Aluminum alloy chip cold pressing induces semi-solid extrusion forging composite forming process for fuel filler manhole covers

Abstract

A composite forming process for semi-solid extrusion and forging of fuel hydrant manhole covers induced by cold pressing of aluminum alloy chips is proposed. First, the dimensions of the cold-pressed aluminum alloy disc required for forming the manhole cover are designed. Then, ZL104 aluminum alloy chips are cold-pressed into the disc shape, and the disc is heated and held at a specific temperature to obtain a semi-solid fine spherulitic material. Next, the obtained semi-solid fine spherulitic material is rapidly placed into a U-shaped cavity formed by the outer and lower molds. The upper mold is pressed down, driving the precision forging mold to achieve rough extrusion deformation of the semi-solid fine spherulitic material and hold the pressure, thus forming a rough-extruded semi-solid fuel hydrant manhole cover. Then, while maintaining the pressure of the upper mold, the precision forging mold is controlled to forge the rough-extruded semi-solid fuel hydrant manhole cover, ultimately obtaining a fuel hydrant manhole cover part possessing both a semi-solid spherulitic structure and a forged deformed structure. This invention features a simple process, low forming force, high material utilization, high product density, and good mechanical properties.

Description

Technical Field

[0001] This invention belongs to the field of fuel filler manhole cover manufacturing technology, and specifically relates to a semi-solid extrusion forging composite forming process for fuel filler manhole covers induced by cold pressing of aluminum alloy chips. Background Technology

[0002] Refueling systems have become one of the most important pieces of equipment in major airports, and the performance and manufacturing technology of their components are of paramount importance. Among them, the well valve refueling plug is an important route for refueling trucks to refuel aircraft, and it serves as the interface between the pipeline refueling truck and the apron pipeline network system for fuel output.

[0003] The refueling hydrant cover is a core component of the refueling hydrant device of the ground well valve. It features high load-bearing capacity and light weight, ensuring good strength and rigidity when large aircraft accelerate, stop, and decelerate through the hydrant cover at full load, while also achieving good sealing, operability for operators, and safety in opening and closing the valve.

[0004] The traditional forming process for fuel hydrant manhole covers mainly involves liquid casting followed by machining. The casting process suffers from defects such as shrinkage cavities and porosity, which severely affect the mechanical properties of the fuel hydrant manhole covers. The subsequent machining process generates a large amount of iron filings, chips, flakes, and serrated iron sheets, as well as irregular metal objects formed by the heat generated during machining. The usual process is to cold press these shavings into cakes and then remelt them in a furnace to produce molten aluminum for reuse. However, the melting process of aluminum alloy shavings emits harmful gases, which clearly does not meet the current requirements for green and environmentally friendly intelligent manufacturing. Summary of the Invention

[0005] To overcome the shortcomings of the prior art, the present invention aims to provide a semi-solid extrusion forging composite forming process for fuel plug manhole covers induced by cold pressing of aluminum alloy chips, through which high-performance fuel plug manhole cover parts with semi-solid spherulitic structure are prepared.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] The semi-solid extrusion forging composite forming process for fuel filler manhole covers induced by cold pressing of aluminum alloy chips includes the following steps:

[0008] 1) Material Dimension Design. The material of the fuel filler manhole cover part 1-1 is ZL104 (cast aluminum alloy) with a volume of V. It is necessary to ensure that the semi-solid, fine spherulitic material 2-2 can be smoothly and quickly placed into the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. Therefore, the diameter D of the cold-pressed deformed aluminum alloy disc 1-3 formed by cold pressing technology needs to be less than or equal to the maximum diameter D of the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. maxTherefore, the diameter D of the cold-pressed deformed aluminum alloy disc 1-3 is the maximum diameter D of the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. max Meanwhile, considering that a certain volume of raw material needs to be reserved during precision forging, the volume of the cold-pressed deformed aluminum alloy disc 1-3 is taken as 1.01 times the volume of the fuel filler manhole cover part 1-1. Therefore, the height of the cold-pressed deformed aluminum alloy disc 1-3 is H = 4.04V / (πDmax). 2 V represents the volume of the fuel hydrant manhole cover component.

[0009] 2) Semi-solid material preparation. First, the ZL104 aluminum alloy chips 1-2 from step 1) are cold-pressed to form cold-pressed deformed aluminum alloy discs 1-3 that meet the size requirements of step 1). Then, the cold-pressed deformed aluminum alloy discs 1-3 are placed in a resistance heating furnace 2-1 and heated to 575℃ for 10 minutes to obtain semi-solid fine spherulitic materials 2-2 with a diameter of 30-50 μm and an average shape factor ≥0.65.

[0010] 3) Semi-solid extrusion forging composite forming 3. The semi-solid fine spherulitic material 2-2 obtained in step 2) is quickly placed into the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. The upper mold 3-3 is controlled to press down at a speed of 10 mm / s and a pressure of 100 MPa. At this time, due to the limiting effect, the upper mold 3-3 will drive the precision forging mold 3-4 to press down at the same speed and pressure, so as to achieve rough extrusion deformation of the semi-solid fine spherulitic material 2-2, making it basically fill the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2, forming a rough extrusion semi-solid refueling hydrant cover 3-5. Then, keeping the pressure of the upper mold 3-3 unchanged, the precision forging mold 3-4 is controlled to press down at a speed of 100 mm / s and a pressure load of 200 MPa to achieve forging deformation of the rough extrusion semi-solid refueling hydrant cover 3-5 and hold the pressure for 5 minutes to obtain a precision forged semi-solid refueling hydrant cover 3-6. Finally, a refueling hydrant cover part 3-7 with both semi-solid spherulitic structure and forged deformation structure is obtained. Subsequently, the upper mold 3-3 and the precision forging mold 3-4 are raised simultaneously to separate the semi-solid refueling hydrant cover part 3-7 from it. Then, the lower mold 3-2 is lowered to separate the refueling hydrant cover part 3-7 from it. Finally, the lower mold 3-2 is raised again to eject the refueling hydrant cover part 3-7. A refueling hydrant cover part with both semi-solid spheroidal structure and forged deformation structure is obtained.

[0011] Compared with existing technologies, the present invention uses a semi-solid extrusion forging composite forming process to manufacture fuel filler manhole covers, which has the following advantages:

[0012] 1. The semi-solid material preparation process induced by cold pressing of aluminum alloy chips does not involve oxidation and the introduction of impurity phases caused by high-temperature overheating liquid during the preparation of semi-solid slurry in the liquid phase method. The prepared semi-solid material is pure and free of pollution.

[0013] 2. Taking into full account that when preparing semi-solid materials by the aluminum alloy chip cold pressing induced method, not only can strain energy be effectively accumulated during the cold pressing stage, but the strain energy existing in the chips themselves can also be utilized; and considering that the diameter D of the cold-pressed deformed aluminum alloy disc 1-3 is less than or equal to the maximum diameter D of the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. max This facilitates the acquisition of high-quality semi-solid fine spherulite material 2-3, which can be directly placed into the mold cavity for forming fuel plug manhole covers, avoiding the traditional semi-solid forming "secondary remelting" step, and realizing short-process, near-net-shape forming of fuel plug manhole covers, significantly improving material utilization.

[0014] 3. Because the contact area between the forming part of the precision forging die 3-4 and the forming part is much smaller than that between the lower die 3-3 and the forming part during precision forging, the pressure generated under the same pressure is greater than that generated by the entire upper die 3-3. Therefore, the forging effect is better and the expected mechanical properties of the material can be achieved more effectively.

[0015] 4. Compared with traditional cutting processes, it can shorten the process flow, save production costs, and improve production efficiency. It also has the advantages of high material density of formed parts, mechanical properties comparable to forgings, and the ability to further improve the performance of parts through heat treatment. Attached Figure Description

[0016] Figure 1 This is a process flow diagram of the present invention.

[0017] Figure 2 This is a schematic diagram of the material size design process of the present invention.

[0018] Figure 3 This is a schematic diagram of the shape and microstructure deformation of the material during the forming process of this invention.

[0019] Figure 4 This describes the removal process of the semi-solid refueling plug cover 3-4 formed by the present invention.

[0020] Explanation of the labels in the diagram:

[0021] Material and Dimension Design 1. Fuel Hydrant Cover Parts 1-1. ZL104 Aluminum Alloy Chips 1-2. Cold Pressed Variable Shape Aluminum Alloy Discs 1-3. Semi-Solid Material Preparation 2. Resistance Heating Furnace 2-1. Semi-Solid Fine Spherulite Material 2-2. Semi-Solid Extrusion Forging Composite Forming 3. Outer Mold 3-1. Lower Mold 3-2. Upper Mold 3-3. Precision Forging Mold 3-4. Rough Extrusion Semi-Solid Fuel Hydrant Cover 3-5. Precision Forging Semi-Solid Fuel Hydrant Cover 3-6. Fuel Hydrant Cover Parts 3-7. Detailed Implementation

[0022] The present invention will now be described in detail with reference to the accompanying drawings.

[0023] Reference Figure 1 , Figure 2 and Figure 3 The semi-solid extrusion forging composite forming process of fuel filler manhole covers induced by cold pressing of aluminum alloy chips includes the following steps:

[0024] 1) Material Dimension Design. The material of the fuel hydrant manhole cover part 1-1 is ZL104 (cast aluminum alloy) with a volume of V. To ensure that the semi-solid, fine spherulitic material 2-2 can be smoothly and quickly placed into the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2, the diameter D of the cold-pressed deformed aluminum alloy disc 1-3 formed by cold pressing technology needs to be less than or equal to the maximum diameter Dmax of the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. Therefore, the diameter D of the cold-pressed deformed aluminum alloy disc 1-3 is taken as the maximum diameter Dmax of the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. Simultaneously, considering the need to reserve a certain amount of raw material volume during precision forging, the volume of the cold-pressed deformed aluminum alloy disc 1-3 is taken as 1.01 times the volume of the fuel hydrant manhole cover part 1-1. Therefore, the height of the cold-pressed deformed aluminum alloy disc 1-3 is H = 4.04V / (πDmax). 2 V represents the volume of the fuel hydrant manhole cover component.

[0025] 2) Semi-solid material preparation. First, the ZL104 aluminum alloy chips 1-2 from step 1) are cold-pressed to form cold-pressed deformed aluminum alloy discs 1-3 that meet the size requirements of step 1). Then, the cold-pressed deformed aluminum alloy discs 1-3 are placed in a resistance heating furnace 2-1 and heated to 575℃ for 10 minutes to obtain semi-solid fine spherulitic materials 2-2 with a diameter of 30-50 μm and an average shape factor ≥0.65.

[0026] 3) Semi-solid extrusion forging composite forming 3. The semi-solid fine spherulitic material 2-2 obtained in step 2) is quickly placed into the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2. The upper mold 3-3 is controlled to press down at a speed of 10 mm / s and a pressure of 100 MPa. At this time, due to the limiting effect, the upper mold 3-3 will drive the precision forging mold 3-4 to press down at the same speed and pressure, so as to achieve rough extrusion deformation of the semi-solid fine spherulitic material 2-2, so that it basically fills the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2, forming a rough extrusion semi-solid refueling hydrant cover 3-5. Then, keeping the pressure of the upper mold 3-3 unchanged, the precision forging mold 3-4 is controlled to press down at a speed of 100 mm / s and a pressure load of 200 MPa to achieve forging deformation of the rough extrusion semi-solid refueling hydrant cover 3-5 and hold the pressure for 5 minutes, finally obtaining a refueling hydrant cover part 3-7 that has both semi-solid spherulitic structure and forged deformation structure. Subsequently, the upper mold 3-3 and the precision forging mold 3-4 are raised simultaneously to separate the semi-solid refueling hydrant cover part 3-7 from it. Then, the lower mold 3-2 is lowered to separate the refueling hydrant cover part 3-7 from it. Finally, the lower mold 3-2 is raised again to eject the refueling hydrant cover part 3-7. A refueling hydrant cover part with both semi-solid spheroidal structure and forged deformation structure is obtained.

[0027] The specific working principle of the ejection of the fuel filler manhole cover component 3-7 after forming in this invention is as follows:

[0028] Reference Figure 4 As shown, after the fuel filler manhole cover part 3-7 is formed, the upper mold 3-3 rises first. At this time, due to the limiting effect, the precision forging mold 3-4 rises at the same speed as the upper mold 3-3. Since the contact area between the fuel filler manhole cover part 3-7 and the upper mold 3-3 and the precision forging mold 3-4 is significantly smaller than the contact area between the fuel filler manhole cover part 3-7 and the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2, the fuel filler manhole cover part 3-7 is left in the "U"-shaped cavity formed by the outer mold 3-1 and the lower mold 3-2, and the upper mold 3-3 and the precision forging mold 3-4 separate from the fuel filler manhole cover part 3-7. Next, the lower mold 3-2 is lowered. Since the outermost ring of the fuel filler manhole cover part 3-7 is limited by the internal structure of the outer mold 3-1, when the lower mold 3-2 descends, the fuel filler manhole cover part 3-7 will be left inside the outer mold 3-1, thus separating from the lower mold 3-2. Finally, the lower mold 3-2 is raised again to eject the formed refueling hydrant cover part 3-7 from the inside of the outer mold 3-1; thus obtaining a refueling hydrant cover part that simultaneously possesses a semi-solid spherulitic structure and a forged deformation structure.

Claims

1. A semi-solid extrusion forging composite forming process for fuel filler manhole covers induced by cold pressing of aluminum alloy chips, characterized in that... Includes the following steps: 1) material size design: the diameter D of the cold-deformed aluminum alloy cake is the maximum diameter Dmax of the "U"-shaped cavity formed by the outer die and the lower die, the volume of the cold-deformed aluminum alloy cake is 1.01 times the volume of the oiling plug well cover part, and the height of the cold-deformed aluminum alloy cake is H=4.04V / (πDmax 2 ), V is the volume of the oiling plug well cover part; 2) Semi-solid material preparation: First, ZL104 aluminum alloy chips are cold-pressed into cold-pressed deformed aluminum alloy discs that meet the size requirements in step 1); then, the cold-pressed deformed aluminum alloy discs are placed in a resistance heating furnace and heated to 575℃ for 10 minutes to obtain semi-solid fine spherulitic materials with a diameter of 30-50μm and an average shape factor ≥0.

65. 3) Semi-solid extrusion forging composite forming: The semi-solid fine spherulite material is placed into the "U"-shaped die cavity. The upper die is controlled to press down at a speed of 10 mm / s and a pressure of 100 MPa. At this time, due to the limiting effect, the upper die will drive the precision forging die to press down at the same speed and pressure, realizing the coarse extrusion deformation of the semi-solid fine spherulite material so that it basically fills the "U"-shaped die cavity, forming a coarse extrusion semi-solid refueling hydrant cover. Then, keeping the pressure of the upper die constant, the precision forging die is controlled to press down at a speed of 100 mm / s... The pressing speed and the pressing load of 200 MPa are used to forge and deform the semi-solid refueling hydrant cover by rough extrusion and hold the pressure for 5 minutes to obtain a refueling hydrant cover part with both semi-solid spheroidal structure and forged deformation structure. Then, the upper die and the precision forging die are raised simultaneously to separate the semi-solid refueling hydrant cover part from them. The lower die is then lowered to separate the refueling hydrant cover part from them. Finally, the lower die is raised again to eject the refueling hydrant cover part, thus obtaining a refueling hydrant cover part with both semi-solid spheroidal structure and forged deformation structure.

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