Continuous Casting Forging Aluminum Wheel Process
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Solution Overview
Problem
Low-pressure casting of aluminum wheels results in inadequate mechanical properties, falling short of forging levels, while maintaining the cost efficiency of the process remains a challenge.
Innovation Solution
A continuous casting and continuous forging process that involves sealing molten aluminum alloy in a mold cavity under low pressure, followed by forced water cooling and extrusion deformation strengthening, allowing for crystallization and solidification, thereby enhancing material strength and toughness without the need for high-tonnage equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-pressure casting process is used, then cost efficiency is maintained, but mechanical properties are inadequate
Solution Approach 1:
The patent changes the physical state parameter of the aluminum alloy from completely liquid to semisolid state, and modifies the pressure parameter from low pressure throughout to high pressure during forging stage. This parameter transformation allows the process to achieve forging-level mechanical properties while maintaining cost efficiency by using a modified casting process rather than traditional high-cost forging equipment
Solution Approach 2:
The patent introduces dynamic control of pressure and temperature parameters during the forming process. The pressure transitions from low holding pressure during casting to high pressure during extrusion and forging. The temperature is dynamically controlled to maintain semisolid state during critical forming operations. This dynamic parameter control enables the material to achieve superior mechanical properties comparable to forging
2Strength
If forging process is used, then mechanical properties are improved, but equipment investment and press tonnage are high
Solution Approach 1:
The patent merges the casting process and forging process into a single integrated continuous process. The aluminum alloy is cast into the wheel shape and then forged in situ without removing the material. This merging eliminates the need for separate high-tonnage forging presses and complex equipment, achieving forging-level mechanical properties with simpler, lower-cost equipment
Solution Approach 2:
The patent implements continuous action where the aluminum alloy remains in the mold cavity throughout the entire process, transitioning from liquid to semisolid to forged state without removal or repositioning. This continuous in-situ processing eliminates the need for multiple handling operations and complex equipment setups required in traditional separate casting and forging processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves mechanical properties comparable to forging while maintaining the cost efficiency of low-pressure casting, with the aluminum wheel exhibiting strength and toughness akin to those produced by pure forging processes.
Implementation Method 1
opening forced water cooling on two sides of corresponding spokes of top and bottom molds
Implementation Method 2
after the temperatures of the top and bottom molds are in a liquid-solid coexistence state of the aluminum alloy
Implementation Method 3
lowering a top pressure module to implement extrusion deformation strengthening
Implementation Method 4
lowering a top pressure module to implement extrusion deformation strengthening
Implementation Method 5
after the temperatures of the top and bottom molds are in a liquid-solid coexistence state of the aluminum alloy
Implementation Method 6
until the molten aluminum alloy is completely crystallized and solidified
Data Source
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AI summary
Disclosed is a continuous casting and continuous forging forming process for an aluminum wheel. The process combines the advantage of low-pressure filling stability of molten aluminum alloy, and utilizes the strengthening effect of extrusion deformation forging of a mold locking ring and a pressure module to improve the mechanical properties of an aluminum wheel material to close to the forging level. A mold cavity is sealed by means of the mold locking ring and a mold locking taper, and the extrusion forging pressure acts on the surface of the aluminum alloy in the closed cavity, so that the requirement of equipment for mold closing tonnage is lowered, and the cost of the equipment is far lower than that of forging equipment and equivalent to that of casting equipment.