FZYJ-12翻台式震压造型机设计【含8张CAD图纸】
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第14页 英文资料翻译9.1英文部分:Plaster casting process for prototyping of die casting based on rapid tooling1. IntroductionIn todays highly competitive marketplace, it is of vital importance for the manufacturing industry to reduce both lead-time and costs for the product development. Accelerating the product development that generally consists of the design process and the tooling development has always been a great challenge for manufacturers. In the design stage, the rapid and economical production of both physical models for the design verification and functional prototypes of the product for a variety of testing is the key to time and cost savings. In the tooling stage, the selection of the tooling method, which enables the production of molds or dies best suitable for the desired time-to-market and the amount of the product, completes the rapid product development. Since it first emerged in 1986 as a new time-reduction method, rapid prototyping (RP) has helped to address the challenges successfully 1,2. Unlike conventional manufacturing processes, RP can readily create physical models of products, regardless of their geometrical complexity, in a layer-by-layer additive fashion. In the early years of development, RP technology was primarily applied to the visualization and design verification of products. Recently, however, significant advances in materials and equipments enable most RP processes to produce physical models that are precise and strong enough to serve as master patterns for a variety of tooling applications 3-5. These RP technologies have an effect on rapid tooling (RT). Many kinds of RT processes have been used for diverse applications including prototyping of die casting products. Conventional prototyping of die casting requires costly steel tools and considerable time to make the steel tools. Even though die casters understood the need for prototyping of die casting, the time and cost for making and repairing steel tools prevented them from prototyping die castings. After the development of a rapid prototyping process that can optimize designs and incorporate changes of a part in the prototyping stage, die casters have realized that prototyping of die casting can be competitive 6, 7. The combination of rapid prototyping and plaster casting has provided a useful means of making prototypes of die casting. Plaster casting can produce metallic castings, such as aluminum, zinc, and magnesium castings, with dimensional accuracy and good surface quality. Unlike in standard die casting, however, in plaster casting molten metal is poured into a plaster mold without additional pressure except gravity and the mold cools much slower than a die-cast mold. In this way, plaster castings have much larger and coarser grain structure than standard die castings. In addition, the gravity pour of plaster casting can cause incomplete filling of thin walls of the mold cavity. Due to poorer mechanical properties of plaster castings, which mainly stem from their large grain structure, and incomplete filling of the thin walls, plaster castings are not suitable enough for the prototyping of die casting 8, 9.The application of vibrations to solidifying metals and alloys has been found to be beneficial in a number of ways. The most notable effect of vibration is the suppression of columnar and dendritic growth and the formation of fine equiaxed grains and consequently a marked improvement in density and mechanical properties. Freedman and Wallace 10 reported the effects of vibration in solidification of various AI alloys and proposed the mechanism of grain refinement on the application of vibration. In this mechanism, the stable or critical nucleus size is decreased by pressure wave induced vibration. Garlick and Wallace 11 conducted an experiment of solidification with nonferrous pure metals and alloys under controlled vibration and obtained refined grain structure to some extent. A1-4.5 was allowed to solidify under the influence of low-frequency vibration energy (50 cycle/s) by Sankaran and Sreenivasa 12. The results showed that the vibrational energy effected a decrease in solidification time, reduction in grain size, and substantial improvement in feeding efficiency, density, and mechanical properties. Ivanic et al. 13 estimated the influence of themophysical features, vibration parameters and moldshape on the resultant grain size in A1-4.5% Cu alloy.The purpose of this study is to propose a new plaster die casting process to improve prototyping of steel die casting, and to develop a plaster die casting machine implementing the process proposed. The rapid prototyping process laminated object manufacturing (LOM) is employed to make the patterns to prepare silicone molds. Even though silicone molding is generally used for producing wax patterns, in this process, it is applied to produce plaster molds repeatedly. In addition, the process combines pressurizing and vibrating the molten metal simultaneously to fill the mold completely and to facilitate the creation of nuclei in the molten metal, respectively. Preliminary experiments examined the effects of pressurization and vibration on the quality of castings 14. Based on the data obtained from the experiments, a plaster die casting machine employing pressurization and vibration has been developed which has a structure similar to that of a die casting machine. The machine utilizes an oil cylinder for pressurization and a magnetic actuator for vibration.2. Problems in conventional simulated die casting Simulated die castings using RP provide a reliable and accurate substitute for prototyping purposes, but there are some differences between the die casting and plaster casting process. Generally, plaster castings have inferior mechanical properties with a range of 70 to 80% of the die castings. Table 1 shows the comparison of mechanical properties between plaster castings anddie castings 8. In die casting, molten metal is forced into a steel mold by high pressure and velocity, and is held under the pressure during solidification so that the molten metal fills the mold completely and rapidly. On the contrary, plaster casting produces castings with low pressure and a longer filling time. Therefore, at pouring, the plaster mold should be kept at a relatively high temperature in order to reduce heat loss and maintain fluidity of the molten metal. Due to their very low heat conductivity of under 0.5 W/InK, plaster molds prevent outward heat transfer from the castings. This slows down the cooling rate of the castings. A slow cooling rate typically yields a large grain structure during solidification of metals. Obviously, plaster castings have larger grainstructures than those of die castings. The cooling rate also affects the surface roughness of the castings. Due to the rapid cooling rate, die castings have a finer surface roughness than plaster castings. In comparison of porosity between die castings and plaster castings, die castings usually have less porosity near the surface due to faster cooling of the part during the solidification. Because most die-cast parts have fine sections and details, the prototyping of die casting using plaster casting can result in incompletely filled prototypes of castings.3 Piaster die casting combined with pressurization and vibration Previous work has shown that the application of vibration to solidifying metals in molds is beneficial to their mechanical properties in many ways. The applied vibration prevents the growthof columnar and dendritic grains and facilitates the formation of fine equiaxed grains during solidification. As a result, the diameter of the critical stable nucleus size of the solidifying castingsdecreases and consequently the castings have improved mechanical properties.In the preliminary experiments, an end clutch cover, a typical die-cast part, has been cast in pure aluminum by using the plaster die casting adopting pressurization and vibration 14. A test apparatus was made to perform the plaster die casting process. In order to examine the effect of pressurization and vibration on the quality of castings, preliminary experiments were carried out fortwo end clutch covers: one by conventional plaster casting and the other by the developed plaster die casting. From the preliminary experiments it was found that the applied vibration during the solidification of castings facilitated the creation of nuclei in the castings and resulted in a finer grain structure and that the pressurization increased the filling rate of in the cavities.Based on the results of the preliminary experiments, a new plaster die casting machine was developed. Pressurization and vibration are applied to the molten metal in the machine, whichhas a structure quite similar to that of a die casting machine.4. Results and discussionIn this section, mechanical properties and microstructures of the prototypes, end clutch covers, which were obtained in the preliminary experiments and by the developed plaster-casting machine, are compared. An end clutch cover is normally manufactured by high-pressure die casting. It has a thickness of 2 mm at the thin section and 5 mm or more in total. Table 2 shows the experimental conditions used in both cases. As shown, the injection speed of the developed plaster die casting machine is ten times faster than that in the preliminary experiments. In the developed casting machine, frequency of vibration is varied from 0 to 60 Hz at the same amplitude of 0.3 mm. The injection speed is controlled by the plunger that forces the molten commercially pure aluminum with a temperature of 750into the mold, Due to the increased injection speed, the temperature of the mold surface can be lowered from 250 to 200 .Fig. 5. Locations for acquiring specimens to examine surface roughness: 1-3 and grain size: A-CTo measure the surface roughness of the prototypes, four specimens were taken from each prototype. The locations where the specimens were picked are shown in Fig. 5. The surface roughness is the average value calculated from the number of repeated measurements on the same specimens. As shown in Table 3, the prototype made by the developed process has a much more improved surface roughness than the prototype from the preliminary experiments. The lower temperature of the mold surface and shorter injection time resulted in the notable improvement insurface roughness. Due to the lower mold temperature, molten metal is solidified rapidly from the surface facing the mold cavity. The smaller amount of air trapped in the casting, especially on the surface, is due to the filling of the molten metal from bottom to top, which contributes to improved surface roughness. The change of frequency did not affect the surface roughness as much as the mold temperature.Table 2. Comparison of experimental conditionsTable 3. Comparison of surface roughnessTable 4. Comparison of grain sizeFig. 6. Variation of grain size with the frequency of vibration Table 4 shows the average size of grain diameter measured from each prototype produced in 15 Hz vibration frequencies. Figure 5 shows the locations where three specimens were taken for measuring grain size. The lower mold temperature as well as the vibration from the plunger during solidification, which activated the creation of a nucleus of the casting, causes the remarkable decrease in the grain size of the prototype made by the developed process. Figure 6 shows the number of grains per unit area with variations in the frequency of induced vibration in the developed process. Vibration with high frequency was conducive to the production of fine-grained castings. The average size of grain varies with the position of the part. Due to slow solidification,specimen sampled at point A with a relatively large volume in the part, had a big grain growth. The grain size of the specimen from point A, which was far from the gate, was finer than that of point C. Since point C was close to the heat source, it gained more heat flux during the solidification. Specimen from point B, which was the farthest away from the heat source and had a small volume, had the finest grain structure. Microstructures were refined in the overall part by means of vibration. Figure 7 shows the representative microstructures of the prototypes produced by each process. Mold temperature, solidification time and vibration frequency affected the grain size of the part in varying degrees.(a) (b) (c)Fig. 7a-c. Microstructures of prototypes made by a conventional plaster casting, b preliminary experiment, and c developed casting process (15 Hz)5. ConclusionsA new plaster die casting process employing pressurization and vibration has been proposed for the improvement of the prototyping of die casting. Mold patterns produced by RP were used as patterns of the room temperature vulcanizing (RTV) process. Silicon molds from the RTV were applied to produce plaster molds for the prototyping of die casting repeatedly. Based on the results obtained from preliminary experiments that had been performed to examine the effects of pressurization and vibration on the properties of a prototype of an end clutch cover, a plaster die casting machine was designed and manufactured to have a structure similar to that of a die casting machine. The developed plaster die casting machine generated a prototype of an end clutch cover that has a much finer surface roughness and microstructure than those of other prototypes manufactured by conventional plaster casting and shown in the preliminary experiments. The improvements in surface roughness and microstructure of the prototype are attributed to the vibration that facilitates the creation of nuclei during solidification, and also to the pressurizationthat lowers the temperature of the mold surface and shortens the injection time. Due to the similar flow system of molten metal like die casting, physical simulation of the process can be conducted. As stated above, using the developed plaster die casting process and machine, prototypes of die castings can be produced more effectively. 9.2中文译文石膏模铸造工艺铸造原型的基础上快速制模1. 简介在当今竞争激烈的市场上，无论是减少铅的时间和产品开发成本，为制造业的极端重要性。加快产品的开发，一般包括设计过程和模具开发一直是制造商极大的挑战。在设计阶段，为设计验证和测试的各种产品的功能原型的物理模型既快速，经济的生产是节省时间和成本的关键。在模具阶段，工装方法的选择，使模具的生产或死亡的最佳所需的时间到市场和产品的数量适当，完成了产品的快速发展。 自1986年首次成为一个新的时间还原法，快速原型（RP）的帮助，以解决面临的挑战成功1,2。不同于传统的制造工艺，RP可以随时创建物理模型，无论其几何复杂性的产品，在一个层按加层的时尚。在发展初期，快速成型技术，主要应用于产品的可视化和设计验证。然而，最近在材料和设备的最显着的进步使RP的工艺，生产的精确度和强大到足以任期为各种应用工具作为主模式3-5物理模型。这些都对RP技术的快速模具（RT）的影响。反转录过程，许多种已经用于包括压铸产品原型设计的各种应用。压铸成型，需要昂贵的常规钢刀具和相当长的时间，使钢的工具。即使死脚轮理解为压铸，成型的时间和成本制造和修理工具钢压铸成型阻止他们的需要。经过了快速原型过程和优化设计，可以纳入在原型阶段的一部分的发展变化，认识到模具脚轮压铸成型，可竞争6，7。 快速原型和石膏铸件的结合提供了原型制作压铸的有效手段。可生产石膏铸件，如铝，锌，镁铸件的金属铸件，具有尺寸精度和表面质量好。不同于标准压铸熔化的金属铸造石膏，但是，倒入石膏模，除了没有额外的压力和重力模具冷却比一压铸模具慢。这样，石膏铸件有更大的和较粗的比标准压铸件晶粒结构。此外，重力铸造石膏倒会导致不完整的模具腔薄壁填充。由于贫穷石膏铸件机械性能，主要从大的晶粒结构茎，薄薄的墙壁，不完全填充，石膏铸件不适合压铸成型8，9不够。凝固型的金属和合金的振动应用已经发现在许多方面是有益的。振动的最显着的效应是抑制柱状和树突状增长和罚款等轴晶的形成，因此，在密度和机械性能显着改善。弗里德曼和华莱士10报道的各种人工智能合金凝固振动的影响，并提出了晶粒细化对振中的应用机制。在这种机制下，临界核尺寸稳定或降低压力波引起的振动。加利克和Wallace11振动控制下进行的与有色纯金属和合金凝固实验，并取得细化晶粒结构有一定影响。格A1- 4.5被允许固化在低频率振动能量（50次/ s）的Sankaran和斯里尼瓦萨12的影响。结果表明，在振动能量影响摄食效率，密度和机械性能，在凝固时间，晶粒尺寸减少，大大改善减少。伊万尼奇等。 13估计themophysical功能，振动参数和模具的影响形状对在A1- 4.5Cu合金产生的晶粒尺寸。本研究的目的是要提出一个新的石膏模铸造工艺提高钢的压铸成型，并制定压铸机实施过程中提出的膏药。快速原型制造过程分层实体制造（LOM）是用来做准备的模式硅胶模具。即使是一般硅胶成型生产模式在这个过程中蜡，使用，它是适用于生产石膏模具反复。此外，结合加压过程和振动熔化的金属模具，同时填补了完全以促进熔融金属的原子核的创作，分别为。初步的实验研究对铸件质量的加压振动的影响14。从实验获得的数据的基础上，采用石膏压铸机和振动加压已经开发了具有结构相似的压铸机。本机采用一种加压和电磁执行器的振动油缸。 2. 在传统的模拟问题压铸 模拟压铸件采用RP原型的目的提供了可靠和准确的替代品，但之间有压铸和铸造工艺石膏一些分歧。一般来说，石膏铸件有70至80之间压铸件力学性能较差。表1显示了石膏铸件机械性能之间的比较压铸件8。在压铸，熔融金属是被迫进入一个高压力和速度钢模具，并在压力下凝固期间举行，使熔化的金属填充模具，全面而迅速。相反，石膏生产低压铸造和铸件充填时间较长。因此，在浇注，石膏模具应保持在相对较高的温度，以减少热损失和保持对熔融金属的流动性。由于其非常低的在0.5瓦/油墨，防止石膏模铸件向外传热导热。这会减慢的铸件冷却速度。一个典型的冷却速度缓慢金属凝固过程中产生大的晶粒结构。显然，有更大的粮食石膏铸件结构比压铸件的。冷却率也影响了铸件表面粗糙度。由于快速的冷却速度，压铸件，比石膏铸件有更好的表面粗糙度。在压铸件之间的孔隙度比较和石膏铸件，压铸件通常较少附近的表面由于更快的部分冷却凝固过程中孔隙率。由于大多数压铸件具有优良的章节和细节，用石膏模具铸造原型可以导致铸件不完全充满原型。3.石膏压铸结合加压和振动 以往的工作表明，振动凝固的金属模具的应用，有利于在许多方面的力学性能。外加振动防止增长树突状的柱状晶粒，并促进细等轴晶凝固过程中形成。作为一个结果，关键铸件的凝固稳定核的大小直径降低，因而改善了铸件的机械性能。在初步实验中，用结束离合器罩，一个典型的压铸零件，铸就了纯铝压铸用石膏采用加压振动14。作了一个测试仪器进行压铸过程的膏药。为了探讨对铸件质量的加压及震动的影响，初步进行了实验，二月底离合器内容包括：传统石膏铸造之
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