压铸产品基本工艺流程及影响铝合金压铸模寿命的因素
目录
绪论·····························································1 第一章 概述····················································2 1.1 压铸工艺概述···············································2 1.11压铸工艺原理···············································3 1.12压铸工艺的特点·············································5 1.13压铸工艺的应用范围·········································6 第二章 压铸合金···············································7 2.1 压铸合金···················································7 2.11对压铸合金的基本要求······································8 2.12各类压铸铝合金·············································9 第三章 压铸件的结构设计······································13 3.1功能结构设计···············································13 3.11压铸件的尺寸精度及加工余量································14 3.12压铸件的表面质量··········································15 第四章 压铸工艺··············································16 4.1 压力·····················································16 4.11压射压力··················································16 4.12 胀模力···················································18 4.2 速度·····················································19 4.21压射速度··················································19 4.22内浇口速度················································20
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4.23内浇口速度与压射速度和压力的关系··························21 4.3 温度·····················································22 4.31合金浇注温度··············································22 4.32内浇口速度对合金温度的影响································23 4.33压铸模的温度··············································24 4.4 时间·····················································24 4.41填充时间和增压建压时间····································24 4.42持压时间和留模时间········································25 4.5 压铸涂料·················································26 4.51压铸涂料的作用和压铸涂料的要求····························26 4.52压铸涂料的使用············································27 第五章 影响铝合金压铸模寿命的因素····························28 5.1模具结构设计的影响·········································28 5.2热处理工艺的影响···········································29 5.3模具制造的影响·············································30 5.4模具装配的影响·············································30 5.5模具的使用维护·············································31 结论··························································32 致谢辞························································33 参考文献······················································34
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绪论
压铸工艺是一种高效率的少、无切削金属的成型工艺，从19世纪初期用铅锡合金压铸印刷机的铅字至今已有150多年的历史。由于压铸工艺在现代工业中用于生产各种金属零件具有独特的技术特点和显著的经济效益，因此长期以来人们围绕压铸工艺、压铸模具及压铸机进行了广泛的研究，取得了可喜的成果。
中国压铸业不断追求技术进步，不断追求高品质生产。压铸总体水平与国外先进水平相比虽有差距，但从某些经常用来评价压铸技术水平的指标来看，这种差距正在缩小。
压铸是一个高度依赖技术经验的行业，中国压铸专业人员不足、整体技术素质偏低。无国界的市场，使我国压铸企业面临发展壮大的机会，同时也面临着日益激烈的竞争风险。人才是企业生存和发展的根本，企业要不断地学习运用先进的生产技术，必须培养高素质的技术和管理人才。只有这样，才能使中国压铸业取得更大进步。
目前，我国的铝合金压铸模具寿命与国外相比相差较大，延长模具寿命对于铝合金压铸行业的发展具有重要的意义。
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第一章 概述
1.1 压铸工艺概述
压铸工艺是把压铸合金、压铸模和压铸机这三个生产要素有机组合和运用的过程。现就压铸工艺的发展历史及有代表性的事件做简要的回顾。 1838年格·勃鲁斯首先用压铸法生产铅字。
1839年一种活塞式压铸机获得了第一个压力铸造专利。 1849年英国人斯都奇斯取得热压室压铸机专利。
1885年奥·默根瑟勒在前人的基础上发明了一种铅字压铸机。 1907年瓦格纳首先制成了气动活塞压铸机。
1920年英国开发了冷压室压铸机，使压铸机有可能生产铝合金和镁合金等压铸件。
1927年捷克人约瑟夫·波拉克设计了立式冷压室压铸机。
1952年前苏联制造出了第一台立式冷压室压铸机。我国在60年代也制造出了此种压铸机。
1958年真空压铸机在美国获得专利。
1966年美国人General Motors公司提出精、速、密压铸法。 1969年美国人爱列克斯提出充氧压铸的无气孔压铸法。
今后压铸生产的发展趋势是：压铸工艺要采用新技术，提高压铸件质量，扩大应用范围；压铸机要实现系列化、大型化及自动化；压铸模要提高使用寿命。总之，为压铸生产开辟更广阔的前景。
压铸工艺流程图示
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1，压铸机调试 2，压铸模安装 5，涂料配制 4，模具预热、涂料 6，模具清理 10浇注压射 7，合型（合模） 3，压铸模设计与制造 8，合金熔炼保温 9，嵌件准备 11，保压 12，开模、抽芯取件 13，表面质量检查 15，时效处理 14，清理（整修） 16，铸件浸渗、喷丸 处理 17，终检验
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