROCESS OF A VACUUM MOLD FOR ALUMINUM OR MAGNESIUM ALLOYS AND DEVICE FOR ITS IMPLEMENTATION. |
| CN2471451Y (en) * | 2001-03-20 | 2002-01-16 | 河北工业大学 | Pressurized casting apparatus with vacuum and protective gas protection alternatively |
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| CN103978183B (en) * | 2014-05-27 | 2016-04-27 | 浙江万丰科技开发股份有限公司 | A kind of counter-pressure casting machine and casting method |
| CN104148611A (en) * | 2014-08-01 | 2014-11-19 | 南京博乔机械有限公司 | Low-pressure aluminum alloy casting machine with vacuum deairing system |
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