Introduction of extrusion die casting die forging technology and equipment technology and application

1. The principle of extrusion die casting die forging
Extrusion die-casting die forging is also called “liquid die forging die-casting” or “die-casting die-forging”. This technology embodies the process of “common die-casting (casting) filling + forging and shrinking”. The extrusion die-casting die-forging equipment is essentially It is a continuous casting and forging equipment, which is a process equipment for continuous casting and forging. Briefly, the filling step can be completed by the injection molding device of the existing die casting machine (low pressure casting machine), and the forging and pressing step is completed by the master cylinder power (forging cylinder). Through the master cylinder power (forging cylinder), the forging pressure is applied to the full projection surface or the main projection surface of the part for solidification and feeding, which satisfies the requirements of the feeding process of the thick parts.
2. Characteristics of extrusion die casting die forging process
Forging pressure ratio (or forging pressure ratio) is the unique process parameter of extrusion die-casting die forging. It refers to the absolute pressure directly applied to the casting blank by the external force during the solidification stage after the casting blank is filled. This pressure is maintained until The slab is solidified. The forging pressure refers to the direct pressure acting on the solidification process (the injection specific pressure refers to the pressure during the injection filling process, which is a liquid "indirect" pressure, and the failure is zero after the filling is completed).
Extrusion die-casting die forging must have a mold forming surface to participate in forging and shrinking;
The extrusion die-casting forging process is finally characterized by "forging", which can completely eliminate the shrinkage and surface defects caused by casting, such as aluminum alloy, the surface finish can be as high as 7-8 (Ra1.6-0.8). The inside of the slab is broken grain, forged structure;
The limit of forging and shrinking is "forging". There must be forging body device (forging head), main body parameters and main function in the equipment.
3. Application range of extrusion die casting die forging process
The invention of extrusion die-casting forging technology greatly expands the range of traditional casting processes and equipment. On the one hand, as long as the metal can be melted, all conventional metal materials (such as ZL203, ZL301, LY12, 6061, 6063, stainless steel) , ferrous metals, etc.) We can all use extrusion die casting forging process; on the other hand, including the traditional "sanding" casting process with sand core filling, low pressure (differential pressure) casting can be applied to the generalized die casting process. , greatly improving labor productivity and process reliability.
An extrusion die-casting forging machine is designed to be compatible with common die casting, low pressure (differential pressure) casting, liquid die forging, continuous casting, forging and semi-solid processing.
If the equipment is filled with a low pressure filling method of 1.4 MPa in the differential pressure casting process, the projected area of ​​the produced parts is 80-100 times, which is the size of the mold that can be installed on the worktable of the existing equipment, and can be filled with a large size. Parts; a squeeze die-casting forging machine with 8000KN clamping force and 8000KN forging and pressing force, which can basically meet the extrusion die-casting of aluminum alloy wheels with certain specialities and large-sized parts. Die forging process requirements.
The piston, connecting rod, car air-conditioner compressor casing or small engine cylinder head and other parts of the automobile internal combustion engine have been produced with the extrusion die-casting forging machine with the die forging force of 2500KN or less.
The production cycle of extrusion die-casting forging machine is the same as that of ordinary die-casting machine. The general production efficiency of small-sized extrusion die-casting forging machine can exceed 300,000-400,000 pieces/year.
Extrusion die-casting forging process can produce the most complex liquid die forging (melting forging) parts, and the surface roughness and precision of the blank are higher than the ordinary die casting process. It can also produce various structurally complex deformed aluminum alloy parts, effectively eliminating the limitations of such materials that can only be produced by the forging process.
4. Feasibility and Benefits of Extrusion Die Casting Forging Process for High Strength and High Hardness Aluminum Alloy Cup-Shaped Parts
The precise extrusion die-casting forging analysis of high-strength and high-hardness aluminum alloy cup-shell type (thick-wall) parts is as follows:
The use of precision forging processing has improved the material utilization rate to a certain extent, but the precision of the blank is poor, the production process is large, the machining allowance is still large, the production efficiency is not high, and the cost is also high.
Adopting the traditional die-casting method, due to the poor fluidity of the high-strength cast aluminum alloy and the deformed aluminum alloy, the high-speed high-pressure filling of the thick-walled castings inevitably produces serious casting defects, which cannot meet the product performance requirements at all.
5 Conclusion
The extrusion die-casting forging process is essentially a continuous casting and forging process, which is an expression form of the mechanical ultimate "final forming" process.
The blank produced by this process has a short process flow and high dimensional precision, and only requires a very small amount of finishing; the surface of the blank is smooth and cleans, almost “copying” the surface roughness of the mold, and having a machining method. luster. The most important thing is that the main power cylinder (forging cylinder) of the equipment forging and shrinking the solidification process of the casting, as long as the forging and pressing parameters are properly selected, theoretically, the defects of the blank thickness can be completely eliminated, and the defect is avoided.
Waste of machining workload, low cost, high efficiency

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