阅读说明：本技术 一种摩托车减震器铝筒的制造工艺 (Manufacturing process of motorcycle shock absorber aluminum cylinder ) 是由 丁其建 于 2019-09-18 设计创作，主要内容包括：本发明公开了一种摩托车减震器铝筒的制造工艺,包括依次顺序以下步骤：铝熔化铝水、将铝水置入保温炉封闭、将铝水注入到模具的型腔中、型芯合模、高压凝固、保压凝固成型、抽芯脱模、冷却取件、检查外观和检测内部质量和成品入库。本发明能够保证减震器铝筒在成型后的密实度和精度,防止生产出来的铝筒中会产生一些气泡,使用寿命延长；改变了传统的低压浇铸工艺,采用了高压循序递增的方式,使铝水循序凝固成型,防止采用低压浇铸的漏油、漏气和形变情况,提高了致密度,从而提高了产品表面质量和机械性能,产品品质得以显著提升,提高了制造效率,产量高,孔位一体成型,无需另外后加工,节约了成本,质量得以减轻,节约了能源消耗,节能环保。(The invention discloses a manufacturing process of an aluminum cylinder of a motorcycle shock absorber, which comprises the following steps in sequence: melting aluminum liquid by aluminum, placing the aluminum liquid into a heat preservation furnace for sealing, injecting the aluminum liquid into a cavity of a mold, closing the mold core, solidifying under high pressure, maintaining pressure for solidification and molding, pulling and demolding the core, cooling and taking a piece, checking the appearance, detecting the internal quality and warehousing a finished product. The invention can ensure the compactness and precision of the aluminum cylinder of the shock absorber after molding, prevent the produced aluminum cylinder from generating some bubbles and prolong the service life; the traditional low-pressure casting process is changed, the mode that high pressure is increased in sequence is adopted, aluminum water is sequentially solidified and formed, the conditions of oil leakage, air leakage and deformation of low-pressure casting are prevented, the density is improved, the surface quality and the mechanical performance of a product are improved, the quality of the product is remarkably improved, the manufacturing efficiency is improved, the yield is high, hole site integrated forming is realized, additional post-processing is not needed, the cost is saved, the quality is lightened, the energy consumption is saved, and the aluminum water-cooling casting process is energy-saving and environment-friendly.)

1. A manufacturing process of an aluminum cylinder of a motorcycle shock absorber is characterized by comprising the following steps: the method comprises the following steps:

(1) melting aluminum water by aluminum; heating and melting a pure aluminum block into pure aluminum water by using a central melting furnace;

(2) putting the molten aluminum into a heat preservation furnace for sealing: adopting a heat preservation furnace to preserve heat and seal the melted pure aluminum water, wherein the heat preservation furnace is provided with an automatic heat preservation system;

(3) injecting molten aluminum into a cavity of the mold: the method comprises the steps of designing and manufacturing a mould and preheating the mould, wherein the mould for the shock absorber aluminium tube is correspondingly manufactured according to the aluminium tube with the required specification and model, the shock absorber aluminium tube is arranged in a pair, so that the mould can be designed to be capable of producing 2 aluminium tubes simultaneously, the preheating temperature of the mould is 320-350 ℃, and the aluminium water is injected into the cavity of the mould by an inclined gravity casting machine;

(4) mold core closing: controlling the die core to be matched through a hydraulic cylinder;

(5) high-pressure solidification: applying high-pressure gas to the surface of the molten aluminum by a high-pressure gas pump at the moment of die assembly of the die, sequentially applying high pressures of 1-3S/0.5MPa, 3-4S/1MPa, 4-5S/2MPa and 5-10S/3MPa at the time of die assembly start, and sequentially solidifying the molten aluminum according to the sequential solidification principle;

(6) pressure maintaining solidification forming: maintaining the pressure for 200 s and 240s under the high pressure of 3MPa, so that the casting is fully pressurized, solidified and formed;

(7) core pulling and demolding: a core-pulling demoulding mechanism is arranged on the shock absorber aluminum cylinder mould, and demoulding is carried out through the core-pulling demoulding mechanism;

(8) and (3) cooling and taking: a cooling system is arranged in the inclined gravity casting machine, the shock absorber aluminum cylinder mould is cooled by the cooling system in the inclined gravity casting machine, and the aluminum cylinder is taken out by the workpiece taking manipulator and is placed in a quenching bath for cooling;

(9) checking appearance and checking internal quality: inspecting the appearance of the aluminum cylinder, cleaning burrs, and sending the aluminum cylinder to a flaw detector to detect the internal quality;

(10) finished products are put in storage: and (5) warehousing after the whole set of combination is finished and the inspection is finished.

Preferably, the central melting furnace is a graphite crucible, the pure aluminum block is melted by heating, the melting temperature is heated to 800 ℃, the central melting furnace is made of graphite materials, the upper and lower temperature difference of the pure aluminum water can be prevented from being larger, the melted pure aluminum water is subjected to purification treatment and degassing treatment, the purity and the heat conductivity of the pure aluminum are ensured, and the defects of air holes and the like in the casting process of the product are prevented.

2. The manufacturing process of the motorcycle shock absorber aluminum cylinder according to claim 1, characterized in that: the pure aluminum block material is added with corresponding chemical elements (such as zinc, manganese, zirconium and the like).

3. The manufacturing process of the motorcycle shock absorber aluminum cylinder according to claim 1, characterized in that: and when the damper aluminum cylinder mold is used for core-pulling and demolding, the demolding agent is sprayed to the cavity of the mold.

4. The manufacturing process of the motorcycle shock absorber aluminum cylinder according to claim 1, characterized in that: when a product problem occurs in the steps of checking the appearance and checking the internal quality, the pressurizing and cooling process should be appropriately adjusted to enter the next cycle.

5. The aluminum tube for a shock absorber in the manufacturing process of the aluminum tube for a motorcycle shock absorber as claimed in claim 1, wherein: the maximum tolerance of the produced aluminum cylinder of the shock absorber is 0.2mm, all the tolerances can meet the requirements of drawings, the aluminum cylinder of the shock absorber comprises an integrally formed assembly hole, and the maximum tolerance of the diameter of the assembly hole is 0.02 mm.

Technical Field

The invention belongs to the technical field of motorcycle shock absorbers, and particularly relates to a manufacturing process of an aluminum cylinder of a motorcycle shock absorber.

Background

The shock absorber aluminum tube is one of the most important parts in common shock absorption parts of motorcycles, electric vehicles and the like, and the whole shock absorption effect is directly influenced by the quality of the shock absorber aluminum tube, so that the comfort and the safety of the whole vehicle in use are influenced.

The traditional shock absorber aluminum cylinder is produced by casting, raw materials are firstly smelted into liquid in the production process, then the aluminum cylinder with the required specification is formed by a low-pressure casting and punching mode, and then an assembly inner hole is machined by post-processing. However, the aluminum cylinder produced by the low-pressure casting and punching mode is easily limited by production equipment, oil leakage and air leakage can occur in the low-pressure casting process, instantaneous exhaust cannot be realized due to uneven temperature, and therefore some bubbles can be generated in the produced aluminum cylinder, and the service life of the aluminum cylinder is limited. In addition, the parts produced by the traditional mode are solid, the aluminum tube of the shock absorber is of a hollow structure, so the parts can be formed only by post-processing such as drilling, the compactness of the whole formed aluminum tube is poor, and the aluminum tube is easy to deform in the using process due to frequent post-processing treatment, the whole production process is slow, the yield is low, the labor force is large, the reject ratio is high, the material manufacturing cost is high, and therefore improvement is needed.

Disclosure of Invention

The invention aims to overcome the defects in the prior art and provides a manufacturing process of an aluminum cylinder of a motorcycle shock absorber, which has the characteristics of preventing oil leakage and air leakage, avoiding air bubbles, improving manufacturing efficiency, high yield, no need of additional post-processing, improving product compactness, preventing deformation and saving cost.

In order to achieve the purpose, the invention adopts the technical scheme that: a manufacturing process of an aluminum cylinder of a motorcycle shock absorber comprises the following steps:

(1) melting aluminum water by aluminum; heating and melting a pure aluminum block into pure aluminum water by using a central melting furnace;

(2) putting the molten aluminum into a heat preservation furnace for sealing: adopting a heat preservation furnace to preserve heat and seal the melted pure aluminum water, wherein the heat preservation furnace is provided with an automatic heat preservation system;

(3) injecting molten aluminum into a cavity of the mold: the method comprises the steps of designing and manufacturing a mould and preheating the mould, wherein the mould for the shock absorber aluminium tube is correspondingly manufactured according to the aluminium tube with the required specification and model, the shock absorber aluminium tube is arranged in a pair, so that the mould can be designed to be capable of producing 2 aluminium tubes simultaneously, the preheating temperature of the mould is 320-350 ℃, and the aluminium water is injected into the cavity of the mould by an inclined gravity casting machine;

(4) mold core closing: controlling the die core to be matched through a hydraulic cylinder;

(5) high-pressure solidification: applying high-pressure gas to the surface of the molten aluminum by a high-pressure gas pump at the moment of die assembly of the die, sequentially applying high pressures of 1-3S/0.5MPa, 3-4S/1MPa, 4-5S/2MPa and 5-10S/3MPa at the time of die assembly start, and sequentially solidifying the molten aluminum according to the sequential solidification principle;

(6) pressure maintaining solidification forming: maintaining the pressure for 200 s and 240s under the high pressure of 3MPa, so that the casting is fully pressurized, solidified and formed;

(7) core pulling and demolding: a core-pulling demoulding mechanism is arranged on the shock absorber aluminum cylinder mould, and demoulding is carried out through the core-pulling demoulding mechanism;

(8) and (3) cooling and taking: a cooling system is arranged in the inclined gravity casting machine, the shock absorber aluminum cylinder mould is cooled by the cooling system in the inclined gravity casting machine, and the aluminum cylinder is taken out by the workpiece taking manipulator and is placed in a quenching bath for cooling;

(9) checking appearance and checking internal quality: inspecting the appearance of the aluminum cylinder, cleaning burrs, and sending the aluminum cylinder to a flaw detector to detect the internal quality;

(10) finished products are put in storage: and (5) warehousing after the whole set of combination is finished and the inspection is finished.

Preferably, the central melting furnace is a graphite crucible, the pure aluminum block is melted by heating, the melting temperature is heated to 800 ℃, the central melting furnace is made of graphite materials, the upper and lower temperature difference of the pure aluminum water can be prevented from being larger, the melted pure aluminum water is subjected to purification treatment and degassing treatment, the purity and the heat conductivity of the pure aluminum are ensured, and the defects of air holes and the like in the casting process of the product are prevented.

Preferably, the pure aluminum block material is added with corresponding chemical elements (such as zinc, manganese, zirconium and the like).

Preferably, when the damper aluminum cylinder mold is subjected to core pulling and demolding, a demolding agent is sprayed to a cavity of the mold.

Preferably, when a product problem occurs at the step of checking the appearance and the inner quality, the pressurizing and cooling process should be appropriately adjusted to enter the next cycle.

Preferably, the maximum tolerance of the produced aluminum cylinder of the shock absorber is 0.2mm, all the tolerances can meet the requirements of drawings, the aluminum cylinder of the shock absorber comprises an integrally formed assembly hole, and the maximum tolerance of the diameter of the assembly hole is 0.02 mm.

After the process flow is adopted, compared with the prior art, the invention has the advantages that: the method has simple and reasonable steps, firstly, the holding furnace can ensure the constant temperature of the pure aluminum water, the inner part of the inclined gravity casting machine is in a constant temperature state and is matched with the machining die of the aluminum cylinder of the shock absorber for use, so that the aluminum cylinder of the shock absorber is in a constant temperature state in the forming process, the compactness and the precision of the aluminum cylinder of the shock absorber after forming can be ensured, certain bubbles can be prevented from being generated in the produced aluminum cylinder, and the service life is prolonged; the traditional low-pressure casting process is changed, the mode that high pressure increases progressively in proper order is adopted, the highest pressure reaches 3MPa, make the aluminium water solidify the shaping in proper order, prevent the oil leak that adopts the low pressure casting, gas leakage and the deformation condition, the density of product has been improved, thereby the surface quality and the mechanical properties of product have been improved, the quality of product can show and promote, manufacturing efficiency has been improved, high output, hole site integrated into one piece, need not in addition postprocessing, the cost is saved, under this prerequisite, product quality can alleviate, energy consumption has been practiced thrift, and is favorable to energy saving and environmental protection.

Drawings

FIG. 1 is a process flow diagram of the present invention.

Fig. 2 is a schematic structural view of a conventional aluminum tube for a shock absorber manufactured according to the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1-2, a process for manufacturing an aluminum tube of a motorcycle shock absorber is characterized in that: the method comprises the following steps:

(1) melting aluminum water by aluminum; heating and melting a pure aluminum block into pure aluminum water by using a central melting furnace;

(2) putting the molten aluminum into a heat preservation furnace for sealing: adopting a heat preservation furnace to preserve heat and seal the melted pure aluminum water, wherein the heat preservation furnace is provided with an automatic heat preservation system;

(3) injecting molten aluminum into a cavity of the mold: the method comprises the steps of designing and manufacturing a mould and preheating the mould, wherein the mould for the shock absorber aluminium tube is correspondingly manufactured according to the aluminium tube with the required specification and model, the shock absorber aluminium tube is arranged in a pair, so that the mould can be designed to be capable of producing 2 aluminium tubes simultaneously, the preheating temperature of the mould is 320-350 ℃, and the aluminium water is injected into the cavity of the mould by an inclined gravity casting machine;

(4) mold core closing: controlling the die core to be matched through a hydraulic cylinder;

(5) high-pressure solidification: applying high-pressure gas to the surface of the molten aluminum by a high-pressure gas pump at the moment of die assembly of the die, sequentially applying high pressures of 1-3S/0.5MPa, 3-4S/1MPa, 4-5S/2MPa and 5-10S/3MPa at the time of die assembly start, and sequentially solidifying the molten aluminum according to the sequential solidification principle;

(6) pressure maintaining solidification forming: maintaining the pressure for 200 s and 240s under the high pressure of 3MPa, so that the casting is fully pressurized, solidified and formed;

(7) core pulling and demolding: a core-pulling demoulding mechanism is arranged on the shock absorber aluminum cylinder mould, and demoulding is carried out through the core-pulling demoulding mechanism;

(8) and (3) cooling and taking: a cooling system is arranged in the inclined gravity casting machine, the shock absorber aluminum cylinder mould is cooled by the cooling system in the inclined gravity casting machine, and the aluminum cylinder is taken out by the workpiece taking manipulator and is placed in a quenching bath for cooling;

(9) checking appearance and checking internal quality: inspecting the appearance of the aluminum cylinder, cleaning burrs, and sending the aluminum cylinder to a flaw detector to detect the internal quality;

(10) finished products are put in storage: and (5) warehousing after the whole set of combination is finished and the inspection is finished.

In the embodiment, the steps are simple and reasonable, firstly, the constant temperature of pure aluminum water can be ensured by the heat preservation furnace, the inner part of the inclined gravity casting machine is in a constant temperature state and is matched with the shock absorber aluminum cylinder processing mold for use, so that the shock absorber aluminum cylinder is in a constant temperature state in the forming process, the compactness and the precision of the shock absorber aluminum cylinder after forming can be ensured, the quality is reliable, some bubbles can be prevented from being generated in the produced aluminum cylinder, and the service life is prolonged; the traditional low-pressure casting process is changed, the mode that high pressure increases progressively in proper order is adopted, the highest pressure reaches 3MPa, make the aluminium water solidify the shaping in proper order, prevent the oil leak that adopts the low pressure casting, gas leakage and the deformation condition, the density of product has been improved, thereby the surface quality and the mechanical properties of product have been improved, the quality of product can show and promote, manufacturing efficiency has been improved, high output, hole site integrated into one piece, need not in addition postprocessing, the cost is saved, under this prerequisite, product quality can alleviate, energy consumption has been practiced thrift, and is favorable to energy saving and environmental protection.

Specifically, the heat preservation temperature of the heat preservation furnace, namely the working temperature of the pure aluminum water is 750 ℃ to 800 ℃, and the melting point of the pure aluminum is about 660 ℃, so that the pure aluminum liquid cannot be crystallized and is kept in a liquid state. When the inclined gravity casting machine is used, the operation of the process of casting parts can be smoother due to the inclined type, the formed parts have higher degree of finish and good matching precision, and the service life of the parts is longer;

further, central melting furnace is graphite crucible, heats and smelts pure aluminium piece, and the temperature of smelting heats to 800 ℃, and central melting furnace uses the graphite material can prevent that pure aluminium water upper and lower difference in temperature is big to carry out purification treatment and degasification to the pure aluminium water after smelting, guarantee the purity and the heat conductivity of pure aluminium, prevent defects such as product gas pocket from appearing in the casting process.

In the embodiment, the melting point of the pure aluminum is about 660 ℃, and the pure aluminum can be well melted by heating the melting temperature to 800 ℃.

Furthermore, the pure aluminum block material is added with corresponding chemical elements (such as zinc, manganese, zirconium and the like).

In this embodiment, the pure aluminum bulk material is added with corresponding chemical elements (such as zinc, manganese, zirconium, etc.) to strengthen the structure, thereby improving the strength and fluidity thereof.

Further, when the damper aluminum cylinder mold is used for core-pulling and demolding, a demolding agent is sprayed to a cavity of the mold.

In the embodiment, the release agent is a special release agent for pure aluminum without silicon and moisture, can solve the problem that pure aluminum is easy to stick to a mold, also avoids the condition that the surface of a workpiece contains silicon, is convenient for subsequent anodic oxidation treatment, is a functional substance between a mold and a finished product, has chemical resistance, is not dissolved when being contacted with chemical components (particularly styrene and amines) of different resins, also has heat resistance and stress resistance, and is not easy to decompose or wear; the release agent adheres to the mold without transferring to the article being processed, and does not interfere with painting or secondary processing operations.

Further, when a product problem occurs at the step of checking the appearance and the inner quality, the pressurizing and cooling process should be appropriately adjusted to enter the next cycle.

In this embodiment, when the appearance is defective and the flaw detector detects a problem in the interior during the inspection, the pressurizing and cooling process should be adjusted appropriately, and the inspection is started again in the next cycle.

Further, the maximum tolerance of the produced aluminum cylinder of the shock absorber is 0.2mm, all the tolerances can meet the requirements of drawings, the aluminum cylinder of the shock absorber comprises an integrally formed assembly hole, and the maximum tolerance of the diameter of the assembly hole is 0.02 mm.

In this embodiment, the precision is higher, and the cooperation effect is better, and part life is longer, and is safe higher, has avoided the post-processing of traditional mode, and integrated into one piece can ensure that holistic intensity is higher, and the quality is better, and life is longer, still saves the part process time.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.