2.2.2 Advanced "pressure casting die forging" process and equipment technology "pressure casting die forging" process and equipment technology referred to as "die casting die forging" technology. The “die casting†inside is not the “high pressure die casting†that we understand in a narrow sense. It is a generalized concept, including the concept of all casting filling methods including high pressure die casting, low pressure casting, gravity casting, vacuum suction casting. .
Therefore, the "die-casting and forging" technology is a continuous casting and forging process that uses "die forging" as the ultimate feature regardless of the casting filling method. Continuous casting and forging processes are therefore also referred to as a "principle process."
The most commonly used equipment at present is the horizontal cold chamber (hot chamber) die-casting forging machine. Its shape is similar to that of a traditional die-casting machine, and it can be used with traditional ironing, spray cooling and pick-up robots. It has been able to produce "die-casting forging" equipment with a maximum forging pressure of 30,000KN or more, and can produce blanks including forged wheels of large trucks and forging cylinders of automobile engines. It can also produce continuous casting and forging blanks of magnesium alloy and ferrous metal. Since the production cycle is basically the same as that of the ordinary die casting machine, the process cost of the workshop production is almost the same as that of the die casting process.
3 Continuous casting and forging production of deformed aluminum alloy
3.1 The similarities and differences between the deformed aluminum alloy and the ordinary cast aluminum alloy continuous casting and forging production. Formally, the continuous casting and forging production of the deformed aluminum alloy is not much different from the continuous casting and forging production of the ordinary cast aluminum alloy. : Like the production equipment, the shape and structure of the mold are the same, but the internal structure of the mold and the production process parameters are quite different.
3.2 Filling process parameters are different. Since the casting fluidity of the deformed aluminum alloy is much lower than that of the cast aluminum alloy, the filling speed and filling pressure are not the same as those of the ordinary cast aluminum alloy, and the filling pressure is generally required to be improved; since the filling speed is relatively small The mold temperature control requirements are more stringent. In normal production, the heat balance requirements for the mold will be higher. In addition, the slowing of the filling speed generally requires that the casting temperature of the soup material be appropriately increased.
3.3 The different points of the internal structure of the mold. Since the flowability of the deformed aluminum alloy is lower than that of the cast aluminum alloy, it also requires that the inner gate of the mold be relatively thick. However, the difference between different deformed aluminum alloys and blanks of different structures still exists. This requires us to solve from a practical point of view. It needs to explore the process of optimal mold structure parameters.
3.4 Comprehensive consideration of the problem of insufficient fluidity of deformed aluminum alloys. We can't look at the fluidity of the deformed aluminum alloy independently, but aim at the final blank forming quality.
The current "die-casting die-forging machine" is designed to be steplessly adjustable in terms of filling speed, filling pressure and die forging force. It provides the broadest means for us to comprehensively weigh the characteristics of different aluminum alloy forming processes. In addition, the control of the initial casting temperature and the final forging temperature, on the one hand, because each parameter has a certain "substitute effect" on other parameters, it requires our technicians to be very skilled in mastering the whole set of equipment and processes, and On the other hand, it also provides us with a wide space for flexible use of this process technology, greatly reducing the technical difficulty of including difficult to deform deformed aluminum alloy.
3.5 Pay attention to the structural process analysis of the blank. The structural process analysis of the blank is the basis for formulating the process implementation plan, which is the key to the process effect and even the success of the process. What it requires is the inherent understanding of the die-casting technology of the process technician.
Among them, the most important is the classification scheme. We can't follow the classification idea of ​​die-casting mold, but should follow the classification idea of ​​forging die. But the biggest challenge is also the extent to which we can core the core. If all the blanks are designed according to the forging process, all the cores are not produced, and the characteristics, economic advantages and practical significance of the continuous casting and forging process are lost!
3.6 residual material removal problem. The strength and toughness of the deformed aluminum alloy are higher than that of the cast aluminum alloy, and the thicker of the inner runner will make the removal of the residual material a new problem. The general recommendation is to consider the details of the design of the runner, and to match the stamping structure of the mold, the action of the forging step is used to form a foldable structure. If manual cutting is not possible, the ease of mechanical cutting should be considered.
4 Conclusion
Continuous casting and forging production of deformed aluminum alloy is a new thing. It adapts to the development requirements of modern industrial products to lighter high strength direction and has a good application prospect. The difference between the continuous casting and forging production of deformed aluminum alloy and the continuous casting and forging production of ordinary cast aluminum alloy is not large, and the technical difficulty is in the operational control. Proficiency in the ordinary casting aluminum alloy continuous casting and forging process, is the basis for the production of continuous casting and forging parts of complex structural deformation aluminum alloy blank. The "extrusion die-casting die forging machine" is the most industrial and economical process and equipment for deformed aluminum alloy continuous casting and forging.
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