CN105774790B - A kind of automobile vacuum booster stent and its manufacturing process - Google Patents
A kind of automobile vacuum booster stent and its manufacturing process Download PDFInfo
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- CN105774790B CN105774790B CN201610129921.7A CN201610129921A CN105774790B CN 105774790 B CN105774790 B CN 105774790B CN 201610129921 A CN201610129921 A CN 201610129921A CN 105774790 B CN105774790 B CN 105774790B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 239000004677 Nylon Substances 0.000 claims abstract description 32
- 229920001778 nylon Polymers 0.000 claims abstract description 32
- 239000003365 glass fiber Substances 0.000 claims abstract description 29
- 239000002131 composite material Substances 0.000 claims abstract description 21
- 238000001746 injection moulding Methods 0.000 claims abstract description 17
- 238000002347 injection Methods 0.000 claims description 25
- 239000007924 injection Substances 0.000 claims description 25
- 239000000155 melt Substances 0.000 claims description 11
- 238000001035 drying Methods 0.000 claims description 9
- 239000000654 additive Substances 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 5
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 4
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 claims description 4
- 229940057995 liquid paraffin Drugs 0.000 claims description 4
- 239000000314 lubricant Substances 0.000 claims description 4
- 230000008569 process Effects 0.000 claims description 4
- 239000008187 granular material Substances 0.000 claims 7
- 230000000996 additive effect Effects 0.000 claims 1
- 230000003750 conditioning effect Effects 0.000 claims 1
- 239000000498 cooling water Substances 0.000 claims 1
- 239000006082 mold release agent Substances 0.000 claims 1
- 230000003014 reinforcing effect Effects 0.000 claims 1
- 238000000465 moulding Methods 0.000 abstract description 4
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 abstract 3
- 239000008188 pellet Substances 0.000 description 19
- 239000000243 solution Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 6
- 239000000203 mixture Substances 0.000 description 3
- 238000005453 pelletization Methods 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000003344 environmental pollutant Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 231100000719 pollutant Toxicity 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003733 fiber-reinforced composite Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000011208 reinforced composite material Substances 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60T—VEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
- B60T17/00—Component parts, details, or accessories of power brake systems not covered by groups B60T8/00, B60T13/00 or B60T15/00, or presenting other characteristic features
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B9/00—Making granules
- B29B9/02—Making granules by dividing preformed material
- B29B9/06—Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0005—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor using fibre reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/78—Measuring, controlling or regulating of temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76531—Temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76595—Velocity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Transportation (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Reinforced Plastic Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
Description
技术领域technical field
本发明具体涉及一种汽车真空助力器支架及其制造工艺。The invention specifically relates to an automobile vacuum booster bracket and a manufacturing process thereof.
背景技术Background technique
“节能减排，加强环境保护，实现可持续发展”已经成为各国政府和广大民众的共识，为了应对日益严格的环境挑战，世界汽车行业正积极行动起来，大力研制环境友好型的汽车。目前，汽车轻量化是实现汽车节能减排并保证汽车安全性的最有效的途径之一，也成为汽车行业发展的推动力。"Energy saving and emission reduction, strengthening environmental protection, and realizing sustainable development" has become the consensus of governments and the general public of various countries. In order to cope with increasingly stringent environmental challenges, the world's auto industry is actively taking action to develop environmentally friendly cars. At present, automobile lightweight is one of the most effective ways to realize automobile energy saving and emission reduction and ensure automobile safety, and it has also become the driving force for the development of the automobile industry.
真空助力器支架作为汽车零部件，用于连接真空助力器和制动踏板支架，一方面可以固定真空助力器，另一方面可以承受制动踏板经真空助力器施加的载荷。传统的真空助力器支架材料为钢铁、铝合金等金属材料，采用铸造工艺制造，因此，传统的真空助力器支架具有重量大、成型周期长、制造成本高、污染物排放量大等缺点。As an auto part, the vacuum booster bracket is used to connect the vacuum booster and the brake pedal bracket. On the one hand, it can fix the vacuum booster, and on the other hand, it can bear the load applied by the brake pedal through the vacuum booster. The traditional vacuum booster bracket is made of metal materials such as steel and aluminum alloy, and is manufactured by casting process. Therefore, the traditional vacuum booster bracket has the disadvantages of heavy weight, long molding cycle, high manufacturing cost, and large pollutant emissions.
发明内容Contents of the invention
本发明的目的在于提供一种汽车真空助力器支架及其制造工艺，它根据真空助力器支架实际工作环境及所受工作载荷，采用长玻纤增强尼龙复合材料注塑成型，具有质量轻、成本低、成型周期短的优点，能满足结构和力学性能使用要求。The purpose of the present invention is to provide an automobile vacuum booster bracket and its manufacturing process. According to the actual working environment and the working load of the vacuum booster bracket, it is injection-molded with long glass fiber reinforced nylon composite material, which has the advantages of light weight and low cost. , The advantages of short molding cycle can meet the requirements of structure and mechanical properties.
本发明解决其技术问题所采用的技术方案是：The technical solution adopted by the present invention to solve its technical problems is:
一种汽车真空助力器支架，该支架由长玻纤增强尼龙复合材料注塑成型，该支架包括可容纳真空助力器推杆的筒体、垂直设置在筒体一端用于安装真空助力器的法兰盘以及倾斜设置在筒体另一端用于安装制动踏板支架的底座；其中，An automobile vacuum booster bracket, which is injection-molded from long glass fiber reinforced nylon composite materials, the bracket includes a cylinder that can accommodate the vacuum booster push rod, and a flange vertically arranged at one end of the cylinder for installing the vacuum booster The disc and the base installed on the other end of the cylinder are used to install the brake pedal bracket; among them,
所述筒体的外周沿着筒体的轴线均匀设置有四组用于加强支撑法兰盘和底座的肋板，每组包括三个肋板，每组肋板中相邻肋板之间的距离为16～18mm，每个肋板的厚度为2.3～2.7mm；The outer circumference of the cylinder is evenly provided with four sets of ribs for strengthening the support flange and the base along the axis of the cylinder, each set includes three ribs, and the ribs between adjacent ribs in each set The distance is 16-18mm, and the thickness of each rib is 2.3-2.7mm;
所述法兰盘朝向底座的一面上位于相邻的两组肋板之间设有法兰盘凸台，所述法兰盘凸台上设有用于安装真空助力器的法兰盘螺栓孔，所述法兰盘的厚度为3.2～3.8mm，所述法兰盘凸台的厚度为3.7～4.3mm；The side of the flange facing the base is provided with a flange boss between two adjacent sets of ribs, and the flange boss is provided with a flange bolt hole for installing a vacuum booster. The thickness of the flange is 3.2-3.8mm, and the thickness of the boss of the flange is 3.7-4.3mm;
所述底座朝向法兰盘的一面上位于相邻的两组肋板之间设有底座凸台，所述底座凸台上设有用于安装制动踏板支架的底座螺栓孔，所述底座的厚度为4.0～5.0mm，所述底座凸台的厚度为4.5～5.0mm。The side of the base facing the flange is provided with a base boss between two adjacent sets of ribs, the base boss is provided with a base bolt hole for installing the brake pedal bracket, and the thickness of the base is is 4.0-5.0 mm, and the thickness of the boss of the base is 4.5-5.0 mm.
按上述技术方案，所述法兰盘与底座之间的夹角为8°。According to the above technical solution, the angle between the flange and the base is 8°.
按上述技术方案，其中两组肋板位于法兰盘与底座距离最大和最小的左右两侧，另外两组肋板位于法兰盘与底座的前后两侧。According to the above technical solution, two sets of ribs are located on the left and right sides where the distance between the flange and the base is the largest and the smallest, and the other two sets of ribs are located on the front and rear sides of the flange and the base.
相应的，本发明提供一种汽车真空助力器支架的制造工艺，包括以下步骤：Correspondingly, the present invention provides a kind of manufacturing process of automobile vacuum booster bracket, comprises the following steps:
S1、造粒：将尼龙PA66、长度为12mm的长玻纤和添加剂置于双螺杆挤出机中，充分混合均匀后挤出得到长玻纤增强尼龙复合材料粒料；S1. Pelletizing: put nylon PA66, long glass fibers with a length of 12 mm and additives in a twin-screw extruder, mix well and then extrude to obtain long glass fiber reinforced nylon composite pellets;
S2、干燥：将步骤S1中得到的长玻纤增强尼龙复合材料粒料置于干燥箱中，并在90～100℃条件下烘干3～6小时；S2. Drying: place the long glass fiber reinforced nylon composite material pellets obtained in step S1 in a drying oven, and dry at 90-100° C. for 3-6 hours;
S3、注射：将步骤S2中干燥后的长玻纤增强尼龙复合材料粒料置于螺杆式注塑机料筒中熔化得到熔融粒料，并将熔融粒料分2段注射入真空助力器支架模具型腔中；S3. Injection: put the dried long glass fiber reinforced nylon composite pellets in step S2 in the barrel of a screw injection molding machine to melt to obtain molten pellets, and inject the molten pellets into the vacuum booster bracket mold in two stages cavity;
S4、保压：注射完成后，对真空助力器支架模具型腔内的熔体分2段进行保压；S4. Pressure keeping: After the injection is completed, the melt in the mold cavity of the vacuum booster bracket is divided into two sections for pressure keeping;
S5、脱模：保压完成后，通过真空助力器模具中的冷却水道采用水冷方式将型腔内熔体温度降至顶出温度，开模并使用脱模剂从注塑机中取出真空助力器支架；S5. Demoulding: After the pressure keeping is completed, the temperature of the melt in the cavity is reduced to the ejection temperature through the cooling channel in the mold of the vacuum booster by water cooling, and the mold is opened and the vacuum booster is taken out from the injection molding machine with a release agent. bracket;
S6、调湿：将脱模后的真空助力器支架浸入90～100℃热水中2～3小时，达到调湿处理时间后，将真空助力器支架缓慢冷却至室温。S6. Humidity adjustment: immerse the demoulded vacuum booster bracket in hot water at 90-100°C for 2-3 hours. After the humidity-adjustment treatment time is reached, slowly cool the vacuum booster bracket to room temperature.
按上述技术方案，步骤S1中，所述尼龙PA66与长玻纤的质量比为7:3，所述添加剂包括硅烷偶联剂KH-550、抗氧化剂1010和润滑剂TAF。According to the above technical solution, in step S1, the mass ratio of nylon PA66 to long glass fiber is 7:3, and the additives include silane coupling agent KH-550, antioxidant 1010 and lubricant TAF.
按上述技术方案，步骤S3中，所述螺杆式注塑机料筒中熔融粒料温度为300～305℃，熔融粒料第1段的注射压力为65～75kg/cm2，注射速度为30～35mm/s，第2段注射压力为50～60kg/cm2，注射速度为20～25mm/s，所述真空助力器支架模具表面温度保持在100℃。According to the above technical solution, in step S3, the temperature of the molten pellets in the barrel of the screw injection molding machine is 300-305°C, the injection pressure of the first stage of the molten pellets is 65-75kg/cm 2 , and the injection speed is 30-35mm /s, the injection pressure in the second stage is 50-60kg/cm 2 , the injection speed is 20-25mm/s, and the surface temperature of the vacuum booster bracket mold is kept at 100°C.
按上述技术方案，步骤S4中，真空助力器支架模具型腔内的熔体第1次保压压力为50～60kg/cm2，时间8秒，第2次保压压力为40～45kg/cm2，时间10秒。According to the above technical solution, in step S4, the first holding pressure of the melt in the mold cavity of the vacuum booster bracket is 50-60kg/cm 2 for 8 seconds, and the second holding pressure is 40-45kg/cm 2 , time 10 seconds.
按上述技术方案，步骤S5中，所述脱模剂为液态石蜡。According to the above technical solution, in step S5, the release agent is liquid paraffin.
本发明产生的有益效果是：本发明利用长玻纤增强尼龙复合材料具有密度低、强度高、绝缘耐腐蚀等良好性能的特点，用来制造真空助力器支架可以显著降低重量，重量低至0.41kg，同时，为了克服传统支架直接使用这种材料注塑成型易发生翘曲变形、体积收缩的缺陷，本发明通过大量模拟和试验对支架的结构进行了改进，使其能够满足结构和力学性能使用要求，具体为一是对法兰盘和底座的厚度进行了合理设计，使其不会因太厚导致支架发生翘曲变形、体积收缩，也不会因太薄导致支架达不到结构使用要求，二是在筒体外周增设了四组肋板，并对肋板的数量、厚度以及安装位置进行了合理设计，使其不会因为肋板数量少了导致力学性能达不到要求，也不会因为肋板太厚导致发生翘曲变形。本发明不仅翘曲与体积收缩较小，而且结构力学性能与钢铁、铝合金等材料相当，可以满足实际使用要求。The beneficial effects produced by the present invention are: the long glass fiber reinforced nylon composite material in the present invention has the characteristics of low density, high strength, insulation and corrosion resistance, etc., and can significantly reduce the weight when used to manufacture vacuum booster brackets, and the weight is as low as 0.41 kg, at the same time, in order to overcome the defects of warping deformation and volume shrinkage caused by injection molding of this material directly in the traditional bracket, the present invention improves the structure of the bracket through a large number of simulations and tests, so that it can meet the requirements of structural and mechanical properties. Requirements, specifically, the thickness of the flange and the base is reasonably designed so that the bracket will not be warped and deformed due to too thick, and the volume will shrink, and the bracket will not fail to meet the structural requirements due to too thin , the second is to add four sets of ribs on the outer periphery of the cylinder, and rationally design the number, thickness and installation position of the ribs, so that the mechanical properties will not meet the requirements due to the small number of ribs, nor will the Warpage can occur because the ribs are too thick. The invention not only has less warpage and volume shrinkage, but also has structural mechanical properties equivalent to those of steel, aluminum alloy and other materials, and can meet the requirements of actual use.
相应的，本发明根据上述真空助力器支架的结构并结合注塑成形工艺特点设计出真空助力器支架模具，合理设计工艺流程和参数，可以保证成形周期短、成型工艺环保、制品尺寸精确、污染物排放少、制造成本低。Correspondingly, the present invention designs a mold for a vacuum booster bracket based on the structure of the above-mentioned vacuum booster bracket and in combination with the characteristics of the injection molding process, and rationally designs the process flow and parameters, which can ensure a short forming cycle, environmentally friendly molding process, accurate product size, and free from pollutants. Less emission and low manufacturing cost.
附图说明Description of drawings
下面将结合附图及实施例对本发明作进一步说明，附图中：The present invention will be further described below in conjunction with accompanying drawing and embodiment, in the accompanying drawing:
图1是本发明实施例中真空助力器支架的主视图；Fig. 1 is the front view of the vacuum booster bracket in the embodiment of the present invention;
图2是本发明实施例中真空助力器支架的后视图；Fig. 2 is the rear view of the vacuum booster bracket in the embodiment of the present invention;
图3是本发明实施中真空助力器支架制造工艺的流程图；Fig. 3 is a flow chart of the vacuum booster bracket manufacturing process in the implementation of the present invention;
图4是本发明实施中真空助力器支架的强度校核图。Fig. 4 is a strength check diagram of the vacuum booster bracket in the implementation of the present invention.
图中：1-筒体、2-法兰盘、201-法兰盘凸台、202-法兰盘螺栓孔、3-底座、301-底座凸台、302-底座螺栓孔、4-肋板。In the figure: 1-cylinder, 2-flange, 201-flange boss, 202-flange bolt hole, 3-base, 301-base boss, 302-base bolt hole, 4-rib .
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.
如图1、图2所示，一种汽车真空助力器支架，该支架由长玻纤增强尼龙复合材料注塑成型，该支架包括可容纳真空助力器推杆的筒体1、垂直设置在筒体1一端用于安装真空助力器的法兰盘2以及倾斜设置在筒体1另一端用于安装制动踏板支架的底座3；其中，As shown in Figure 1 and Figure 2, a car vacuum booster bracket, the bracket is injection molded by long glass fiber reinforced nylon composite material, the bracket includes a cylinder 1 that can accommodate the vacuum booster push rod, vertically arranged on the cylinder body 1 one end is used to install the flange 2 of the vacuum booster and the base 3 obliquely arranged on the other end of the cylinder 1 is used to install the brake pedal bracket; wherein,
筒体1的外周沿着筒体1的轴线均匀设置有四组用于加强支撑法兰盘2和底座3的肋板4，每组包括三个肋板4，每组肋板中相邻肋板4之间的距离为16～18mm，每个肋板4的厚度为2.3～2.7mm；Four groups of ribs 4 are evenly arranged along the axis of the cylinder 1 on the outer periphery of the cylinder 1 to strengthen the support flange 2 and the base 3, each group includes three ribs 4, and the adjacent ribs in each group of ribs The distance between the plates 4 is 16-18 mm, and the thickness of each rib 4 is 2.3-2.7 mm;
法兰盘2朝向底座3的一面上位于相邻的两组肋板之间设有法兰盘凸台201，法兰盘凸台201上设有用于安装真空助力器的法兰盘螺栓孔202，法兰盘2的厚度为3.2～3.8mm，法兰盘凸台201的厚度为3.7～4.3mm；On the side of the flange 2 facing the base 3, a flange boss 201 is provided between two adjacent sets of ribs, and the flange boss 201 is provided with a flange bolt hole 202 for installing a vacuum booster. , the thickness of the flange 2 is 3.2-3.8 mm, and the thickness of the flange boss 201 is 3.7-4.3 mm;
底座3朝向法兰盘2的一面上位于相邻的两组肋板之间设有底座凸台301，底座凸台301上设有用于安装制动踏板支架的底座螺栓孔302，底座3的厚度为4.0～5.0mm，底座凸台301的厚度为4.5～5.0mm。On the side of the base 3 facing the flange 2, a base boss 301 is provided between two adjacent sets of ribs. The base boss 301 is provided with a base bolt hole 302 for installing the brake pedal bracket. The thickness of the base 3 is 4.0-5.0 mm, and the thickness of the base boss 301 is 4.5-5.0 mm.
在本发明的优选实施例中，如图1、图2所示，法兰盘2与底座3之间的夹角为8°。In a preferred embodiment of the present invention, as shown in FIG. 1 and FIG. 2 , the angle between the flange 2 and the base 3 is 8°.
在本发明的优选实施例中，如图1、图2所示，其中两组肋板位于法兰盘2与底座3距离最大和最小的左右两侧，另外两组肋板位于法兰盘2与底座3的前后两侧。In a preferred embodiment of the present invention, as shown in Fig. 1 and Fig. 2, two sets of ribs are located on the left and right sides where the distance between the flange 2 and the base 3 is the largest and the smallest, and the other two sets of ribs are located on the flange 2 and the front and rear sides of the base 3.
相应的，如图3所示，一种汽车真空助力器支架的制造工艺，包括以下步骤：Correspondingly, as shown in Figure 3, a manufacturing process for an automobile vacuum booster bracket includes the following steps:
S1、造粒：将尼龙PA66、长度为12mm的长玻纤和添加剂置于双螺杆挤出机中，充分混合均匀后挤出得到长玻纤增强尼龙复合材料粒料；S1. Pelletizing: put nylon PA66, long glass fibers with a length of 12 mm and additives in a twin-screw extruder, mix well and then extrude to obtain long glass fiber reinforced nylon composite pellets;
S2、干燥：将步骤S1中得到的长玻纤增强尼龙复合材料粒料置于干燥箱中，并在90～100℃条件下烘干3～6小时；S2. Drying: place the long glass fiber reinforced nylon composite material pellets obtained in step S1 in a drying oven, and dry at 90-100° C. for 3-6 hours;
S3、注射：将步骤S2中干燥后的长玻纤增强尼龙复合材料粒料置于螺杆式注塑机料筒中熔化得到熔融粒料，并将熔融粒料分2段注射入真空助力器支架模具型腔中；S3. Injection: put the dried long glass fiber reinforced nylon composite pellets in step S2 in the barrel of a screw injection molding machine to melt to obtain molten pellets, and inject the molten pellets into the vacuum booster bracket mold in two stages cavity;
S4、保压：注射完成后，对真空助力器支架模具型腔内的熔体分2段进行保压；S4. Pressure keeping: After the injection is completed, the melt in the mold cavity of the vacuum booster bracket is divided into two sections for pressure keeping;
S5、脱模：保压完成后，通过真空助力器模具中的冷却水道采用水冷方式将型腔内熔体温度降至顶出温度，开模并使用脱模剂从注塑机中取出真空助力器支架；S5. Demoulding: After the pressure keeping is completed, the temperature of the melt in the cavity is reduced to the ejection temperature through the cooling channel in the mold of the vacuum booster by water cooling, and the mold is opened and the vacuum booster is taken out from the injection molding machine with a release agent. bracket;
S6、调湿：将脱模后的真空助力器支架浸入90～100℃热水中2～3小时，达到调湿处理时间后，将真空助力器支架缓慢冷却至室温。S6. Humidity adjustment: immerse the demoulded vacuum booster bracket in hot water at 90-100°C for 2-3 hours. After the humidity-adjustment treatment time is reached, slowly cool the vacuum booster bracket to room temperature.
在本发明的优选实施例中，步骤S1中，尼龙PA66与长玻纤的质量比为7:3，添加剂包括硅烷偶联剂KH-550、抗氧化剂1010和润滑剂TAF。In a preferred embodiment of the present invention, in step S1, the mass ratio of nylon PA66 to long glass fiber is 7:3, and the additives include silane coupling agent KH-550, antioxidant 1010 and lubricant TAF.
在本发明的优选实施例中，步骤S3中，螺杆式注塑机料筒中熔融粒料温度为300～305℃，熔融粒料第1段的注射压力为65～75kg/cm2，注射速度为30～35mm/s，第2段注射压力为50～60kg/cm2，注射速度为20～25mm/s，真空助力器支架模具表面温度保持在100℃。In a preferred embodiment of the present invention, in step S3, the temperature of the molten pellets in the cylinder of the screw injection molding machine is 300-305°C, the injection pressure of the first stage of the molten pellets is 65-75kg/cm 2 , and the injection speed is 30 ～35mm/s, the injection pressure in the second stage is 50～60kg/cm 2 , the injection speed is 20～25mm/s, and the surface temperature of the vacuum booster bracket mold is kept at 100°C.
在本发明的优选实施例中，步骤S4中，真空助力器支架模具型腔内的熔体第1次保压压力为50～60kg/cm2，时间8秒，第2次保压压力为40～45kg/cm2，时间10秒。In a preferred embodiment of the present invention, in step S4, the first holding pressure of the melt in the mold cavity of the vacuum booster bracket is 50-60 kg/cm 2 for 8 seconds, and the second holding pressure is 40 ~45kg/cm 2 , time 10 seconds.
在本发明的优选实施例中，步骤S5中，脱模剂为液态石蜡。In a preferred embodiment of the present invention, in step S5, the release agent is liquid paraffin.
本发明根据长玻纤增强尼龙复合材料的特性，并结合真空助力器支架实际工作环境及所受工作载荷，合理设计一种真空助力器支架。本发明在具体应用时，该支架主要结构包括法兰盘、筒体、底座、肋板和螺栓固定孔，整体尺寸为148*126*109mm，重量为0.41kg。其中，法兰盘的外径为128mm，内径为66mm，法兰盘厚度为3.5mm，法兰盘凸台上设有法兰盘螺栓孔，法兰盘凸台厚度为4mm；底座厚度为4.5mm，底座凸台厚度为4.7mm，底座凸台上设有底座螺栓；肋板厚度为2.5mm，相邻肋板间距16mm，每组包括3个肋板，其中左右两侧肋板无倾斜角，前后两侧肋板与底座之间的倾斜角为8°。According to the characteristics of the long glass fiber reinforced nylon composite material, combined with the actual working environment and the working load of the vacuum booster bracket, the invention rationally designs a vacuum booster bracket. In the specific application of the present invention, the main structure of the bracket includes a flange, a cylinder, a base, ribs and bolt fixing holes, the overall size is 148*126*109mm, and the weight is 0.41kg. Among them, the outer diameter of the flange is 128mm, the inner diameter is 66mm, the thickness of the flange is 3.5mm, there are flange bolt holes on the flange boss, the thickness of the flange boss is 4mm; the thickness of the base is 4.5mm mm, the thickness of the base boss is 4.7mm, and there are base bolts on the base boss; the thickness of the ribs is 2.5mm, and the distance between adjacent ribs is 16mm. Each group includes 3 ribs, and the left and right ribs have no inclination angle , the inclination angle between the ribs on the front and rear sides and the base is 8°.
本发明还根据所设计的真空助力器支架并结合注塑成形工艺特点设计出相应地真空助力器支架模具。本发明以尼龙PA66、长玻纤等材料配制增强复合材料，采用注塑成型工艺，通过合理设置工艺参数制造长玻纤增强尼龙复合材料真空助力器支架。本发明的制造工艺在具体应用时，包括以下步骤：The present invention also designs a corresponding vacuum booster bracket mold according to the designed vacuum booster bracket and in combination with the characteristics of the injection molding process. The invention uses nylon PA66, long glass fiber and other materials to prepare reinforced composite materials, adopts injection molding technology, and manufactures long glass fiber reinforced nylon composite material vacuum booster brackets by setting process parameters reasonably. The manufacturing process of the present invention comprises the following steps during concrete application:
S1、造粒：将尼龙PA66，长度为12mm的长玻纤，添加剂置于双螺杆挤出机中充分混合均匀后挤出得到长玻纤增强尼龙复合材料粒料,其中尼龙PA66与长玻纤的质量比为7:3；添加剂包括硅烷偶联剂KH-550，抗氧化剂1010，润滑剂TAF，脱模剂为液态石蜡；S1. Pelletizing: Put nylon PA66, long glass fiber with a length of 12mm, and additives in a twin-screw extruder to fully mix and evenly extrude to obtain long glass fiber-reinforced nylon composite material pellets, in which nylon PA66 and long glass fiber The mass ratio is 7:3; additives include silane coupling agent KH-550, antioxidant 1010, lubricant TAF, and release agent is liquid paraffin;
S2、干燥：将步骤S1中得到的长玻纤增强尼龙复合材料粒料置于干燥箱中，并在90～100℃条件下烘干3～6小时；S2. Drying: place the long glass fiber reinforced nylon composite material pellets obtained in step S1 in a drying oven, and dry at 90-100° C. for 3-6 hours;
S3、注射：将步骤S2中干燥后的长玻纤增强尼龙复合材料粒料置于螺杆式注塑机料筒中熔化，保持置于料筒中熔融粒料温度为300～305℃左右，将尼龙长玻纤增强复合材料熔融粒料分2段注射入真空助力器支架模具型腔中，其中第1段注射压力为70kg/cm2，注射速度为35mm/s，第2段注射压力为55kg/cm2，注射速度为20mm/s，模具表面温度保持在100℃；S3. Injection: Put the long glass fiber reinforced nylon composite pellets dried in step S2 into the barrel of a screw injection molding machine to melt, keep the temperature of the molten pellets in the barrel at about 300-305°C, and pour the nylon long glass The molten pellets of fiber-reinforced composite materials are injected into the cavity of the vacuum booster bracket mold in two stages, the injection pressure of the first stage is 70kg/cm 2 , the injection speed is 35mm/s, and the injection pressure of the second stage is 55kg/cm 2 , the injection speed is 20mm/s, and the mold surface temperature is kept at 100°C;
S4、保压：注射完成后，对真空助力器支架模具型腔内的熔体分2段进行保压，其中第1次保压压力为55kg/cm2，时间8秒，第2次保压压力为40kg/cm2，时间10秒；S4. Holding pressure: After the injection is completed, the melt in the cavity of the vacuum booster bracket mold is divided into two sections to maintain pressure. The pressure for the first time is 55kg/cm 2 for 8 seconds, and the pressure for the second time is The pressure is 40kg/cm 2 , and the time is 10 seconds;
S5、脱模：保压阶段完成后，通过真空助力器支架模具中的冷却水道采用水冷方式将型腔内熔体温度降至顶出温度，开模并利用脱模剂从注塑机中取出真空助力器支架；S5. Demoulding: After the pressure holding stage is completed, the temperature of the melt in the cavity is reduced to the ejection temperature by water cooling through the cooling channel in the mold of the vacuum booster bracket, and the mold is opened and the vacuum is taken out from the injection molding machine by using the release agent. booster bracket;
S6、调湿：将脱模后的真空助力器支架浸入90～100℃热水中2～3小时，达到调湿处理时间后，将真空助力器支架缓慢冷却至室温。S6. Humidity adjustment: immerse the demoulded vacuum booster bracket in hot water at 90-100°C for 2-3 hours. After the humidity-adjustment treatment time is reached, slowly cool the vacuum booster bracket to room temperature.
如图4所示，以真空助力器支架实际工作中所能承受的最大载荷为标准，校核本发明中采用长玻纤增强尼龙复合材料制作的真空助力器支架的强度，所得强度参数见下表。As shown in Figure 4, with the maximum load that the vacuum booster bracket can bear in actual work as a standard, check the strength of the vacuum booster bracket made of long glass fiber reinforced nylon composite material in the present invention, and the obtained strength parameters are as follows surface.
经校核，根据支架的工作环境，把最大工作载荷加到支架上，支架此时的最大强度131.9MPa，小于支架材料本身的强度极限，符合力学强度要求。After checking, according to the working environment of the bracket, the maximum working load is added to the bracket. The maximum strength of the bracket at this time is 131.9MPa, which is less than the strength limit of the bracket material itself and meets the mechanical strength requirements.
应当理解的是，对本领域普通技术人员来说，可以根据上述说明加以改进或变换，而所有这些改进和变换都应属于本发明所附权利要求的保护范围。It should be understood that those skilled in the art can make improvements or changes based on the above description, and all these improvements and changes should belong to the protection scope of the appended claims of the present invention.
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