CN110918900A - Formula and preparation process of high-carbon brake disc - Google Patents
Formula and preparation process of high-carbon brake disc Download PDFInfo
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- CN110918900A CN110918900A CN201911331854.7A CN201911331854A CN110918900A CN 110918900 A CN110918900 A CN 110918900A CN 201911331854 A CN201911331854 A CN 201911331854A CN 110918900 A CN110918900 A CN 110918900A
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- brake disc
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
Abstract
The invention relates to the technical field of brake disc casting, and discloses a formula and a preparation process of a high-carbon brake disc, wherein the formula comprises the following steps of sand core preparation, template preparation, molding sand preparation, batching, smelting, pouring and shot blasting cleaning, and the sand core preparation comprises the following steps: s1, selecting 40-70-mesh Dahliang sand as a raw material, wherein the content of SiO2 in the Dahliang sand is more than or equal to 85% and less than or equal to 92%, and meanwhile, the normal-temperature tensile strength of the Dahliang sand is required to be more than or equal to 1.1Mpa, the gas evolution is less than or equal to 18ml/g, and the mud content is less than 1.5%; s2, spraying a layer of solid resin film on the surface of the raw material selected in the step S1 to form precoated sand; and S3, standing the precoated sand obtained in the step S2 for 36-48 hours to remove ammonia, and drying and cooling to room temperature. The invention fully utilizes the high-carbon material for remelting, avoids the loss and waste of precious alloy and the alloy pollution to common materials, and the brake disc produced by the adopted preparation process has good processing performance and high casting comprehensive yield, thereby greatly improving the quality of the brake disc.
Description
Technical Field
The invention relates to the technical field of brake disc casting, in particular to a formula of a high-carbon brake disc and a preparation process thereof.
Background
The brake disc is a key braking part on an automobile, has various types and is characterized by thin wall, consists of a disc and a sand core at the center and has higher requirement on the internal quality of a casting, so the quality of the brake disc directly influences the braking of the automobile.
Chinese patent discloses a brake disc and a preparation method thereof (No. CN 105972114A), the technology of the patent improves the wear resistance and the heat resistance of the brake disc, but the brake disc is easy to cause loss and waste of precious alloy and alloy pollution to common materials, and the yield is low, thereby leading to higher production cost. Therefore, the formula of the high-carbon brake disc and the preparation process thereof are provided by the technical personnel in the field so as to solve the problems in the background technology.
Disclosure of Invention
The invention aims to provide a formula of a high-carbon brake disc and a preparation process thereof, and aims to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
the formula of the high-carbon brake disc and the preparation process thereof comprise sand core preparation, template preparation, molding sand preparation, batching, smelting, pouring and shot blasting cleaning, wherein the sand core preparation comprises the following steps:
s1, selecting 40-70-mesh Dahliang sand as a raw material, wherein the content of SiO2 in the Dahliang sand is more than or equal to 85% and less than or equal to 92%, so that the Dahliang sand has enough fire resistance strength during casting and good deformability among sand grains during quartz expansion, and meanwhile, the Dahliang sand is required to be guaranteed to have the normal-temperature tensile strength more than or equal to 1.1MPa, the gas evolution less than or equal to 18ml/g and the mud content less than 1.5%;
s2, spraying a layer of solid resin film on the surface of the raw material selected in the step S1 to form precoated sand;
s3, standing the precoated sand obtained in the step S2 for 36-48 hours to remove ammonia, drying and cooling to room temperature, and meanwhile ensuring that the surface of the sand core is required to be smooth and round, has no flow marks, no accumulated lumps, no visual micropores and no defects of fins, dislocation of rib parts, collision, abrasion and the like in appearance.
As a still further scheme of the invention: the template preparation comprises single-piece variety preparation and double-piece variety preparation, wherein the single-piece variety adopts a center forced feeding hot riser pouring process, the variety with the inner cavity depth smaller than 20mm of the single-piece variety adopts an external overheating riser and center blank pressing feeding riser process, the variety with the single-piece thickness smaller than 10mm of the double-piece variety adopts a rear ground surface scattered gate process, and the variety with the gate thickness of 3-5 mm and the single-piece thickness larger than or equal to 10mm of the double-piece variety adopts an external overheating feeding hot riser process.
As a still further scheme of the invention: the double-piece variety comprises a single-layer casting double-piece variety and a double-layer casting double-piece variety, wherein the double-layer casting double-piece variety adopts an external scattered gate process, and when shrinkage porosity or looseness occurs, a top positioning hole and a feeding blank pressing and riser process is adopted.
As a still further scheme of the invention: the preparation method of the molding sand comprises the following steps:
s1, adding new sand in a normalized mode, wherein the adding amount of the new sand is 2-3%, then adopting 40-70-mesh forest sand, and the content of SiO2 is more than or equal to 85% and less than or equal to 92%, performing mixed pouring, ensuring that a cavity has enough fire resistance strength during pouring and good deformability between sand grains when quartz expands, improving the air permeability of molding sand, and eroding the gas evolution amount of the unburned core sand;
s2, monitoring various indexes of the molding sand on line to ensure that the qualified molding sand is used for producing castings, if no old line of an online automatic monitoring device exists, putting devices for measuring air permeability, wet tensile strength, compaction rate and wet pressure into a sand processing control chamber as much as possible, ensuring the timeliness of monitoring and preventing the quality of the molding sand from generating large fluctuation;
s3, on the basis of S2, controlling the wet compression strength of the molding sand to be 0.11-0.15 Mpa, the wet tensile strength to be more than or equal to 0.02Mpa, the air permeability to be more than or equal to 180-200, the water content to be less than or equal to 2.5-3%, the gas forming amount to be less than or equal to 25ml/g, the compaction rate to be more than or equal to 40-5%, the mud content and the effective bentonite to be more than or equal to 8%.
As a still further scheme of the invention: 30-40% of batching scrap steel, 60-70% of remelting, 1.5-1.9% of carburant (C content 95%), 0.3-0.5% of copper (99%), 0.32-0.36% of ferrochrome (60%) and 0.13% of tin and iron (99%).
As a still further scheme of the invention: the smelting comprises the following steps:
s1, putting a small amount of scrap iron into the smelting furnace to bottom up, then putting 10% of scrap steel and 40% of carburant into the smelting furnace in sequence, and then putting the rest scrap steel and the rest carburant into the smelting furnace in sequence;
s2, putting the returning and the ferrochrome into the smelting furnace in sequence, and then continuing to put the returning into the furnace for smelting until the smelting furnace is full;
s3, adding a covering agent along the furnace wall at 1300 ℃, heating to 1400 ℃ and detecting the components of the molten iron by spectrum;
s4, adjusting the contents of carbon, silicon, copper and chromium according to the detection result, heating to 1520 ℃ after the components are adjusted to be qualified, discharging to a pouring ladle, wherein the inoculation amount in front of the furnace is about 0.25%;
s5, adding tin when the molten iron is poured into the pouring ladle, adding a covering agent, removing slag once, adding the covering agent, and keeping the temperature, wherein the inoculant in the pouring ladle is about 0.05%.
As a still further scheme of the invention: the total time from the discharging to the pouring is controlled within 20 minutes to prevent the pregnancy from declining, the time in a box is controlled within 1.2 hours after the pouring is finished, when constant-temperature pouring equipment is provided, the pouring temperature is controlled to be 1380-1420 ℃ in double pieces, the single piece is controlled to be 1360-1400 ℃, when the constant-temperature pouring equipment is not provided, the pouring temperature of double-piece flaming varieties is controlled to be 1430-1480 ℃, the pouring temperature of non-flaming varieties is controlled to be 1410-1460 ℃, and the pouring temperature of the single piece is controlled to be 1380-1430 ℃.
Compared with the prior art, the invention has the beneficial effects that:
the invention fully utilizes the high-carbon material for remelting, avoids the loss and waste of precious alloy and the alloy pollution to common materials, and the brake disc produced by the adopted preparation process has good processing performance and high casting comprehensive yield, thereby greatly improving the quality of the brake disc, improving the production efficiency of the brake disc and reducing the production cost of the brake disc.
Drawings
FIG. 1 is a flow chart of a formula of a high-carbon brake disc and a preparation process thereof.
Detailed Description
Referring to fig. 1, in the embodiment of the present invention, a formula of a high-carbon brake disc and a preparation process thereof include sand core preparation, template preparation, molding sand preparation, blending, smelting, pouring and shot blasting, and preferably, the sand core preparation includes the following steps:
s1, selecting 40-70-mesh Dahliang sand as a raw material, wherein the content of SiO2 in the Dahliang sand is more than or equal to 85% and less than or equal to 92%, so that the Dahliang sand has enough fire resistance strength during casting and good deformability among sand grains during quartz expansion, and meanwhile, the Dahliang sand is required to be guaranteed to have the normal-temperature tensile strength more than or equal to 1.1MPa, the gas evolution less than or equal to 18ml/g and the mud content less than 1.5%;
s2, spraying a layer of solid resin film on the surface of the raw material selected in the step S1 to form precoated sand;
s3, standing the precoated sand obtained in the step S2 for 36-48 hours to remove ammonia, drying and cooling to room temperature, and meanwhile ensuring that the surface of the sand core is required to be smooth and round, has no flow marks, no accumulated lumps, no visual micropores and no defects of fins, dislocation of rib parts, collision, abrasion and the like in appearance.
Preferentially, the template preparation comprises single-piece variety preparation and double-piece variety preparation, wherein the single-piece variety adopts a center forced feeding hot riser pouring process, the variety with the inner cavity depth less than 20mm of the single-piece variety adopts an external overheating riser and center blank pressing feeding riser process, the variety with the single-piece thickness less than 10mm of the double-piece variety adopts a rear ground surface scattered gate process, and the variety with the gate thickness of 3-5 mm and the single-piece thickness more than or equal to 10mm of the double-piece variety adopts an external overheating feeding riser process.
Preferably, the two-piece variety comprises a single-layer casting two-piece variety and a double-layer casting two-piece variety, the double-layer casting two-piece variety adopts an external scattered gate process, and when shrinkage porosity or looseness occurs, a top positioning hole and a feeding blank pressing and riser process are adopted.
Preferably, the molding sand preparation comprises the following steps:
s1, adding new sand in a normalized mode, wherein the adding amount of the new sand is 2-3%, then adopting 40-70-mesh forest sand, and the content of SiO2 is more than or equal to 85% and less than or equal to 92%, performing mixed pouring, ensuring that a cavity has enough fire resistance strength during pouring and good deformability between sand grains when quartz expands, improving the air permeability of molding sand, and eroding the gas evolution amount of the unburned core sand;
s2, monitoring various indexes of the molding sand on line to ensure that the qualified molding sand is used for producing castings, if no old line of an online automatic monitoring device exists, putting devices for measuring air permeability, wet tensile strength, compaction rate and wet pressure into a sand processing control chamber as much as possible, ensuring the timeliness of monitoring and preventing the quality of the molding sand from generating large fluctuation;
s3, on the basis of S2, controlling the wet compression strength of the molding sand to be 0.11-0.15 Mpa, the wet tensile strength to be more than or equal to 0.02Mpa, the air permeability to be more than or equal to 180-200, the water content to be less than or equal to 2.5-3%, the gas forming amount to be less than or equal to 25ml/g, the compaction rate to be more than or equal to 40-5%, the mud content and the effective bentonite to be more than or equal to 8%.
Preferably, 30-40% of scrap steel, 60-70% of remelting, 1.5-1.9% of carburant (C content 95%), 0.3-0.5% of copper (99%), 0.32-0.36% of ferrochrome (60%) and 0.13% of tin and iron (99%).
Preferably, the smelting comprises the following steps:
s1, putting a small amount of scrap iron into the smelting furnace to bottom up, then putting 10% of scrap steel and 40% of carburant into the smelting furnace in sequence, and then putting the rest scrap steel and the rest carburant into the smelting furnace in sequence;
s2, putting the returning and the ferrochrome into the smelting furnace in sequence, and then continuing to put the returning into the furnace for smelting until the smelting furnace is full;
s3, adding a covering agent along the furnace wall at 1300 ℃, heating to 1400 ℃ and detecting the components of the molten iron by spectrum;
s4, adjusting the contents of carbon, silicon, copper and chromium according to the detection result, heating to 1520 ℃ after the components are adjusted to be qualified, discharging to a pouring ladle, wherein the inoculation amount in front of the furnace is about 0.25%;
s5, adding tin when the molten iron is poured into the pouring ladle, adding a covering agent, removing slag once, adding the covering agent, and keeping the temperature, wherein the inoculant in the pouring ladle is about 0.05%.
Preferably, the total time from discharging to pouring is controlled within 20 minutes to prevent pregnancy from declining, the time in a box is controlled within 1.2 hours after pouring is finished, when constant-temperature pouring equipment is provided, the pouring temperature is controlled to be 1380-1420 ℃ in double pieces, the single piece is controlled to be 1360-1400 ℃, when the constant-temperature pouring equipment is not provided, the pouring temperature of double-piece choked varieties is controlled to be 1430-1480 ℃, the pouring temperature of non-choked varieties is controlled to be 1410-1460 ℃, and the pouring temperature of single piece is controlled to be 1380-1430 ℃.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention are equivalent to or changed within the technical scope of the present invention.
Claims (7)
1. A formula of a high-carbon brake disc and a preparation process thereof comprise sand core preparation, template preparation, molding sand preparation, batching, smelting, pouring and shot blasting cleaning, and are characterized in that the sand core preparation comprises the following steps:
s1, selecting 40-70-mesh Dahliang sand as a raw material, wherein the content of SiO2 in the Dahliang sand is more than or equal to 85% and less than or equal to 92%, so that the Dahliang sand has enough fire resistance strength during casting and good deformability among sand grains during quartz expansion, and meanwhile, the Dahliang sand is required to be guaranteed to have the normal-temperature tensile strength more than or equal to 1.1MPa, the gas evolution less than or equal to 18ml/g and the mud content less than 1.5%;
s2, spraying a layer of solid resin film on the surface of the raw material selected in the step S1 to form precoated sand;
s3, standing the precoated sand obtained in the step S2 for 36-48 hours to remove ammonia, drying and cooling to room temperature, and meanwhile ensuring that the surface of the sand core is required to be smooth and round, has no flow marks, no accumulated lumps, no visual micropores and no defects of fins, dislocation of rib parts, collision, abrasion and the like in appearance.
2. The formula and the preparation process of the high-carbon brake disc according to claim 1, wherein the template preparation comprises single-piece variety preparation and double-piece variety preparation, the single-piece variety adopts a center forced feeding hot riser casting process, the variety with the inner cavity depth less than 20mm of the single-piece variety adopts an external overheating riser and center blank-pressing feeding riser process, the variety with the single-piece thickness less than 10mm adopts a post-grinding surface dispersed gate process, and the variety with the gate thickness of 3-5 mm and the single-piece thickness more than or equal to 10mm of the double-piece variety adopts an external overheating feeding riser process.
3. The formulation and process for preparing a high-carbon brake disc according to claim 2, wherein the two-piece variety comprises a single-layer cast two-piece variety and a double-layer cast two-piece variety, the double-layer cast two-piece variety adopts an external scatter-gate process, and when shrinkage porosity or looseness occurs, a top positioning hole and a feeding blank holder riser process are adopted.
4. The formulation of a high-carbon brake disc and the preparation process thereof according to claim 1, wherein the preparation of the molding sand comprises the following steps:
s1, adding new sand in a normalized mode, wherein the adding amount of the new sand is 2-3%, then adopting 40-70-mesh forest sand, and the content of SiO2 is more than or equal to 85% and less than or equal to 92%, performing mixed pouring, ensuring that a cavity has enough fire resistance strength during pouring and good deformability between sand grains when quartz expands, improving the air permeability of molding sand, and eroding the gas evolution amount of the unburned core sand;
s2, monitoring various indexes of the molding sand on line to ensure that the qualified molding sand is used for producing castings, if no old line of an online automatic monitoring device exists, putting devices for measuring air permeability, wet tensile strength, compaction rate and wet pressure into a sand processing control chamber as much as possible, ensuring the timeliness of monitoring and preventing the quality of the molding sand from generating large fluctuation;
s3, on the basis of S2, controlling the wet compression strength of the molding sand to be 0.11-0.15 Mpa, the wet tensile strength to be more than or equal to 0.02Mpa, the air permeability to be more than or equal to 180-200, the water content to be less than or equal to 2.5-3%, the gas forming amount to be less than or equal to 25ml/g, the compaction rate to be more than or equal to 40-5%, the mud content and the effective bentonite to be more than or equal to 8%.
5. The formula and the preparation process of the high-carbon brake disc according to claim 1 are characterized in that 30-40% of the batching scrap steel, 60-70% of the tempering furnace, 1.5-1.9% of the carburant (C content 95%), 0.3-0.5% of copper (99%), 0.32-0.36% of ferrochrome (60%) and 0.13% of tin and iron (99%).
6. The formula and the preparation process of the high-carbon brake disc according to claim 1, wherein the smelting comprises the following steps:
s1, putting a small amount of scrap iron into the smelting furnace to bottom up, then putting 10% of scrap steel and 40% of carburant into the smelting furnace in sequence, and then putting the rest scrap steel and the rest carburant into the smelting furnace in sequence;
s2, putting the returning and the ferrochrome into the smelting furnace in sequence, and then continuing to put the returning into the furnace for smelting until the smelting furnace is full;
s3, adding a covering agent along the furnace wall at 1300 ℃, heating to 1400 ℃ and detecting the components of the molten iron by spectrum;
s4, adjusting the contents of carbon, silicon, copper and chromium according to the detection result, heating to 1520 ℃ after the components are adjusted to be qualified, discharging to a pouring ladle, wherein the inoculation amount in front of the furnace is about 0.25%;
s5, adding tin when the molten iron is poured into the pouring ladle, adding a covering agent, removing slag once, adding the covering agent, and keeping the temperature, wherein the inoculant in the pouring ladle is about 0.05%.
7. The formulation and preparation process of a high-carbon brake disc as claimed in claim 6, wherein the total time from tapping to pouring is controlled within 20 minutes to prevent the decline of pregnancy, the time in the box is controlled within 1.2 hours after pouring, when constant temperature pouring equipment is provided, the pouring temperature is controlled between 1380 ℃ and 1420 ℃ for the two discs, between 1360 ℃ and 1400 ℃ for the single disc, when constant temperature pouring equipment is not provided, the pouring temperature for the two disc flaming variety is controlled between 1430 ℃ and 1480 ℃, the pouring temperature for the non-flaming variety is controlled between 1410 ℃ and 1460 ℃, and the pouring temperature for the single disc is controlled between 1380 ℃ and 1430 ℃.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911331854.7A CN110918900A (en) | 2019-12-21 | 2019-12-21 | Formula and preparation process of high-carbon brake disc |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911331854.7A CN110918900A (en) | 2019-12-21 | 2019-12-21 | Formula and preparation process of high-carbon brake disc |
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| CN110918900A true CN110918900A (en) | 2020-03-27 |
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