A method for manufacturing a tubular automobile sample

Abstract

The invention discloses a method for manufacturing an automobile tubular sample, which comprises the following steps: S1, using the SLA-3D process to obtain an outer contour prototype part of the tubular sample and an inner cavity prototype part of the tubular sample; S2, using the outer contour prototype part of the tubular sample to make an outer contour silicone mold of the tubular sample, and using the inner cavity prototype part of the tubular sample to make an inner cavity silicone mold of the tubular sample; S3, pouring gypsum into the inner cavity silicone mold of the tubular sample, and after the gypsum solidifies, taking out the gypsum inner cavity mold and polishing the surface; S4, loading the gypsum inner cavity mold into the outer contour silicone mold of the tubular sample, and then pouring molten material into the outer contour silicone mold of the tubular sample, and forming a tubular sample after cooling; S5, removing the gypsum inner cavity mold in the tubular sample, repairing, polishing and surface treating the tubular sample to obtain a finished product. It can form a tubular sample in one piece, has high structural strength and good air tightness, and the performance parameters are basically consistent with the design parameters.

Description

Technical Field

[0001] The invention relates to the manufacture of automobile parts, and in particular to a method for manufacturing automobile tubular samples. Background Art

[0002] In the prototype development stage of new automobile R&D, it is often necessary to produce small batches of tubular samples such as air ducts and bellows to verify the layout of design data, design evaluation, interference inspection, and certain functional tests. Currently, there are three ways to produce tubular samples: rapid prototyping, silicone mold replication, and trial steel mold.

[0003] Rapid prototyping is mainly divided into CNC and 3D printing, which is the most widely used production method at present. Its advantages are short production cycle and fast response time when tasks change, but the production cost is relatively high. It is suitable for single-piece production but not for small-batch sample production.

[0004] Trial steel mold proofing is to use the injection molding process to make samples. The advantage is that the process of trial products is consistent with that of mass production, and the materials are also the same. Therefore, the performance of the samples is basically consistent with that of mass production products. However, the disadvantage is that the trial steel mold production cycle is long and the cost is high. When the data changes, the mold structure change time is long, which is not suitable for short-term rapid verification of samples.

[0005] The advantages of silicone molds are short production cycle and low cost, and it is suitable for small batch sample production. However, when making tubular samples, due to the limitations of the inner cavity structure of the tubular samples, the tubular samples cannot be formed in one piece using the mold-reproduction process. The tube needs to be split into multiple pieces, which are molded separately and then glued together. This method has the following problems: many molds, long mold production cycle and high cost; and the sample structure is weak in strength, poor in performance and low in air tightness due to block bonding. Summary of the invention

[0006] The object of the present invention is to provide a method for manufacturing an automobile tubular sample, which can form the tubular sample in one piece, has high structural strength, good air tightness, and the performance parameters are basically consistent with the design parameters.

[0007] The method for manufacturing the automobile tubular sample of the present invention comprises the following steps:

[0008] S1, using SLA-3D process to make the outer contour prototype of the tubular sample and the inner cavity prototype of the tubular sample;

[0009] S2, using the outer contour prototype of the tubular sample to make an outer contour silicone mold of the tubular sample, and using the inner cavity prototype of the tubular sample to make an inner cavity silicone mold of the tubular sample;

[0010] S3, pouring gypsum into the inner cavity silicone mold of the tubular sample, and after the gypsum solidifies, taking out the gypsum inner cavity mold and polishing the surface;

[0011] S4, inserting the plaster inner cavity mold into the outer contour silicone mold of the tubular sample, and then pouring the molten material into the outer contour silicone mold of the tubular sample, and forming the tubular sample after cooling;

[0012] S5, removing the plaster inner cavity mold in the tubular sample, repairing, grinding and surface treatment of the tubular sample to obtain a finished product.

[0013] Further, the outer contour silicone mold of the tubular sample in S2 includes a first upper mold and a first lower mold, and the first upper mold and the first lower mold are molded together to form an outer contour cavity for molding the tubular sample;

[0014] The inner cavity silicone mold of the tubular sample comprises a second upper mold and a second lower mold, and the second upper mold and the second lower mold are combined to form a tubular sample with a plaster inner cavity mold.

[0015] Further, the upper surface of the first lower mold is provided with at least one first groove for accommodating a transverse positioning pin, and the first upper mold is provided with a first positioning groove corresponding to the transverse positioning pin;

[0016] The upper surface of the second lower mold is provided with at least one second groove for accommodating a transverse positioning pin, and the second upper mold is provided with a second positioning groove corresponding to the transverse positioning pin.

[0017] Furthermore, a plurality of first vertical positioning pins are connected between the first upper die and the first lower die, and a plurality of second vertical positioning pins are connected between the second upper die and the second lower die.

[0018] Furthermore, the molten material in S4 is polyurethane rubber.

[0019] Further, the polyurethane rubber comprises 100 parts by weight of a main agent A, 100 parts by weight of a curing agent B and 0 to 320 parts by weight of a hardness adjusting agent C, and S4 specifically comprises the following steps:

[0020] S41, pouring the single-component main agent A into the first pouring cup, and pouring the curing agent B and the hardness adjusting agent C into the second pouring cup;

[0021] S42, installing the first pouring cup, the second pouring cup and the outer contour silicone mold of the heated tubular sample with the gypsum inner cavity mold into a vacuum injection molding machine;

[0022] S43, after vacuuming, stirring and mixing the main agent A in the first pouring cup with the curing agent B and the hardness adjusting agent C in the second pouring cup to obtain a mixture;

[0023] S44, pouring the mixed material into the outer contour silicone mold of the tubular sample, pressurizing, heat-insulating, curing, cooling, opening the mold and taking out the tubular sample.

[0024] Furthermore, the Shore A hardness of the mixture in S43 is 20-90, the mixing temperature is 25°C, and the mixing time is 30s.

[0025] Furthermore, the pouring process parameters in S44 are as follows: pouring operation time is 340-1020s, insulation environment temperature is 60°C, insulation time is 60-150min, and natural cooling.

[0026] Compared with the prior art, the present invention has the following beneficial effects.

[0027] 1. The present invention first uses the outer contour prototype of the tubular sample to make the outer contour silicone mold of the tubular sample, uses the inner cavity prototype of the tubular sample to make the inner cavity silicone mold of the tubular sample, and then uses the duplication process to make the tubular sample with the plaster inner cavity mold, and then removes the plaster inner cavity mold in the tubular sample, repairs, polishes and surface-treats the tubular sample to obtain a finished product, which solves the problem that the tubular sample cannot be integrally formed due to the limitation of the inner cavity structure, reduces the number of molds, shortens the production cycle, and reduces costs.

[0028] 2. The manufacturing method of the present invention can produce tubular samples with different hardness, strength and elasticity. It is an one-piece molded sample with high structural strength and good air tightness. The performance parameters are basically consistent with the design parameters, and can well meet the needs of appearance design verification, structural inspection, performance testing, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 is a flow chart of a method for manufacturing a tubular automobile sample according to the present invention;

[0030] Figure 2 It is a schematic diagram of the structure of the outer contour silicone mold of the tubular sample;

[0031] Figure 3 It is a schematic diagram of the structure of the inner cavity silicone mold of the tubular sample.

[0032] In the figure, 1 is the first upper mold, 2 is the first lower mold, 3 is the second upper mold, 4 is the second lower mold, 5 is the gypsum inner cavity membrane, 6 is the horizontal positioning pin, 7 is the first vertical positioning pin, 8 is the second vertical positioning pin, 9 is the first pouring gate, 10 is the first exhaust port, 11 is the first clamp, 12 is the second pouring gate, 13 is the second exhaust port, and 14 is the second clamp. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution in the embodiment of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiment of the present invention. Obviously, the described embodiment is only a part of the embodiment of the present invention, not all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0034] See also Figure 1 , the manufacturing method of the automobile tubular sample shown in the figure comprises the following steps:

[0035] S1, design the outer contour data, inner cavity data, silicone mold draft, etc. of the tubular sample in CATIA software, and use SLA-3D process to make the outer contour prototype and inner cavity prototype of the tubular sample.

[0036] S2, using the outer contour prototype of the tubular sample to make the outer contour silicone mold of the tubular sample, and using the inner cavity prototype of the tubular sample to make the inner cavity silicone mold of the tubular sample.

[0037] See also Figure 2 The outer contour silicone mold of the tubular sample shown includes a first upper mold 1 and a first lower mold 2. The first upper mold 1 and the first lower mold 2 form an outer contour cavity for molding the tubular sample after being molded together. The lower surface of the first upper mold 1 and the upper surface of the first lower mold 2 are provided with wavy protrusions that correspond to each other, so as to facilitate the rapid alignment of the first upper mold 1 and the first lower mold 2 when the molds are closed. The upper surface of the first lower mold 2 is provided with two first grooves arranged in parallel for accommodating the transverse positioning pins 6, and the first upper mold 1 is provided with a first positioning groove corresponding to the transverse positioning pins 6; in order to further improve the mold closing accuracy between the first upper mold 1 and the first lower mold 2, four first vertical positioning pins 7 are connected between the first upper mold 1 and the first lower mold 2.

[0038] The first upper mold 1 is provided with a first pouring port 9 for introducing gypsum. The first lower mold 2 is provided with a first exhaust port 10 for exhausting gas in the mold after mold closing. A first clamping plate 11 is arranged around the first upper mold 1 and the first lower mold 2.

[0039] See also Figure 3 The inner cavity silicone mold of the tubular sample shown includes a second upper mold 3 and a second lower mold 4. The second upper mold 3 and the second lower mold 4 are molded together to form a tubular sample with a gypsum inner cavity mold 5.

[0040] The upper surface of the second lower mold 3 is provided with two second grooves for accommodating the transverse positioning pins 6 , and the second upper mold 2 is provided with second positioning grooves corresponding to the transverse positioning pins 6 .

[0041] In order to further improve the mold closing accuracy between the second upper mold 3 and the second lower mold 4 , four second vertical positioning pins 8 are connected between the second upper mold 3 and the second lower mold 4 .

[0042] The second upper mold 3 has a second pouring port 12 on the top surface for introducing gypsum. The second upper mold 3 also has a second exhaust port 13 on the top surface for exhausting gas in the mold after mold closing. A second clamping plate 14 is arranged around the second upper mold 3 and the second lower mold 4.

[0043] S3, install the transverse positioning pin 6 in the first groove of the first lower mold 2, and then align the first upper mold 1 and the first lower mold 2 through the wave-shaped protrusions, insert four first vertical positioning pins 7, and insert the first clamping plate 11 around. Then wrap the mold with transparent tape around it and place the mold vertically. Then pour the gypsum from the first pouring port 9 into the inner cavity silicone mold of the tubular sample. After the gypsum solidifies, take out the gypsum inner cavity mold 5 with the transverse positioning pin 6 and polish the surface.

[0044] S4, install the plaster inner cavity mold 5 with the transverse positioning pins 6 into the second lower mold 4 of the outer contour silicone mold of the tubular sample, and then align the second upper mold 3 and the second lower mold 4 through the wave-shaped protrusions to close the mold, insert four second vertical positioning pins 8, and insert the second clamping plate 14 around. Then wrap the mold around the transparent tape and place the mold vertically. Pour the molten material into the outer contour silicone mold of the tubular sample, and form the tubular sample after cooling; the molten material is polyurethane rubber.

[0045] The polyurethane rubber comprises 100 parts by weight of a main agent A, 100 parts by weight of a curing agent B and 0 to 320 parts by weight of a hardness adjusting agent C, and the pouring specifically comprises the following steps:

[0046] S41, pouring the single-component main agent A into the first pouring cup, and pouring the curing agent B and the hardness adjusting agent C into the second pouring cup;

[0047] S42, installing the first pouring cup, the second pouring cup and the outer contour silicone mold of the heated tubular sample with the gypsum inner cavity mold into a vacuum injection molding machine;

[0048] S43, after vacuuming, the main agent A in the first pouring cup and the curing agent B and hardness adjuster C in the second pouring cup are stirred and mixed to obtain a mixture; the Shore A hardness of the mixture is 20~90, the mixing temperature is 25°C, and the mixing time is 30s.

[0049] S44, pouring the mixture into the outer contour silicone mold of the tubular sample, pressurizing, heat preservation, curing, cooling, opening the mold and taking out the tubular sample. The specific pouring process parameters are: pouring operation time is 340~1020s, heat preservation environment temperature is 60℃, heat preservation time is 60~150min, and natural cooling.

[0050] S5, removing the plaster inner cavity mold in the tubular sample, repairing, grinding and surface treatment the tubular sample to obtain a finished tubular sample.

[0051] After removing the plaster inner cavity mold in the tubular sample, first check the structure, size, surface quality, etc. of the tubular sample. If the inspection result is qualified, proceed to the next step. If the inspection result is unqualified, repeat step S4 by modifying the silicone mold, adjusting the molding process parameters, etc. until the inspection result is qualified;

[0052] After passing the inspection, the tubular sample is repaired, polished and surface treated, packaged and delivered to obtain the finished tubular sample.

[0053] The above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. A method for manufacturing a tubular automobile sample, characterized in that: The steps include: S1, using SLA-3D process to make the outer contour prototype of the tubular sample and the inner cavity prototype of the tubular sample; S2, using the outer contour prototype of the tubular sample to make an outer contour silicone mold of the tubular sample, and using the inner cavity prototype of the tubular sample to make an inner cavity silicone mold of the tubular sample; The outer contour silicone mold of the tubular sample comprises a first upper mold and a first lower mold, and the first upper mold and the first lower mold are combined to form an outer contour cavity for molding the tubular sample; The inner cavity silicone mold of the tubular sample comprises a second upper mold and a second lower mold, and the second upper mold and the second lower mold are combined to form a tubular sample with a plaster inner cavity mold; The lower surface of the first upper mold and the upper surface of the first lower mold are provided with wavy protrusions corresponding to each other, the upper surface of the first lower mold is provided with at least one first groove for accommodating a transverse positioning pin, and the first upper mold is provided with a first positioning groove corresponding to the transverse positioning pin; The lower surface of the second upper mold and the upper surface of the second lower mold are provided with wavy protrusions that correspond to each other, the upper surface of the second lower mold is provided with at least one second groove that accommodates a transverse positioning pin, and the second upper mold is provided with a second positioning groove that corresponds to the transverse positioning pin; A plurality of first vertical positioning pins are connected between the first upper die and the first lower die, and a plurality of second vertical positioning pins are connected between the second upper die and the second lower die; S3, pouring gypsum into the inner cavity silicone mold of the tubular sample, and after the gypsum solidifies, taking out the gypsum inner cavity mold and polishing the surface; S4, inserting the plaster inner cavity mold into the outer contour silicone mold of the tubular sample, and then pouring the molten material into the outer contour silicone mold of the tubular sample, and forming the tubular sample after cooling; S5, removing the plaster inner cavity mold in the tubular sample, repairing, grinding and surface treatment of the tubular sample to obtain a finished product.

2. The method for manufacturing a tubular automobile sample according to claim 1, characterized in that: The molten material in S4 is polyurethane rubber.

3. The method for manufacturing a tubular automobile sample according to claim 2, characterized in that: The polyurethane rubber comprises 100 parts by weight of a main agent A, 100 parts by weight of a curing agent B and 0 to 320 parts by weight of a hardness adjusting agent C. S4 specifically comprises the following steps: S41, pouring the single-component main agent A into the first pouring cup, and pouring the curing agent B and the hardness adjusting agent C into the second pouring cup; S42, installing the first pouring cup, the second pouring cup and the outer contour silicone mold of the heated tubular sample with the gypsum inner cavity mold into a vacuum injection molding machine; S43, after vacuuming, stirring and mixing the main agent A in the first pouring cup with the curing agent B and the hardness adjusting agent C in the second pouring cup to obtain a mixture; S44, pouring the mixed material into the outer contour silicone mold of the tubular sample, pressurizing, heat-insulating, curing, cooling, opening the mold and taking out the tubular sample.

4. The method for manufacturing a tubular automobile sample according to claim 3, characterized in that: The Shore A hardness of the mixture in S43 is 20~90, the mixing temperature is 25℃, and the mixing time is 30s.

5. The method for manufacturing a tubular sample for an automobile according to claim 3, characterized in that: The specific pouring process parameters in S44 are: pouring operation time is 340~1020s, insulation environment temperature is 60℃, insulation time is 60~150min, and natural cooling.

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