Thin-walled part forming method

Abstract

This invention provides a thin-walled part molding method that can suppress deformations such as warping and lifting from the mold. [Solution] The thin-walled part forming method is a thin-walled part forming method that forms a part by casting using a mold 100 having a release mold 10 and a fixed mold 20, and includes the steps of: pushing out a raw material 30 from both the release mold 10 and the fixed mold 20 using an ejector pin 40 to lift the raw material 30 from the release mold 10 and the fixed mold 20; and cooling the raw material 30 by spraying mist M from the tip 41 of the ejector pin 40 while maintaining the restraining force of the release mold 10 and the fixed mold 20.

Description

Technical Field

[0001] The present invention relates to a method for forming thin-walled parts.

Background Art

[0002] For example, there is a rough material cooling method for cooling a rough material in a high-temperature state formed by a mold composed of a fixed mold and a movable mold (see, for example, Japanese Patent Application Laid-Open No. 2009-255118). In this rough material cooling method, after the mold is opened, the rough material is cooled while being restrained by the movable mold.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the method according to the above prior art, since the mold restraining force acts only on one side, it is difficult to suppress deformations such as warping that cause the part to lift off the mold.

[0005] The present invention provides a method for forming thin-walled parts capable of suppressing deformations such as warping that cause the part to lift off the mold.

Means for Solving the Problems

[0006] A method for forming a thin-walled part according to one aspect of the present invention is a method for forming a part by casting using a mold having a release mold and a fixed mold, the method including: a step of pushing out a rough material from both the release mold and the fixed mold using a push pin to lift the rough material off the release mold and the fixed mold; and a step of cooling the rough material by injecting mist from the tip of the push pin while maintaining the restraining force of the release mold and the fixed mold.

Effects of the Invention

[0007] According to one aspect of the present invention, a method for forming thin-walled parts that can suppress deformations such as warping and lifting from the mold can be provided. [Brief explanation of the drawing]

[0008] [Figure 1] This is a cross-sectional view showing a mold and a raw material according to one embodiment. [Figure 2] This is a cross-sectional view showing a mold and raw material according to one embodiment, illustrating a state in which the raw material is floating above the mold. [Figure 3] This is an enlarged cross-sectional view showing the mist being sprayed into the gap between the mold and the raw material. [Modes for carrying out the invention]

[0009] The following describes a thin-walled part forming method according to an embodiment of the present invention. Figure 1 is a cross-sectional view showing a mold 100 and a raw material 30 according to one embodiment. Figure 2 is a cross-sectional view showing the mold 100 and the raw material 30 according to one embodiment, showing the state in which the raw material 30 is floating from the mold 100. Figure 3 is an enlarged cross-sectional view showing the state in which mist M is sprayed into the gaps 101 and 102 between the mold 100 and the raw material 30. Each figure is illustrated with arrows indicating the X-axis, Y-axis, and Z-axis directions which are orthogonal to each other. The directions include the directions indicated by the arrows and their reverse directions.

[0010] The thin-walled parts forming method is a method of manufacturing parts (products) using a casting mold 100 with a forming material such as aluminum alloy. In the thin-walled parts forming method, a raw material (casting raw material) 30 is formed by the mold 100, then heat treatment such as heating and hardening is performed on this raw material 30, and finally, the parts are manufactured by machining such as trimming, bolt hole drilling, and deburring.

[0011] In the thin-walled parts forming method, when transitioning from the forming process to the machining process, in order to shorten the overall work time (cycle time) required for manufacturing the parts and to improve the dimensional accuracy of the parts, the raw material 30 is cooled as rapidly as possible from its temperature immediately after forming (high temperature) to a temperature that can be handled by the operator (for example, around 60°C).

[0012] The mold 100 has a release mold 10 and a fixed mold 20. A molding surface 11 is formed on the release mold 10, and a molding surface 21 is formed on the fixed mold 20. By clamping the release mold 10 and the fixed mold 20 together, a cavity is formed between the molding surface 11 of the release mold 10 and the molding surface 21 of the fixed mold 20. In the thin-walled part forming method, molten aluminum alloy is poured into the cavity. Then, by leaving it for a predetermined time, the aluminum alloy is solidified and the raw material 30 is formed.

[0013] The release mold 10 has a through hole 12 for inserting an ejector pin 40. Similarly, the fixed mold 20 has a through hole 22 for inserting an ejector pin 40. During molding of the raw material 30, the through holes 12 and 22 may be closed. For example, a rod-shaped member may be inserted into the through holes 12 and 22 to prevent the molding material from flowing out.

[0014] The thin-walled member forming method includes the step of extruding the raw material 30 from both the release die 10 and the fixed die 20 using an ejector pin 40 to lift the raw material 30 from the release die 10 and the fixed die 20. The raw material 30 may have a portion whose thickness direction is aligned with the Z-axis direction. The raw material 30 has a first surface 31 and a second surface 32 that are opposite each other in the Z-axis direction. The first surface 31 is the surface formed by the molding surface 11 of the release die 10. The second surface 32 is the surface formed by the molding surface 21 of the fixed die 20. The raw material 30 may also include a portion whose thickness direction is aligned with the X-axis direction and a portion whose thickness direction is aligned with the Y-axis direction.

[0015] As shown in Figure 2, the release mold 10 and the fixed mold 20 are movable in the Z-axis direction relative to the raw material 30. In the step of lifting the raw material 30 from the release mold 10 and the fixed mold 20, as shown in Figure 3, the ejector pin 40 is inserted in the Z-axis direction, and the tip 41 of the ejector pin 40 is pressed against the raw material 30 to lift the raw material 30 from the release mold 10 and the fixed mold 20. Specifically, the ejector pin 40 is inserted into the release mold 10, and the tip 41 is pressed against the first surface 31 of the raw material 30. This creates a gap 101 between the molding surface 11 of the release mold 10 and the first surface 31 of the raw material 30. Similarly, the ejector pin 40 is inserted into the fixed mold 20, and the tip 41 is pressed against the second surface 32 of the raw material 30.

[0016] A nozzle (opening) for spraying cooling mist is formed at the tip 41 of the ejector pin 40. The nozzle is formed on the side of the tip 41. In addition, a channel for the flow of cooling liquid is formed inside the ejector pin. The cooling liquid may be water, for example, or any other liquid.

[0017] The thin-walled part forming method includes a step of cooling the raw material 30 by spraying mist from the tip 41 of the ejector pin 40 while maintaining the restraining force of the release mold 10 and the fixed mold 20. Cooling liquid that flows inside the ejector pin 40 reaches the tip 41, from which mist is sprayed. The sprayed mist spreads into the gap 101 between the raw material 30 and the molding surface 11 of the release mold 10, and into the gap 102 between the raw material 30 and the molding surface 21 of the fixed mold 20. This allows the raw material 30 to be cooled.

[0018] "While maintaining the restraining force of the release mold 10 and the fixed mold 20" may include the case where a portion of the raw material 30 is in contact with the release mold 10 and the fixed mold 20. For example, when the raw material 30 is separated from the release mold 10 and the fixed mold 20 in the Z-axis direction, the surface along the Z-axis direction is in contact with the release mold 10 and the fixed mold 20, and the raw material 30 is restrained in the X-axis direction and the Y-axis direction. In this state where such restraining force is maintained, deformation such as bending of a portion of the raw material 30 in the Z-axis direction is suppressed. The surface along the Z-axis direction includes a surface parallel to the Z-axis direction.

[0019] The thin-walled part forming method according to this embodiment is a thin-walled part forming method for forming a part by casting using a mold 100 having a movable mold 10 and a fixed mold 20. The method includes a step of extruding a blank 30 from both the movable mold 10 and the fixed mold 20 using an extrusion pin 40 and floating the blank 30 from the movable mold 10 and the fixed mold 20, and a step of spraying mist from a tip portion 41 of the extrusion pin 40 to cool the blank 30 while maintaining the restraining force of the movable mold 10 and the fixed mold 20.

[0020] According to the thin-walled part forming method according to this embodiment, by extruding from both the movable mold 10 and the fixed mold 20, deformation of the blank 30, which is a thin-walled part, can be suppressed. By pressing a plurality of extrusion pins 40 against the blank 30, deformation of the blank 30 can be suppressed. The extrusion pins 40 are supported by the movable mold 10 and the fixed mold 20. According to the thin-walled part forming method according to this embodiment, while maintaining the restraining force by the movable mold 10 and the fixed mold 20, mist can be sprayed from the tip portion 41 of the extrusion pin 40 to cool the blank 30. By spraying mist for cooling, it is possible to cope with a blank 30 having a complicated shape and temperature distribution.

[0021] According to the thin-walled part forming method according to this embodiment, deformation of the blank 30 can be suppressed when forming a large-sized thin-walled part by casting.

[0022] As described above, the preferred embodiments of the present invention have been described in detail. However, the present invention is not limited to these embodiments, and various modifications or changes are possible within the scope of the gist of the present invention described in the claims.

Explanation of Reference Numerals

[0023] 10... movable mold, 20... fixed mold, 30... blank, 40... extrusion pin, 41... tip portion, 100... mold, M... mist.

Claims

[Claim 1] A method for forming thin-walled parts by casting using a mold having a release mold and a fixed mold, A step of using an ejector pin to push out the rough material from both the release mold and the fixed mold, thereby lifting the rough material from the release mold and the fixed mold, A method for forming a thin-walled part, comprising the step of cooling the raw material by spraying mist from the tip of the ejector pin while maintaining the restraining force of the release mold and the fixed mold.

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