JPH06238388A - Production of actuator housing - Google Patents

Abstract

PURPOSE:To eliminate possibility of generating cavity or pin hole in a housing as finished part, accordingly reducing a rejection rate. CONSTITUTION:Al material 1 after casting is inspected for cavity or pin hole in the inside. Successively, Al material 1 is cut to a stock 1A, heating it to a temp. near the melting point (500-630 deg.C) in a heat treatment furnace 2. At this heated state, the stock 1A is pressed in a press header 3 die to be formed to the shape close to the housing as nearly finished part. After this process, the stock 1A is subjected to the prescribed heat treatment and machining, and then water immersion test, the part passed the test is a finished part 5.

Description

Detailed Description of the Invention

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an actuator housing used in, for example, an automobile brake system.

2. Description of the Related Art Conventionally, an anti-skid brake system for an automobile has been known, and various flow path switching valves as an actuator for varying brake fluid pressure have been known as a component thereof. And conventionally, the housing of the flow path switching valve as the above-mentioned actuator is manufactured by casting using aluminum or the like as a material.

By the way, when the housing of the actuator is manufactured by casting as in the above-mentioned conventional case, a cavity or a pinhole may occur in the completed housing. If such cavities or pinholes are generated, it will lead to liquid leakage from the housing after the assembly is completed. Therefore, conventionally, it has been inspected whether or not liquid leakage occurs after the housing is completely cast. In the past, about 10% of the housing manufactured by casting was found to be defective at the time of this inspection. As described above, conventionally, since the actuator housing is manufactured by casting, the incidence of defective products due to cavities and pinholes is high.

In view of the above-mentioned circumstances, the present invention provides an inspection step for inspecting cast rod-shaped aluminum for the presence of cavities, pinholes, or the like.
A cutting step of cutting the rod-shaped aluminum through the inspection step into a material of a required size, a heating step of heating the material at a temperature close to and not exceeding the melting point, and forging the material in the heated state. Forging process to adjust the shape as the housing of the general actuator, and a cutting process for performing the required cutting process on the material adjusted to the shape of the housing of the general actuator, and finally, finishing the cutting process Provided is a method for manufacturing an actuator housing, which comprises a finishing inspection step of injecting a material completed as a housing into an inspection liquid and inspecting whether the material completed as the housing has no liquid leakage. .

According to such a construction, first, aluminum as a material is inspected for the presence of cavities and pinholes inside. Also, after forging the material after this inspection, it is cut into the shape of the approximate housing and then cut,
Finally, finish inspection is performed. As a result, there is no room for forming cavities, pinholes, or the like in the housing after completion, and therefore, the incidence of defective products can be reduced as compared with the conventional case.

Embodiments Embodiments in which the present invention is applied to manufacture of a housing of a flow path switching valve in an anti-skid brake system will be described below. First, as shown in FIG. 1 (A), purchase aluminum 1 which is a material cast in the shape of a round bar, and make sure that there is no nest or pinhole inside the aluminum 1 that is the material by an inspection device (not shown). To inspect. If a nest or pinhole is found inside the aluminum 1 as a material, the material is not used. Next, when it is confirmed in the above inspection that there are no cavities or pinholes inside the aluminum 1 as a material, the aluminum 1 is cut into a material 1A having a required size with a saw or the like (FIG. 1B). Next, the material 1A is housed in the heat treatment furnace 2 at a temperature close to the melting point of aluminum, but not exceeding the melting point (for example, about 5
Heating is performed at 00 ° C. to 630 ° C. (FIG. 1C). Next, in this heated state, the material 1A is moved into the press-hetter mold 3 provided at the position adjacent to the heat treatment furnace 2, and the material 1A is pressed from above and below. And
As a result, the material 1A is first prepared in a preliminary shape, and then prepared to a shape 1A 'which is almost the same as the finished housing (FIG. 1C). After this, material 1A '
After being taken out from the press-hetter mold 3 and stored again in the heat treatment furnace 2, it is heated at 510 ° C. for about 8 hours, and then rapidly cooled with cold water. Heated for about 4 hours (Fig. 1
(D)). Next, the material 1A 'is taken out from the heat treatment furnace 2 and subjected to necessary cutting such as cutting of unnecessary portions on the outer peripheral portion of the material 1A' and axial drilling with a cutting tool 4 or the like. As a result, the housing 5 of the flow path switching valve as the actuator is completed (FIG. 1 (E)). Finally, both ends of the through hole and the opening of the hole in the housing 5 as the finished product are completely sealed with vinyl chloride or the like, and the housing 5 as the finished product in that state.
Submerge for the required time. After that, the housing 5 is taken out from the water, and it is inspected whether or not water leakage has occurred in the housing 5, and those having no water leakage are regarded as acceptable products, and those having water leakage are discarded (F). Note that FIG.
3 is a front view of the housing 5 manufactured by the manufacturing method of this embodiment, and FIG. 3 is a right side view of FIG. As described above, in the present invention, first, it is inspected whether the aluminum 1 as a material has cavities, pinholes, or the like, and then the housing 5 is manufactured by the above-described processing steps. Therefore, it is possible to favorably prevent formation of cavities and pinholes in the completed housing 5, and it is possible to reduce the incidence of defective products. In contrast to the present embodiment, the housing 5 described above is conventionally manufactured by casting, and thus the completed housing 5 is manufactured.
Nests and pinholes may be formed in the inner part, and therefore the defective product rate was high. By the way, although the housing 5 manufactured by the manufacturing method of the present embodiment was not able to find a defective product even if the above-mentioned submersion test was performed, when a conventional housing manufactured by casting was submerged test, it was generated in the housing. Approximately 10% of the inspection targets were defective products due to the nests and pinholes. In the above example, aluminum as a commercially available material was purchased and inspected for any cavities or pinholes, but after the initial purchase, the aluminum was inspected once. When purchasing the material for the second time and thereafter, the inspection for the presence of the above-mentioned nest or pinhole may be omitted.

As described above, according to the present invention, it is possible to obtain an effect that the rate of defective products can be reduced as compared with the conventional case.

[Brief description of drawings]

FIG. 1 is a process chart showing an embodiment of the present invention.

FIG. 2 is a front view of a housing manufactured by the manufacturing method of the present invention.

FIG. 3 is a right side view of FIG.

[Explanation of symbols]

 1 Aluminum 1A Material 2 Heat Treatment Furnace 3 Press Hetter 5 Housing (Completed)

Claims (1)

[Claims] 1. An inspection step for inspecting cast rod-shaped aluminum for the absence of cavities and pinholes, and a cutting step for cutting the rod-shaped aluminum through the inspection step into a material of a required size. And a heating step of heating the material at a temperature close to and not exceeding the melting point, a forging step of forging the material in the heating state into a shape as a housing of a general actuator, and a housing for a general actuator. A cutting process that applies the required cutting process to the shaped material, and finally, finish the cutting process and put the completed material as the actuator housing into the inspection liquid and complete the housing And a finishing inspection step for inspecting whether the material has leaked or not, Production method.