A processing method of a cast aluminum flask for an automobile testing machine
By using a processing method for cast aluminum sand casting parts for automotive inspection, the problems of difficulty in setting reference, numerous sand holes, uneven cooling, and difficulty in removing residual stress in cast aluminum sand casting parts have been solved, enabling the production of high-quality cast aluminum sand casting parts and improving the plasticity and weldability of the products.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ROYAL GAUGE IND
- Filing Date
- 2024-08-30
- Publication Date
- 2026-07-14
AI Technical Summary
Cast aluminum sand castings suffer from problems such as difficulty in setting references, numerous sand holes, uneven cooling, difficulty in removing internal residual stress, and poor processing performance during the processing, resulting in high defect rates and poor plasticity and welding performance.
The machining method of cast aluminum sand casting parts using automotive inspection tools is adopted. By determining the X, Y, and Z references, precise roughing is performed using insert cutters and high-speed steel cutters to eliminate sand holes and internal stress. High-pressure flattening and lifting plane technology is used to ensure reference positioning and plane verification, including precise machining of the reverse and front work stations.
It achieves accurate benchmark positioning and plane verification, reduces the defect rate, improves the plasticity and weldability of cast aluminum parts, and enhances processing performance.
Smart Images
Figure CN118893475B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the technical field of aluminum casting processing methods, and more particularly to a processing method for aluminum casting sand casting parts for automotive inspection tools. Background Technology
[0002] Cast aluminum parts are widely used in aerospace, automotive, and machinery industries due to their excellent properties such as low density, high specific strength, and corrosion resistance. In particular, they are widely used in the automotive industry to reduce fuel consumption, improve energy efficiency, and save manufacturing costs.
[0003] As one of the most commonly used cast aluminum parts, cast aluminum sand castings encounter many difficulties in actual processing: (1) It is difficult to set the reference during processing, and it is time-consuming and laborious to calibrate the plane; (2) There are many sand holes, and the uneven cooling of aluminum water on complex functional curved surfaces leads to a high defect rate; (3) It is difficult to remove residual stress inside the workpiece. Residual stress will cause the parts to deform and crack, affecting the size of the parts and reducing fatigue strength; (4) Poor processing performance, the cast aluminum sand casting products produced have low plasticity, poor corrosion resistance and welding performance. Summary of the Invention
[0004] In order to overcome the above-mentioned defects in the existing processing methods of cast aluminum sand casting parts, this invention proposes a new processing method for cast aluminum sand casting parts of automotive inspection fixtures.
[0005] Specifically, this invention provides a processing method for cast aluminum sand-cast parts for automotive inspection fixtures, such as... Figure 14 As shown, this method includes the following steps:
[0006] S1. Roughing test cut on the reverse side of cast aluminum sand casting parts to confirm the roughing datum: Determine the X and Y datum and Z-axis allowance of cast aluminum sand casting parts. Add 10mm allowance in X and Y respectively. Drill lifting holes. Then, select equal height blocks of 5 times the height difference of the scaffold to clamp the parts.
[0007] S2. Roughing and cutting of cast aluminum sand casting parts: On the front of the cast aluminum sand casting parts, X and Y datums are marked, and the Z value is tested to ensure that the X and Y datums are consistent with the machining datums of the front station. During machining, first perform local roughing of 8mm, then remove 0.5mm with a insert cutter. After confirming that there are no sand holes in the local roughing position, continue roughing to 3mm with an insert cutter. After roughing is completed, drill lifting holes, and then select equal height blocks to clamp the parts according to the height difference of the mounting bracket.
[0008] S3. Roughing and cutting of cast aluminum sand casting parts: Use the X, Y, and Z references as the machining references for the reverse side station. Test the X, Y, and Z allowances of 15mm to ensure they are consistent with the machining references for the front side station. Roughen to 3mm with insert cutters. Remove the blank material, machine the venting gate and process pillars on the reverse side, and finally roughen the surface.
[0009] S4. After roughing, allow it to age naturally for 24 hours to eliminate internal stress.
[0010] Furthermore, step S1 of the processing method for the cast aluminum sand-cast part of the automotive inspection fixture of the present invention includes:
[0011] S11. Based on the height of the shims, padded the cast aluminum sand casting parts, find two shims as rough references, use a dial indicator to straighten the line, and then select one of the shims as the reference.
[0012] S12. Roughly define the X and Y reference points for cast aluminum sand casting parts: Press the workpiece with a pressure plate, use a sharp needle to define the X and Y reference edges, and input them into the machine tool coordinate system;
[0013] S13. Determine the X and Y reference points for cast aluminum sand-cast parts;
[0014] S14. Determine the Z-axis allowance for cast aluminum sand casting parts. Use a pointed needle to test the Z value. After leveling according to the regular plane and the joint, smooth the joint into a plane or mill it to a multiple of 5 according to the drop.
[0015] S15. Select a Φ16 machining datum, with a 10mm allowance in both X and Y, drill lifting holes, and then select equal-height blocks to clamp the parts according to the height difference of the mounting brackets.
[0016] Furthermore, step S13 of the processing method for the cast aluminum sand-cast part of the automotive inspection fixture of the present invention includes:
[0017] S131. For the inner and outer contours and regular joints of the trial-cast aluminum sand casting parts, Φ32 white steel cutter is used. The allowance of the straight trial workpiece is re-determined according to the movement of the workpiece by the trial cutter. A 15mm allowance is reserved on each side of the cast aluminum sand casting parts.
[0018] S132. If the allowance of the test workpiece is 8mm or more, proceed with machining;
[0019] S133. When the workpiece allowance is less than 8mm during the trial cut, adjust the workpiece until the workpiece allowance reaches more than 8mm before proceeding with machining.
[0020] Furthermore, in step S15 of the processing method for the cast aluminum sand casting part of the automotive inspection tool of the present invention, the depth of the lifting hole is not less than 20mm.
[0021] Furthermore, step S2 of the processing method for the cast aluminum sand-cast part of the automotive inspection fixture of the present invention includes:
[0022] S21. Set the machining reference on the front side of the cast aluminum sand casting part, and use the X and Y references as the machining references for the front station program;
[0023] S22. Select a Φ16 tool to cut out a straight line and X and Y references. Use the tool to cut out auxiliary references and check whether the cut edge is correct to the test tool reference. Use a dial indicator to check the straight edge, record the deviation of the X and Y edges from the test tool reference, and input it into the machine tool coordinate system.
[0024] S23. Verify the X and Y references. Use a Φ32 stainless steel knife to test the inner and outer contours and regular joints of the test workpiece. Use a pointed needle to test the Z value to ensure that it is consistent with the front workpiece reference.
[0025] S24. When machining the front side, first use a Φ63R6 insert cutter to locally roughen 8mm, then use a Φ16R8 insert cutter to remove 0.5mm. After confirming that there are no sand holes in the locally roughened area, continue machining.
[0026] S25. Use a Φ63R6 insert cutter to continue roughing to 3mm, feed 4000m / min;
[0027] S26. After roughing is completed, the height difference of the smooth scaffold surface is a multiple of 5;
[0028] S27. Drill lifting holes, and then select equal-height blocks to clamp the parts according to the height difference of the gantry.
[0029] Furthermore, in step S25 of the processing method for the cast aluminum sand casting part of the automotive inspection tool of the present invention, during the roughing process, check whether the cutting tool is loose, worn, or has excessive allowance. If any of the above situations exist, deal with them immediately.
[0030] In step S27, the depth of the lifting hole shall not be less than 20mm.
[0031] Furthermore, step S3 of the processing method for the cast aluminum sand-cast part of the automotive inspection fixture of the present invention includes:
[0032] S31. Set the machining datum on the front side of the cast aluminum sand casting part, and use the X, Y, and Z datums as the machining datums for the reverse side station program;
[0033] S32. Test the cutting again, check the X, Y, and Z allowances of 15mm, and confirm that they are consistent with the machining datum of the front station.
[0034] S33. Use a Φ63R6 insert cutter to roughen to 3mm, feed 4000m / min;
[0035] S34. Remove the blank material, first process the reverse venting gate, then process the process column, and finally roughen the surface.
[0036] Furthermore, the processing method of the cast aluminum sand casting part of the automotive inspection tool of the present invention adopts strong pressure flattening and lifting plane during the front roughing, and repairs the reference joint and reference plane under the lifting and clamping state after the roughing is completed.
[0037] Furthermore, the processing method of the cast aluminum sand casting parts of the automotive inspection tool of the present invention involves roughing the front and back of the cast aluminum sand casting parts with a 3mm allowance on each side, and roughing the front and back of the semi-precision cast aluminum sand casting parts with a 1mm allowance on each side, and then finishing to zero position.
[0038] In summary, the processing method for cast aluminum sand casting parts of automotive inspection tools of the present invention can accurately and effectively perform benchmark positioning and plane verification, and can promptly detect sand holes and remove residual stress inside the workpiece. This method has excellent processing performance and a low defect rate. The cast aluminum sand casting parts produced by this method have high plasticity, good corrosion resistance and weldability. Attached Figure Description
[0039] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the following drawings are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0040] Figure 1 This is a schematic diagram of a coarse reference assembly according to an embodiment of the present invention.
[0041] Figure 2 This is a schematic diagram illustrating the coarse determination of X and Y references according to an embodiment of the present invention.
[0042] Figure 3 This is a schematic diagram illustrating the determination of the X and Y reference points for a cast aluminum sand-cast part according to an embodiment of the present invention.
[0043] Figure 4 This is a schematic diagram of the processing and hoisting plan according to an embodiment of the present invention. Figure 1 .
[0044] Figure 5 This is a schematic diagram of the lifting hole depth (20mm) according to an embodiment of the present invention.
[0045] Figure 6 This is a schematic diagram illustrating the determination of the processing reference for the test shape in one embodiment of the present invention.
[0046] Figure 7 This is a schematic diagram of partial roughening in one embodiment of the present invention.
[0047] Figure 8 This is a schematic diagram illustrating the determination of whether a part has pinholes according to an embodiment of the present invention.
[0048] Figure 9 This is a schematic diagram of the roughing toolpath according to an embodiment of the present invention.
[0049] Figure 10 This is a schematic diagram of the processing and hoisting plan according to an embodiment of the present invention. Figure 2 .
[0050] Figure 11 This is a schematic diagram of the machining hole depth according to an embodiment of the present invention.
[0051] Figure 12 This is a schematic diagram of the gate in one embodiment of the present invention.
[0052] Figure 13 This is a schematic diagram of the reverse roughing toolpath according to an embodiment of the present invention.
[0053] Figure 14 This is a flowchart illustrating the overall implementation process of the method of the present invention. Detailed Implementation
[0054] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. This invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this invention.
[0055] At the same time, it should be understood that the scope of protection of the present invention is not limited to the specific embodiments described below; it should also be understood that the terminology used in the embodiments of the present invention is for describing specific embodiments and not for limiting the scope of protection of the present invention.
[0056] Example: A method for machining cast aluminum parts for automotive inspection fixtures
[0057] 1. Perform roughing test on the reverse side of the cast aluminum sand casting part to confirm the roughing datum.
[0058] 1. Based on the height of the shims, shim the cast aluminum sand-cast parts, find two shims as rough references, and use a dial indicator to straighten the line ( Figure 1 Then select one of the pairs as the benchmark.
[0059] 2. Roughly define the X and Y reference points for cast aluminum parts: Hold the workpiece in place with a pressure plate, and use a pointed needle to roughly define the X and Y reference edges, then input them into the machine tool coordinate system. Figure 2 ).
[0060] 3. Determine the X and Y reference points for cast aluminum parts, and determine the Z value.
[0061] (1) Determine the X and Y references for the cast aluminum sand casting parts: Use Φ32 white steel cutter for the inner and outer contours and regular joints of the trial cast aluminum sand casting parts. Based on the movement of the workpiece during the trial cutter, redetermine the allowance for the straight trial workpiece. A 15mm allowance is reserved on each side of the cast aluminum sand casting parts. Figure 3 ).
[0062] (2) If the allowance of the test workpiece is above 8mm, then it can be processed.
[0063] (3) If the workpiece allowance is less than 8mm, adjust the workpiece until the workpiece allowance is more than 8mm before processing.
[0064] (4) If not properly adjusted, excessive error can easily cause the workpiece to move and the tool to break during roughing. If the design model allows, the allowance for machining to the required depth can be kept within 5mm.
[0065] 4. Determine the Z-axis allowance for the cast aluminum sand casting part. Use a pointed needle to test the Z-value. After leveling according to the regular plane and joint, finish the joint as a plane or mill it to a multiple of 5 according to the drop. Figure 4 ).
[0066] 5. Select a Φ16 machining datum, with a 10mm allowance in both X and Y, and drill M10 lifting holes with a depth of not less than 20mm. Figure 5 Then, select equal-height blocks in multiples of 5 according to the height difference of the scaffolding to clamp the parts.
[0067] II. Front-side cutting and roughing of cast aluminum sand-cast parts
[0068] 1. The reference is set on the front side, and the X and Y references are the machining references for the first station (front station) program.
[0069] 2. Select a Φ16 cutting tool to create a straight line and X and Y references. Use the tool to finish the auxiliary references and verify that the edge being cut is correct relative to the test reference. Use a dial indicator to verify the straight edge, record the deviation of the X and Y edges from the test reference, and input it into the machine coordinate system.
[0070] 3. Verify the reference datum. Use a Φ32 stainless steel knife to test the inner and outer contours and regular joints of the test workpiece, and use a pointed needle to test the Z value to ensure consistency with the reference datum of the first station. Figure 6 ).
[0071] 4. During front-side machining, determine if the part meets the requirements, inspect for sand holes, and use a Φ63R6 insert cutter to locally roughen the part by 8mm. Figure 7 Then use a Φ16R8 insert cutter to remove 0.5mm, and roughen the area locally if there are no sand holes. Figure 8 If the quality is poor, continue processing; otherwise, return it to the foundry.
[0072] 5. Use a Φ63R6 insert cutter to roughen to 3mm. Figure 9 Feed at 4000 m / min. During roughing, check whether the cutting tool is loose, worn, or has excessive allowance. If any of the above conditions are found, deal with them immediately.
[0073] 6. After roughing is completed, the height difference of the smooth scaffold surface should be a multiple of 5. Figure 10).
[0074] 7. Drill M10 lifting holes with a depth of not less than 20mm. Figure 11 Then, select equal-height blocks to clamp the parts according to the height difference of the scaffold.
[0075] III. Reverse cutting and roughing of cast aluminum parts
[0076] 1. The reference is set on the front side, and the X, Y, and Z references are the machining references for the two-station (reverse station) program.
[0077] 2. Test the cutting again, checking the X, Y, and Z margins at 15mm to ensure they align with the front reference.
[0078] 3. Use a Φ63R6 insert cutter to roughen to 3mm, with a feed rate of 4000m / min.
[0079] 4. Maximize the removal of raw material by first machining the reverse side venting gate. Figure 12 ), then the process column is further processed to prevent uneven cutting and breakage, and finally the rough surface is opened ( Figure 13 ).
[0080] IV. Results of Process Optimization
[0081] 1. When roughing the front side, do not artificially level or flatten the hoisting plane. Instead, use strong pressure to flatten it. After roughing is completed, repair the reference frame and reference plane while the hoisting is in a tightened state.
[0082] 2. After roughing, allow it to age naturally for 24 hours to eliminate internal stress.
[0083] 3. Large cast aluminum parts should follow the 3-1-0 principle. For cast aluminum sand casting parts, roughing at the first and second stations should leave a 3mm allowance on one side. For semi-precision cast aluminum sand casting parts, roughing at the first and second stations should leave a 1mm allowance on one side. Finishing should be done to the zero position to meet product quality requirements.
[0084] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to obtain equivalent embodiments without departing from the scope of the technical solution of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the technical solution of the present invention should be included within the scope of protection of the claims of the present invention.
Claims
1. A method for processing cast aluminum sand-cast parts for automotive inspection fixtures, characterized in that, The method includes: S1. Roughing test cut on the reverse side of cast aluminum sand casting parts to confirm the roughing datum: Determine the X and Y datum and Z-axis allowance of cast aluminum sand casting parts, with 10mm allowance in both X and Y, drill lifting holes, and then select equal height blocks of 5 times the height difference of the mounting bracket to clamp the parts. S2. Roughing and cutting of cast aluminum sand casting parts: On the front of the cast aluminum sand casting parts, X and Y datums are marked, and the Z value is tested to ensure that the X and Y datums are consistent with the machining datums of the front station. During machining, first perform local roughing of 8mm, then remove 0.5mm with a insert cutter. After confirming that there are no sand holes in the local roughing position, continue roughing to 3mm with an insert cutter. After roughing is completed, drill lifting holes, and then select equal height blocks to clamp the parts according to the height difference of the mounting bracket. S3. Roughing and cutting of cast aluminum sand casting parts: Use the X, Y, and Z references as the machining references for the reverse side station. Test the X, Y, and Z allowances of 15mm to ensure they are consistent with the machining references for the front side station. Roughen to 3mm with insert cutters. Remove the blank material, machine the venting gate and process pillars on the reverse side, and finally roughen the surface. S4. After roughing, allow it to age naturally for 24 hours to eliminate internal stress.
2. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 1, characterized in that, Step S1 includes: S11. Based on the height of the shims, padded the cast aluminum sand casting parts, find two shims as rough references, use a dial indicator to straighten the line, and then select one of the shims as the reference. S12. Roughly define the X and Y reference points for cast aluminum sand casting parts: Press the workpiece with a pressure plate, use a sharp needle to define the X and Y reference edges, and input them into the machine tool coordinate system; S13. Determine the X and Y reference points for cast aluminum sand-cast parts; S14. Determine the Z-axis allowance for cast aluminum sand casting parts. Use a pointed needle to test the Z value. After leveling according to the regular plane and the joint, smooth the joint into a plane or mill it to a multiple of 5 according to the drop. S15. Select a Φ16 machining datum, with a 10mm allowance in both X and Y, drill lifting holes, and then select equal-height blocks to clamp the parts according to the height difference of the mounting brackets.
3. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 2, characterized in that, Step S13 includes: S131. For the inner and outer contours and regular joints of the trial-cast aluminum sand casting parts, Φ32 white steel cutter is used. The allowance of the straight trial workpiece is re-determined according to the movement of the workpiece by the trial cutter. A 15mm allowance is reserved on each side of the cast aluminum sand casting parts. S132. If the allowance of the test workpiece is 8mm or more, proceed with machining; S133. When the workpiece allowance is less than 8mm during the trial cut, adjust the workpiece until the workpiece allowance reaches more than 8mm before proceeding with machining.
4. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 2, characterized in that, In step S15, the depth of the lifting hole shall not be less than 20mm.
5. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 1, characterized in that, Step S2 includes: S21. Set the machining reference on the front side of the cast aluminum sand casting part, and use the X and Y references as the machining references for the front station program; S22. Select a Φ16 tool to cut out a straight line and X and Y references. Use the tool to cut out auxiliary references and check whether the cut edge is correct to the test tool reference. Use a dial indicator to check the straight edge, record the deviation of the X and Y edges from the test tool reference, and input it into the machine tool coordinate system. S23. Verify the X and Y references. Use a Φ32 stainless steel knife to test the inner and outer contours and regular joints of the test workpiece. Use a pointed needle to test the Z value to ensure that it is consistent with the front workpiece reference. S24. When machining the front side, first use a Φ63R6 insert cutter to locally roughen 8mm, then use a Φ16R8 insert cutter to remove 0.5mm. After confirming that there are no sand holes in the locally roughened area, continue machining. S25. Use a Φ63R6 insert cutter to continue roughing to 3mm, feed 4000m / min; S26. After roughing is completed, the height difference of the smooth scaffold surface is a multiple of 5; S27. Drill lifting holes, and then select equal-height blocks to clamp the parts according to the height difference of the gantry.
6. The processing method for cast aluminum sand-cast parts of automotive inspection fixtures according to claim 5, characterized in that, In step S25, during the roughing process, check whether the cutting tool is loose, worn, or has excessive allowance. If any of the above situations are found, deal with them immediately. In step S27, the depth of the lifting hole shall not be less than 20mm.
7. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 1, characterized in that, Step S3 includes: S31. Set the machining datum on the front side of the cast aluminum sand casting part, and use the X, Y, and Z datums as the machining datums for the reverse side station program; S32. Test the cutting again, check the X, Y, and Z allowances of 15mm, and confirm that they are consistent with the machining datum of the front station. S33. Use a Φ63R6 insert cutter to roughen to 3mm, feed 4000m / min; S34. Remove the blank material, first process the reverse venting gate, then process the process column, and finally roughen the surface.
8. The processing method for cast aluminum sand-cast parts of automotive inspection fixtures according to claim 1, characterized in that, The method employs a strong flattening and hoisting plane during front roughing, and after roughing is completed, the reference frame and reference plane are repaired under the hoisting and clamping state.
9. The processing method for cast aluminum sand-cast parts for automotive inspection fixtures according to claim 1, characterized in that, The method involves roughing the front and back of the cast aluminum sand casting parts with a 3mm allowance on each side, and roughing the front and back of the semi-precision cast aluminum sand casting parts with a 1mm allowance on each side, followed by finishing to the zero position.