A method for producing thin-walled irregular parts with double flanges

Abstract

The production method of the double-flange thin-walled irregular part of the present invention involves removing the original window end process clamps and openings on the mold, reducing the wax temperature and increasing the mold shell strength during the wax molding process, increasing the liquid stirring speed during argon refining in the melting process, using steel wire mesh for anti-collision isolation on the product surface during solution treatment, and three rounds of high and low temperature treatment. This ensures that the local wall thickness of the window processing is sufficient during processing, the intersection point of the outer circle surface and the four window surfaces is concentric, the inner opening size is stable, and the flange surfaces at both ends are perpendicular to the center line. During the machining process, the product size remains stable as the wall thickness decreases, and the overall pass rate of the cylinder frame reaches 90%.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of flange processing, and particularly relates to a production method of a double-flange thin-wall special-shaped part. BACKGROUND

[0002] The cylinder holder is a material ZL101A-T6 I part, which is similar to a product with a hollow cylinder connected between two flanges, and the outer circle of the hollow cylinder is composed of irregular special-shaped bosses in different directions. The product needs to meet the following conditions: the outer circle of the center cylinder is required to be non-machined, the cylindricity is 0.05, the wall thickness of the finished product is 1.5 mm, the diameter tolerance is 0.2 mm, and the wall thickness tolerance is not more than 0.1 mm; the inner end faces of the two flanges are required to be non-machined, the wall thickness tolerance of the finished product is 0.1; the perpendicularity between the cylinder and the flange is 0.05; the distance between the flanges is 389 mm, and the tolerance is 0.2. Under such strict size requirements and shape and position tolerance requirements, it is difficult for personnel in the field to produce qualified products, and the comprehensive qualified rate of small-batch production products has been below 30% all the time, and the following problems exist:

[0003] Firstly, the local wall thickness is insufficient due to shrinkage after window processing; secondly, the intersection points of the outer circle surface and the four window surfaces are not concentric; thirdly, the inner opening size is unstable, and the two end flange surfaces are in a wave shape and are not perpendicular to the center line; and fourthly, the product size is unstable during the machining process as the wall thickness decreases. SUMMARY

[0004] In order to solve the problems in the prior art, the present application provides a production method of a double-flange thin-wall special-shaped part to improve the stability of the machining size, and the specific technical scheme is as follows:

[0005] A production method of a double-flange thin-wall special-shaped part, comprising the following steps:

[0006] (1) The original window end process chuck and the window are removed on the mold, the process chuck is directly removed in the wax pressing stage to reduce the casting stress concentration, the window is opened on the mold, which is beneficial to the bifurcation of the window large head in the machining process, and also avoids the uneven wall thickness caused by deformation in the large end machining process;

[0007] (2) The wax temperature is reduced during the wax pressing process, the wax mold strength is improved, the initial deformation is reduced, and the rolling is reduced during the tree assembly process;

[0008] (3) After the third layer of paint is dried, fine iron wires are wound on the surface to improve the mold shell strength, reduce the mold shell deformation under high temperature and high pressure during dewaxing, and reduce the mold shell during high-temperature baking;

[0009] (4) The liquid stirring speed is increased during argon refining in the melting process to make the aluminum liquid as uniform as possible and reduce segregation;

[0010] (5) Solid solution treatment, the product surface is prevented from colliding by using a steel wire mesh, and the time from opening the furnace door to entering the water must be controlled within 8s;

[0011] (6) The shaping process adopts a two-step separation targeted shaping method, a first transverse avoids the male boss from locking the middle circular hole, locks four nuts, ensures the cylindricity and outer circle tolerance, and the pressure is 15 tons for 20s; a second vertical pressure two end tooling blocks ensure the remaining size and shape tolerance, and the pressure is 15 tons for 25s;

[0012] (7) High and low temperature treatment is carried out at-55 to-60℃ and then at 175℃ for three cycles of high and low temperature treatment;

[0013] (8) Machining: align the cylinder by clamping the small head process boss, machine the two end faces and leave a margin, machine the inner circular hole and leave a margin; position the inner hole by the inner support claw, and use a rubber band to bundle the outer circular window end, finish machining the two disc faces, and finish machining the inner hole in the reverse direction.

[0014] Further, in step (2), the temperature is reduced from 60℃ to 56℃.

[0015] Further, in step (4), the liquid stirring speed is increased from 380R / min to 500R / min.

[0016] Further, in step (7), the temperature is kept at-55 to-60℃ for 3 hours, and the temperature is kept at 175℃ for 6 to 8 hours.

[0017] Further, in step (8), the rough machining feed amount is not more than 1mm, and the finish machining feed amount is not more than 0.5mm.

[0018] Compared with the prior art, the technical effect of the present application is embodied in:

[0019] Through the method of the present application, the local wall thickness of the window is sufficient, the intersection points of the outer circular surface and the four window surfaces are concentric, the inner opening size is stable, the two end flange surfaces are perpendicular to the center line, the product size is stable during the machining process as the wall thickness decreases, and the comprehensive qualified rate of the cylinder frame reaches 90%, which has been mass-produced. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 The special-shaped part made by the present application;

[0021] Figure 2 The performance detection report of the special-shaped part of the present application;

[0022] Figure 3 The tensile strength comparison curve of the embodiment and the comparative example of the present application. DETAILED DESCRIPTION

[0023] The technical solutions of the present application will be further limited in combination with specific embodiments, but the scope of protection is not limited to the description.

[0024] Example 1

[0025] A production method of a double-flange thin-wall special-shaped part, comprising the following steps:

[0026] (1) removing the original window end process chuck and opening the window on the mold, directly removing the process chuck during the wax pressing stage to reduce the casting stress concentration, opening the window on the mold is beneficial to the bifurcation of the window large head during the machining process, and also avoids the wall thickness unevenness caused by deformation during the large end machining process;

[0027] (2) reducing the wax temperature during the wax pressing process, from 60℃ to 56℃, improving the wax mold strength, reducing the initial deformation, and reducing the tumbling during the tree assembly process;

[0028] (3) after the third layer of paint is dried, fine iron wires are wound on the surface to improve the mold shell strength, reduce the mold shell deformation under high temperature and high pressure during dewaxing, and reduce the shell spring during high temperature baking;

[0029] (4) increasing the liquid stirring speed from 380R / min to 500R / min during argon refining during the melting process, to make the aluminum liquid as uniform as possible and reduce segregation;

[0030] (5) using a steel wire mesh to do anti-collision isolation on the product surface during the solid solution treatment, and the time from opening the door to entering the water must be controlled within 8s;

[0031] (6) adopting a two-step separate targeted shaping method (as shown in the figure), the first horizontal direction avoids the special-shaped boss from being locked in the middle circular hole, locks four nuts, ensures the cylindrical degree and the outer circle tolerance, and the pressure is 15 tons and the pressure is maintained for 20s; the second vertical direction presses the two end tooling blocks to ensure the remaining size and shape tolerance, and the pressure is 15 tons and the pressure is maintained for 25s;

[0032] (7) high and low temperature treatment is adopted for three times, -55℃ for three hours and 175℃ for six hours;

[0033] (8) machining: aligning the cylinder with the small head process boss, turning the two end faces with a margin, and turning the inner circular hole with a margin; positioning the inner hole with the inner support claw, turning the outer circle (the window end is tied with a rubber band), fine turning the two disc surfaces, and fine turning the inner hole in the reverse direction. The rough turning feed amount is not greater than 1mm, and the fine turning feed amount is not greater than 0.5mm. The random selection of 3 test results in Example 1 is shown in Figure 2 .

[0034] The attached Figure 2 It can be seen that the special-shaped part made by the method of the present application has excellent performance and can fully meet the production needs.

[0035] Scale settings:

[0036]

[0037] The tensile strength of Comparative Examples 1-3 was compared with that of Example 1; see Appendix. Figure 3 (The average value is taken from Example 1). From Figure 3 It can be seen that the products manufactured using this invention have better performance, superior parameters, and can achieve good results.

Claims

1. A method of producing a double-flanged thin-walled profiled member, characterized in that, Includes the following steps: (1) Remove the original window end process clamp and window opening on the mold. Remove the process clamp directly during the wax mold pressing stage to reduce casting stress concentration. The window opening on the mold is conducive to the branching of the large end of the window opening during the machining process, and also avoids uneven wall thickness caused by deformation during the machining process of the large end. (2) The wax temperature is reduced during the pressing process, the wax strength is increased, the initial deformation is reduced, and the tumbling is reduced during the tree assembly process; (3) After the third layer of coating dries, thin iron wire is wrapped around the surface to improve the strength of the mold shell and reduce the deformation of the mold shell under high temperature and high pressure during dewaxing and the shell popping during high temperature baking; (4) During the argon refining process, increase the stirring speed of the liquid to make the aluminum liquid as uniform as possible and reduce segregation; (5) During solution treatment, the product surface is protected by wire mesh, and the time from opening the furnace door to entering the water must be controlled within 8 seconds; (6) The shaping process adopts a two-step separation targeted shaping method. First, the horizontal part avoids the irregular boss and locks the middle round hole, and locks the four nuts to ensure the cylindricity and outer circle tolerance. The pressure is 15 tons and held for 20 seconds. Second, the vertical part presses the tooling round blocks at both ends to ensure the remaining dimensions and geometric tolerances. The pressure is 15 tons and held for 25 seconds. (7) The high and low temperatures are treated at -55 to -60℃ and then at 175℃, for three rounds of high and low temperature treatment; (8) Machining: Align the small end process boss with the cylinder, machine both ends with allowance, and machine the inner hole with allowance; position the inner hole with the inner support claw, machine the outer window end with rubber band and tie it, finish machine both discs, and finish machine the inner hole of the reverse clamp process boss.

2. The method of producing a double-flanged thin-wall special-shaped member according to claim 1, characterized by, In step (2), the wax temperature is reduced from 60°C to 56°C.

3. The method of claim 1, wherein the method further comprises the steps of: providing a first flange plate; providing a second flange plate; and joining the first flange plate and the second flange plate to form a double flange plate. In step (4), the liquid stirring speed is increased from 380 R / min to 500 R / min.

4. The method of claim 1, wherein the method further comprises the steps of: providing a first flange plate; providing a second flange plate; and joining the first flange plate and the second flange plate to form a double flange plate. In step (7), the temperature is maintained at -55 to -60°C for 3 hours and at 175°C for 6 to 8 hours.

5. The method of claim 1, wherein the method further comprises the steps of: providing a first flange plate; providing a second flange plate; and joining the first flange plate and the second flange plate to form a double flange plate. In step (8), the roughing feed rate is no more than 1 mm, and the finishing feed rate is no more than 0.5 mm.

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