Manufacturing method of swash plate seat

Abstract

The embodiment of the invention discloses a swash plate seat manufacturing method which comprises the steps that materials with preset components are smelted to obtain melt, the materials with the preset components comprise carbon, silicon, manganese, phosphorus, sulfur, copper and iron, and the mass fraction of the copper is 0.5-0.8%; transferring the molten liquid into a preheated casting mold for pouring and casting to obtain a casting intermediate; cooling the casting intermediate in a mold cavity to obtain a swash plate base body, wherein the cooling rate is 20-50 DEG C / min; the large lug, the small lug and the shaft center hole of the swash plate base body are subjected to induction quenching according to preset induction heating and quenching parameters until the surface hardness of the large lug and the small lug of the swash plate base body is 40-60 HRC and the hardening depth of the large lug and the small lug is 1-2 mm, and the surface hardness of the shaft center hole of the swash plate base body is 45-62 HRC and the hardening depth of the shaft center hole of the swash plate base body is 1-3 mm; and the mass fraction of copper and the cooling rate after smelting and casting are controlled, so that the problem that the swash plate seat is easily damaged due to over-high hardness after induction quenching caused by over-high pearlite content after normalizing is solved, a normalizing process is not needed, and the cost is reduced and the efficiency is increased.

Description

Technical Field

[0001] The invention relates to the technical field of automobile air-conditioning manufacturing, and in particular to a method for manufacturing a slant plate seat. Background Art

[0002] The automobile air-conditioning compressor compresses, cools and discharges the working fluid through the rotation of the swash plate assembly. The typical structure of the swash plate seat in the swash plate assembly is as follows: Figure 1 As shown, the large ear (1) and the small ear (2) contact and rub against the pin during use, and the shaft center hole (3) contacts and rubs against the main shaft. These positions will be subjected to greater stress and fatigue load, so a certain strength and toughness are required.

[0003] At present, the common material of the inclined disc seat of automobile air-conditioning compressor is ductile iron, and the process from raw material to finished product is complicated; the main process flow in the usual preparation method is: smelting → casting → cooling → normalizing → machining → induction quenching. Among them, induction quenching is mainly to improve the surface hardness of the big ear (1), the small ear (2) and the center hole of the shaft (3), and to obtain a suitable hardening depth, and normalizing is mainly to obtain a suitable core hardness and structure, and to prepare the structure for induction quenching. However, the process has the following problems in actual application: after the inclined disc seat blank is normalized, the matrix pearlite content sometimes reaches or even exceeds 90%, which leads to excessive surface hardness, too deep hardened layer depth, increased brittleness, and the obtained inclined disc seat is easily damaged when the compressor is running. Summary of the invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a method for manufacturing a swash plate seat to solve the problem that the surface hardness of the current swash plate seat is too high and the brittleness increases, resulting in easy damage during operation.

[0005] Specifically, the present invention provides a method for manufacturing a swash plate seat, comprising:

[0006] Smelting materials of preset components to obtain a melt, wherein the materials of preset components include: carbon, silicon, manganese, phosphorus, sulfur, copper and iron, wherein the mass fraction of copper is 0.5-0.8%;

[0007] Transferring the molten metal to a preheated casting mold for pouring and casting to obtain a casting intermediate;

[0008] Cooling the casting intermediate in the mold cavity to obtain a swash plate seat base, wherein the cooling rate is 20-50° C. / min;

[0009] The big ears, small ears and the center hole of the swash plate seat base are induction hardened with preset induction heating and quenching parameters until the surface hardness of the big ears and small ears of the swash plate seat base is 40-60HRC and the hardening depth is 1-2mm, and the surface hardness of the center hole of the swash plate seat base is 45-62HRC and the hardening depth is 1-3mm.

[0010] Based on the manufacturing method of the inclined disc seat provided above, the pearlite content in the inclined disc seat is effectively controlled by controlling the mass fraction of copper in the inclined disc seat raw material and the cooling rate after smelting and casting, thereby solving the problem that the inclined disc seat is too hard and brittle after induction quenching due to excessive pearlite content after normalizing, which is easy to be damaged. At the same time, the normalizing process is eliminated to reduce costs and increase efficiency.

[0011] In one embodiment of the above-mentioned method for manufacturing the inclined plate seat, in the material of the preset components, the mass fraction of carbon is 3-4%; the mass fraction of silicon is 1.8-3.3%; the mass fraction of manganese is 0.2-0.8%; the mass fraction of phosphorus is less than or equal to 0.05%; the mass fraction of sulfur is less than or equal to 0.012%; and iron is the remainder.

[0012] Furthermore, the mass fraction of copper is 0.5%-0.8%.

[0013] Furthermore, the mass fraction of the copper is 0.65%-0.75%.

[0014] Furthermore, the molten metal is transferred to a preheated casting mold for pouring and casting to obtain a casting intermediate, and the temperature of the molten metal is 1350-1550°C.

[0015] Furthermore, the temperature of the melt is greater than or equal to 1300° C. when the transfer is completed.

[0016] In one embodiment of the above-mentioned method for manufacturing the swash plate seat, the casting intermediate is cooled in the mold cavity to obtain the swash plate seat base, and the cooling time is 30-60 minutes.

[0017] Furthermore, the temperature of the swash plate seat base is 50-100°C.

[0018] In one embodiment of the above-mentioned swash plate seat manufacturing method, the step of induction quenching the target position of the swash plate seat substrate with preset induction heating and quenching parameters until the hardness and hardened layer depth of the target position meet the preset target hardness and preset target hardening depth comprises:

[0019] In one embodiment of the above-mentioned method for manufacturing a swash plate seat, after cooling the casting intermediate in the mold cavity to obtain a swash plate seat base, before induction quenching the target position of the swash plate seat base with preset induction heating and quenching parameters until the hardness of the target position meets the preset target hardness, the method further includes:

[0020] The target position of the swash plate seat base is machined so that the ear hole in the swash plate seat base has a diameter of 7.025-7.040 mm.

[0021] One or more of the above embodiments of the present invention have at least one or more of the following beneficial effects:

[0022] By controlling the mass fraction of copper in the raw material of the inclined disc seat and the cooling rate after smelting and casting, the pearlite content in the inclined disc seat is effectively reduced, thereby solving the problem that the inclined disc seat has too high a pearlite content after normalizing, which easily leads to excessive hardness after induction quenching and increased brittleness and easy damage.

[0023] Furthermore, machining the swash plate seat base before induction hardening can compensate for the deviation of deformation of the large and small ear holes and the shaft center hole caused by the change of the swash plate seat base structure in the subsequent induction hardening.

[0024] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The disclosure of the present invention will become more easily understood with reference to the accompanying drawings. It is easy for those skilled in the art to understand that these drawings are only for illustrative purposes and are not intended to limit the scope of protection of the present invention. In addition, similar numbers in the figures are used to represent similar components, among which:

[0026] Figure 1 It is a schematic diagram of the structure of the inclined disc seat;

[0027] Figure 2 is a method flow chart of the method for manufacturing the swash plate seat provided in the present application;

[0028] Figure 3 It is a metallographic structure diagram sampled from a slant disc seat manufactured by the slant disc seat manufacturing method provided in the present application.

[0029] Description of Reference Numerals

[0030] 1. Big ears; 2. Small ears; 3. Center hole of the shaft. DETAILED DESCRIPTION

[0031] Some embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0032] As described in the background technology, the swash plate seat in the swash plate assembly will be subjected to large stress and fatigue load at the large ears, small ears and the shaft center hole in actual use, which requires certain strength and toughness. The current swash plate seat has too high surface hardness and too deep hardened layer, which increases brittleness and decreases toughness, and is easily damaged during continuous operation of the compressor.

[0033] In order to solve the above problems, the present application creatively proposes a method for manufacturing an inclined disc seat. By controlling the mass fraction of copper in the inclined disc seat raw material and the cooling rate after smelting and casting, the pearlite content in the inclined disc seat is effectively controlled, thereby solving the problem that the inclined disc seat has too high a pearlite content after normalizing, which easily causes excessive hardness after induction quenching and increased brittleness and easy damage.

[0034] This embodiment provides a method for manufacturing a swash plate seat, referring to Figure 2 As shown, including:

[0035] S1. Smelting materials of preset components to obtain a melt, wherein the materials of preset components include: carbon, silicon, manganese, phosphorus, sulfur, copper and iron, wherein the mass fraction of copper is 0.5-0.8%.

[0036] It is found that the composition of copper is highly correlated with the pearlite content in the subsequently prepared inclined disc seat. The pearlite content required subsequently is controlled by strictly controlling the composition of copper. The mass fraction of copper can be 0.5%, 0.55%, 0.6%, 0.65%, 0.68%, 0.7%, 0.72%, 0.75%, 0.78%, 0.8% or any other value within the range of 0.5%-0.8%, which is not specifically limited in this embodiment. Preferably, the mass fraction of copper is 0.65-0.75%.

[0037] In one embodiment, in the material of the preset components, the mass fraction of carbon is 3-4%; the mass fraction of silicon is 1.8-3.3%; the mass fraction of manganese is 0.2-0.8%; the mass fraction of phosphorus is less than or equal to 0.05%; the mass fraction of sulfur is less than or equal to 0.012%; and iron is the remainder. Specifically, the mass fraction of carbon can be 3%, 3.3%, 3.6%, 3.8%, 3.9%, 4% or any other value in the interval of 3-4%; the mass fraction of silicon can be 1.8%, 2.0%, 2.3%, 2.7%, 3.0%, 3.3% or any other value in the interval of 1.8-3.3%; the mass fraction of manganese can be 0.2%, 0.4%, 0.6%, 0.8% or any other value in the interval of 0.2-0.8%; the mass fraction of phosphorus can be 0.05%, 0.04, 0.03%, 0.02%, 0.01% or any other value in the interval of 0-0.05%; the mass fraction of sulfur can be 0.012%, 0.0115, 0.011%, 0.0105, 0.010%, 0.012% or any other value in the interval of 0-0.012%.

[0038] S2. Transfer the molten metal to a preheated casting mold for pouring and casting to obtain a casting intermediate.

[0039] Preferably, before pouring the molten metal into a preheated mold for casting to obtain a casting intermediate, the method further comprises:

[0040] Furthermore, in step S2, the temperature of the melt is 1350-1550°C.

[0041] Specifically, during the pouring process, the temperature of the molten metal, i.e., the molten iron, is maintained at 1350-1550° C. When the molten iron is transferred to the casting mold, the initial temperature of the molten iron is about 1550° C. As time passes during the transfer process, the temperature of the molten metal injected into the casting mold cavity decreases continuously.

[0042] Preferably, the temperature of the molten metal when the transfer is completed is greater than or equal to 1300° C. When the temperature of the molten metal drops to 1300° C. but the pouring is not completed, the remaining molten iron needs to be returned to the furnace for re-smelting and the composition of the molten metal needs to be reconfigured.

[0043] S3. Cooling the casting intermediate in the mold cavity to obtain a swash plate seat base, wherein the cooling rate is 20-50° C. / min.

[0044] In one embodiment, the casting intermediate is cooled in the mold cavity to obtain the inclined disc seat base, and the cooling time is 30-60 minutes. Specifically, the cooling after pouring is carried out in the sand mold cavity of the casting mold, and the whole process lasts 30-60 minutes. Furthermore, the temperature of the inclined disc seat base is 50-100°C, that is, the temperature of the inclined disc seat base after cooling is 50-100°C, and the cooling rate is 20-50°C / min. Due to the different ambient temperatures in summer and winter, the cooling time and cooling rate vary in actual operation. Exemplarily, the cooling time is 40±2min in summer and 50±2min in winter.

[0045] In one embodiment, after step S3 and before step S4, the manufacturing method further includes SA1.

[0046] SA1. Machine the target position of the swash plate seat base so that the ear hole in the swash plate seat base has a diameter of 7.025-7.040 mm.

[0047] Specifically, since the material of the preset components and the cooling process bring about changes in the matrix structure of the inclined disc seat, the pin hole deformation of the matrix structure of the inclined disc seat is reduced during the subsequent induction quenching process. This embodiment compensates for the reduction in the pin hole deformation during the induction quenching process caused by the change in the matrix structure of the inclined disc seat through machining. The diameter range of the ear hole of the inclined disc seat matrix controlled by machining is 7.025-7.040mm, and the diameter range of the ear hole after induction quenching is 7.003-7.020mm. Compared with the ear hole diameter of 7.03mm before induction quenching and 7.035mm before induction quenching in the current technology, it is reduced by 3-8μm.

[0048] S4. Induction hardening is performed on the big ears, small ears and the center hole of the inclined disc seat base with preset induction heating and quenching parameters until the surface hardness of the big ears and small ears of the inclined disc seat base is 40-60HRC and the hardening depth is 1-2mm, and the surface hardness of the center hole of the inclined disc seat base is 45-62HRC and the hardening depth is 1-3mm.

[0049] The manufacturing method of the inclined disc seat provided in this embodiment effectively reduces the pearlite content in the inclined disc seat by controlling the mass fraction of copper in the inclined disc seat raw material and the cooling rate after smelting and casting, thereby solving the problem of the inclined disc seat having too high hardness and increased brittleness and easy damage.

[0050] The present invention will be described in detail below through specific embodiments.

[0051] Embodiment 1: This embodiment provides a method for manufacturing a swash plate seat, the method comprising:

[0052] S1. Smelting materials of preset components to obtain a melt, wherein the materials of preset components include: 3.66% by mass of carbon, 2.89% by mass of silicon, 0.70% by mass of manganese, 0.021% by mass of phosphorus, 0.010% by mass of sulfur, 0.72% by mass of copper, and the remainder is iron.

[0053] S2. Transfer the molten metal to a preheated casting mold for pouring and casting to obtain a casting intermediate.

[0054] The initial temperature of the melt when it starts to transfer is 1550°C, and the temperature when the transfer is completed is 1320°C.

[0055] S3. Cooling the casting intermediate in the mold cavity to obtain a swash plate seat base, with a cooling rate of 40°C / min.

[0056] After cooling for 38 minutes and then air cooling, the obtained inclined disc seat matrix has a pearlite content of 65-70% and a hardness of 244HB.

[0057] S4. Induction hardening is performed on the big ears, small ears and the center hole of the inclined disc seat base with preset induction heating and quenching parameters until the surface hardness of the big ears and small ears of the inclined disc seat base is 40-60HRC and the hardening depth is 1-2mm, and the surface hardness of the center hole of the inclined disc seat base is 45-62HRC and the hardening depth is 1-3mm.

[0058] Specifically, before induction quenching, the ear holes on the inclined disk seat base are machined according to the target inner hole diameter of 7.030mm, so that the inner diameters of the large and small ear holes after induction quenching are in the range of 7.003 to 7.020mm. At the same time, the surface hardness of the small ear hole is 49HRC, the hardened layer depth is 1.7mm, and the surface hardness of the large ear hole is 49HRC, and the hardened layer depth is 1.5mm.

[0059] Embodiment 2: This embodiment provides a method for manufacturing a swash plate seat, which differs from Embodiment 1 in that:

[0060] In this embodiment, the materials of the preset composition include: 3.66% carbon by mass, 2.98% silicon by mass, 0.70% manganese by mass, 0.022% phosphorus by mass, 0.011% sulfur by mass, 0.75% copper by mass, and the remainder is iron.

[0061] The cooling rate is 25℃ / min, the cooling time is 52min, and the pearlite content in the inclined disc base obtained after cooling is 55-60%, and the hardness is 237HB. The surface hardness of the small ear hole of the inclined disc base is 46HRC, the hardened layer depth is 1.4mm, and the surface hardness of the large ear hole is 47HRC, and the hardened layer depth is 1.7mm.

[0062] Embodiment 3: This embodiment provides a method for manufacturing a swash plate seat, which differs from Embodiment 1 in that:

[0063] In this embodiment, the materials of the preset composition include: 3.75% carbon by mass, 2.98% silicon by mass, 0.60% manganese by mass, 0.032% phosphorus by mass, 0.011% sulfur by mass, 0.58% copper by mass, and the remainder is iron.

[0064] The cooling rate is 30℃ / min, the cooling time is 50min, and the pearlite content in the inclined disc base obtained after cooling is 45-50%, and the hardness is 230HB. The surface hardness of the small ear hole of the inclined disc base is 43HRC, the hardened layer depth is 1.4mm, and the surface hardness of the large ear hole is 46HRC, and the hardened layer depth is 1.5mm.

[0065] Embodiment 4: This embodiment provides a method for manufacturing a swash plate seat, which differs from Embodiment 1 in that:

[0066] In this embodiment, the materials of the preset composition include: 3.75% carbon by mass, 2.95% silicon by mass, 0.70% manganese by mass, 0.024% phosphorus by mass, 0.011% sulfur by mass, 0.75% copper by mass, and the remainder is iron.

[0067] The cooling rate is 35℃ / min, the cooling time is 40min, and the pearlite content in the inclined disc base obtained after cooling is 70-75%, and the hardness is 269HB. The surface hardness of the small ear hole of the inclined disc is 53HRC, the hardened layer depth is 1.5mm, and the surface hardness of the large ear hole is 50HRC, and the hardened layer depth is 1.6mm.

[0068] Embodiment 5: This embodiment provides a method for manufacturing a swash plate seat, which differs from Embodiment 1 in that:

[0069] In this embodiment, the materials of the preset composition include: 3.68% carbon by mass, 2.97% silicon by mass, 0.70% manganese by mass, 0.022% phosphorus by mass, 0.010% sulfur by mass, 0.68% copper by mass, and the remainder is iron.

[0070] The cooling rate is 35℃ / min, the cooling time is 40min, and the pearlite content in the inclined disc base obtained after cooling is 60-65%, and the hardness is 242HB. The surface hardness of the small ear hole of the inclined disc base is 49HRC, the hardened layer depth is 1.7mm, and the surface hardness of the large ear hole is 48HRC, and the hardened layer depth is 1.6mm.

[0071] Embodiment 6: This embodiment provides a method for manufacturing a swash plate seat, which differs from Embodiment 1 in that:

[0072] In this embodiment, the materials of the preset composition include: 3.73% carbon by mass, 2.97% silicon by mass, 0.70% manganese by mass, 0.022% phosphorus by mass, 0.010% sulfur by mass, 0.72% copper by mass, and the remainder is iron.

[0073] The cooling rate is 40℃ / min, the cooling time is 38min, and the pearlite content in the inclined disc base obtained after cooling is 65-70%, and the hardness is 243HB. The surface hardness of the small ear hole of the inclined disc base is 50HRC, the hardened layer depth is 1.6mm, and the surface hardness of the large ear hole is 49HRC, and the hardened layer depth is 1.6mm.

[0074] Ten inclined disc seats were sampled from the batch-produced inclined disc seats in the above embodiment. The hardness and pearlite content of the inclined disc seats after cooling in step S3 are shown in Table 1. The metallographic structure diagram is shown in Figure 3 shown.

[0075] Table 1

[0076]

[0077] Ten pieces were randomly selected from the inclined disc seats after induction quenching. The surface hardness and hardening depth results of the ten randomly selected inclined disc seats at different positions after induction quenching are shown in Table 2.

[0078] Table 2

[0079]

[0080]

[0081] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0082] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0083] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify, replace and vary the above embodiments within the scope of the present invention.

Claims

1. A method for manufacturing a swash plate seat, characterized in that: include: Smelting materials of preset components to obtain a melt, wherein the materials of preset components include: carbon, silicon, manganese, phosphorus, sulfur, copper and iron, wherein the mass fraction of copper is 0.5-0.8%; Transferring the molten metal to a preheated casting mold for pouring and casting to obtain a casting intermediate; Cooling the casting intermediate in the mold cavity to obtain a swash plate seat base, wherein the cooling rate is 20-50° C. / min; The big ears, small ears and the center hole of the swash plate seat base are induction hardened with preset induction heating and quenching parameters until the surface hardness of the big ears and small ears of the swash plate seat base is 40-60HRC and the hardening depth is 1-2mm, and the surface hardness of the center hole of the swash plate seat base is 45-62HRC and the hardening depth is 1-3mm.

2. The method for manufacturing a swash plate seat according to claim 1, characterized in that: In the material of the preset components, the mass fraction of carbon is 3-4%; the mass fraction of silicon is 1.8-3.3%; the mass fraction of manganese is 0.2-0.8%; the mass fraction of phosphorus is less than or equal to 0.05%; the mass fraction of sulfur is less than or equal to 0.012%; and iron is the remainder.

3. The method for manufacturing a swash plate seat according to claim 2, characterized in that: The mass fraction of the copper is 0.5%-0.8%.

4. The method for manufacturing a swash plate seat according to claim 3, characterized in that: The mass fraction of the copper is 0.65-0.75%.

5. The method for manufacturing a swash plate seat according to claim 1, characterized in that: The molten metal is transferred to a preheated casting mold for pouring and casting to obtain a casting intermediate, and the temperature of the molten metal is 1350-1550°C.

6. The method for manufacturing a swash plate seat according to claim 5, characterized in that: The temperature of the melt is greater than or equal to 1300° C. when the transfer is completed.

7. The method for manufacturing a swash plate seat according to claim 1, characterized in that: The casting intermediate is cooled in the mold cavity to obtain the inclined disc seat base, and the cooling time is 30-60 minutes.

8. The method for manufacturing a swash plate seat according to claim 7, characterized in that: The temperature of the swash plate base is 50-100°C.

9. The method for manufacturing a swash plate seat according to claim 1, characterized in that: After the casting intermediate is cooled in the mold cavity to obtain the swash plate seat base, the target position of the swash plate seat base is induction hardened with preset induction heating and quenching parameters until the hardness of the target position meets the preset target hardness, the method further includes: The target position of the swash plate seat base is machined so that the ear hole in the swash plate seat base has a diameter of 7.025-7.040 mm.

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