JP2002028765A - Injection molding method for metal materials - Google Patents

Abstract

(57) [Problem] To provide a technique for reducing the cost of a product formed of a metal material. SOLUTION: A casting 45 including a product part 47 formed in a cavity 22 and a non-product part 47 remaining in a gate 24 is taken out from a mold at a high temperature, and the non-product part 47 is separated from the casting 45 in a high temperature state. Then, the high-temperature non-product part 47 is formed into a billet member 48, and the billet member 48 is charged into an injection cylinder 25, and the injection cylinder 25 is filled with a semi-solid Al alloy 41 to form a billet. The member 48 was melted in the semi-solid Al alloy 41 to prepare for the next injection.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal material injection molding method for supplying a metal material in an injection cylinder to a cavity to obtain a product having a desired shape.

[0002]

2. Description of the Related Art FIG. 13 is a cross-sectional view of a typical conventional disk brake for an automobile.
2 shows a state in which a hub 101 is attached to the hub 101, a disc rotor 103 of a disc brake 102 is attached to the hub 101, and the disc rotor 103 is inserted into a caliper 106. The hydraulic pressure is transmitted from the supply flow path 108 to a cylinder (not shown) of the caliper 106 so that the brake pads 107, 10
7 is pressed against the disk portion 105 of the disk rotor 103 to brake the wheel 109.

The disk portion 105 of the disk rotor 103
The disc pads 103 need to be formed of a high-strength material. On the other hand, in order to reduce the weight of the vehicle body, it is preferable that the disk rotor 103 be made of a light material.
Metal matrix composite material (M
An MC (metal matrix composite) is known. For example, it is possible to reduce the weight by using an Al (aluminum) alloy as the metal matrix, and to include SiC (silicon carbide) particles in the Al alloy matrix. Higher strength can be achieved. Next, a method for manufacturing the disk rotor 103 using an Al alloy matrix composite material will be described with reference to the following drawings.

FIG. 14 is a cross-sectional view of a conventional injection molding apparatus for a metal matrix composite material, in which a movable mold 110 and a fixed mold 111 form a cavity 112, and a cavity 11 is formed.
An injection cylinder 115 is connected to the injection cylinder 115 via a gate 113, a plunger 116 is attached to the injection cylinder 115 so as to be able to move up and down, and an MMC supply means 118 is connected to the injection cylinder 115 via a supply path 117, and the outlet side of the supply path 117. Shows a state in which the on-off valve 119 is attached.

[0005] Opening the on-off valve 119, MMC supply means 1
From 18, the Al alloy matrix composite material is supplied into the injection cylinder 115 as indicated by the arrow a, and the plunger 116 is raised as indicated by the outline arrow b to fill the cavity 112 with the Al alloy matrix composite material through the gate 113. Next, the movable mold 110 is lifted up as shown by the white arrows c, c to open the mold and take out the casting from the mold. Hereinafter, the removed casting will be described.

FIG. 15 is an explanatory view of a casting taken out of a mold, and shows a state in which a casting 120 is separated into a product part 121 and a non-product part 122. The product part 121 is a member of an Al alloy matrix composite material formed in the cavity 112, and is processed to form the disk rotor 1 shown in FIG.
Get 03. The non-product part 122 is a member of the Al alloy matrix composite material remaining on the gate 113 (shown in FIG. 14).

[0007]

The non-product part 122 remaining on the gate 113 is also an Al alloy matrix composite material in which SiC grains are contained in the Al alloy matrix. For this reason, since the Al alloy matrix composite material cannot be reused as it is, it is necessary to separate SiC grains from the Al alloy matrix in order to reuse it. However, this separation is technically difficult and, if possible, expensive. Therefore, the current situation is that the non-product part 122 is disposed of, which means that the product part 1 formed of an Al alloy matrix composite material (that is, a metal material) is used.
21 will increase the cost.

On the other hand, some injection molded products do not require high strength. Since this product does not require SiC particles for increasing the strength, it can be injection-molded with a normal aluminum alloy material (that is, a metal material) or the like. For this reason, when reusing the non-product part remaining in the gate, when the non-product part
Since there is no need to separate the grains, it is easy to think about reusing them easily.

However, in order to reuse the non-product part as molten metal for injection molding, it is necessary to melt the non-product part, and heat energy for melting the non-product part increases. For this reason, at present, non-product parts are discarded, which causes an increase in the cost of a product formed of an Al alloy material (that is, a metal material).

An object of the present invention is to reduce the cost of an injection-molded product made of a metal material by enabling the non-product portion remaining in the gate to be reused.

[0011]

According to a first aspect of the present invention, there is provided an injection cylinder made of a semi-solid metal material or a molten metal material, which is filled into a mold cavity through a gate by an injection cylinder. In the method of injection molding a metal material, a casting comprising a product part molded in the cavity and a non-product part remaining in the gate is taken out from the mold at a high temperature, and the non-product part is separated from the casting in a high temperature state. The high temperature non-product part is formed into a billet member, the billet member is put into an injection cylinder, and the injection cylinder is filled with the injection material to melt the billet member into the injection material. It is characterized in that it prepares for the next injection.

The non-product part is formed into a billet member at a high temperature, and the billet member is melted in the injection cylinder utilizing the heat of the injection material. By utilizing the heat of the injection material to melt the billet member, the heat energy cost required to melt the billet member is reduced. In addition, since the billet member is melted at a high temperature, the heat energy cost can be further reduced. Therefore, the non-product part remaining in the gate can be reused without being disposed.

According to a second aspect of the present invention, a semi-solid metal material and a molten metal matrix composite material are prepared as injection materials, and each of the metal material is disposed on the plunger side and the metal matrix composite material is disposed on the gate side. A material is filled in the injection cylinder, and the metal matrix composite material and the metal material are injected into the cavity in this order.

By injecting the metal matrix composite material and the metal material into the cavity in this order, the metal matrix composite material is filled into the cavity, and the metal material is left on the gate.
This eliminates the need to separate the reinforcing material, such as SiC grains, from the metal matrix composite when reusing the non-product portion remaining in the gate. In addition, as in claim 1,
By charging the non-product part into the injection cylinder, the non-product part is melted by using the heat of the injection material. Thereby, the heat energy cost required for melting the non-product part is suppressed.

A third aspect of the present invention is characterized in that a high-temperature non-product part is disposed in an injection cylinder, and the non-product part is pressure-formed on a billet member by a plunger in the injection cylinder.
A high-temperature non-product part is charged into an injection cylinder, and the non-product part is pressure-formed into a billet member by a plunger in the injection cylinder. As a result, the cost of equipment for pressurization is reduced by effectively using the injection cylinder and the plunger.

In the case where the injection cylinder is not used when the non-product part is pressure-formed into the billet member, first, the non-product part is conveyed to the pressure-forming equipment, and then subjected to pressure-forming in the pressure-forming equipment. It is necessary to transport the billet member to the injection cylinder. For this reason, it takes time and effort to carry, and it is difficult to increase the productivity. On the other hand, a third aspect of the present invention press-molds the non-product part in the injection cylinder, thereby eliminating the trouble of transporting the non-product part to the pressure molding equipment.

[0017]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a perspective view of a disk rotor manufactured by an injection molding method (first embodiment) of a metal material according to the present invention. The disk rotor 10 includes a cylindrical hub portion 11 and a disk-shaped disk portion 18 formed integrally with the hub portion 11.

The hub portion 11 has a lid 13 on the outer end of the peripheral wall 12.
Are integrally formed, an opening 14 is opened in the center of the lid 13, and bolt holes 15... (A plurality is shown; the same applies hereinafter) and stud holes 16. It is open. Bolts (not shown) are inserted through the bolt holes 15 and the disk rotor 10 is attached to the drive shaft (not shown) with these bolts. The stud holes 16 are holes for press-fitting studs (not shown) in order to attach wheels to the disk rotor 10. The disk portion 18 is a portion facing the brake pad of the caliper (not shown) and pressing the brake pad from both sides. For this reason, the disk portion 18 is required to have high strength and excellent wear resistance.

FIG. 2 is a sectional view taken along line 2-2 of FIG. Since the hub portion 11 is a portion to be attached to the drive shaft side, it is not required that the hub portion 11 be as strong as the disk portion 18 or be excellent in wear resistance. Therefore, the hub 1
No. 1 was constituted by impregnating an Al alloy into an Al alloy matrix composite material. The region E1 in which the Al alloy matrix composite material is impregnated with the Al alloy is indicated by oblique lines. Since the disc portion 18 presses the brake pads from both sides, the disc portion 18 is required to have high strength and excellent wear resistance. For this reason, the disk portion was formed only of the Al alloy matrix composite material. The region E2 of the Al alloy matrix composite material is shown by a mesh.

Hereinafter, a metal material injection molding apparatus for molding a disk rotor will be described. FIG. 3 is a cross-sectional view of a metal material injection molding apparatus according to the present invention. The metal material injection molding apparatus 20 includes a movable mold 21 that can move up and down, and a movable mold 2.
1, a fixed die 23 forming a cavity 22, an injection cylinder 25 mounted on the fixed die 23, a plunger 30 mounted on the injection cylinder 25 so as to be movable up and down, and an Al alloy supply means for supplying an Al alloy to the injection cylinder 25. 34, an Al alloy supply path 35 connecting the Al alloy supply means 34 to the injection cylinder 25, an Al alloy opening / closing valve 36 attached to the outlet side 35a of the Al alloy supply path 35, and an Al alloy matrix composite material in the injection cylinder 25. M to supply
MC supply means 37, an MMC supply path 38 connecting the MMC supply means 37 to the injection cylinder 25, and an MMC supply path 38
And an MMC on-off valve 39 attached to the outlet side 38a.

The fixed mold 23 is a member in which a gate 24 connecting the cavity 22 and the injection cylinder 25 is formed.
The injection cylinder 25 is provided with a heater 26 on the outer periphery near the upper end of the plunger 30,
5a is a member attached to the gate 24 of the fixed mold 23 by inserting the same, and is a member configured to be detachable from the fixed mold 23 by extracting the tip 25a from the concave portion 23a.

The plunger 30 is a member which is movably disposed in the injection cylinder 25 and pushes out an Al alloy matrix composite material or an Al alloy in the injection cylinder 25 into the cavity 22 through the gate 24. Advance and retreat as shown by the arrows.

The Al alloy supply means 34 feeds the semi-solidified Al alloy from the Al alloy supply hole 27 of the injection cylinder 25 to the injection cylinder 2 with the Al alloy on-off valve 36 opened.
5 is supplied. The MMC supply means 37
With the MC on-off valve 39 open, the molten Al alloy matrix composite material is supplied into the injection cylinder 25 from the MMC supply hole 28 of the injection cylinder 25.

Next, the injection molding method (first embodiment) of the metal matrix composite material according to the present invention will be described. The Al alloy on-off valve 36 and the MMC on-off valve 39
The state of “closed” is indicated by black. FIGS. 4A and 4B are first explanatory views of the metal material injection molding method (first embodiment) according to the present invention. In (a), the on-off valve 39 for MMC is closed and the on-off valve 36 for Al alloy is opened,
The Al alloy supply means 34 converts the semi-solidified Al alloy 41 to A.
The plunger 30 is filled with a semi-solidified Al alloy 41 by supplying it from the 1 alloy supply hole 27 into the injection cylinder 25 as shown by an arrow. The filling amount of the Al alloy 41 will be described with reference to FIG.

In (b), the on / off valve 36 for Al alloy is closed and the on / off valve 39 for MMC is opened, and the MMC supply means 37 supplies the molten Al alloy matrix composite material 42.
Is supplied from the MMC supply hole into the injection cylinder 25 as shown by the arrow. As a result, the injection cylinder 25 is filled with the injection material 40 including the semi-solid Al alloy (semi-solid metal material) 41 and the molten Al alloy matrix composite material (molten metal material) 42. The filling amount of the metal matrix composite material 42 is shown in FIG.
This will be described in (b).

By setting the Al alloy 41 in a semi-solid state and the Al alloy matrix composite material 42 in a molten state, A
The 1 alloy matrix composite material 42 can be separately filled on the Al alloy 41.

FIGS. 5A and 5B are second explanatory views of the injection molding method (first embodiment) for a metal material according to the present invention. In (a), after closing the on-off valve 39 for MMC, the plunger 30 is moved by the operating means as indicated by a white arrow. The semi-solidified Al alloy 41 rises and supplies the molten Al alloy matrix composite 42 to the cavity 22 through the gate 24.

In (b), the plunger 30 is moved until it reaches the lower surface of the fixed die 23. Al in semi-solid state
Filling the gate 24 with the alloy 41 allows the molten A
The disk portion 22 a of the cavity 22 is filled with the alloy matrix composite material 42. The region filled with the Al alloy matrix composite material 42 is indicated by a mesh, and this region corresponds to the region E2 in FIG. Here, the filling amount of the metal matrix composite material 42 described in FIG. 4B is substantially the same as the mesh area.

On the other hand, a part of the Al alloy 41 enters the cavity 22 from the gate 24 and impregnates the Al alloy matrix composite material 42. The region 43 in which the Al alloy 41 is impregnated in the Al alloy matrix composite material 42 is indicated by oblique lines,
This area corresponds to E1 in FIG. Here, FIG.
The filling amount of the Al alloy 41 described in (1) is substantially the same as the area obtained by adding the region of the gate 24 to the hatched region 43. Next, the movable mold 21 is moved as indicated by a white arrow to open the mold.

FIGS. 6A and 6B are third explanatory views of the injection molding method (first embodiment) for a metal material according to the present invention. In (a), a casting 45 composed of a product part 46 formed in the cavity 22 and a non-product part 47 remaining in the gate 24 is heated to a high temperature (for example, 400 to
100 ° C., ie a temperature slightly lower than the solidification temperature).

If the temperature of the casting 45 exceeds 400 ° C., the casting 45 may not be able to be taken out of the mold in a solidified state. If the temperature of the casting 45 is lower than 100 ° C., the melting of the non-product part 47 may occur. Requires a lot of thermal energy costs. Therefore, the temperature of the casting 45 is set to 400 to 100 ° C. so that the heat energy cost for melting the non-product part 47 is suppressed, and the casting 45 can be taken out of the mold in the solidified state K.

Next, the non-product part 47 is separated from the casting 45 taken out from the casting 45 while keeping the high temperature state. Thereby, the product part 46 is obtained. By processing this product part 46, the disk rotor 10 shown in FIG. 2 is obtained. On the other hand, casting 4
After removing 5 from the mold, the plunger 30 is lowered as shown by the arrow.

In (b), the tip 25a of the injection cylinder 25 is pulled out of the recess 23a by descending the injection cylinder 25 as shown by the arrow. Thereby, the injection cylinder 25 is removed from the fixed mold 23. Next, the injection cylinder 25 is moved in the horizontal direction as indicated by the arrow.

FIGS. 7A and 7B are fourth explanatory views of the injection molding method (first embodiment) for a metal material according to the present invention. In (a), the high-temperature non-product part 47 is put into the injection cylinder 25 from above the injection cylinder 25 as shown by an arrow. At the same time, the non-product part 47 is heated by the heater 26.
In (b), with the non-product part 47 placed on the upper end of the plunger 30 of the injection cylinder 25, the pressurizing plunger 49 is inserted from the tip 25a of the injection cylinder 25 as shown by an arrow.

FIGS. 8A and 8B are fifth explanatory views of the injection molding method (first embodiment) for a metal material according to the present invention. In (a), the billet member 48 is obtained by pressing the hot non-product portion 47 between the pressurizing plunger 49 and the plunger 30 to press-mold. Next, the pressurizing plunger 49 is raised as shown by the arrow, and
Evacuate from inside 5. Then, the injection cylinder 25 is attached to the fixed mold 23 by inserting the tip 25a of the injection cylinder 25 into the recess 23a of the fixed mold 23 in a procedure reverse to the procedure described with reference to FIG.

In (b), the MMC on-off valve 39 is closed, the Al alloy on-off valve 36 is opened, and the Al alloy 41 in the semi-solid state is injected from the Al alloy supply hole 27 by the Al alloy supply means 34 into the injection cylinder. The aluminum alloy 41 in a semi-solid state is filled on the billet member 48 by supplying it into the inside 25 as shown by an arrow. Here, the filling amount of the Al alloy 41 can be reduced by the billet member 48 from the filling amount of FIG.

FIG. 9 is a sixth explanatory view of the metal material injection molding method (first embodiment) according to the present invention. By filling the injection cylinder with the semi-solid Al alloy 41, the billet member 48 shown in FIG. 8B is melted by the heat of the Al alloy 41 and the heat of the heater 26, and the semi-solid Al alloy 4 is melted.
Mix into one.

After filling the semi-solidified Al alloy 41,
The Al alloy on-off valve 36 is closed, the MMC on-off valve 39 is opened, and the molten Al alloy matrix composite material 42 is supplied from the MMC supply hole 38 into the injection cylinder 25 by the MMC supply means 37 as shown by the arrow. To prepare for the next shot.

According to the metal material injection molding method of the present invention, the Al alloy matrix composite material 42, the Al alloy 41
Are injected into the cavity 22 in this order, so that the Al alloy matrix composite material 41 is filled into the cavity 22,
The alloy 41 can be left in the gate 24. For this reason, when the non-product part 47 remaining in the gate 24 is reused, it is not necessary to separate the SiC particles from the Al alloy matrix composite material 42, so that the cost of separating the SiC particles can be omitted.

In addition, the non-product part 47 is formed into a billet member 48 at a high temperature (for example, 400 to 100 ° C., that is, a temperature slightly lower than the solidification temperature). And semi-solid Al
The alloy 41 is melted using heat. By utilizing the heat of the Al alloy 41 to melt the billet member 48, it is possible to reduce the heat energy cost required to melt the billet member 48. In addition, since the billet member 48 is melted at a high temperature, the heat energy cost can be further reduced. Therefore, the non-product part 47 can be reused without being discarded, and the cost of the product part 46 (that is, the disk rotor 10) can be reduced.

Further, the high-temperature non-product part 47 is charged into the injection cylinder 25, and the non-product part 47 is formed into a billet member 48 by the plunger 30 in the injection cylinder 25. For this reason, since the injection cylinder 25 and the plunger 30 can be effectively used, the equipment cost for pressurization can be reduced. Therefore, the cost of the product unit 46 can be further reduced.

In the case where the non-product part 47 is formed under pressure into the billet member 48 outside the injection cylinder 25, the non-product part 47 is transported to a pressure forming equipment (not shown), and is injected after the pressure forming. It is necessary to convey to the cylinder 25.
For this reason, it takes time and effort to carry, and it is difficult to increase the productivity. On the other hand, according to the injection molding method of the metal material of the present invention, by performing pressure molding on the billet member 48 in the injection cylinder 25, it is possible to save time and effort for carrying and improve productivity.

The billet member 48 obtained by press-molding the non-product 47 was disposed on the upper surface of the plunger 30. Therefore, at the time of injection molding, the semi-solidified Al alloy 41 in which the billet member 48 is melted does not enter the cavity 22,
Gate 24 remains. Therefore, even if impurities are mixed in the billet member 48, the impurities do not enter the product part 46.

Next, a second embodiment will be described.
The same members as those in the first embodiment are denoted by the same reference numerals, and description thereof is omitted. FIG. 10 is a sectional view of a disk rotor formed by the metal material injection molding method (second embodiment) according to the present invention. As in the first embodiment, the disk rotor 50 has a cylindrical hub portion 51 and a hub portion 51.
And a disk-shaped disk portion 54 integrally molded with
The hub portion 51 and the disk portion 54 are made of only an Al alloy matrix composite material.

Next, an injection molding method (second embodiment) of a metal matrix composite material will be described. FIG. 11 is an explanatory view of a first operation of the injection molding method (second embodiment) for a metal material according to the present invention. First, as in the first embodiment,
After supplying the semi-solidified Al alloy 41 and the molten Al alloy matrix composite material 42 into the injection cylinder 25 by the Al alloy supply means 34 and the MMC supply means 37, as shown in FIG. On-off valve 39
Close. The filling amount of the Al alloy 41 is smaller than the filling amount of the first embodiment, and the metal matrix composite material 42
Is made larger than the filling amount of the first embodiment.

Next, the plunger 30 is moved until it reaches the lower surface of the fixed mold 23. By filling the gate 24 with the Al alloy 41 in a semi-solid state, the cavity 22 is filled with the Al alloy matrix composite material 42 in a molten state. The area filled with the Al alloy matrix composite material 42 is indicated by a mesh. On the other hand, part of the Al alloy 41
Through the cavity 22 to impregnate the Al alloy matrix composite material 42. The region 43 in which the Al alloy 41 is impregnated in the Al alloy matrix composite material 42 is indicated by oblique lines. Next, the movable mold 21 is moved as shown by the arrow to open the mold.

FIG. 12 is an explanatory view of a second operation of the injection molding method (second embodiment) for a metal material according to the present invention. The casting 55 is taken out from the opened mold, and the non-product part 57 is separated from the product part 56 of the casting 55. The disk rotor 50 shown in FIG. 7 is obtained by processing the product part 56. Here, since the portion 52 of the Al alloy included in the product portion 56 is small, it is removed when the product portion 56 is processed. On the other hand, the non-product 57 can be reused because it is composed only of the Al alloy. As a result, similarly to the first embodiment, the cost of the disk rotor 50 can be reduced.

In the above embodiment, the metal matrix composite material 42 is an Al alloy matrix composite material in which AlC matrix contains SiC particles.
The present invention can be applied to a metal matrix composite material in which a fibrous, particulate, or plate-like reinforcing material (such as SiC or alumina) is added to the metal matrix using another metal material as a matrix. In addition, the casting is disc rotor 1
Although described as 0,50, it can be applied to other castings.

Further, the amount of the metal matrix composite material 42 of the first embodiment filled in the injection cylinder 25 has been described with reference to FIG. Although the filling amount in the inside has been described with reference to FIGS. 11 and 12, the filling amount of the metal matrix composite material 42 may be appropriately changed. In addition, Al alloy 41
Can be arbitrarily changed.

Further, in the first embodiment, an example will be described in which the billet member 48 is obtained by putting the high-temperature non-product part 47 into the injection cylinder 25 and then press-molding the same with the plunger 49 and the plunger 30. However, the billet member 48 may be charged into the injection cylinder 25 after the high-temperature non-product part 47 is pressure-formed on the billet member 48.

Further, in the first embodiment, the example in which the billet member 48 is melted by both the heat of the Al alloy 41 in the semi-solid state and the heat of the heater 26 has been described. It is also possible to configure so that the billet member 48 is melted only by the heat.

In addition, in the above embodiment, the molten A
An example in which the high-strength disk rotor 10 is formed by filling the cavity 22 with the 1 alloy matrix composite material 42 and leaving the semi-solid Al alloy 41 in the gate 24 has been described. The injection molding method can be applied to the case where a product is injection-molded using only the Al alloy 41 or another metal material.

[0053]

According to the present invention, the following effects are exhibited by the above configuration. Claim 1 separates the non-product part from the hot casting.
The separated non-product part is formed into a billet member at a high temperature. The billet member is melted in the injection material in the injection cylinder to prepare for the next injection. The non-product part is formed into a billet member at a high temperature, and the billet member is melted in the injection cylinder by utilizing the heat of the injection material. By utilizing the heat of the injection material to melt the billet member, the heat energy cost required to melt the billet member can be reduced. In addition, since the billet member is melted at a high temperature, the heat energy cost can be further reduced. As a result, the non-product part remaining in the gate can be reused without being discarded, and the cost of the product part can be reduced.

Claim 2 is a metal matrix composite material,
Injecting the metal material into the cavity in order allows the metal matrix composite to fill the cavity and leave the metal material at the gate. For this reason, when the non-product part remaining in the gate is reused, there is no need to separate the reinforcing material such as SiC particles from the metal matrix composite material, so that the cost of separating the reinforcing material can be saved.

In addition, as in the first aspect, the non-product part is put into the injection cylinder, so that the non-product part is melted by utilizing the heat of the injection material. For this reason, the heat energy cost required to melt the non-product part can be suppressed. Therefore, the non-product part remaining in the gate can be reused without being discarded, and the cost of the product part can be reduced.

According to a third aspect of the present invention, a high-temperature non-product part is charged into an injection cylinder, and the non-product part is pressure-formed into a billet member by a plunger in the injection cylinder. Therefore, the injection cylinder and the plunger can be used effectively,
Equipment costs for pressurization can be reduced. Therefore, the cost of the product section can be further reduced.

When the non-product part is formed into a billet member outside the injection cylinder under pressure, it is necessary to convey the non-product part to the pressure forming equipment, and after the pressure forming, to the injection cylinder. For this reason, it takes time and effort to carry, and it is difficult to increase the productivity. On the other hand, according to the third aspect, by performing pressure molding on the billet member in the injection cylinder, it is possible to save time and effort for carrying and improve productivity.

[Brief description of the drawings]

FIG. 1 is a perspective view of a disk rotor manufactured by a metal material injection molding method according to the present invention (first embodiment).

FIG. 2 is a sectional view taken along line 2-2 of FIG.

FIG. 3 is a cross-sectional view of a metal material injection molding apparatus according to the present invention.

FIG. 4 is a first explanatory view of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 5 is a second explanatory view of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 6 is a third explanatory view of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 7 is a fourth explanatory diagram of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 8 is a fifth explanatory view of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 9 is a sixth explanatory diagram of the metal material injection molding method (first embodiment) according to the present invention.

FIG. 10 is a diagram showing a method of injection molding a metal material according to the present invention (second example).
Sectional view of a disk rotor molded in the embodiment)

FIG. 11 is a diagram illustrating a method of injection molding a metal material according to the present invention (second method).
(Embodiment 2) First operation explanatory diagram

FIG. 12 is a diagram illustrating a method of injection-molding a metal material according to the present invention (second example).
(Embodiment 2) Second operation explanatory view

FIG. 13 is a cross-sectional view of a typical conventional disc brake for an automobile.

FIG. 14 is a cross-sectional view of a conventional metal matrix composite injection molding apparatus.

FIG. 15 is an explanatory view of a casting taken out of a mold.

[Explanation of symbols]

Reference numeral 20: injection molding apparatus for metal material, 21: movable mold, 22:
Cavity, 23: fixed type, 24: gate, 25: injection cylinder, 30: plunger, 40: Al alloy, 42:
Metal matrix composite material, 45, 55 ... casting, 46,
56: product part, 47, 57: non-product part, 48: billet member, 49: plunger for pressurization.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B22D 19/14 B22D 19/14 A 31/00 31/00 Z F16D 65/12 F16D 65/12 EZ ( 72) Inventor Sugaya advantageous 1-10-1, Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd. (72) Inventor Takashi Kato 1-10-1, Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd. (72) Inventor Ryuji Echigo 1-10-1 Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd. F term (reference) 3J058 AA41 BA61 CB11 CD20 EA08 EA40 FA01

Claims (3)

[Claims] 1. A metal material injection molding method for filling an injection material made of a semi-solid metal material or a molten metal material into a cavity of a mold through an injection cylinder through a gate. Remove the remaining non-product casting from the mold at high temperature,
The non-product part is separated from the casting in a high-temperature state, the high-temperature non-product part is formed into a billet member, the billet member is put into an injection cylinder, and the injection cylinder is filled with an injection material. A method of injection molding a metal material, wherein the billet member is dissolved in the injection material so as to prepare for the next injection. 2. A semi-solid metal material and a molten metal matrix composite material are prepared as the injection material,
The injection cylinder is filled with each material so that the metal material is on the plunger side and the metal matrix composite material is on the gate side, and the metal matrix composite material and the metal material are injected into the cavity in this order. An injection molding method for a metal material according to claim 1. 3. The non-product part having a high temperature is arranged in an injection cylinder, and the non-product part is pressure-formed on a billet member by a plunger in the injection cylinder.
Or the injection molding method of the metal material according to claim 2.