CN109048200B - Method for repairing thermal cracks of brake disc of railway passenger car by laser bionic locking pinning - Google Patents
Method for repairing thermal cracks of brake disc of railway passenger car by laser bionic locking pinning Download PDFInfo
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- CN109048200B CN109048200B CN201810748595.7A CN201810748595A CN109048200B CN 109048200 B CN109048200 B CN 109048200B CN 201810748595 A CN201810748595 A CN 201810748595A CN 109048200 B CN109048200 B CN 109048200B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
Abstract
The invention relates to a method for repairing a thermal crack on the surface of a brake disc by bionic locking and pinning of laser, which is characterized in that a plurality of locking and pinning points are prepared along the extending direction of a crack for an extended crack with the length of the surface of the brake disc being more than 5 mm; and preparing a reticular bionic unit body consisting of a circular bionic unit body and a bionic strip-shaped unit body for a working area with short cracks of which the length is less than 5mm on the surface of the brake disc. The invention effectively solves the problems of long time consumption and high material consumption for repairing the brake disc, the locking pinning points distributed on the cracks with the length of more than 5mm are beneficial to releasing the concentrated stress for cracking the cracks, meanwhile, the point-shaped pinning points prepared at the tips of the cracks make the cracks more difficult to crack, the cracks with the length of less than 5mm are sealed inside the reticular surface by the annular strip-shaped area surface, the short cracks can be effectively prevented from further growing and the stress distribution on the surface of the brake disc is changed, the blank surface stress of the unit which is not prepared is reduced, and the cracking of the cracks is further prevented.
Description
Technical Field
The invention belongs to the technical field of repair of brake discs of low-speed railway vehicles, and relates to a method for repairing thermal cracks of brake discs of railway vehicles by bionic locking pinning of laser.
Background
Disc-shaped brake devices are adopted for basic braking of low-speed railway passenger cars, and for low-speed railway trains below 200Km/h, brake devices formed by matching cast iron brake discs and powder metallurgy brake pads are generally adopted. The brake disc is the most important part of a disc brake assembly and must convert the large kinetic energy of the train into frictional heat energy by friction with the brake lining and dissipate the heat to the surrounding environment. The structure of the composite material requires good friction performance, good heat cracking resistance and good ventilation and heat dissipation performance. For the brake disc structure of the low-speed railway passenger car, the first factor to be considered is that the brake disc structure has good thermal expansion performance so as to reduce the thermal stress generated during braking to the maximum extent, and the disc body material of the brake disc has a remarkable influence on the service life of the brake disc. During braking, a large temperature gradient occurs in the brake disc, the brake disc is subjected to great thermal stress, and fatigue failure of the brake disc can occur after multiple thermal stress cycles. The failure of the brake disc of the railway passenger car with the speed of 200KM/h or below takes the fatigue crack length and the wear degree as criteria, namely, the maximum crack length is not more than 50mm, the crack distance from the edge of the disc is not less than 10mm, the thickness of the brake disc is not less than 112mm, and the unilateral wear is not more than 7 mm. In addition, the thermal cracks on the surface of the brake disc mainly consist of extended cracks with the length of 30-50mm, the width of 0.2-0.6mm and the depth of 1-6mm, which cause failure, and cracks with the length of less than 5mm extending over the surface of the brake disc. Because the length and the number of the cracks are different, the service requirement is difficult to meet by adopting a single repairing method.
Disclosure of Invention
The invention aims to provide a method for repairing the thermal cracks of a brake disc of a railway passenger car by bionic locking pinning of laser, which can solve the problem that the brake disc of a low-speed railway passenger car is difficult to regenerate due to different lengths, numbers and depths of fatigue cracks.
In order to solve the problems, the method for repairing the thermal cracks on the surface of the brake disc by laser bionic locking pinning is characterized in that a plurality of locking pinning points are prepared along the extending direction of cracks for extended cracks with the length of the surface of the brake disc being more than 5 mm; and preparing a reticular bionic unit body consisting of a circular bionic unit body and a bionic strip-shaped unit body for a working area with short cracks of which the length is less than 5mm on the surface of the brake disc.
Aiming at an expanded crack with the surface length of the brake disc being more than 5mm, B-type locking pinning points are prepared at two tips of the crack, and the surface diameter R of the B-type locking pinning points32-3mm, depth H3Is 0.4-0.6 mm; preparing a class A locking pinning point in a region between two class B locking pinning points; class A pinning sites prepared in the region of crack width less than 0.4mm and having surface diameter R10.6-0.8mm, depth H1Is 2-4mm, and has a spacing D1Is 3-5 mm; class A pinning sites prepared in the region of crack width greater than 0.4mm and having surface diameter R20.8-1.5mm, depth H2Is 3-5mm, and has a spacing D2Is 5-7 mm.
The B-type locking pinning point is U-shaped in cross section and is prepared by a one-time laser fusion method, the laser processing energy density is 4.55-6.03J/mm2, the laser frequency is 2.5-3.5HZ, and the processing time is 2 seconds.
The section of the A-type locking pinning point is in a deep v shape, and the A-type locking pinning point is prepared by adopting a method of 3 times of melting and additional multiple times of cladding of pure iron powder until the processed pinning point is 0.1 mm higher than the surface; the laser processing energy density at the fusing stage is 8-12J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 2 seconds; the energy density of laser processing at the multiple cladding stage is 8.05J-14J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 3 seconds.
For a working area with short cracks with the length less than 5mm on a brake disc, a plurality of strip-shaped bionic unit bodies which are inclined in the same direction are prepared in a ring belt between an initial circular bionic unit body and a maximum circular bionic unit body, an included angle A between a connecting line of an initial point of two adjacent strip-shaped bionic unit bodies and the circle center of a revolving body is set to be an included angle theta 1, theta 1 is 9-18 degrees, an included angle B between the strip-shaped bionic unit bodies and a circle tangent line of a processing initial point is set to be an included angle theta 2, and theta 2 is 15-30 degrees.
The cross section of the strip-shaped bionic unit body is arched, the width-to-height ratio of the cross section is 0.8-1.05, the bionic unit body is prepared by adopting a laser melting method, and the laser added functional energy density is 6.63-8.05J/mm2The laser frequency is 2.5-3.5Hz, and the scanning speed is 1-2.0 mm/s.
The distance between the circular bionic unit bodies in the ring belt and the included angle theta 1 of the A are selected according to the number of short cracks with the length being less than 5 mm.
Drawing a circular arc line with the length of 20mm on the surface 50mm away from the edge of the brake disc; for the passing area of the circular arc line, when the number of the short cracks is smallIn 3 cases, the distance D of the circular bionic unit bodies used in the girdle320-30 mm, and the included angle theta 1 of A is 12-18 degrees; when the number of the short cracks is more than 3, the distance D of the circular bionic unit bodies used in the girdle315-20 mm, and the included angle theta 1 of A is 9-12 degrees.
The invention changes the existing method for repairing the brake disc by full-surface surfacing, adopts a locking and pinning method by applying the bionic idea, and adopts a single locking and pinning method for cracks with the length of more than 5 mm; and adopting a full-surface bionic strengthening method for the cracks with the length less than 5 mm. The problems that the time consumption for repairing the brake disc is long and the material consumption is high and the repair is difficult are effectively solved. The locking pinning points on the cracks with the length of more than 5mm have higher strength than that of the parent body, and are discretely distributed according to a certain distance in the crack expansion direction, the distribution is beneficial to releasing the concentrated stress for cracking the cracks, and meanwhile, the point-shaped nail points prepared at the tips of the cracks have higher strength, so that the cracks are more difficult to crack. The cracks with the length less than 5mm are sealed inside the reticular surface by the annular strip-shaped area surface, so that the surface effectively prevents the short cracks from further growing, the stress distribution on the surface of the brake disc can be changed due to the existence of the reticular units, the blank surface stress of the units which are not prepared is reduced, and the cracks are further prevented from cracking.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
FIG. 1 is a schematic diagram of the present invention employing laser technology to repair extended cracks of brake discs having a length exceeding 5 mm.
FIG. 2a and FIG. 2B are schematic longitudinal sectional views of class A lock pin points and class B lock pin points, respectively.
FIG. 3 is a schematic view of the surface of a brake disc with a ring-shaped bionic unit body prepared by a laser technology.
Detailed Description
As shown in figures 1 and 3, the method for repairing the thermal cracks on the surface of the brake disc by the bionic locking pinning of the laser provided by the invention has the advantages that for the extended cracks with the length of the surface of the brake disc being more than 5mm, a plurality of A-type locking pinning points with different sizes are prepared along the extending direction of the cracks, and B-type locking pinning points are prepared at the tips of the cracks; and preparing a ring-shaped annular strengthening unit for a working area with short cracks with the length less than 5mm on the surface of the brake disc.
As shown in FIG. 2a and FIG. 2b, for extended cracks with a length greater than 5mm, different types A locking and pinning points with different sizes are adopted according to the width of the crack, and the cross section of the extended crack is in a deep v shape. Specifically, in the region where the crack width is less than 0.4mm, the surface diameter R of the class A lock pinning point is used10.6-0.8mm, depth H1Is 2-4mm, and has a spacing D1Is 3-5 mm; in the region with crack width larger than 0.4mm, the surface diameter R of the A-type locking pinning point is used20.8-1.5mm, depth H2Is 3-5mm, and has a spacing D2Is 5-7 mm; class B lock-in pinning points at the tips of the cracks having a U-shaped cross-section and a surface diameter R32-3mm, depth H3Is 0.4-0.6 mm.
The class A locking pinning point is prepared by adopting a method of melting for 3 times and additionally cladding pure iron powder for multiple times until the processed pinning point is 0.1 mm higher than the surface; the laser processing energy density at the fusing stage is 8-12J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 2 seconds; the energy density of laser processing at the multiple cladding stage is 8.05J-14J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 3 seconds. The strength of the A-type locking pinning point is 512MPa-540MPa, which is improved by 1.2-1.4 times compared with the parent body, so that the service life of the brake disc is prolonged by 1.1-2 times.
The B-type locking pinning point is prepared by a one-time laser fusing method, the laser processing energy density is 4.55-6.03J/mm2, the laser frequency is 2.5-3.5HZ, and the processing time is 2 seconds. The strength of the B-type locking pinning point is 526-533MPa, so that the further expansion of cracks can be effectively prevented, and the service life of the brake disc is further prolonged by 2.1-3.5 times.
And for a working area with short cracks with the length less than 5mm on the brake disc, processing a net-shaped full-surface bionic unit body consisting of a circular bionic unit body and a bionic strip-shaped unit body on the surface of the working area. The radius of the starting circular bionic unit body is 100mm, and the radius of the largest circular bionic unit body is 320 mm; girdle band between starting circular bionic unit body and maximum circular bionic unit bodyA plurality of strip bionic unit bodies inclined in the same direction are prepared. And setting an included angle between the starting point of two adjacent strip-shaped bionic unit bodies and the connecting line of the circle centers of the revolving bodies as an included angle theta 1, and setting an included angle between the strip-shaped bionic unit bodies and the circle tangent of the processing starting point as an included angle theta 2. The distance between the annular bionic unit bodies in the ring belt and the included angle theta 1A are selected according to the number of short cracks with the length being less than 5mm, and the method specifically comprises the following steps: drawing a circular arc line with the length of 20mm on the surface 50mm away from the edge of the brake disc along the circumferential direction, and using a circular ring space D when the number of cracks is less than 3 for the area where the circular arc line passes through3When the included angle A is 20-30 mm, the included angle theta 1 is 12-18 degrees. Ring spacing D used when the number of cracks is greater than 33When the diameter is 15-20 mm, the included angle theta 1 of A is 9-12 degrees.
The cross section of the strip-shaped bionic unit body is arched, the width-to-height ratio of the cross section is 0.8-1.05, the bionic unit body is prepared by adopting a laser melting method, and the laser added functional energy density is 6.63-8.05J/mm2The laser frequency is 2.5-3.5Hz, and the scanning speed is 1-2.0 mm/s.
The specific repair process is as follows:
the method comprises the following steps of firstly, preprocessing the surface of a brake disc of the railway carriage after being abraded by utilizing mechanical milling, and flattening the surface while removing various stains and oxide skins on the surface;
step two, determining the included angle theta 1 of A and the distance D between the annular bionic unit bodies according to the number of the cracks with the surface length of the brake disc less than 5mm for the short cracks with the surface length of the brake disc less than 5mm3. The processing starting radius of the brake disc is 100mm, and the distance is D3The maximum radius of the circular bionic unit bodies is 320mm, strip-shaped bionic unit bodies which incline in the same direction are prepared in the girdle band, the included angle (A included angle theta 1) between the starting point of two adjacent strip-shaped bionic unit bodies which incline in the same direction and the connecting line of the circle centers of the revolution bodies is 9-18 degrees, and the included angle (B included angle) theta 2 between the strip-shaped bionic unit bodies and the circle tangent line of the processing starting point is 15-30 degrees.
Step three, preparing A-type locking pinning points with different sizes for the extended cracks with the length exceeding 5mm according to different crack widths, specifically, preparing the surface diameter R of the A-type locking pinning points used in the region with the crack width smaller than 0.4mm1Is 0.6-0.8mmDepth H1Is 2-4mm, and has a spacing D1Is 3-5 mm. Region with crack width greater than 0.4mm, surface diameter R of A-type locking pinning point20.8-1.5mm, depth H2Is 3-5mm apart2Is 5-7 mm.
Fourthly, preparing a B-type locking pinning point at the tip of the expanded crack, wherein the section of the B-type locking pinning point is U-shaped, and the surface diameter R of the B-type locking pinning point3Is 2-3mm, depth H3Is 0.4-0.6 mm.
An example of a laser biomimetic locking pinned prosthetic cast iron brake disc application is shown in table 1.
TABLE 1
Claims (5)
1. A method for repairing the thermal cracks on the surface of a brake disc by bionic laser locking and pinning is characterized in that a plurality of locking and pinning points are prepared along the extending direction of cracks for extended cracks with the length of the surface of the brake disc being more than 5 mm; preparing a reticular bionic unit body consisting of a circular bionic unit body and a strip-shaped bionic unit body for a working area with short cracks with the length less than 5mm on the surface of the brake disc; aiming at an expanded crack with the surface length of the brake disc being more than 5mm, B-type locking pinning points are prepared at two tips of the crack, and the surface diameter R of the B-type locking pinning points32-3mm, depth H30.4-0.6 mm; preparing a class A locking pinning point in a region between two class B locking pinning points; class A pinning sites prepared in the region of crack width less than 0.4mm and having surface diameter R10.6-0.8mm, depth H1Is 2-4mm, and has a spacing D1Is 3-5 mm; class A pinning sites prepared in the region of crack width greater than 0.4mm and having surface diameter R20.8-1.5mm, depth H2Is 3-5mm, and has a spacing D2Is 5-7 mm; the B-type locking pinning point has a U-shaped cross section and is prepared by a one-step laser melting methodThe laser processing energy density is 4.55-6.03J/mm2The laser frequency is 2.5-3.5HZ, and the processing time is 2 seconds; the section of the A-type locking pinning point is in a deep v shape, and the A-type locking pinning point is prepared by adopting a method of 3 times of melting and additionally cladding pure iron powder for multiple times until the processed pinning point is 0.1 mm higher than the surface; the laser processing energy density at the fusing stage is 8-12J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 2 seconds; the energy density of laser processing at the multiple cladding stage is 8.05J-14J/mm2The laser frequency is 2.5-3.5Hz, and each processing time is 3 seconds.
2. The method for repairing the thermal cracks on the surface of the brake disc by the laser bionic locking pinning according to claim 1, wherein for a working area with short cracks with the length of less than 5mm on the brake disc, a plurality of strip-shaped bionic unit bodies inclined in the same direction are prepared in an annular zone between an initial circular bionic unit body and a maximum circular bionic unit body, an included angle between the initial point of two adjacent strip-shaped bionic unit bodies and a connecting line of the circle centers of the brake disc is an included angle A1, the included angle theta 1 is 9-18 degrees, an included angle between the strip-shaped bionic unit bodies and a circle tangent of the machining initial point is an included angle B2, and the included angle theta 2 is 15-30 degrees.
3. The method for repairing the thermal cracks on the surface of the brake disc through the laser bionic locking pinning according to claim 2, wherein the cross section of the strip-shaped bionic unit body is arched, the width-to-height ratio of the cross section is 0.8-1.05, the bionic unit body is prepared through a laser fusing method, and the laser adding energy density of the bionic unit body is 6.63-8.05J/mm2The laser frequency is 2.5-3.5Hz, and the scanning speed is 1-2.0 mm/s.
4. The method for repairing the thermal cracks on the surface of the brake disc through the laser bionic locking pinning according to claim 2, wherein the distance between the circular bionic unit bodies in the annular band and the included angle theta 1 between the circular bionic unit bodies in the annular band are selected according to the number of short cracks with the length being less than 5 mm.
5. The method for repairing the thermal cracks on the surface of the brake disc by the bionic laser locking pinning according to claim 4, wherein the distance between the laser bionic locking pinning and the edge of the brake disc is 50mDrawing a circular arc line with the length of 20mm on the surface of the m; for the passing area of the arc line, when the number of the short cracks is less than 3, the distance D of the circular bionic unit bodies used in the ring belt320-30 mm, and the included angle theta 1 of A is 12-18 degrees; when the number of the short cracks is more than 3, the distance D of the circular bionic unit bodies used in the girdle315-20 mm, and the included angle theta 1 of A is 9-12 degrees.
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| CN110029342B (en) * | 2019-02-27 | 2021-03-23 | 吉林大学 | Method for bionic regeneration of creeping iron brake disc of low-speed railway passenger car by laser |
| CN114150309B (en) * | 2021-12-14 | 2023-08-29 | 长春工业大学 | Aluminum-based metal bionic surface containing pinning structure strengthening layer and preparation method thereof |
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