Method for Locally Cutting Ultra-Thick Runner of Aluminum Die Casting and Aluminum Die Casting

Abstract

The present disclosure provides a method for locally cutting an ultra-thick sprue of an aluminum die-casting and an aluminum die-casting. The method for locally cutting the ultra-thick sprue of the aluminum die-casting includes the following steps: providing an aluminum die-casting; setting a cutting loop area at the connection between the die-casting body and the rectangular-shaped sprue imitation, and the width of the cutting loop area is 1.2 mm; controlling the rotating vibration cutting member to rotate the aluminum die-casting, and synchronously controlling the double-axis moving laser member to emit a laser beam to perform a pre-cutting operation along the cutting loop as a path, so as to obtain a laser pre-cutting groove, and the power of the laser beam is less than 1.2 kw; controlling the rotating vibration cutting member to output a power source to the vibration cutting power source intervention area, and the frequency of the vibration cutting power source is less than 20 Hz; controlling the rotating vibration cutting member to rotate the aluminum die-casting, and synchronously controlling the double-axis moving laser member to emit a laser beam to perform a cutting operation along the vibration cutting crack as a path, so as to obtain a laser cutting groove; repeating steps S140-S150 until the die-casting body and the rectangular-shaped sprue imitation are separated with the laser cutting groove or the vibration cutting crack as a boundary.

Description

Technical Field

[0001] The present invention relates to the technical field of lasers and vibration cutting, and particularly relates to a method for locally cutting an ultra-thick runner of an aluminum die-cast part and an aluminum die-cast part. Background Art

[0002] Aluminum die-cast parts, such as the electronic control box of new energy, the electric drive box, and the exhaust valve of the engine of a hybrid vehicle, etc., are all manufactured by aluminum die-casting.

[0003] During the die-casting process, the aluminum liquid needs to be poured into the mold cavity through the pouring gate, and inevitably, runners will be generated. The runners are connected to the main body structure of the product, and the runners need to be removed during the finished product. Specifically, for runners with a relatively thin thickness (i.e., a thickness less than or equal to 3 mm), generally, the method of cutting the runner is adopted, including cutting the runner with a mold or cutting it with a hydraulic shear, etc.; for runners with a medium-sized thickness (i.e., a thickness of 3.5 mm - 5 mm), generally, a saw line is first made at the pre-breaking point, and then the runner is removed by vibration cutting.

[0004] However, with the rapid development of new energy vehicles, the requirements for the surface flatness and the consistency of surface performance of the box or shell structure of its core components are relatively high, and the number of runners is required to be less and less. At the same time, the requirements for the pouring of aluminum liquid are getting higher and higher, which will also lead to an increase in the thickness of the runners, even reaching (6 mm - 8 mm). Although currently, CNC machine tools are used in the market to cut the runners, using CNC machine tools easily results in high processing costs of the products.

[0005] Furthermore, when there is a complex curved surface structure at the runner, higher matching requirements are put forward in terms of fixture design and CNC cutting tools, which all limit the use of CNC machine tools for cutting ultra-thick runners.

[0006] Therefore, the problem of cutting ultra-thick runners generated by the development and supporting of the electronic control box, electric drive box of new energy, and the exhaust valve of the engine of a hybrid vehicle needs to be solved urgently. Summary of the Invention

[0007] The purpose of the present invention is to overcome the deficiencies in the prior art, and provide a method for locally cutting an ultra-thick runner of an aluminum die-cast part and an aluminum die-cast part, which can remove and separate the ultra-thick runner, synchronously reduce the processing cost of removing the runner of the aluminum die-cast part, and effectively replace the traditional method of removing the runner.

[0008] The purpose of the present invention is achieved by the following technical solutions:

[0009] A method for locally cutting an ultra-thick runner of an aluminum die-cast part includes the following steps:

[0010] S110: Provide an aluminum die-casting part, where the aluminum die-casting part includes a die-casting body and a rectangular-shaped imitation runner, and the thinnest thickness of the rectangular-shaped imitation runner is greater than 6 mm;

[0011] S120: Set a cutting loop area at the connection between the die-casting body and the rectangular-shaped imitation runner. The width of the cutting loop area is 1.2 mm. A cutting loop is set in the middle of the cutting loop area, and a vibration cutting power source intervention area is set in the area of the rectangular-shaped imitation runner away from the cutting loop. Clamp the vibration cutting power source intervention area by rotating a vibration cutting part;

[0012] S130: Control the rotation of the aluminum die-casting part by the rotating vibration cutting part, and synchronously control the double-axis moving laser part to emit a laser beam to perform a pre-cutting operation along the cutting loop as a path, obtaining a laser pre-cutting groove. The power of the laser beam is less than 1.2 kw;

[0013] S140: Control the rotating vibration cutting part to output a power source to the vibration cutting power source intervention area to form a vibration cutting crack groove at the bottom of the laser pre-cutting groove. The frequency of the vibration cutting power source is less than 20 Hz;

[0014] S150: Control the rotation of the aluminum die-casting part by the rotating vibration cutting part, and synchronously control the double-axis moving laser part to emit a laser beam to perform a cutting operation along the vibration cutting crack groove as a path, obtaining a laser cutting groove;

[0015] S160: Determine whether the die-casting body is separated from the rectangular-shaped imitation runner; if not, repeat steps S140 - S150 until the die-casting body is separated from the rectangular-shaped imitation runner with the laser cutting groove or the vibration cutting crack groove as the boundary.

[0016] In one embodiment, in step S150, the step of the double-axis moving laser part emitting a laser beam to perform a cutting operation along the vibration cutting crack groove as a path includes:

[0017] Collect an image of the aluminum die-casting part where the vibration cutting crack groove is formed to obtain vibration cutting crack groove image information corresponding to the vibration cutting crack groove;

[0018] Perform image processing and fitting according to the vibration cutting crack groove image information to obtain a crack groove contour image corresponding to the vibration cutting crack groove;

[0019] Calculate according to the crack groove contour image to obtain a laser cutting path; where the laser cutting path is the center line of the crack groove contour;

[0020] Control the double-axis moving laser part to emit a laser beam to perform a cutting operation along the laser cutting path,

[0021] In one embodiment, the power of the laser beam emitted by the biaxial motion laser in step S150 is less than the power of the laser beam emitted by the biaxial motion laser in step S130.

[0022] In one embodiment, after step S130 and before step S140, the method for locally cutting the ultra-thick runner of the aluminum die-casting part further includes:

[0023] Performing a cooling operation on the aluminum die-casting part.

[0024] In one embodiment, the specific steps of performing a cooling operation on the aluminum die-casting part are: using compressed air and atomized coolant to perform mixed spraying on the aluminum die-casting part, and the time of the mixed spraying is less than 15 s.

[0025] In one embodiment, in step S120, the rotating vibration cutting part uses a pneumatic clamping mechanism to clamp the vibration cutting power source intervention area, and the vibration cutting power source intervention area is provided with an anti-slip clamping surface, and the roughness of the anti-slip clamping surface is Ra12.5 μm.

[0026] In one embodiment, after step S110 and before step S120, the method for locally cutting the ultra-thick runner of the aluminum die-casting part further includes:

[0027] Performing a cleaning operation on the release agent on the outer surface of the aluminum die-casting part;

[0028] Spraying a nano-aluminum oxide light-absorbing coating on the aluminum die-casting part after the cleaning operation.

[0029] In one embodiment, the thickness range of the nano-aluminum oxide light-absorbing coating is 2 μm to 10 μm.

[0030] In one embodiment, after step S160, the method for locally cutting the ultra-thick runner of the aluminum die-casting part further includes:

[0031] Performing image scanning on the actual cross-section formed by the die-casting body through a CCD camera to obtain a three-dimensional stereoscopic image of the actual cross-section;

[0032] Comparing the three-dimensional stereoscopic image of the actual cross-section with the three-dimensional stereoscopic image of the reference cross-section to obtain comparison data;

[0033] Controlling a grinding device to perform a grinding operation on the actual cross-section according to the comparison data.

[0034] An aluminum die-casting part is processed by using the method for locally cutting the ultra-thick runner of the aluminum die-casting part in any one of the above embodiments.

[0035] Compared with the prior art, the present invention has at least the following advantages:

[0036] 1. The local cutting method for the ultra-thick nozzle of the aluminum die-casting part in this application first provides the aluminum die-casting part; then, a low-power laser beam is used to perform a pre-cutting operation along the cutting loop line to obtain a laser pre-cutting groove; then, by rotating the vibration cutting part to output a low-frequency power source to the vibration cutting power source intervention area, a vibration cutting crack groove is formed at the bottom of the laser pre-cutting groove, and then a low-power laser beam is used to perform a cutting operation on the vibration cutting crack groove. Repeat the above operation steps until the die-casting body and the imitation rectangular nozzle are separated with the laser cutting groove or the vibration cutting crack groove as the boundary. By adopting a processing method combining low-power laser beam cutting and low-frequency vibration cutting, the ultra-thick nozzle can be cut step by step, ensuring the effective removal of the ultra-thick nozzle.

[0037] 2. Compared with the traditional method of cutting the nozzle by a CNC machine tool, the cutting method in this application first forms a laser pre-cutting groove by laser cutting, then forms a vibration cutting crack groove by vibration cutting, and then performs laser cutting on the vibration cutting crack groove. It should be noted that the local heating cutting method of laser cutting can effectively cut the product, and can synchronously reduce the processing cost of removing the nozzle of the aluminum die-casting part on the premise of meeting the requirements of the surface flatness and surface performance consistency of the product.

[0038] 3. When removing a complex curved surface at the nozzle, the cutting method in this application does not require designing a complex fixture structure, nor does it require higher requirements for CNC tools. It can be achieved by rotating the vibration cutting part to clamp the vibration cutting power source intervention area, and by adopting an alternating combination processing method of laser cutting and vibration cutting of the aluminum die-casting part, thus completing the removal and separation processing of the ultra-thick nozzle, avoiding the problems of higher matching requirements in fixture design and CNC tools when processing a nozzle with a complex curved surface structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required to be used in the embodiments. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can also be obtained based on these drawings without creative efforts.

[0040] Figure 1 It is a flowchart of the local cutting method for the ultra-thick nozzle of the aluminum die-casting part in an embodiment;

[0041] Figure 2 It is a structural schematic diagram of the aluminum die-casting part in an embodiment;

[0042] Figure 3 It is a structural schematic diagram of the rotating vibration cutting part in an embodiment;

[0043] Figure 4 is Figure 3 the partial enlarged view of the A position of the shown rotating vibration cutting part;

[0044] Reference numerals: aluminum die-casting part 10; die-casting body 100, rectangular imitation water inlet 200; rotating vibration cutting part 20; frame 300; installation platform 310; material collection area 301; vibration source output component 400; rotating clamping component 500; rotating driving part 510; clamping frame body 520; hollow area 5201; clamping base 5210; telescopic driving part 530; material collection cart 600. Detailed implementation manners

[0045] To facilitate the understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. The preferred embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the understanding of the content of the present invention more thorough and comprehensive.

[0046] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are only for the purpose of illustration and do not represent the only embodiments.

[0047] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which the present invention belongs. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0048] The present disclosure provides a method for locally cutting an ultra-thick sprue of an aluminum die-casting part, comprising the following steps: S110: Provide an aluminum die-casting part, which includes a die-casting body and a rectangular-shaped sprue-like structure, and the thinnest thickness of the rectangular-shaped sprue-like structure is greater than 6 mm; S120: Set a cutting loop area at the connection between the die-casting body and the rectangular-shaped sprue-like structure, the width of the cutting loop area is 1.2 mm, a cutting loop is arranged in the middle of the cutting loop area, and a vibration cutting power source intervention area is set in the area of the rectangular-shaped sprue-like structure away from the cutting loop, and the vibration cutting power source intervention area is clamped by a rotating vibration cutting part; S130: Control the rotating vibration cutting part to rotate the aluminum die-casting part, and simultaneously control a two-axis moving laser part to emit a laser beam to perform a pre-cutting operation along the cutting loop as a path, so as to obtain a laser pre-cutting groove, and the power of the laser beam is less than 1.2 kw; S140: Control the rotating vibration cutting part to output a power source to the vibration cutting power source intervention area, so as to form a vibration cutting crack groove at the bottom of the laser pre-cutting groove, and the frequency of the vibration cutting power source is less than 20 Hz; S150: Control the rotating vibration cutting part to rotate the aluminum die-casting part, and simultaneously control the two-axis moving laser part to emit a laser beam to perform a cutting operation along the vibration cutting crack groove as a path, so as to obtain a laser cutting groove; S160: Repeat steps S140 - S150 until the die-casting body and the rectangular-shaped sprue-like structure are separated with the laser cutting groove or the vibration cutting crack groove as a boundary.

[0049] Please refer to Figure 1 , which is a flowchart of the method for locally cutting an ultra-thick sprue of an aluminum die-casting part according to an embodiment of the present disclosure. The method for locally cutting an ultra-thick sprue of an aluminum die-casting part includes some or all of the following steps.

[0050] S110: Provide an aluminum die-casting part, including a die-casting body and a rectangular-shaped sprue-like structure, and the thinnest thickness of the rectangular-shaped sprue-like structure is greater than 6 mm.

[0051] In this embodiment, an aluminum die-casting part is provided. The aluminum die-casting part includes a die-casting body and a rectangular-shaped sprue-like structure, and the thinnest thickness of the rectangular-shaped sprue-like structure is greater than 6 mm. Further, the step of providing the aluminum die-casting part includes: first injecting aluminum liquid into the cavity of the die-casting mold, and then performing a pressure holding, cooling and mold opening and ejecting process on the die-casting mold to obtain the aluminum die-casting part. Among them, the part where the rectangular-shaped sprue-like structure is connected to the die-casting body is the liquid inlet, the cross-section of the liquid inlet is rectangular-shaped, and the thinnest thickness of the rectangular-shaped sprue-like structure after cooling and forming is greater than 6 mm.

[0052] S120: Set a cutting loop area at the connection between the die-casting body and the rectangular-shaped sprue-like structure, the width of the cutting loop area is 1.2 mm, a cutting loop is arranged in the middle of the cutting loop area, and a vibration cutting power source intervention area is set in the area of the rectangular-shaped sprue-like structure away from the cutting loop, and the vibration cutting power source intervention area is clamped by a rotating vibration cutting part.

[0053] In this embodiment, the cutting loop line is the center line of the cutting loop area. The distances from the center line to the two side edges of the cutting loop area are equal, that is, the distances from any point on the center line to the two side edges of the cutting loop area are equal. Among them, the vibration cutting power source intervention area is the handle part of the sprue, that is, the rotating vibration cutting part realizes the clamping and positioning of the die-casting body and the rectangular-like sprue by clamping the handle part of the sprue.

[0054] Specifically, in one embodiment, after step S110 and before step S120, the method for locally cutting the ultra-thick sprue of the aluminum die-casting further includes:

[0055] First, perform a cleaning operation on the mold release agent on the outer surface of the aluminum die-casting to remove the mold release agent on the outer surface of the aluminum die-casting;

[0056] Then, spray a nano-aluminum oxide light-absorbing coating on the aluminum die-casting after the cleaning operation. The thickness range of the nano-aluminum oxide light-absorbing coating is between 2μm and 10μm. In this embodiment, the melting point of the nano-aluminum oxide light-absorbing coating is higher than that of the aluminum die-casting. By spraying the nano-aluminum oxide light-absorbing coating in the cutting loop area, since the melting point of the nano-aluminum oxide light-absorbing coating is higher than that of the aluminum die-casting, the notch edge of the formed laser pre-cutting groove is not easy to generate cutting burrs and irregular flanging, so that the surface finish of the cutting and the cutting precision can be significantly improved, and further the quality of laser cutting can be effectively improved, that is, the quality of the subsequent laser cutting of the formed laser pre-cutting groove by the biaxial motion laser part can be effectively improved. At the same time, after the nano-aluminum oxide light-absorbing coating is sprayed on the cutting loop area, due to the good light-absorbing performance of the nano-aluminum oxide light-absorbing coating, the absorption rate of the laser beam energy can be significantly improved, and the reflection effect of the laser beam can be reduced, thereby reducing the laser power of the biaxial motion laser part, that is, reducing the energy consumption of the biaxial motion laser part. Moreover, the thickness range of the nano-aluminum oxide light-absorbing coating is between 2μm and 10μm, so as to ensure the adhesion quality of the nano-aluminum oxide light-absorbing coating, that is, improve the adhesion of the nano-aluminum oxide light-absorbing coating.

[0057] Further, the step of performing a cleaning operation on the mold release agent on the outer surface of the aluminum die-casting is specifically: using ultrasonic cleaning to perform a cleaning operation on the mold release agent on the outer surface of the aluminum die-casting to efficiently remove the mold release agent and other adhering dirt on the outer surface of the aluminum die-casting.

[0058] In one embodiment, before the step of spraying the nano-aluminum oxide light-absorbing coating on the aluminum die-cast part after the cleaning operation, the method for locally cutting the ultra-thick sprue of the aluminum die-cast part further includes: drying the aluminum die-cast part after the cleaning operation, so that the nano-aluminum oxide light-absorbing coating can be better sprayed and formed on the aluminum die-cast part. Specifically, the step of drying the aluminum die-cast part after the cleaning operation is specifically: using a dryer to dry the aluminum die-cast part, so as to effectively improve the drying rate of the outer surface of the aluminum die-cast part.

[0059] Furthermore, before the step of spraying the nano-aluminum oxide light-absorbing coating on the aluminum die-cast part after the cleaning operation, the method for locally cutting the ultra-thick sprue of the aluminum die-cast part further includes: cooling the aluminum die-cast part after the drying operation. Specifically, the aluminum die-cast part is naturally left standing at room temperature, or the aluminum die-cast part after the drying operation is cooled by means of air cooling, so as to accelerate the cooling of the aluminum die-cast part, thereby reducing the influence of high temperature on the spraying of the nano-aluminum oxide light-absorbing coating, and avoiding the problem that the temperature of the aluminum die-cast part is too high when spraying the nano-aluminum oxide light-absorbing coating, resulting in partial volatilization of the nano-aluminum oxide light-absorbing coating and the defect of pore structure in the nano-aluminum oxide light-absorbing coating.

[0060] In order to ensure the adhesion of the nano-aluminum oxide light-absorbing coating, furthermore, before the step of spraying the nano-aluminum oxide light-absorbing coating on the cutting loop area, the method for locally cutting the ultra-thick sprue of the aluminum die-cast part further includes: dust removal operation on the cutting loop area. Specifically, in this embodiment, a pneumatic air gun is used to remove dust from the cutting loop area to blow off the dust on the cutting loop area.

[0061] S130: Control the rotating vibration cutting part to rotate the aluminum die-cast part, and synchronously control the double-axis moving laser part to emit a laser beam to perform a pre-cutting operation along the cutting loop as a path, so as to obtain a laser pre-cutting groove, and the power of the laser beam is less than 1.2 kw;

[0062] In this embodiment, since the double-axis moving laser part emits a laser beam to perform a pre-cutting operation along the cutting loop as a path, there is a preset distance between the cutting loop and the outer contour line of the die-casting body. In this way, when the laser beam performs a pre-cutting operation along the cutting loop as a path, it effectively avoids the laser beam directly melting the die-casting body, thereby ensuring the structural integrity of the die-casting body and reducing the defective rate of the die-casting body.

[0063] S140: After the laser pre-cutting groove is cooled, control the rotating vibration cutting part to output a power source to the vibration cutting power source intervention area, so as to form a vibration cutting crack groove at the bottom of the laser pre-cutting groove, and the frequency of the vibration cutting power source is less than 20 Hz.

[0064] In this embodiment, the driving control rotates the vibrating cutting member to output a power source to the aluminum die-casting through the vibrating cutting power source intervention area, and the frequency of the vibrating cutting power source is less than 20 Hz, so that a vibrating cutting crack groove is preferably formed at the bottom of the laser pre-cutting groove. If the frequency of the vibrating cutting power source is too large, that is, the frequency is equal to or greater than 20 Hz, it is easy to generate a deeper vibrating cutting crack groove, resulting in damage to the die-casting body by the vibrating cutting crack groove, and even causing the vibrating cutting crack groove to directly crack into the interior of the die-casting body in a crack form, making the actual cross-section formed by the cut die-casting body unable to be further processed and leading to scrapping.

[0065] S150: Control the rotating vibrating cutting member to rotate the aluminum die-casting, and simultaneously control the double-axis moving laser member to emit a laser beam to perform a cutting operation along the vibrating cutting crack groove as a path to obtain a laser cutting groove.

[0066] In this embodiment, the double-axis moving laser member emits a laser beam to cut along the vibrating cutting crack groove at the bottom of the laser pre-cutting groove. Since the vibrating cutting crack groove is generated by controlling the rotating vibrating cutting member to output a power source to the vibrating cutting power source intervention area, that is, vibrating cutting processing, at the bottom of the laser pre-cutting groove, and the laser pre-cutting groove is obtained by controlling the double-axis moving laser member to emit a laser beam to perform a pre-cutting operation along the cutting loop as a path. That is to say, by using a combined processing flow of laser pre-processing, vibrating cutting processing and laser processing, the laser pre-cutting groove, the vibrating cutting crack groove and the laser cutting groove are successively processed from the surface to the center of the water inlet to be cut. The laser pre-cutting groove plays a role of processing reference for the vibrating cutting crack groove processing, and the vibrating cutting crack groove also plays a role of processing reference for the laser cutting groove processing. The step-by-step cutting process is carried out until the die-casting body is cut off and separated from the rectangular water inlet, and at the same time, the deviation amount of the step-by-step cutting of the ultra-thick water inlet is reduced.

[0067] S160: Judge whether the die-casting body is separated from the rectangular water inlet; if not, repeat steps S140-S150 until the die-casting body is separated from the rectangular water inlet with the laser cutting groove or the vibrating cutting crack groove as the boundary.

[0068] In this embodiment, after the laser cutting groove obtained by step S150 is processed, judge whether the die-casting body is separated from the rectangular water inlet; set the laser cutting groove obtained by step S150 as the primary laser cutting groove. If not, that is, the die-casting body is not separated from the rectangular water inlet, then repeat steps S140-S150, that is, on the basis of the primary laser cutting groove obtained by step S150, control the rotating vibrating cutting member to output a power source to the vibrating cutting power source intervention area again to form a secondary vibrating cutting crack groove at the bottom of the primary laser cutting groove; then control the double-axis moving laser member to emit a laser beam to perform a cutting operation along the secondary vibrating cutting crack groove as a path to obtain a secondary laser cutting groove, and so on in a cyclic and alternating manner until the die-casting body is separated from the rectangular water inlet, so as to effectively cut and separate the ultra-thick water inlet, and synchronously reduce the deviation amount of the ultra-thick water inlet cutting.

[0069] In this embodiment, for the method of locally cutting the ultra-thick sprue of the aluminum die-cast part of the present application, first provide the aluminum die-cast part; then use a low-power laser beam to perform a pre-cutting operation along the cutting loop as the path to obtain a laser pre-cutting groove; then output a low-frequency power source to the power source intervention area of the vibration cutting by rotating the vibration cutting part, so as to form a vibration cutting crack groove at the bottom of the laser pre-cutting groove, and then use a low-power laser beam to perform a cutting operation on the vibration cutting crack groove. Repeat the above operation steps until the die-cast body and the rectangular-shaped sprue are separated with the laser cutting groove or the vibration cutting crack groove as the boundary. By adopting a processing method combining low-power laser beam cutting and low-frequency vibration cutting, the ultra-thick sprue can be cut step by step, ensuring that the ultra-thick sprue is effectively removed.

[0070] Furthermore, compared with the method of cutting the sprue by a traditional CNC machine tool, the cutting method of the present application first forms a laser pre-cutting groove by laser cutting, then forms a vibration cutting crack groove by vibration cutting, and then performs laser cutting on the vibration cutting crack groove. It should be noted that the local heating cutting method of laser cutting can effectively cut the product, and can synchronously reduce the processing cost of removing the sprue of the aluminum die-cast part on the premise of meeting the requirements of the surface flatness and surface performance consistency of the product.

[0071] Still further, when removing a complex curved surface at the sprue, the cutting method of the present application does not require a complex fixture structure design, nor higher requirements for CNC tools. It only needs to rotate the vibration cutting part to clamp the power source intervention area of the vibration cutting, and by adopting an alternating combined processing method of laser cutting and vibration cutting of the aluminum die-cast part, the removal and separation processing of the ultra-thick sprue can be completed, avoiding the problems of higher matching requirements for fixture design and CNC tools when processing the sprue with a complex curved surface structure.

[0072] As Figure 2 and Figure 3 shown, in one of the embodiments, the rotating vibration cutting part 20 includes a frame 300, a vibration source output component 400 and a rotating clamping component 500; the vibration source output component 400 is installed on the frame 300, and the vibration source output component 400 is used to output a power source; the rotating clamping component 500 is arranged at the vibration source output end of the vibration source output component 400, and the rotating clamping component 500 is used to clamp the power source intervention area of the vibration cutting and drive the aluminum die-cast part 10 to rotate during the pre-cutting operation and the cutting operation.

[0073] It can be understood that in this embodiment, the movement path of the dual-axis motion laser component is limited to the motion plane formed by the X-axis and the Y-axis. Therefore, the rotating clamping component 500 is fixed to the vibration-cutting source intervention area through the clamping end, and the vibration-cutting source intervention area is rotated during the pre-cutting operation and the cutting operation, that is, the aluminum die-casting 10 is driven to rotate during the pre-cutting operation and the cutting operation, so as to cooperate with the laser beam emitted by the dual-axis motion laser component to perform pre-cutting and cutting operations on the aluminum die-casting 10, thereby enabling the dual-axis motion laser component to perform pre-cutting operations along the cutting loop as a path, and perform cutting operations along the vibration-cutting crack groove as a path. Specifically, in step S140, the rotating clamping component 500 is controlled to drive the aluminum die-casting 10 to rotate and reset, and then the vibration source output component 400 is controlled to output the dynamic source to the vibration-cutting source intervention area, that is, the dynamic source is transmitted from the rotating clamping component 500 to the vibration-cutting source intervention area of the aluminum die-casting 10, so that a vibration-cutting crack groove is formed at the bottom of the laser pre-cutting groove.

[0074] It should be noted that the structure of the vibration source output component 400 and the principle of its output source are both prior art and will not be described in detail herein. For example, the vibration source output component 400 is an ultrasonic vibration component.

[0075] Furthermore, the vibration source output component 400 is installed on the frame 300 through a vibration-damping pad to prevent the vibration source generated by the vibration source output component 400 from affecting the frame, thereby simultaneously reducing the loss of the vibration source, thereby enabling the vibration source to better act on the aluminum die casting 10.

[0076] like Figure 3 and Figure 4 As shown, in one embodiment, the rotating clamping assembly 500 includes a rotating driving member 510, a clamping frame 520 and a telescopic driving member 530; the rotating driving member 510 is fixed to the vibration source output end of the vibration source output assembly 400, and the power output end of the rotating driving member 510 is fixedly connected to the clamping frame 520, and a hollow area 5201 is provided on the side of the clamping frame 520 away from the rotating driving member 510, and a clamping base is convexly provided on the hollow area 5201. 5210, the telescopic driving member 530 is arranged on the clamping frame 520, the telescopic end of the telescopic driving member 530 extends to the hollow area 5201, and the telescopic end of the telescopic driving member 530 is arranged opposite to the clamping base 5210, wherein the telescopic end of the telescopic driving member 530 moves in the direction close to the clamping base 5210 until the telescopic end of the telescopic driving member 530 and the clamping base 5210 are jointly clamped and positioned in the vibration-cutting source intervention area.

[0077] It can be understood that in this embodiment, since the clamping base 5210 is used to locate the vibration cutting power source intervention area, and the telescopic end of the telescopic driving member 530 extends to the hollow area 5201 and is arranged opposite to the clamping base 5210, by driving the telescopic end of the telescopic driving member 530 to move towards the clamping base 5210, a fixed clamping of the vibration cutting power source intervention area is formed by the telescopic end of the telescopic driving member 530 and the clamping base 5210, that is, a fixed clamping of the handle part of the sprue is formed, and thus the rapid positioning and fixed clamping of the aluminum die-casting 10 can be realized, and the structure is simple and practical. In one embodiment, the clamping frame body 520 is in a U shape.

[0078] Further, the rotation driving member 510 is a rotary motor. In this embodiment, when the vibration source output assembly 400 outputs the power source, it simultaneously drives the rotation driving member 510 and the aluminum die-casting 10 to vibrate together.

[0079] As Figure 3 and Figure 4 shown, in one embodiment, the telescopic driving member 530 is an oil cylinder driving member, a cylinder driving member or an electric cylinder driving member. In this embodiment, the telescopic driving member 530 is an oil cylinder driving member, which can provide a reliable clamping force to cooperate with the clamping base 5210 to realize the rapid positioning and stable clamping of the aluminum die-casting 10, so that the aluminum die-casting 10 does not need to be disassembled and assembled during the laser cutting process and the vibration cutting process, that is, the same clamping station is used throughout the processing, effectively shortening the processing cycle.

[0080] As Figures 2 to 4 shown, in one embodiment, the machine frame 300 is provided with an installation platform 310, the vibration source output assembly 400 is located on the installation platform 310, a material collection area 301 is provided on one side of the machine frame 300 adjacent to the installation platform 310, the material collection area 301 is located below the clamping frame body 520, and the material collection area 301 is used to collect the die-casting body 100 or the imitation rectangular sprue 200.

[0081] Specifically, in this embodiment, a material collection cart 600 can be accommodated in the material collection area 301. In this way, the clamping frame body 520 extends to the upper part of the material collection area 301, so that the separated die-casting body 100 or the imitation rectangular sprue 200 can fall into the material collection tank of the material collection cart 600, which is convenient for the subsequent turnover and transportation of the materials.

[0082] In one embodiment, in order to ensure the consistency of the laser cutting of the vibration cutting crack by the biaxial motion laser part. In step S150, the step of the biaxial motion laser part emitting a laser beam to perform a cutting operation along the vibration cutting crack includes:

[0083] Image acquisition is performed on the aluminum die-cast part forming the vibration cutting groove to obtain the vibration cutting groove image information corresponding to the vibration cutting groove;

[0084] Image processing and fitting are performed based on the vibration cutting groove image information to obtain the groove profile image corresponding to the vibration cutting groove;

[0085] Calculation is performed based on the groove profile image to obtain the laser cutting path; wherein, the laser cutting path is the center line of the groove profile;

[0086] Control the biaxial motion laser to emit a laser beam to perform cutting operations along the laser cutting path, thereby improving the accuracy of laser cutting, further improving the processing accuracy of the laser cutting groove, and at the same time realizing automated processing and reducing manual intervention.

[0087] Furthermore, the step of controlling the biaxial motion laser to emit a laser beam to perform cutting operations along the laser cutting path is specifically as follows:

[0088] Obtain the dynamic distance value from the laser beam emission end of the biaxial motion laser to the bottom of the vibration cutting groove in real time along the laser cutting path;

[0089] Judge whether the dynamic distance value is within a preset dynamic distance interval;

[0090] If not, adjust the focal length of the laser beam according to the power adjustment table to perform cutting operations.

[0091] Specifically, the step of adjusting the focal length of the laser beam is as follows: when the dynamic distance value is greater than the maximum value of the preset dynamic distance interval, adjust and increase the focal length of the laser beam according to the power adjustment table; when the dynamic distance value is less than the minimum value of the preset dynamic distance interval, adjust and shorten the focal length of the laser beam according to the power adjustment table. It can be understood that the aluminum die-cast part 10 rotates under the drive of the rotating vibration cutting part 20, so that the distance value from the laser beam emission end of the biaxial motion laser to the cutting loop area will change; at the same time, as the laser pre-cutting groove deepens, the distance value from the laser beam emission end to the laser pre-cutting groove also increases synchronously; and when the biaxial motion laser emits a laser beam to perform cutting operations along the vibration cutting groove as the path, as the laser cutting progresses, the depth of the laser cutting also increases synchronously. The above focal length adjustment method improves the applicability of laser processing, and at the same time enables the focal length of the laser beam to be adjusted in real time during the process of performing cutting operations along the laser cutting path, avoiding the laser beam from cutting inappropriately or over-cutting. It should be noted that in the above focal length adjustment method, the power of the biaxial motion laser is constant.

[0092] In this embodiment, a laser triangulation system is adopted and integrated at the laser beam emitting end of the biaxial motion laser component, that is, the laser head of the biaxial motion laser component, so as to monitor in real time the distance value from the laser beam emitting end of the biaxial motion laser component to the bottom of the vibration cutting groove, that is, to monitor the change of the dynamic distance value in real time, and feed the real-time change data of the dynamic distance value back to the control end of the biaxial motion laser component, so as to adjust the focal length of the laser beam of the biaxial motion laser component. The above-mentioned laser triangulation system can realize a non-contact measurement method, effectively ensuring the efficiency and accuracy of laser cutting of the biaxial motion laser component.

[0093] It should be noted that the method for automatically adjusting the focal length of the biaxial motion laser component and the ranging method of the laser triangulation system belong to the prior art and will not be introduced in detail here.

[0094] Further, if not, before the step of adjusting the focal length of the laser beam according to the power adjustment table to perform the cutting operation, the step of the biaxial motion laser component emitting a laser beam to perform the cutting operation along the laser cutting path further includes: establishing a power adjustment table in which a plurality of dynamic distance values correspond one-to-one to the focal lengths of a plurality of laser beams, improving the applicability of laser processing.

[0095] In one embodiment, the power of the laser beam emitted by the biaxial motion laser component in step S150 is less than the power of the laser beam emitted by the biaxial motion laser component in step S130. Synchronously, the laser cutting speed of the biaxial motion laser component in step S150 is lower than the laser cutting speed of the biaxial motion laser component in step S130. In this way, by controlling the output of two parameters, namely the power of the laser beam and the cutting speed, the laser beam emitted by the biaxial motion laser component in step S150 can perform fine cutting on the vibration cutting groove, ensuring that the surface consistency of the obtained laser cutting groove is better, making the flatness of the actual cross-section formed by the die-casting body 100 better, and reducing the subsequent grinding time of the actual cross-section.

[0096] Among them, during the laser cutting process of the biaxial motion laser component, a ventilation device is synchronously used to collect the slag and smoke during the laser cutting process, so as to avoid the accumulation of slag and the pollution of smoke.

[0097] In one embodiment, after step S130 and before step S140, the method for locally cutting the ultra-thick sprue of the aluminum die-casting 10 further includes: performing a cooling operation on the aluminum die-casting 10.

[0098] It can be understood that in this embodiment, the specific steps for cooling the aluminum die-casting 10 are as follows: compressed air and atomized coolant are used for mixed spraying on the aluminum die-casting 10, and the time of the mixed spraying is less than 15 s. In this way, the laser pre-cutting groove can be quickly cooled from a high-temperature state to room temperature. Moreover, compared with the traditional pure air-cooling method, the high-speed cooling method combining compressed air and atomized coolant has a more excellent cooling rate, shorter cooling time, and reduces the problem of thermal deformation and warping around the laser pre-cutting groove, thereby ensuring that in step 140, the aluminum die-casting 10 is vibrationally cut by rotating the vibration cutting member 20, making the shape of the formed vibration cutting crack groove more regular and consistent.

[0099] Further, in order to improve the accuracy of the mixed spraying of compressed air and atomized coolant, in one embodiment, three-dimensional image acquisition of the laser pre-cutting groove is performed to obtain a three-dimensional image of the laser pre-cutting groove; path analysis of the three-dimensional image of the laser pre-cutting groove is performed to obtain a three-dimensional path image; according to the three-dimensional path image, the cooling spraying device is controlled to perform circumferential mixed spraying on the laser pre-cutting groove. In this way, accurate spraying and cooling of the laser pre-cutting groove can be achieved, and at the same time, waste of the spraying dose can be better avoided.

[0100] Still further, in order to solve the problem of environmental pollution in the workshop caused by the mixed spraying of compressed air and atomized coolant, in one embodiment, when performing mixed spraying on the laser pre-cutting groove, an air suction device is used to synchronously suck the surrounding air of the aluminum die-casting 10. In this way, the content of atomized coolant dispersed in the air is reduced, thereby avoiding pollution of the workshop environment by the atomized coolant.

[0101] In one embodiment, in step S120, the rotating vibration cutting member 20 uses a pneumatic clamping mechanism to clamp the vibration cutting power source intervention area, and the vibration cutting power source intervention area is provided with an anti-slip clamping surface, and the roughness of the anti-slip clamping surface is Ra12.5 μm.

[0102] It can be understood that in this embodiment, using a pneumatic clamping mechanism can improve the convenience and reliability of clamping the vibration cutting power source intervention area; and by setting the anti-slip clamping surface and making the roughness of the anti-slip clamping surface Ra12.5 μm, the friction coefficient of the anti-slip clamping surface is significantly increased, so that the pneumatic clamping mechanism has good stability in clamping the vibration cutting power source intervention area, thereby effectively reducing the sliding offset amount of the vibration cutting power source intervention area during the vibration cutting process, and further ensuring the accuracy of the subsequent laser cutting by the two-axis motion laser part.

[0103] In one embodiment, after step S160, the method for locally cutting the ultra-thick sprue of the aluminum die-casting 10 further includes:

[0104] An image scan is performed on the actual cross-section formed by the die-casting body 100 through a CCD camera to obtain a three-dimensional stereoscopic image of the actual cross-section;

[0105] The three-dimensional stereoscopic image of the actual cross-section is compared with the three-dimensional stereoscopic image of the reference end face to obtain comparison data;

[0106] According to the comparison data, a grinding device is controlled to perform a grinding operation on the actual cross-section.

[0107] In this embodiment, an image scan is performed on the actual cross-section formed by the die-casting body 100 through a CCD camera, that is, the cross-section formed by separating the die-casting body 100 and the rectangular-shaped imitation runner 200 with a laser cutting groove or a vibration cutting crack as the boundary, to obtain a three-dimensional stereoscopic image of the actual cross-section; then the three-dimensional stereoscopic image of the actual cross-section is compared with the three-dimensional stereoscopic image of the reference end face to obtain comparison data. Among them, by analyzing the comparison data, cross-section protrusion data greater than 0.3 mm is obtained in the three-dimensional stereoscopic image of the actual cross-section compared with the three-dimensional stereoscopic image of the reference end face. In this way, when controlling the grinding device to perform a grinding operation on the actual cross-section according to the comparison data, the grinding device can be assisted to adjust the grinding operation on the actual cross-section according to the cross-section protrusion data, that is, the area with more cross-section protrusions can be targeted for grinding, and at the same time, the grinding time of the above area can be extended, so as to ensure the overall grinding quality of the cross-section, and at the same time realize the automatic grinding operation, reduce manual intervention, and improve the grinding efficiency and accuracy.

[0108] The present disclosure also provides an aluminum die-casting 10, which is processed by using the method for locally cutting an ultra-thick runner of an aluminum die-casting 10 based on low-power laser and low-frequency vibration cutting described in any one of the above embodiments. The aluminum die-casting 10 includes a die-casting body 100 and a rectangular-shaped imitation runner 200, and the die-casting body 100 and the rectangular-shaped imitation runner 200 are integrally die-cast.

[0109] The above aluminum die-casting 10 is processed by using the above method for locally cutting an ultra-thick runner of an aluminum die-casting. The above method for locally cutting an ultra-thick runner of an aluminum die-casting can perform step-by-step cutting on the ultra-thick runner by adopting a processing method combining low-power laser beam cutting and low-frequency vibration cutting, so as to ensure that the ultra-thick runner is effectively removed.

[0110] Furthermore, compared with the traditional method of cutting the runner by a CNC machine tool, the aluminum die-casting 10 obtained by the cutting method of the present application specifically adopts a method of first forming a laser pre-cutting groove by laser cutting, then forming a vibration cutting crack by vibration cutting, and then performing laser cutting on the vibration cutting crack. It should be noted that the local heating cutting method of laser cutting can effectively cut the product, and can synchronously reduce the processing cost of removing the runner of the aluminum die-casting on the premise of meeting the requirements of the surface flatness and surface performance consistency of the product.

[0111] Furthermore, when removing a sprue with a complex curved surface, the cutting method of the present application does not require the design of a complex fixture structure, nor higher requirements for CNC tools. It is only necessary to rotate the vibration cutting member to clamp the vibration cutting power source intervention area, and by adopting an alternating combined processing method of laser cutting and vibration cutting of aluminum die-castings, the removal and separation processing of the ultra-thick sprue can be completed, avoiding the problem of higher matching requirements for fixture design and CNC tools when processing a sprue with a complex curved surface structure.

[0112] Compared with the prior art, the present disclosure has at least the following advantages:

[0113] 1. For the local cutting method of the ultra-thick sprue of the aluminum die-casting of the present application, first provide the aluminum die-casting; then use a low-power laser beam to perform a pre-cutting operation along the cutting loop as the path to obtain a laser pre-cutting groove; then output a low-frequency power source to the vibration cutting power source intervention area by rotating the vibration cutting member, so that a vibration cutting crack groove is formed at the bottom of the laser pre-cutting groove, and then use a low-power laser beam to perform a cutting operation on the vibration cutting crack groove, and repeat the above operation steps until the die-casting body and the rectangular-shaped sprue are separated with the laser cutting groove or the vibration cutting crack groove as the boundary. By adopting a processing method combining low-power laser beam cutting and low-frequency vibration cutting, the ultra-thick sprue can be cut step by step, ensuring the effective removal of the ultra-thick sprue.

[0114] 2. Compared with the traditional method of cutting the sprue by a CNC machine tool, the cutting method of the present application first forms a laser pre-cutting groove by laser cutting, then forms a vibration cutting crack groove by vibration cutting, and then performs laser cutting on the vibration cutting crack groove. It should be noted that the local heating cutting method of laser cutting can effectively cut the product, and can synchronously reduce the processing cost of removing the sprue of the aluminum die-casting on the premise of meeting the requirements of the surface flatness and surface performance consistency of the product.

[0115] 3. When removing a sprue with a complex curved surface, the cutting method of the present application does not require the design of a complex fixture structure, nor higher requirements for CNC tools. It is only necessary to rotate the vibration cutting member to clamp the vibration cutting power source intervention area, and by adopting an alternating combined processing method of laser cutting and vibration cutting of aluminum die-castings, the removal and separation processing of the ultra-thick sprue can be completed, avoiding the problem of higher matching requirements for fixture design and CNC tools when processing a sprue with a complex curved surface structure.

[0116] The above-described embodiments merely represent several implementation manners of the present invention. The description thereof is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all fall within the protection scope of the present invention. Therefore, the protection scope of the present invention patent shall be subject to the appended claims.

Claims

1. A method for locally cutting an extra-thick sprue of an aluminum die-casting part, characterized in that, It includes the following steps: S110: Provide an aluminum die-casting part, which includes a die-casting body and a rectangular-shaped imitation runner. The thinnest thickness of the rectangular-shaped imitation runner is greater than 6 mm; S120: Set a cutting loop area at the connection between the die-casting body and the rectangular-shaped imitation runner. The width of the cutting loop area is 1.2 mm. A cutting loop is set in the middle of the cutting loop area, and a vibration cutting power source intervention area is set in the area of the rectangular-shaped imitation runner away from the cutting loop. Clamp the vibration cutting power source intervention area by rotating the vibration cutting part; S130: Control the rotation of the aluminum die-casting part by the rotating vibration cutting part, and synchronously control the double-axis moving laser part to emit a laser beam to perform a pre-cutting operation along the cutting loop as the path, obtaining a laser pre-cutting groove. The power of the laser beam is less than 1.2 kw; S140: Control the rotating vibration cutting part to output a power source to the vibration cutting power source intervention area to form a vibration cutting crack groove at the bottom of the laser pre-cutting groove. The frequency of the vibration cutting power source is less than 20 Hz; S150: Control the rotation of the aluminum die-casting part by the rotating vibration cutting part, and synchronously control the double-axis moving laser part to emit a laser beam to perform a cutting operation along the vibration cutting crack groove as the path, obtaining a laser cutting groove; S160: Judge whether the die-casting body is separated from the rectangular-shaped imitation runner; if not, repeat steps S140 - S150 until the die-casting body and the rectangular-shaped imitation runner are separated with the laser cutting groove or the vibration cutting crack groove as the boundary.

2. The method for locally cutting an ultra-thick sprue of an aluminum die casting according to claim 1, characterized in that, In step S150, the step of the double-axis moving laser part emitting a laser beam to perform a cutting operation along the vibration cutting crack groove as the path includes: Perform image acquisition on the aluminum die-casting part forming the vibration cutting crack groove to obtain the vibration cutting crack groove image information corresponding to the vibration cutting crack groove; Perform image processing and fitting according to the vibration cutting crack groove image information to obtain the crack groove contour image corresponding to the vibration cutting crack groove; Calculate according to the crack groove contour image to obtain a laser cutting path; wherein, the laser cutting path is the center line of the crack groove contour; Control the double-axis moving laser part to emit a laser beam to perform a cutting operation along the laser cutting path.

3. The local cutting method for the ultra-thick sprue of aluminum die-castings according to claim 1, wherein, The power of the laser beam emitted by the double-axis moving laser part in step S150 is less than the power of the laser beam emitted by the double-axis moving laser part in step S130.

4. The method for locally cutting an ultra-thick sprue of an aluminum die casting according to claim 1, characterized in that, After step S130 and before step S140, the local cutting method for the ultra-thick runner of the aluminum die-casting part further includes: Perform a cooling operation on the aluminum die-casting part.

5. The method for locally cutting an extra-thick sprue of an aluminum die casting according to claim 4, characterized in that, The specific steps for performing a cooling operation on the aluminum die-casting part are: Use compressed air and atomized coolant to perform mixed spraying on the aluminum die-casting part, and the time of the mixed spraying is less than 15 s.

6. The local cutting method for the ultra-thick sprue of aluminum die-castings according to claim 1, characterized in that, In step S120, the rotating vibration cutting part uses a pneumatic clamping mechanism to clamp the vibration cutting power source intervention area. The vibration cutting power source intervention area is provided with an anti-slip clamping surface, and the roughness of the anti-slip clamping surface is Ra12.5 μm.

7. The method for locally cutting an ultra-thick sprue of an aluminum die casting according to claim 1, wherein, After step S110 and before step S120, the local cutting method for the ultra-thick runner of the aluminum die-casting part further includes: Perform a cleaning operation on the release agent on the outer surface of the aluminum die-casting part; Spray a nano-aluminum oxide light-absorbing coating on the aluminum die-casting after the cleaning operation.

8. The method for locally cutting an ultra-thick sprue of an aluminum die casting according to claim 7, characterized in that, The thickness range of the nano-aluminum oxide light-absorbing coating is 2 μm to 10 μm.

9. The method for locally cutting the ultra-thick runner of an aluminum die-casting part according to claim 1, characterized in that, After step S160, the method for locally cutting the ultra-thick sprue of the aluminum die-casting further includes: Performing image scanning on the actual cross-section formed by the die-casting body through a CCD camera to obtain a three-dimensional stereoscopic image of the actual cross-section; Comparing the three-dimensional stereoscopic image of the actual cross-section with the three-dimensional stereoscopic image of the reference end face to obtain comparison data; Controlling a grinding device to perform a grinding operation on the actual cross-section according to the comparison data.

10. An aluminum die-casting, characterized in that, It is obtained by using the method for locally cutting the ultra-thick sprue of the aluminum die-casting according to any one of claims 1-9.

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