CN108253046B

CN108253046B - Lightweight composite brake disc and processing method thereof

Info

Publication number: CN108253046B
Application number: CN201810258497.5A
Authority: CN
Inventors: 李振
Original assignee: Yantai Winhere Auto Part Manufacturing Co ltd
Current assignee: Yantai Winhere Auto Part Manufacturing Co ltd
Priority date: 2018-03-27
Filing date: 2018-03-27
Publication date: 2023-08-04
Anticipated expiration: 2038-03-27
Also published as: CN108253046A

Abstract

The invention relates to a lightweight composite brake disc, which comprises a disc cap and a friction ring arranged on the disc cap, wherein the disc cap is processed by ductile cast iron, and the friction ring is processed by gray cast iron; the disk cap comprises a flange mounting surface with a central hole, a mounting hole and a positioning hole, a cap barrel and a cap peak, wherein a plurality of grooves which are uniformly distributed are formed in the outer ring of the cap peak, and petals are arranged between two adjacent grooves; the friction ring comprises an upper friction ring and a lower friction ring, ribs are arranged between the upper friction ring and the lower friction ring, an air channel is formed between the upper friction ring and the ribs, an inner ring of the upper friction ring is provided with a mounting groove for mounting a cap peak, and a notch matched with a groove on the cap peak is formed at the edge of the inner ring of the mounting groove. And a method of machining a brake disc. According to the invention, the brake disc is manufactured by adopting the split structure of the disc cap and the friction ring, so that the weight of the brake disc is reduced, the ventilation of the brake disc is improved by changing the structure, and the service life of the brake disc is prolonged.

Description

Lightweight composite brake disc and processing method thereof

Technical Field

The invention relates to a lightweight composite brake disc and a processing method thereof, and belongs to the technical field of brake disc processing.

Background

The conventional brake disc used at present is made of gray cast iron, and the gray cast iron is low in strength, so that the hat is large in thickness and large in overall weight. In order to reduce the weight of the vehicle body and the energy consumption, the weight of the brake disc is increasingly reduced. The technical proposal of the light weight of the brake disc in the industry mainly comprises an aluminum cap composite disc, a ceramic disc, a steel cap composite disc and the like, and the former two mainly adopt materials with smaller density to realize the light weight; the last one is to use the material with larger intensity and reduce the thickness of the material to realize the light weight. The existing brake disc has high cost and complex process in the processing production, and special equipment is required to process the brake disc meeting the required standard.

Disclosure of Invention

The invention provides a new solution to the problem of light weight of a brake disc, provides a light weight composite brake disc, and designs a new processing method for the brake disc.

The technical scheme for solving the technical problems is as follows: the lightweight composite brake disc comprises a disc cap and a friction ring arranged on the disc cap, and is characterized in that the disc cap is processed by ductile cast iron, and the friction ring is processed by gray cast iron; the disk cap comprises a flange mounting surface with a central hole, a mounting hole and a positioning hole, a cap barrel connected with the flange mounting surface and a radially outward cap peak connected with the cap barrel, wherein a plurality of grooves which are uniformly distributed are formed in the outer ring of the cap peak, and petals are arranged between two adjacent grooves; the friction ring include friction ring and lower friction ring, be provided with the rib between the upper and lower friction ring, form the wind channel between upper and lower friction ring and the rib, the inner circle of upper friction ring be provided with the mounting groove of installation brim of a hat, and be provided with the breach with recess matched with on the brim of a hat at the edge of the inner circle of mounting groove. The number of the grooves on the tray cap and the number of petals determined by the number of the grooves are determined according to the production requirement, and can be 10-30, and the number of the ribs is also determined according to the production requirement. The inner ring of the upper friction ring is provided with the mounting groove and the notch, the cap peak of the disc cap adopts a petal structure, and a gap serving as a vent is reserved between the notch on the friction ring and the groove on the disc cap after the disc cap is combined with the friction ring, so that the petal structure is beneficial to the ventilation and heat dissipation, simultaneously, the weight of the brake disc is reduced, and the purpose of light weight is realized; the disc cap and the friction ring are of a split design, different materials can be adopted for the disc cap and the friction ring, the disc cap in the design is made of spheroidal graphite cast iron, and the friction ring is made of conventional gray cast iron, so that compared with a traditional brake disc, the single gray cast iron is adopted for integral processing, the weight of the composite brake disc is further reduced, the spheroidal graphite cast iron is high in strength, the thickness can be properly thinned, the weight is reduced, and the purpose of light weight is generally achieved.

On the basis of the technical scheme, the invention can also make the following improvements for the technical scheme in order to achieve the convenience of use and the stability of equipment:

further, the combined structure after the groove and the notch are matched and installed is reserved with a ventilation hole. The air ventilation hole is reserved to increase ventilation condition, reduce heat generated by friction of the brake disc, save materials required by processing of the brake disc and reduce cost.

Further, the ribs are distributed in three circles in the friction ring, and the ribs of the middle circle are arranged in a staggered manner with the ribs of the inner circle and the outer circle. The inner ring is square or diamond ribs, the middle ring is diamond ribs, and the outer ring is fan-shaped ribs; the ribs are designed with rounded designs at the corners.

Meanwhile, in order to realize the lightweight brake disc, the invention also provides a processing method of the lightweight brake disc, which comprises the following steps: the processing method of the lightweight composite brake disc is characterized by comprising the following processing steps of: casting, core making, core assembling, modeling and casting of the ductile iron plate; the casting of the ductile iron plate is as follows: casting spheroidal graphite cast iron into the shape of a disk cap; the core making means: manufacturing an air duct core and a ring core; the core assembly refers to: the disc cap is arranged in the middle of the ring core, and then the combination piece of the disc cap and the ring core is arranged on the upper part of the air duct core to form a combination core; the modeling refers to: the combined core is put into a sand mould cavity of a molding line to obtain a molding; the casting is as follows: pouring gray cast iron molten iron into the model, and cleaning and shot blasting after the molten iron is cooled to form the composite brake disc casting.

The core making process comprises the following steps: firstly, core sand is mixed by a sand mixer, and the mixing process is as follows: adding additives (iron oxide red and vein eliminating) and resin into the raw sand, and uniformly mixing. After the core sand is mixed, the mixture is sent to a core making machine for core making: firstly, sand is shot into a core box, the core box is filled with the core sand, then triethylamine is blown into the core box after the sand shooting is finished, the triethylamine plays a role in catalysis, resin reaction is accelerated, the core sand is rapidly hardened, and the sand core is obtained after the core sand hardening is finished. And after the blowing is finished, the core box is opened, and the sand core is taken out.

For the processing method, part of operations are refined:

further, after the casting step, a machining step is added, wherein the machining means: turning off the surface oxide skin of the brake disc casting, and processing a mounting hole and a positioning hole on the flange surface of the disc cap.

Further, a drilling and spraying step is added after the machining step, wherein the drilling and spraying means that: holes which are distributed in a vortex shape are processed on the friction ring, the brake disc is sprayed, and the coating is adopted to spray on the surface of the brake disc. Wherein the sand mold is formed by a template; the spraying has the effects of rust prevention and beautiful appearance.

Further, the manufacturing process of the air duct core and the ring core comprises the following steps: firstly, designing and manufacturing a core box, and then installing the core box on a core making machine, wherein the specific core making process comprises the following steps: and adding a certain amount of binder into the new sand, and rapidly solidifying under the action of a triethylamine catalyst to obtain higher hardness of the sand core and rapidly forming the sand core, thereby forming a corresponding air duct core and a corresponding ring core.

Further, the ring core is provided with a ring core boss matched with the groove on the cap peak. The height of the ring core boss is the same as the thickness of the cap peak, namely the top surface of the ring core boss is flush with the surface of the cap peak, and the purpose of flushing the top surface of the ring core boss and the surface of the cap peak is to ensure that no gap exists between the ring core boss and the air duct core after the ring core boss and the cap peak are combined together through glue, so that molten iron can not be drilled during pouring, and the attractive appearance is ensured. And the ring core and the disk cap are bonded through glue. The adhesive adopts strong adhesive, and can be adhesive which can bond the sand core and cast iron together, such as good brothers.

Further, in the combination process of the combination core, the disc cap is arranged in the middle of the ring core, and the disc cap and the ring core are combined after two thumb-sized glues are smeared at the position, close to the cap peak, of the lower part of the cap ring of the disc cap; the assembly of the disk cap and the ring core is mounted on the air duct core, and the assembly is adhered with the air duct core disk after four glue is smeared below the cap peak.

The invention has the advantages that: the cap part of the invention is mainly made of ductile cast iron material with high strength, thin thickness and light weight, so the cap can be made into thinner thickness without affecting the physical property of the cap; the cap of the spheroidal graphite cast iron and the gray cast iron friction ring are cast together in a compound casting mode, meanwhile, the spheroidal graphite cast iron cap and the gray cast iron friction ring are respectively designed into petal shapes, namely, the cap and the friction ring are tightly meshed, and meanwhile, because a gap (formed by a groove and a notch) is formed at the junction of the cap and the friction ring, the ventilation effect is enhanced, the weight of a brake disc is reduced, and the unsprung weight is finally reduced, and the energy consumption is finally reduced. In summary, the invention realizes that the brake disc is made of metals with different materials by arranging the disc cap and the friction ring into a split structure, so as to lighten the weight of the brake disc, realize the improvement of ventilation of the brake disc and prolong the service life of the brake disc by changing the structure.

Drawings

FIG. 1 is a schematic perspective view of a lightweight composite brake disc according to the present invention;

FIG. 2 is a schematic view of the bottom-up perspective of FIG. 1;

FIG. 3 is a schematic cross-sectional view of a lightweight composite brake disc;

FIG. 4 is a schematic view of a notch combination structure of a groove and an upper friction ring of a disk cap

FIG. 5 is a schematic structural view of a disk cap;

FIG. 6 is a cross-sectional view in the direction B-B of FIG. 5;

FIG. 7 is a schematic diagram of an assembled structure of a disk cap and a ring core;

fig. 8 is a schematic structural view of the composite core.

The reference numerals are recorded as follows: 1-disk cap, 1.1-flange mounting surface, 1.2-petal, 1.3-cap barrel, 1.4-mounting hole, 1.5-locating hole, 1.6-groove, 2-friction ring, 2.1-upper friction ring, 2.2-lower friction ring, 2.3-rib, 2.4-notch, 3-air duct core, 4-ring core and 4.1-ring core boss.

Detailed Description

The principles and features of the present invention are described below with reference to the drawings, the examples are illustrated for the purpose of illustrating the invention and are not to be construed as limiting the scope of the invention.

A lightweight composite brake disc (see fig. 1-6), comprising a disc cap 1 and a friction ring 2 arranged on the disc cap 1, wherein the disc cap 1 is processed by ductile cast iron, and the friction ring 2 is processed by gray cast iron; the disk cap 1 comprises a flange mounting surface 1.1 with a central hole, a mounting hole 1.4 and a positioning hole 1.5, a cap barrel 1.3 connected with the flange mounting surface 1.1 and a radially outward cap peak connected with the cap barrel 1.3, wherein a plurality of grooves 1.6 which are uniformly distributed are arranged on the outer ring of the cap peak, and petals 1.2 are arranged between two adjacent grooves 1.6; the friction ring 2 include friction ring 2.1 and lower friction ring 2.2, be provided with rib 2.3 between the upper and lower friction ring, form the wind channel between upper and lower friction ring and the rib, the inner circle of upper friction ring 2.1 be provided with the mounting groove of installation brim of a hat, and be provided with the breach 2.4 with recess 1.6 matched with on the brim of a hat at the edge of the inner circle of mounting groove.

The number of the grooves on the tray cap and the number of petals determined by the number of the grooves are determined according to the production requirement, and can be 10-30, and the number of the ribs is also determined according to the production requirement.

On the basis of the technical scheme, in order to achieve the convenience of use and the stability of equipment, the following improvements can be made to the technical scheme, and the following improvements can be implemented singly or in combination:

the combined structure after the grooves 1.6 and the notches 2.4 are matched and installed is reserved with an air ventilation hole.

The ribs 2.3 are distributed in three circles in the friction ring, and the ribs of the middle circle are arranged in a staggered manner with the ribs of the inner circle and the outer circle.

Meanwhile, in order to realize the lightweight brake disc, the invention also provides a processing method (see fig. 1-8) of the lightweight brake disc, which specifically comprises the following steps: the processing method of the lightweight composite brake disc comprises the following processing steps: casting, core making, core assembling, modeling and casting of the ductile iron plate; the casting of the ductile iron plate is as follows: casting spheroidal graphite cast iron into the shape of a disk cap; the core making means: manufacturing an air duct core and a ring core; the core assembly refers to: the disc cap 1 is arranged in the middle of the ring core 4, and then the combination piece of the disc cap 1 and the ring core 4 is arranged on the upper part of the air duct core 3 to form a combination core; the modeling refers to: the combined core is put into a sand mould cavity of a molding line to obtain a molding; the casting is as follows: pouring gray cast iron molten iron into the model, and cleaning and shot blasting after the molten iron is cooled to form the composite brake disc casting.

For the processing method, part of operations are refined:

Further, the manufacturing process of the air duct core 3 and the ring core 4 includes: firstly, designing and manufacturing a core box, and then installing the core box on a core making machine, wherein the specific core making process comprises the following steps: and adding a certain amount of binder into the new sand, and rapidly solidifying under the action of a triethylamine catalyst to obtain higher hardness of the sand core and rapidly forming the sand core, thereby forming a corresponding air duct core and a corresponding ring core.

Further, the ring core is provided with a ring core boss 4.1 matched with the groove 1.6 on the cap peak.

The foregoing description of the preferred embodiments of the invention is not intended to limit the invention to the precise form disclosed, and any such modifications, equivalents, and alternatives falling within the spirit and scope of the invention are intended to be included within the scope of the invention.

Claims

1. The processing method of the lightweight composite brake disc comprises a disc cap and a friction ring arranged on the disc cap, and is characterized in that the disc cap is processed by ductile cast iron, and the friction ring is processed by gray cast iron; the disk cap comprises a flange mounting surface with a central hole, a mounting hole and a positioning hole, a cap barrel connected with the flange mounting surface and a radially outward cap peak connected with the cap barrel; the outer ring of the cap peak is provided with a plurality of grooves which are uniformly distributed, and petals are arranged between two adjacent grooves; the friction ring comprises an upper friction ring and a lower friction ring, ribs are arranged between the upper friction ring and the lower friction ring, an air channel is formed between the upper friction ring and the ribs, an inner ring of the upper friction ring is provided with a mounting groove for mounting a cap peak, and a notch matched with a groove on the cap peak is formed at the edge of the inner ring of the mounting groove;

the method also comprises the following processing steps: casting, core making, core assembling, modeling and casting of the ductile iron plate; the casting of the ductile iron plate is as follows: casting spheroidal graphite cast iron into the shape of a disk cap; the core making means: manufacturing an air duct core and a ring core; the core assembly refers to: the disc cap is arranged in the middle of the ring core, and then the combination piece of the disc cap and the ring core is arranged on the upper part of the air duct core to form a combination core; the modeling refers to: the combined core is put into a sand mould cavity of a molding line to obtain a molding; the casting is as follows: pouring gray cast iron molten iron into the model, and cleaning and shot blasting after the molten iron is cooled to form the composite brake disc casting.

2. The method for manufacturing a lightweight composite brake disc according to claim 1, wherein the air-permeable hole is reserved in the combined structure after the groove and the notch are assembled in a matching manner.

3. The method for manufacturing a lightweight composite brake disc according to claim 1, wherein the ribs are distributed in three circles in the friction ring, and the ribs of the middle ring are arranged in a staggered manner with the ribs of the inner ring and the outer ring.

4. The method of manufacturing a lightweight composite brake disc as set forth in claim 1, wherein a machining step is added after the casting step, said machining being: turning off the surface oxide skin of the brake disc casting, and processing a mounting hole and a positioning hole on the flange surface of the disc cap.

5. The method for manufacturing a lightweight composite brake disc according to claim 4, wherein a drilling and spraying step is added after the machining step, and the drilling and spraying means: holes which are distributed in a vortex shape are processed on the friction ring, the brake disc is sprayed, and the coating is adopted to spray on the surface of the brake disc.

6. The method for manufacturing the lightweight composite brake disc according to claim 1, wherein the manufacturing process comprises the steps of: firstly, designing and manufacturing a core box, and then installing the core box on a core making machine, wherein the specific core making process comprises the following steps: and adding a certain amount of binder into the molding sand, and rapidly solidifying under the action of a triethylamine catalyst to obtain higher hardness of the sand core and rapidly forming the sand core, thereby forming a corresponding air duct core and a corresponding ring core.

7. The method for manufacturing a lightweight composite brake disc according to claim 1, wherein the annular core is provided with an annular core boss which is matched with the groove on the cap peak.

8. The method for manufacturing the lightweight composite brake disc according to claim 1, wherein in the process of combining the combined cores, the disc cap is arranged in the middle of the ring core, and the disc cap and the ring core are combined after glue with the size of two thumbs is coated at the position, close to the brim, of the lower part of the cap ring of the disc cap; the assembly of the disk cap and the ring core is mounted on the air duct core, and the assembly is adhered with the air duct core disk after four glue is smeared below the cap peak.