JP2004098083A - Work casting method and work produced by casting method - Google Patents

Abstract

In a case where a plurality of members are integrally joined, the number of molds is not increased even if the cast portion has the same shape and only the shape and length of the portion to be cast are different. And a casting method of a work capable of producing a plurality of types of works.
The present invention includes connecting members (11, 12) formed in advance and a plurality of casting parts (13, 14) to be cast, and a part of the connecting member is integrally cast into the plurality of casting parts to form a plurality of casting parts. A method for casting a workpiece 10 in which casting parts are connected via a connecting member, wherein each of the plurality of casting parts is cast and a plurality of molds 32 and 33 are provided so as to be relatively movable toward and away from each other. A step of disposing a connecting member, and a step of relatively moving a plurality of molds along the longitudinal direction of the disposed connecting member in accordance with the length of the connecting member.
[Selection diagram] FIG.

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for casting a work and a work produced by the casting method.
[0002]
[Prior art]
When designing and manufacturing automobiles, structural parts such as suspension parts represented by suspensions are required to have a high level of strength and elongation, and are also required to be lightweight. On the other hand, it is required to suppress the manufacturing cost. In order to solve these problems, it is more preferable to use a plurality of members having different characteristics than to configure a component from a single member. A great advantage of using a plurality of members having different characteristics is that mode control when an impact is applied is facilitated by intensively deforming members that are easily deformed between the members. Further, it is easy to form a simple shaped portion (same cross section) and a hollow portion, which is advantageous from the viewpoint of weight reduction. As a method of integrally joining a plurality of members, there is a method of casting one of different members by the other member (for example, see Patent Document 1).
[0003]
[Patent Document 1]
JP-A-11-222152
[Problems to be solved by the invention]
However, in the conventional method of casting, if the casting portion has the same shape and only the shape and length of the casting portion are different, it is necessary to prepare a plurality of entire molds.
[0005]
The present invention has been made in order to solve the above-mentioned problems of the related art, and in a case where a plurality of members are integrally joined, a cast portion has the same shape, and the shape and length of a portion to be cast-in. It is an object of the present invention to provide a method of casting a work capable of producing a plurality of types of works without increasing the number of molds, and a work manufactured by the casting method, even if the only difference is in the number of molds.
[0006]
[Means for Solving the Problems]
The object of the present invention is achieved by the following means.
[0007]
A connecting member formed in advance and a plurality of casting parts to be cast are provided, and a part of the connecting member is integrally cast into the plurality of casting parts, and the plurality of casting parts form the connecting member. A method of casting a workpiece connected via
A step of arranging the connection member in a plurality of molds provided so as to be relatively close to and away from each other while casting each of the plurality of casting parts,
Moving the plurality of molds relative to each other along the longitudinal direction of the arranged connecting member according to the length of the connecting member.
[0008]
【The invention's effect】
The present invention configured as described above has the following effects.
[0009]
When multiple parts are joined together, even if the cast part has the same shape and only the shape and length of the part to be cast are different, multiple types without increasing the number of molds It is an object of the present invention to provide a work casting method capable of manufacturing the above-mentioned work and a work manufactured by the casting method.
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0011]
(1st Embodiment)
FIGS. 1A and 1B are diagrams showing works 10 and 20 having different sizes (longitudinal lengths) of connecting members.
[0012]
2. Description of the Related Art In recent years, in the design of undercarriage of automobiles, designs that use the same shape for the side members at both ends and that differ only in the connection members are increasing. A manufacturing method that effectively utilizes the fact that the side members are common is desired.
[0013]
A work 10 shown in FIG. 1A includes connection members 11 and 12 formed in advance and a plurality of side members 13 and 14 (corresponding to a casting portion) to be cast. A part is integrally cast into the plurality of side members 13 and 14, and the plurality of side members 13 and 14 are connected via the connecting members 11 and 12. A work 20 shown in FIG. 1 (B) is formed by integrally connecting connecting members 21 and 22 to side members 13 and 14 which are the same components as the work 10.
[0014]
In order to produce a workpiece having the same appearance as the workpieces 10 and 20, there is also a method of integrally joining a plurality of members to form a structural component, and joining each member by welding. However, joining by welding requires a welding process, and in some cases, a heat treatment process or the like for removing a thermal effect is required. Welding between dissimilar materials increases the burden of welding management and requires high welding skills for workers. Furthermore, when the composition between different materials is significantly different, it may be difficult to use such a combination from the viewpoint of welding technology.
[0015]
If the joining by casting is used, a welding step, a heat treatment step, and the like are not required, and further, consideration for different compositions of the members can be reduced. In addition, welding must be performed for each joint portion. However, in the case of casting, joining can be reliably performed only by pouring, and the workpieces 10 and 20 can be easily manufactured.
[0016]
The workpieces 10 and 20 of the present embodiment use an aluminum alloy to reduce the weight. The connection members 11, 12, 21, and 22 emphasize characteristics of elongation, and 5052 (JIS) is preferable. The side members 13 and 14 emphasize strength characteristics, and AC4CH (JIS) is preferable. The connecting members 11, 12, 21, and 22 may use 6061 (JIS) with emphasis on strength. In consideration of cost, strength characteristics, and the like, other combinations may be used, and materials other than aluminum alloys may be used.
[0017]
FIGS. 2A and 2B are cross-sectional views showing a main part of a casting apparatus 30 for producing the works 10 and 20 of the present embodiment. FIG. It is sectional drawing which shows a part. FIGS. 3A and 3B are cross-sectional views showing the right half of the casting apparatus 30 according to the present embodiment. FIGS. 4A, 4B, and 4C are enlarged cross-sectional views of the slide portions 41, 42, and 43 of the casting apparatus 30. FIG.
[0018]
In order to manufacture the works 10 and 20 of the present embodiment, a casting device 30 shown in FIGS. 2A and 2B and FIGS. 3A and 3B is used.
[0019]
Since the side members 13 and 14 to be cast are made of an aluminum alloy, the casting device 30 uses a die-casting type.
[0020]
The casting apparatus 30 has a main mold 31 that holds the entire structure. The main mold 31 is provided with cavity inserts 32 and 32 ′ (corresponding to a mold) and runner inserts 33 and 33 ′. The cavity inserts 32 and 32 'can move freely within the main mold 31 so as to move close to and away from each other. The runner inserts 33 and 33 ', like the cavity inserts 32 and 32', can move within the main mold 31 so as to be able to move close to and away from each other. Cavities 15, 16 for forming the side members 13, 14 are formed in the cavity inserts 32, 32 '. Runners 35, 36, 35 ', 36' for supplying molten metal to the cavities 15, 16 are formed in the runner inserts 33, 33 '. In the cavity inserts 32, 32 ', weirs 45, 45' are formed for communicating the cavities 15, 16 with the runners 35, 36, 35 ', 36'.
[0021]
The main mold 31 is formed with a basin 37 for supplying molten metal and gates 38, 38 '. Further, exhaust runners 46a and 46b for degassing and a vent 39 communicating with the exhaust runner 46a or 46b are formed as shown in FIGS. 3 (A) and 3 (B). Although only the right half is shown for degassing, the same applies to the left half.
[0022]
When the workpiece 10 is manufactured using the casting apparatus 30, the cavity inserts 32 and 32 'are brought closer to the center corresponding to the lengths of the connecting members 11 and 12, and the end faces 32a and 32'a are brought into contact. Let it. At the same time, the runner inserts 33 and 33 'are separated from each other and moved until the end surfaces 33b and 33'b come into contact with the surrounding surfaces 31a and 31b. By these movements, the basin 37, the gates 38, 38 ', the runners 35, 35', and the cavities 15, 16 communicate with each other via the weirs 45, 45 '(FIGS. 2A and 3A). reference). On the other hand, when the work 20 is manufactured, the cavity inserts 32 and 32 'are separated from each other in accordance with the lengths of the connecting members 21 and 22 until the end faces 32b and 32'b come into contact with the surrounding faces 31a and 31b. Moving. At the same time, the runner inserts 33 and 33 'are made to approach the center, and the end faces 33a and 33'a are brought into contact. By these movements, the basin 37, the gates 38, 38 ', the runners 36, 36', and the cavities 15, 16 communicate with each other via the weirs 45, 45 '(FIGS. 2B and 3B). reference).
[0023]
As described above, the casting apparatus 30 moves the runners 35, 36, 35 ', 36' by relatively moving the runner inserts 33, 33 'in response to the relative movement of the cavity inserts 32, 32'. The molten metal can be supplied to the cavities 15 and 16 by switching.
[0024]
In the case of the casting method using the casting apparatus 30 of the present embodiment, when the side members 13 and 14 can be used in common, a plurality of types of works, for example, both the works 10 and 20 can be formed only by the casting apparatus 30. It can be manufactured (see FIGS. 2A and 2B).
[0025]
Next, a structure for moving the cavity inserts 32, 32 'and the runner inserts 33, 33' toward and away from each other will be described with reference to FIGS. 3A, 3B, 4A, 4B, and 4C.
[0026]
When the cavity inserts 32, 32 'and the runner inserts 33, 33' are moved toward and away from each other, a large load is applied to the sliding surfaces, and there is a possibility that the operation will not be performed smoothly. As a structure for smoothly moving the sliding surface in order to prevent such a problem, there is a structure using a bearing. However, in a structure using a bearing, there is a possibility that a malfunction or a failure may occur due to thermal expansion or the like because the structure is affected by the heat of the supplied molten metal. In view of this, the casting device 30 is provided with sliding portions 41, 42, 43, and 44 made of a smooth plate on the sliding surface.
[0027]
The slide portion 41 shown in FIG. 4A is provided for smoothly moving the cavity insert 32 and the runner insert 33. The slide portion 41 has a plate 41 a attached to the cavity insert 32, a plate 41 b fixed to the main mold 31, and a plate 41 c attached to the runner insert 33. The slide movement of the cavity insert 32 and the runner insert 33 is guided by the plate 41b.
[0028]
The slide portion 42 shown in FIG. 4B has a plate 42 a attached to the main mold 31 and a plate 42 b attached to the cavity insert 32.
[0029]
The slide portion 43 shown in FIG. 4C has a plate 43b attached to the main mold 31 and a plate 43a attached to the cavity insert 32.
[0030]
Although not shown, the slide portion 44 of the vent 39 similarly has a plate that matches the slide width of the main mold 31 and a plate that is attached to the vent 39, and guides the slide movement of the vent 39. I do.
[0031]
Each plate is formed with a hole selectively communicating with each of the runners 35 and 36, the weir 45, the exhaust runners 46a and 46b, and the vent 39. With these holes, casting can be performed without interrupting the supply of the molten metal.
[0032]
Each plate is made of a material having a hardness of about HRC60, and is much harder than the cavity insert 32 having a hardness of about HRC45. Since each plate is made of a hard material, it is possible to prevent abrasion at a sliding portion and to reduce resistance and malfunction such as catching at the time of sliding. In order to prevent slippage due to dust entering between the plates, it is more preferable to provide a groove for accommodating dust in the plates.
[0033]
In addition, only the right half of the casting apparatus 30 is shown because it has been outlined along FIG. 3, but the left half has the same configuration.
[0034]
FIG. 5A is a perspective view showing a portion including a piercing portion 51 as a slip-out preventing means, FIG. 5B is a front view, and FIG. It is sectional drawing which follows the 5C-5C line | wire of the same figure (B) which shows the state couple | bonded with the members 13 and 14 integrally.
[0035]
When the joining surface of the work manufactured by the casting method is smooth, the resistance to pulling out of the joining portion decreases.
[0036]
Therefore, in the present embodiment, when the work 10 is taken as an example, the connecting members 11 and 12 have slip-off preventing means for preventing a part to be cast-in from slipping out of the side surface member. The detachment preventing means forms a concave portion and / or a convex portion at a portion of the connecting members 11 and 12 where the connection member is cast. More specifically, in the detachment prevention means, a plurality of piercing portions 51 as through holes are formed as concave portions in the joint portion. Hot water enters when the side surface members 13 and 14 are formed in the piercing portion 51, and a non-slip is formed in a direction orthogonal to the longitudinal direction of the connecting members 11 and 12. (See FIG. 5C). Although the piercing portion 51 is provided on the U-shaped connecting member, the piercing portion can be provided even if the connecting member has another shape, for example, a flat plate or a cylinder.
[0037]
By providing the vias 51, the connecting members 11, 12 and the side members 13, 14 are securely engaged. Further, since a larger fitting area can be obtained as compared with the case where the connecting surface is smooth, a greater resistance to pull-out can be obtained.
[0038]
Next, the operation of the casting device 30 will be described.
[0039]
In order to produce the work 10, the connecting members 11, 12 are cast in the cavity inserts 32, 32 'which are provided so as to be capable of relatively moving toward and away from each other by casting each of the plurality of side members 13, 14. Deploy. The plurality of cavity inserts 32, 32 'are relatively moved along the longitudinal direction of the arranged connecting members 11, 12 according to the length of the connecting members 11, 12.
[0040]
The connection members 11 and 12 have a pierce portion 51 formed in advance in a portion to be cast by the side members 13 and 14. When the cavity inserts 32 and 32 'are moved toward the center and the end faces 32a and 32'a are brought into contact with each other, the gap between the cavities 15 and 16 is set at a position where the connecting members 11 and 12 can be cast.
[0041]
At the same time, the runners 35, 36, 35 ', 36' are switched according to the relative movement of the plurality of cavity inserts 32, 32 '. To switch the runners 35, 36, 35 ', 36', the runner inserts 33, 33 'are moved away from each other, and the end faces 33b, 33'b are brought into contact with the surrounding faces 31a, 31b. A hydraulic cylinder (not shown) is used to move the cavity inserts 32, 32 'and the runner inserts 33, 33'. After the movement, a force is applied by a hydraulic cylinder to prevent the cavity inserts 32, 32 'and the runner inserts 33, 33' from being displaced by the pressure of the molten metal. By these movements, the basin 37, the gates 38, 38 ', the runners 35, 35', and the cavities 15, 16 communicate with each other (see FIGS. 2A and 3A). The molten metal can be supplied to each of the plurality of cavity inserts 32, 32 ', and the cavities 15, 16 are filled with the molten metal to form the side members 13, 14. After the hot water in the cavities 15 and 16 has solidified, the work 10 is removed from the mold. After performing post-processing such as deburring, the work 10 is completed.
[0042]
When manufacturing the work 20, the connecting members 21 and 22 on which the piercing portions 51 are formed are prepared. The cavity inserts 32, 32 'are moved away from each other to bring the end faces 32b, 32'b into contact with the surrounding faces 31a, 31b. The runner inserts 33 and 33 'are moved toward the center to bring the end faces 33a and 33'a into contact.
[0043]
By these movements, the basin 37, the gates 38, 38 ', the runners 36, 36', and the cavities 15, 16 are communicated (see FIGS. 2B and 3B). The molten metal can be supplied to each of the plurality of cavity inserts 32, 32 ', and the cavities 15, 16 are filled with the molten metal to form the side members 13, 14. After the hot water in the cavities 15 and 16 has hardened, the work 20 is removed from the mold. After performing post-processing such as deburring, the work 20 is completed.
[0044]
On the other hand, in a casting apparatus 40 for producing a comparative work 10 shown in FIG. 2C, cavities 15 and 16 are fixed, and connecting members 21 and 22 are used instead of connecting members 11 and 12. The work 20 cannot be manufactured.
[0045]
In a case where a plurality of members are integrally joined by producing a work by a casting method using the casting apparatus 30 shown in the present embodiment, the cast portion has the same shape, and the shape of the portion to be cast-in Even if only the length differs, a plurality of types of workpieces can be produced without increasing the number of molds. That is, it is possible to cope with a plurality of works without preparing a plurality of casting devices. In addition, since the connecting member is installed in the cavity and cast, the molding and joining can be performed simultaneously, and the steps can be omitted. Since a welding process is not required, costs required for the welding process and the welding equipment can be reduced.
[0046]
The casting apparatus shown in the present embodiment can switch the runner according to the relative movement of the plurality of cavity inserts and supply the molten metal to each of the plurality of cavity inserts, so that the casting of the workpiece can be reliably performed. It can be carried out.
[0047]
The connecting member according to the present embodiment has a slip-off preventing means for preventing a cast-in portion from slipping out of the side member. The disengagement prevention means forms a pierced portion at the portion of the connecting member that is to be cast-in, so that the connection between the connecting member and the side member can be ensured.
[0048]
(Modification of First Embodiment)
In the first embodiment, a die casting mold is used, but a cavity insert made of a sand mold, a wooden mold, or the like may be slid. A more versatile casting device can be provided.
[0049]
Although the work was made for the suspension member, which is a large undercarriage part, various parts such as door inners and side members, which often use common parts, can also be used. In addition, if the cast portions have the same shape on both the left and right sides, a work other than those described above can be manufactured by moving one cavity insert.
[0050]
In the first embodiment, the cavity inserts 32, 32 'are moved relative to each other. In a modification, one cavity insert and the runner insert are fixed, and the other cavity insert and the runner insert are moved toward and away from each other. With such a structure, the fixed-side cavity insert and the runner insert can be integrated. Further, only one set of hydraulic cylinders and the like used for moving the cavity insert and the runner insert is required, and the management of the equipment can be facilitated.
[0051]
FIG. 6A is a perspective view showing a portion including a groove 52 as a slip-off preventing means, FIG. 6B is a front view, and FIG. It is sectional drawing which follows the 6C-6C line of the same figure (B) which shows the state couple | bonded. FIG. 7A is a perspective view showing a part including a collar part 53 as a slip-off preventing means, FIG. 7B is a front view, and FIG. FIG. 7B is a cross-sectional view taken along the line 7C-7C in FIG.
[0052]
The piercing portion 51 is not limited to the piercing portion 51 as long as the piercing portion 51 can be engaged against the pulling force. For example, a groove 52 shown in FIG. 6 or a collar 53 shown in FIG. 7 may be provided. Further, two or more of the slip-off preventing means 51, 52, 53 may be provided in combination.
[0053]
Even if the piercing portion 51 is not suitable, it is possible to select a slip-off preventing means according to the shape of the connecting member. In addition, by providing a plurality of detachment preventing means in combination, the engagement between the connecting member and the side member can be further ensured.
[0054]
(Second embodiment)
FIG. 8 is a diagram illustrating a work 80 manufactured using the slip prevention unit according to the second embodiment. FIG. 9 is a diagram illustrating an outline of a process of manufacturing the slip prevention means of the second embodiment.
[0055]
In the second embodiment, the connecting members 81 and 82 are installed across the cavity 88 as anti-slip means, and the caulking portions 81a and 82a are formed at portions that are in contact with the outer edge of the cavity 88.
[0056]
The process of manufacturing the caulking portions 81a and 82a will be outlined with reference to FIG.
[0057]
The movable core 85 is moved to abut against the ends of the connecting members 81 and 82 installed across the cavity 88 to ensure the fixing of the connecting members 81 and 82 (see FIG. 9A). The molten metal is poured into the cavity 88 and solidified to produce the side members 83 and 84. The cavity insert 89 is opened corresponding to the amount of deformation of the caulking portions of the connecting members 81 and 82 (see FIG. 9B). The movable core 85 moves toward the side members 83 and 84, deforms the connecting members 81 and 82, and forms the swaging portions 81a and 82a (see FIG. 9C). The advance limit of the movable core 85 is limited by the side members 83 and 84. The movable core 85 is removed from the ends of the connecting members 81 and 82, and the cavity 88 is also removed (see FIG. 9D).
[0058]
By forming the caulked portion, the joining between the connecting member and the side surface member can be reliably performed without forming a piercing or the like on the connecting member in advance.
[0059]
(Modification of Second Embodiment)
The caulking portion and the piercing portion shown in the first embodiment can be used in combination. Also, the inner portions 81b and 82b of the side members may be caulked. The caulking of the inner portions 81b and 82b is preferably performed while applying a jig because the deformation does not affect other portions of the connecting members 81 and 82. The joint between the connecting member and the side member can be more reliably performed by using the slip-off preventing means shown in the first embodiment together. In addition, by caulking the inner portion, the joining between the connecting member and the side surface member can be reliably performed without forming a disconnection preventing means in the connecting member in advance.
[0060]
(Third embodiment)
FIG. 10 is a diagram illustrating a work 90 according to the third embodiment.
[0061]
In the first and second embodiments, the work having two side members has been described. By using the casting method of the present invention, as shown in FIG. 10, a work 90 having an intermediate member 96 in addition to the two side members 94 and 95 can be manufactured. A large number of parts can be connected, and it is possible to cope with more complicated work.
[0062]
Further, the connecting member does not have to be installed across all of the side members 94 and 95 and the intermediate member 96 like the connecting member 91, and may be arranged as shown in the connecting members 92 and 93. By using different materials for the connecting members 92 and 93, the design can be made flexible.
[Brief description of the drawings]
FIGS. 1A and 1B are views showing works having different sizes of connecting members.
FIGS. 2A and 2B are cross-sectional views showing a main part of a casting apparatus for producing the work of the present embodiment, and FIG. 2C is a main part of a comparative casting apparatus. FIG.
FIGS. 3A and 3B are cross-sectional views showing a right half of the casting apparatus according to the present embodiment.
FIGS. 4A, 4B, and 4C are cross-sectional views in which a slide portion of the casting apparatus is enlarged.
5 (A) is a perspective view showing a portion including a piercing portion 51 as a slip-off preventing means, FIG. 5 (B) is a front view, and FIG. 5 (C) is a piercing portion. It is sectional drawing which follows the 5C-5C line | wire of the same figure (B) which shows the state which the part 51 was integrally couple | bonded with the side surface members 13 and 14. FIG.
6 (A) is a perspective view showing a part including a groove as a slip-off preventing means, FIG. 6 (B) is a front view, and FIG. 6 (C) is a view showing a casting part; It is sectional drawing which follows the 6C-6C line | wire of the same figure (B) which shows the state couple | bonded integrally.
7 (A) is a perspective view showing a portion including a collar portion as a slip-off preventing means, FIG. 7 (B) is a front view, and FIG. It is sectional drawing which follows the 7C-7C line | wire of the same figure (B) which shows the state couple | bonded integrally.
FIG. 8 is a diagram showing a work according to a second embodiment.
FIGS. 9A to 9D are views showing a process of manufacturing a dropout prevention unit according to the second embodiment.
FIG. 10 is a diagram showing a work according to a third embodiment.
[Explanation of symbols]
10, 20, 80, 90 ... Work 11, 12, 21, 22, 81, 82, 91, 92, 93 ... Connecting members 13, 14, 83, 84, 94, 95 ... Side members (cast parts)
15, 16, 88: cavity 32, 32 ': cavity insert (mold)
35, 36, 35 ', 36' ... runner 51 ... piercing part (meaning prevention means)
52 ... Groove part (means for preventing detachment)
53 ... Neck part
81a, 82a ... crimping portion (meaning prevention means)
96 ... Intermediate member (casting part)

Claims (7)

A connecting member formed in advance and a plurality of casting parts to be cast are provided, and a part of the connecting member is integrally cast into the plurality of casting parts, and the plurality of casting parts form the connecting member. A method for casting a workpiece connected via
A step of arranging the connecting member in a plurality of molds provided to be relatively close to and movable while casting each of the plurality of casting parts,
Moving the plurality of molds relative to each other along the longitudinal direction of the arranged connecting member according to the length of the connecting member. 2. The method according to claim 1, wherein a molten metal is supplied to each of the plurality of molds by switching a runner according to a relative movement of the plurality of molds. The connecting member,
2. The method according to claim 1, further comprising means for preventing a part to be cast-in from coming off from the casting. The detachment prevention means,
The method according to claim 3, wherein a concave portion and / or a convex portion is formed at a portion of the connection member that is to be cast. The detachment prevention means,
The method according to claim 3, wherein the connecting member is installed across the cavity, and a portion in contact with an outer edge of the cavity is caulked. A workpiece manufactured by the method for casting a workpiece according to claim 1. The work according to claim 6, which is a suspension member, a door inner, or a side member.

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