JPH0241758A - Method of molding metallic molding having recess - Google Patents

Abstract

PURPOSE:To prevent the collapse of a pipe material by the pouring pressure of a metallic molding material and the infiltration of the metallic molding material to the pipe material by using the pipe material which is formed of a material having the m.p. higher than the m.p. of the metallic molding material and has the rigidity to withstand the pouring pressure of the metallic molding material at the time of molding. CONSTITUTION:The pipe material A which is formed of the material having the m.p. higher than the m.p. of the metallic molding material and has the rigidity to withstand the pouring pressure of the metallic molding material at the time of the molding is spanned to adjacent core parts 3 forming the respective recesses W2 of the metal molding W of a forming mold in the state of closing both ends thereof. The metallic molding material is then poured under a high pressure into the forming mold to form the molding W and thereafter, the closed parts a1 at both ends of the pipe material are cut. As a result, the collapse of the pipe material A and the infiltration of the metallic molding material to the pipe material A are prevented. The molding W communicated surely with the adjacent recesses W2 by the pipe material A is efficiently obtd. in this way without being restricted by the shapes of the recesses.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for molding a metal molded product having a plurality of recesses, in which adjacent recesses communicate with each other.

(Prior Art) Conventionally, as a brake system for a vehicle, for example, there is a disc brake which is arranged in a plurality of rotor braking pistons or a caliper. It is formed correspondingly.

As this so-called multi-cylinder caliper, for example, as disclosed in Japanese Utility Model Application Publication No. 59-42328, a caliper body is provided with a hydraulic balance passage that allows adjacent cylinders to communicate with each other. It has been known. In order to obtain such a caliper in which adjacent cylinders are connected through a hydraulic balance passage, when a normal molding machine is used, the mold member for forming the hydraulic balance passage gets in the way and the caliper is molded. Since it is impossible to remove the caliper from the mold, it has been common practice to first cast the caliper without a hydraulic balance passage, and then drill the adjacent cylinders to make them communicate with each other.

(Problems to be Solved by the Invention) However, the above-mentioned conventional method requires a machining process called drilling in addition to the casting process, so there is a problem in that it takes time and effort to manufacture. Additionally, when adjacent recesses formed in a metal molded product such as a caliper are made to communicate with each other, if the inner diameter of each recess is small, the drilling operations described above are restricted, making it difficult to form a communicating hole. Sometimes it becomes.

Therefore, during molding, a pipe material made of a material whose melting point is higher than that of the metal molding material is passed between adjacent core parts forming each recess of the metal molded product of the mold. At the same time, it is conceivable to form communication holes in the molded product to eliminate the disadvantages such as a decrease in manufacturing efficiency and restrictions on the shape of the recesses due to the post-processing.

However, when this method is applied to a molding method in which metal molding material is injected into a mold at high pressure, depending on the material of the pipe material, the pipe material may be crushed by the injection pressure of the metal molding material, or the metal molding material may be crushed by the injection pressure of the metal molding material. Simply embedding the pipe material in a molded product cannot be put to practical use because there is a risk that the pipe material may enter the pipe material and cease to function as a communicating hole.

The present invention has been made in view of the above-mentioned problems, and as mentioned above, the purpose of the present invention is to create a metal molded product such as a caliper under high pressure by high pressure casting method etc. using a pipe material as a means for forming a communicating hole. When molding, by specifying the material of the pipe material mentioned above and taking appropriate measures to prevent the pipe material from collapsing due to the injection pressure of the metal molding material and from infiltration of the metal molding material into the pipe material, etc. To efficiently form a metal molded product in which adjacent recesses are surely communicated without being constrained by the shape of the recesses by performing simple measures after that.

(Means for Solving the Problems) In order to achieve the above object, the solving means of the present invention molds a metal molded product having a plurality of recesses, in which adjacent recesses communicate with each other. First, a pipe material that is made of a material whose melting point is higher than that of the metal forming material and has enough rigidity to withstand the injection pressure of the metal forming material during forming is formed with both ends closed. It spans over adjacent core portions forming each recess of the molded product of the mold. Next, a metal molding material is injected into the mold at high pressure to form a molded product, and then both end closed portions of the pipe material are cut off, thereby creating a molded product in which adjacent concave portions are communicated with each other through the pipe material. Try to get the following.

(Function) With the above configuration, in the method of the present invention, the pipe material is set in the mold with both ends closed, and after forming the metal molded product by high-pressure injection of the metal molding material, the pipe material is The occlusion is severed. In this case, the pipe material is made of a material whose melting point is higher than that of the metal forming material,
In addition, since it has the rigidity to withstand the injection pressure of the metal forming material during molding, it prevents the pipe material from collapsing due to the injection pressure of the metal forming material, and also prevents the metal forming material from penetrating into the pipe material. This is prevented by the above-mentioned both end closure parts. Then, by subsequently cutting the both end closed portions, a molded product in which adjacent recesses are reliably communicated can be efficiently molded without being restricted by the shape of the recesses.

(Example) Embodiments of the present invention will be described below based on the drawings.

FIG. 5 shows an A11 alloy multi-cylinder caliper W for disc brakes installed on vehicles, as a metal molded product obtained by the method of the present invention.

The caliper W has rotor braking cylinders W2 and W2 as two recesses in the caliper body w1, and both cylinders W2 and W2 communicate with each other using a hole in the pipe material as a communication hole w3, The communication hole w3 is used as a hydraulic pressure balance passage.

To explain the casting procedure for this caliper W, first, as shown in enlarged detail in FIG. A pipe material A made of, for example, iron and having a rigidity capable of withstanding the injection pressure of the metal forming material at the time of injection is prepared. By the way, the melting point of pure Aρ is about 660°C1 The melting point of iron is about 1540°C
It is °C.

The material of the pipe material A may be appropriately selected depending on the molding conditions of the metal molded product such as the caliper W.

Next, both ends of the pipe tJ'A are pressed and closed, and in this state, the pipe material A is inserted into the second
As shown in the figures and FIG. 3, it is provided in the core mold 1 of the molding mold so as to protrude into the cavity of a cavity mold (not shown), and is spanned over two core parts 2, 2 forming each cylinder W2 of the caliper W. . Specifically, both core portions 2,
As shown in enlarged detail in FIG. 1, support portions 3, 3 for supporting both ends of the pipe material A are formed in the opposing tip portions of the pipe material A, and on both sides of the base support portion 3, support portions 3, 3 are formed. , a pair of protrusions 4, 4 are integrally formed, and by fitting the both end closed parts allal of the pipe material A into the supporting parts 3, 3 respectively and sandwiching them between the protrusions 4.4, the pipe material A can be held at both ends. Support so that it does not fall off from the core parts 2, 2.

After that, after clamping the mold, Aρ
The caliper W is cast by injecting molten alloy under high pressure. At this stage, both cylinders W2 of the caliper W,
As shown in enlarged detail in FIG. 4, W2 has both end closed portions al+a1 of the pipe material A projected therefrom.

Thereafter, this caliper W is subjected to a predetermined rough machining to form both end closed portions aI+ protruding into each cylinder w2 of the pipe material A.
After cutting the Al at the same time as rough machining, by applying a prescribed heat treatment to homogenize the structure, both cylinders w2 and w2 are connected through pipe material A, as shown in enlarged detail in Fig. 5. The calculated caliper W is obtained.

As described above, in this embodiment, the pipe material A forming the communication hole w3 of the caliper W is made of a material such as iron with high rigidity, and both core parts 2 of the core mold 1 are closed with both ends thereof closed. ，
2, even if the molten Aρ alloy is injected into the mold at high pressure, the pipe material A can sufficiently withstand the injection pressure and will not collapse, and the pipe material A of the molten Aρ alloy will not collapse. Infiltration into A can be prevented by the both end closing portions al, al. Furthermore, in the above embodiment, the pipe material A
Since it is made of a material whose melting point is higher than that of the Aρ alloy, the pipe material A does not melt even when the heat of the molten A9 alloy acts on it. Therefore, after the caliper W is cast, both end closed portions al of the pipe material A,
By rough cutting the aluminum, both cylinders W
2. A caliper W in which W2 is reliably communicated with the pipe material A can be obtained efficiently and without being restricted by the shape of the recess.

In the above embodiment, both ends of the pipe material A were caulked using a press, but the present invention is not limited to this. For example, it is also possible to fill both ends of the pipe material A with filler and cover it with a lid. It is possible, and the means of blocking it does not matter.

Further, in the above embodiment, a case where the caliper W of a disc brake equipped on a vehicle etc. is cast is shown, but the application is not limited to this, and it is of course applicable to other cast products and metal molded products. It is. Also, the number of recesses is not limited to two, but three.
The number may be two or more, as long as adjacent recesses of the plurality of recesses communicate with each other.

(Effects of the Invention) As explained above, according to the method of the present invention, the material is made of a material whose melting point is higher than that of the metal forming material, and has a rigidity capable of withstanding the injection pressure of the metal forming material during molding. The pipe material is wrapped around adjacent core portions forming each concave portion of the metal molded product of the mold with both ends thereof closed, and then,
After the metal molding material is injected into the mold at high pressure to form a molded product, the closed ends of the pipe material are cut off, which prevents the pipe material from being crushed during molding and the metal molding material from penetrating into the pipe material. This makes it possible to efficiently obtain a molded product in which adjacent recesses are reliably communicated by the pipe material without being restricted by the shape of the recess.

[Brief explanation of the drawing]

The drawings show embodiments of the present invention, in which Fig. 1 is an enlarged front view of the main part showing a pipe material set in the core mold of a mold, Fig. 2 is a front view of the core mold, and Fig. 3 is an enlarged front view of the main part showing the pipe material set in the core mold of the mold. 4 and 5 are enlarged longitudinal sectional front views of the main parts of the caliper before and after forming the communicating holes, and FIG. 6 is an enlarged longitudinal sectional front view of the pipe with both ends closed. 2...Core part, A...Pipe material, al...Closing part, W...Caliper (molded product), W2...Cylinder (
recess). Patent applicant: Hiroshima Aluminum Industry (pipe forest)

Claims (1)

[Claims] (1) A method for molding a metal molded product having a plurality of recesses, in which adjacent recesses among the recesses communicate with each other,
A pipe material made of a material with a melting point higher than that of the metal forming material and having a rigidity capable of withstanding the injection pressure of the metal forming material during molding is placed in the mold with both ends closed. Spread over the adjacent core parts forming each recess,
Next, a metal molding material is injected into the mold at high pressure to form a molded product, and then both end closed portions of the pipe material are cut off, thereby creating a molded product in which adjacent concave portions are communicated with each other through the pipe material. A method for forming a metal molded product having a concave portion, the method comprising: obtaining a molded metal product having a concave portion;