CN111114197A - Bimetallic brake hub shell, metal wheel, cylindrical metal component and manufacturing method thereof - Google Patents
Bimetallic brake hub shell, metal wheel, cylindrical metal component and manufacturing method thereof Download PDFInfo
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- CN111114197A CN111114197A CN202010138434.3A CN202010138434A CN111114197A CN 111114197 A CN111114197 A CN 111114197A CN 202010138434 A CN202010138434 A CN 202010138434A CN 111114197 A CN111114197 A CN 111114197A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
- B60B27/00—Hubs
- B60B27/0047—Hubs characterised by functional integration of other elements
- B60B27/0057—Hubs characterised by functional integration of other elements the element being a brake drum
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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
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
Abstract
The invention discloses a bimetal brake hub shell, a metal wheel, a cylindrical metal component and a manufacturing method thereof. Waste metal materials are centrifugally cast into a circular casting blank, and then the casting blank is subjected to hot extrusion to form a pot-shaped intermediate. Then, the pot-shaped intermediate body is subjected to spinning operation. And then a bimetallic brake hub shell, a metal wheel or a cylindrical metal component is manufactured. The formed product has good metallographic structure, high material performance, light weight and high strength. The manufacturing method of the cylindrical part can be used for manufacturing a metal part with a larger cylinder body, does not need to weld and connect the cylinder bottom part and the cylinder body part, improves the mechanical strength, and has lower material cost than the cylindrical part formed by stamping a metal plate.
Description
Technical Field
The invention relates to a method for manufacturing an automobile brake hub shell, in particular to a method for manufacturing a bimetal brake hub shell of a steel shell, and also relates to the brake hub shell manufactured by the method. The invention also relates to a method for manufacturing a metal wheel, a tubular metal part and a manufacturing method.
Background
The conventional truck generally uses a drum brake system, wherein a cylindrical metal brake hub is arranged on an inner ring of a hub and is fixedly connected with the hub through an end flange, and a brake pad and the brake system are arranged in an inner space of the brake hub.
Originally, automotive brake hubs were cast from gray cast iron, which has also once occupied the major market for automotive brake hubs, since gray cast iron is a relatively good friction material. However, the gray cast iron brake hub has obvious defects that the arrangement structure of metal crystals is not compact, the cast state is loose, the strength of gray cast iron is not high, and the brake hub needs to be made thick in order to keep the shape stability and the structural integrity of the cast iron brake hub. The defects that the casting process cannot overcome are large in weight, low in strength and poor in metallographic structure.
Later, a bi-metallic brake hub was developed. The aim of light weight is achieved, the weight and the thickness of the brake hub are reduced, the outer shell layer made of steel materials is selected to ensure the mechanical strength, and the inner layer is friction-braked by taking gray cast iron as a friction layer. Since the steel material has much higher mechanical strength than cast iron, the overall thickness and weight can be reduced. The transition from mechanical bonding to metallurgical casting bonding between the inner and outer layers of the bimetallic brake hub now forms a cast bonded bimetallic brake hub as shown in fig. 1. The brake hub is composed of a rim portion 1 of a brake hub shell and a friction layer 2, the friction layer 2 is cast and combined in the rim portion 1 of the brake hub shell, and the shell is made of steel, so that the thickness can be reduced, the weight is reduced, the strength is increased, and the mechanical strength is guaranteed. The rim part 1 and the flange part 4 of the shell are in integral transition connection through a bend 3, the flange part is provided with a screw hole 401 and a central hole 403, and a weight-reducing pit 402 can also be arranged. Because the friction layer 2 is cast inside the shell, the shell in the prior art is generally formed by cutting and spinning a steel plate, and the metal crystal structures are arranged more closely. The overall thickness and weight of the brake hub is greatly reduced.
But also results in a significant cost increase as the weight and thickness of the brake hub are reduced and performance is improved. For example, although the cast iron brake hub is large in material consumption, the material price is low, the processing procedures are few, and the material cost and the processing cost are low. The bimetallic brake hub has high material cost and high processing cost. For example, the housing of the bimetallic brake hub in the prior art is made of a steel plate through cutting, blanking and spinning by a spinning machine. In the process, the brake hub shell needs to be cut into circular steel plate materials. Because the formed commercial steel plate does not contain the material with the specification structure, but only has the formed square, rectangular or coiled plate material, a large amount of corners and central parts need to be cut off during blanking, and leftovers directly become scrap steel, thereby causing the waste of the steel plate material. As shown in fig. 2 and 3, when the square steel plate is used, it is required to cut into circular ring plates with portions C and D reserved, and the edge portions a and the central circular center portion B can be used only as scrap steel, which is high in scrap rate. If the circular steel plate with the outer diameter of 1000 mm and the inner diameter of 300 mm is cut, the scrap rate is 28.5%. And meanwhile, the cost of the steel plate material is high, so that the manufacturing cost of the integral brake hub is not reduced. Also, a seamless steel pipe is used as a starting material, for example, in patent 2012200610272, the seamless steel pipe is used as a starting material, and the manufacturing method is more expensive and unacceptable, and is not suitable for the current automobile brake hub manufacturing field at all.
In the prior art, a brake hub is manufactured by a double centrifugal casting method, a shell is formed by cast steel centrifugal casting, and a friction layer is formed by gray cast iron centrifugal casting. However, the strength of the brake hub shell still has the problem that the strength of the brake hub shell is still high because the metallographic structure of the shell formed by the cast steel is not changed when the shell is not forged or rolled, the defects of casting sand holes, air holes and the like exist, the mechanical strength is poor, and the brake hub shell still needs to be thick to meet the requirements of the brake hub.
In summary, the improvement of the present bimetallic brake hub is mainly on the brake housing, and of course, more important is how to reduce the manufacturing cost of the brake hub housing.
The cast steel hot extrusion process is not developed in the field of brake hub manufacturing, the metallographic structure of the cast steel hot extrusion can be changed, the tensile strength and the shear strength are improved, and the metallographic structure of the common cast steel can be changed after the hot extrusion process so that metal crystals are uniformly and compactly arranged.
Meanwhile, most of the existing metal wheels are in a punch forming or welding structure, for example, the rim part is formed by spin forming and then welded with the flange part, so that quilting occurs at the joint part, and the mechanical strength of the joint part is affected. Moreover, most cylindrical metal components are generally stamped and formed or welded structures, and the welded structures have welded seams. The stamping structure is not suitable for manufacturing cylindrical parts with larger cylinder bodies, such as low-pressure containers and the like.
In view of the foregoing, the present invention has been tested to develop a new method for manufacturing a bimetallic brake hub shell, a metal wheel and a cylindrical metal part with improved strength and reduced manufacturing costs.
Disclosure of Invention
The invention aims to provide a manufacturing method of a bimetal brake hub shell, which can solve the problems of heavy weight and poor mechanical strength of the bimetal brake hub and can reduce the manufacturing cost of the bimetal brake hub.
It is another object of the present invention to provide a method of manufacturing a metal wheel and a cylindrical metal part.
The bimetal brake hub shell is suitable for a brake hub which takes steel materials as the shell and takes centrifugally cast gray cast iron as a friction layer. The brake hub shell is made by melting and casting scrap steel serving as an original material to form an annular casting blank, cooling the annular casting blank, then preserving the temperature and adjusting the temperature to 1180-1320 ℃, then extruding the annular casting blank on an extruder by using a die to form a pot-shaped intermediate, and spinning, thinning and rounding the pot-shaped intermediate.
In the bimetallic brake hub shell, the brake hub shell comprises a flange part and a rim part, and the flange part and the rim part are integrally bent and transitionally connected; the thickness of the flange part is between 10 millimeters and 20 millimeters, the metallographic grain size grade of the material of the flange part is 8-9 grades, and the mechanical properties of the material are as follows: the tensile strength is not less than 400MPa, the yield strength is not less than 300MPa, and the elongation is not less than 22%; the thickness of the rim part is 3.5 mm to 6 mm, the metallographic grain size grade of the material of the rim part is 10-11 grades, and the mechanical properties of the material are as follows: the tensile strength is not less than 650MPa, the yield strength is not less than 500MPa, and the elongation is not less than 8%.
In the bimetallic brake hub shell, the flange part is provided with a screw hole and a pit; the opening part of rim portion is provided with the receipts limit of inside buckling, and the barrel body position of rim portion sets up wavy annular bulge.
The manufacturing method of the bimetal brake hub shell comprises the following steps:
a: casting: melting waste steel materials, casting the waste steel materials into a circular casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, then sending the casting blank into a temperature regulating box for heat preservation and temperature regulation, heating to a temperature higher than the recrystallization temperature and reaching the uniform temperature inside and outside the casting blank, and extruding the casting blank on an extruder by using a die to prepare an intermediate body of a flange part and a rim part with an integral structure;
c: spinning: and spinning, thinning and rounding the rim part of the intermediate body to form the cylindrical brake hub shell.
In the manufacturing method of the bimetal brake hub shell, a shot blasting treatment process is further included after the casting blank is cooled, and before temperature adjustment and heat preservation, so that casting sand, an oxidation layer and impurities on the surface of the casting blank are removed.
In the manufacturing method of the bimetal brake hub shell, after the spinning, thinning and rounding processes are completed, a rolling process is further included, and the wavy annular bulge of the wheel ring portion and the edge of the opening are formed through rolling.
In the above method for manufacturing the bimetal brake hub shell, the centrifugal casting temperature is controlled to be 1520-1680 ℃, and the casting rotation speed is controlled to be 450-550.
In the manufacturing method of the bimetal brake hub shell, shot blasting can be performed when the casting blank is naturally cooled to the temperature of less than or equal to 200 ℃, and then the temperature is raised and adjusted to 1180-1320 ℃, so that the internal and external temperature equalization is achieved.
The metal wheel of the present invention has the following features: the metal wheel takes waste metal as an original material, and a circular casting blank is formed by melting and casting; cooling the annular casting blank to surface hardening, and then preserving heat and adjusting temperature to be above the metal recrystallization temperature; then, extruding an intermediate body with a flange part and a rim part on an extruder by a mould; spinning, thinning and rounding to obtain the metal wheel; the metal wheel structure comprises a flange part and a rim part, wherein the flange part and the rim part are integrally bent and transitionally connected.
In the metal wheel, the flange part of the wheel is formed by extrusion after casting, the material gold of the flange part conforms to the metallographic characteristics of extrusion, and the material performance numerical value conforms to the numerical characteristics of extrusion; the wheel rim part is formed by extrusion and spinning after casting, the metallographic phase of the material of the wheel rim part accords with the metallographic phase characteristic of spinning forming, and the material performance numerical value accords with the numerical value characteristic of spinning forming.
The manufacturing method of the metal wheel comprises the following steps:
a: casting: melting waste metal materials, casting into a circular casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, conveying the casting blank into a temperature regulating box, keeping the temperature and regulating the temperature to be higher than the metal recrystallization temperature to reach the internal and external uniform temperature, and extruding the casting blank on an extruder by using a die to prepare an intermediate body of a flange part and a rim part with an integral structure;
c: spinning: and spinning, thinning and rounding the rim part of the intermediate body to form the cylindrical wheel.
In the manufacturing method of the metal wheel, after the spinning, thinning and rounding treatment is finished, the rolling treatment process is further included, and the shapes of the inner edge and the outer edge of the wheel rim part of the wheel are formed.
The present invention provides a cylindrical metal member, including the following features: the metal cylindrical component takes waste metal as an original material, and is melted and cast to form a circular ring-shaped or circular ring-shaped casting blank; cooling the casting blank to surface hardening, and then preserving heat and adjusting temperature to be above the metal recrystallization temperature; then, extruding the mixture on an extruder by using a die to form an intermediate body with a barrel body part and a barrel bottom part; spinning, thinning and rounding to obtain a metal cylinder body; the cylindrical metal part structure comprises a cylinder body part and a cylinder bottom part, wherein the cylinder body part and the cylinder bottom part are integrally bent and transitionally connected.
In the cylindrical metal component, the bottom of the component barrel is formed by extrusion after casting, the metallographic phase of a material at the barrel bottom accords with the metallographic characteristic of extrusion, and the material performance numerical value accords with the numerical characteristic of extrusion forming; the barrel part is formed by extrusion and spinning after casting, the metallographic phase of the material of the barrel part accords with the metallographic characteristic of spinning forming, and the performance numerical value of the material accords with the numerical characteristic of spinning forming.
A method of manufacturing a cylindrical metal member according to the present invention includes the steps of:
a: casting: melting waste metal materials, casting into a circular or round cake-shaped casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, sending the casting blank into a temperature regulating box, preserving heat, regulating temperature to be higher than the metal recrystallization temperature to reach the internal and external uniform temperature, and extruding the casting blank on an extruder by using a die to prepare an intermediate body with an integral structure, namely a barrel body part and a barrel bottom part;
c: spinning: and spinning, thinning and rounding the cylinder body part of the intermediate body to form the cylindrical part.
The manufacturing method of the bimetal brake hub shell and the metal wheel can achieve the following beneficial effects:
1. the method has the advantages that the manufacturing cost of the brake hub is obviously reduced, the raw material used by the method is the waste metal material, the material cost is very low, the hot extrusion is carried out on the extruder in the cooling process after the casting blank is formed, the reheating cost of the casting billet is reduced, and the method is greatly reduced compared with the method that the steel plate is used as the raw material to manufacture the shell material of the brake hub.
2. The material performance and the strength of the brake hub shell formed by hot extrusion of the casting blank are obviously higher than those of a cast steel material, the strength is enough to meet the strength requirement of the brake hub steel shell, a cold-rolled sheet with better performance is not required to be reused, and the waste of the material performance is avoided.
The manufacturing method of the cylindrical part can be used for manufacturing a metal part with a larger cylinder body, does not need to weld and connect the cylinder bottom part and the cylinder body part, improves the mechanical strength, and has lower material cost than the cylindrical part formed by stamping a metal plate.
Drawings
FIG. 1 is a cross-sectional view of a bi-metallic brake hub housing;
FIG. 2 is a schematic view of a prior art blanking and cutting structure of a shell of a steel plate brake hub;
FIG. 3 is a schematic structural diagram of a steel plate brake hub shell after blanking and cutting in the prior art;
FIG. 4 is a schematic view of the structure of a cast circular ring billet in the method of the present invention;
FIG. 5 is a schematic structural view of a first intermediate body of a circular ring-shaped cast steel blank hot extrusion molding in the method of the present invention;
FIG. 6 is a schematic structural view of a second intermediate body of a circular ring-shaped cast steel blank hot extrusion molding in the method of the present invention;
FIG. 7 is a schematic structural view of a spinning-finished semi-finished product in the method of the present invention;
FIG. 8 is a schematic sectional view showing the flow deformation direction of the hot extrusion material in the process of the present invention;
fig. 9 to 11 are schematic cross-sectional views illustrating the extrusion process according to the method of the present invention.
Detailed Description
The method for manufacturing a bimetallic brake hub shell according to the present invention will be described in detail with reference to the accompanying drawings and specific embodiments, which are provided for illustration purposes only and are not intended to limit the scope of protection.
Example 1: as shown in fig. 1, the present embodiment is described by taking a brake hub with an outer diameter of 470 mm and a height of 292 mm as an example, and the specific dimensions of the brake hub shell are 472 mm and 462 mm outer diameter, wherein the wall thickness of the rim portion 1 is 5 mm, the thickness of the flange portion 4 is 14.5 mm, the inner diameter of the central hole 403 of the flange portion 4 is 282 mm, and the rim portion 1 and the flange portion 4 are integrally connected at the bend 3 in a transition manner without splicing. The weight of the finished brake hub shell is 27 kg, and when the thickness of the gray cast iron 2 at the thickest position is 21 mm, the whole weight of the brake hub is 55 kg.
The opening of the rim portion 1 of the brake hub shell of the present embodiment is provided with an inward-bent flange 101, which serves to block the outflow and leakage of molten iron when the gray cast iron layer is centrifugally cast. Meanwhile, the barrel body part of the rim part 1 is provided with a wave-shaped annular bulge 102, which aims to increase the contact area with the cast iron layer and improve the heat dissipation effect and the strength. The flange portion 4 is further provided with a screw hole 401 and a weight-reduction recess 402, the screw hole 401 being used for connection, and the recess 402 being used for weight reduction with strength permitting.
First, 29 kg of scrap steel is selected, a cast billet is prepared from the scrap steel, the scrap steel is melted, and cast into an annular cast billet 5 by casting or centrifugal casting, and the centrifugal casting effect is good, and the resulting cast billet has an annular shape as shown in fig. 3. After the waste steel material is melted, the molten steel is kept at 1520-1680 ℃ for centrifugal casting, and the rotating speed of a centrifugal machine is controlled between 450-550 revolutions. As shown in fig. 4, the outer diameter of the annular cast billet 5 formed after casting was 400 mm, the inner diameter thereof was 276 mm, and the thickness thereof was 55 mm, and the weight of the cast billet 5 was 29 kg. To improve throughput and efficiency, a multi-station centrifugal caster may be used.
And then, naturally cooling the circular ring casting billet 5, and when the surface of the casting billet 5 is cooled to be below 200 ℃, the surface of the billet is in a black iron state and is solidified and hardened. This process takes approximately 60 minutes, but at this point the surface may already be blasted.
And thirdly, performing shot blasting treatment on the cast steel billet to remove an oxide layer, impurities and the like on the surface. The shot blasting process does not need to be described too much, and the shot blasting parameters known to the skilled person can be obtained.
And fourthly, conveying the shot-blasted cast steel billet 5 into a heat preservation box for temperature rise and adjustment, wherein the purpose of the adjustment is to make the internal and external temperatures of the cast steel billet uniform by the temperature regulation box and keep the temperature suitable for hot extrusion. The temperature control after temperature adjustment must be higher than the recrystallization temperature, and the temperature control in this embodiment is preferably 1180-1320 ℃, at which the cast steel material is easy to be extruded and deformed but will not change shape directly in the form of liquid, which is beneficial to the material flow to realize a compact metallographic structure. This process takes approximately 15 seconds.
Fifth, the extrusion process refers to fig. 9 to 11. The first hot extrusion is followed by placing the temperature-adjusted cast billet in a hot extrusion die 9, and performing an extrusion operation to cause a flow deformation to form a pot-shaped first intermediate body 6 as shown in fig. 5, and the first intermediate body 6 is formed with an annular flange portion 604 and a trumpet-shaped rim portion 601. The operating extrusion pressure of the extruder is preferably controlled to be between 2000 tons and 3000 tons. The extrusion time was 10 seconds. The thickness of the annular flange 604 is 16 mm. The outer diameter of the opening of the horn-shaped rim portion 601 reaches 500 mm, the outer diameter of the bottom of the horn-shaped rim portion is equivalent to that of the flange portion 604, the height is 170 mm, and the thickness of the rim portion 601 is 10 mm. The weight of the first intermediate 6 was 28.8 g.
As shown in fig. 9, the extrusion die is divided into an upper die 901, a lower die 902 and an extrusion die 903, wherein after the lower die 902 is matched with the upper die 901, a metal extrusion opening 904 is formed, the extrusion opening 904 is annular, and an extrusion arc 905 is formed to ensure the requirement of the overall size during extrusion. After the upper die 901 and the lower die 902 are fixed, a circular casting blank 5 is placed, and then the circular extrusion die 903 is used for downward extrusion, so that metal is continuously extruded and molded from an annular extrusion outlet 904, and the metal is molded into a horn shape along an extrusion arc 905.
Sixth, the second hot extrusion is performed, and the flange portion 604 of the formed pan-shaped first intermediate body 6 is not yet formed with the weight-reducing dimples 402 and the screw holes 401, and thus the dimples 402 and the screw holes 401 need to be machined. And (3) performing secondary hot extrusion on the formed first intermediate body 6, replacing the extrusion die 903 with the lug and the convex column, continuously performing hot extrusion on the flange part 604 of the first intermediate body 6 again, extruding the lug and the convex column of the extrusion die to other parts of the material of the weight-reducing pit 402 and the screw hole 401, thinning the flange part 601, forming the weight-reducing pit 402 and the screw hole 401, and forming the flange part 601 with the thickness of 14.5 mm, namely forming the brake housing flange part 4, wherein the second intermediate body 7 is formed as shown in fig. 6. The weight reduction pits 402 serve to reduce the weight as much as possible without affecting the strength of the flange, and form pits with natural weight reduction. The secondary extrusion does not operate the rim section at all.
And seventhly, spinning, wherein the rim part 701 of the second intermediate body 7 formed by extrusion is still in a horn shape, the opening is large and the bottom is small, the specific size can be controlled by the shape of a die, but the size difference between the opening and the bottom exists anyway, the rim part 1 cannot be directly used as the rim part, and further processing is needed. The inner diameter and the outer diameter of the opening of the rim part after spinning are basically consistent with those of the bottom, the outer diameter reaches 472 mm, and the thickness of the barrel wall of the rim part 1 is between 5 mm. At this time, the semi-finished brake hub shell 8 shown in fig. 7 is formed, and the rim portion 801 is not formed with the wavy annular protrusions and the edge of the curved needle, and the weight is 28.5 kg.
Eighthly, after the processing is finished, basically having the structure and the performance of the brake hub shell, rolling is needed again, and the purpose is to form the wavy annular bulge 102 of the bimetallic brake hub and the inward bent edge 101 at the opening as shown in fig. 1. The manufacture of the protrusion 101 is beneficial to the strength improvement and braking heat dissipation of the cast combination with the cast iron layer 2, and the inward-bent edge 102 at the opening is used for avoiding the molten iron loss during the centrifugal casting of gray cast iron.
In the manufacturing process, as the cast steel billet is cast and molded by directly adopting the scrap steel, the defects of high cost and more waste materials caused by using the plate as the initial raw material are avoided, and the material cost can be greatly reduced.
The brake hub shell obtained through the above steps has a weight of 27 kg, a wall thickness of 5 mm, a flange thickness of 14.5 mm, an outer diameter dimension of 472 mm, and a height of 292 mm. Wherein the wheel rim part is made of materials through centrifugal casting, extrusion, spinning and rolling, and the metallographic structure is detected according to GB/T6394 and 2017 Metal average grain size determination method: the grain size grade is 10-11 grades. According to the detection of 'Bao Steel Enterprise Standard Q/BQ 310-2009 detection method', the mechanical properties of the material reach: the tensile strength is not less than 650MPa, the yield strength is not less than 500MPa, and the elongation is not less than 8%. The flange part is subjected to centrifugal casting and extrusion processes and detected according to GB/T6394-2017 Metal average grain size determination method, and the metallographic structure is as follows: the grain size grade is 8-9 grades. According to the detection of 'Bao Steel Enterprise Standard Q/BQ 310-2009 detection method', the mechanical properties of the material reach: tensile strength is not less than 400MPa, yield strength is not less than 300MPa, and elongation is not less than 22%. Therefore, the performance of the brake hub shell formed by the method is greatly improved compared with the brake hub shell formed by casting, and the cost is greatly reduced compared with the brake hub formed by directly cutting a steel plate.
Example 2: this embodiment is substantially the same as the embodiment except that the fifth step and the sixth step of embodiment 1 are combined into one pressing operation, and a complete flange structure is formed in one pressing. At the moment, the convex columns and the concave pits need to be manufactured on a die during one-time extrusion.
The production cost and the performance of the brake hub shell, the cast steel brake hub shell and the steel plate brake hub shell are compared.
Comparison of Material Properties
| Object | Metallographic structure | Tensile strength | Yield strength | Elongation percentage |
| Cast steel | Grade 5-6 of crystal grain | ≧240Mpa | ≧170Mpa | ≧30％ |
| Steel plate | Grade 10-11 of crystal grain | 385Mpa | ≧285Mpa | ≧36％ |
| The invention | Grade 10-11 of crystal grain | ≧400Mpa | ≧300Mpa | ≧22％ |
Comparison of Material costs and Process costs (in terms of same Specification per 10000 parts of product)
| Object | Amount of material used | Cost of materials | Completion time | Energy consumption | Total cost of |
| Cast steel | 39.5Kg | 81 Yuan | 92 seconds per piece | 43.96 yuan | 124.96 yuan |
| Steel plate | 45Kg | 126 yuan | 80 seconds per piece | 28.72 yuan | 154.72 yuan |
| The invention | 29Kg | 81 Yuan | 55 seconds per piece | 30.78 yuan | 111.78 yuan |
Through the comparison, the brake hub shell produced by the method has better performance than cast steel, and the manufacturing cost is much lower than that of a steel plate.
The method of the present invention can also be used to manufacture metal wheels and other metal parts having a flange portion and a rim portion integrally formed.
Example 3: steel wheels were directly fabricated according to the parameters and methods of example 1 above. The flange part of the wheel is formed by extrusion after casting, the material gold of the flange part conforms to the metallographic characteristics of the extrusion forming, and the material performance numerical value conforms to the numerical characteristics of the extrusion forming; the wheel rim part is formed by extrusion and spinning after casting, the metallographic phase of the material of the wheel rim part accords with the metallographic phase characteristic of spinning forming, and the material performance numerical value accords with the numerical value characteristic of spinning forming. The metallographic structural characteristics and material properties of this example were the same as those of example 1.
Example 4: steel cylindrical components were directly manufactured according to the parameters and method of example 1. The barrel bottom of the barrel-shaped component is formed by extrusion after casting, the metallographic phase of the material at the barrel bottom accords with the metallographic phase characteristic of extrusion, and the material performance numerical value accords with the numerical value characteristic formed by extrusion; the barrel body part is formed by extrusion and spinning after casting, the metallographic phase of the material accords with the metallographic characteristic of spinning forming, and the performance numerical value of the material accords with the numerical characteristic of spinning forming. The metallographic structural characteristics and material properties of this example were the same as those of example 1.
Example 5, according to the method of the above example 1, a person skilled in the art can directly manufacture a corresponding metal wheel by combining parameters of specific metal materials. The flange part of the wheel is formed by extrusion after casting, the material gold of the flange part conforms to the metallographic characteristics of the extrusion forming, and the material performance numerical value conforms to the numerical characteristics of the extrusion forming; the wheel rim part is formed by extrusion and spinning after casting, the metallographic phase of the material of the wheel rim part accords with the metallographic phase characteristic of spinning forming, and the material performance numerical value accords with the numerical value characteristic of spinning forming.
Example 6: according to the method of example 1, a person skilled in the art can directly manufacture the corresponding metal cylindrical component according to the parameters of the specific metal material. The barrel bottom of the barrel-shaped component is formed by extrusion after casting, the metallographic phase of the material at the barrel bottom accords with the metallographic phase characteristic of extrusion, and the material performance numerical value accords with the numerical value characteristic formed by extrusion; the barrel body part is formed by extrusion and spinning after casting, the metallographic phase of the material accords with the metallographic characteristic of spinning forming, and the performance numerical value of the material accords with the numerical characteristic of spinning forming.
Claims (10)
1. A bimetallic brake hub shell suitable for use with brake hubs having a shell of steel material and a friction layer of centrifugally cast gray cast iron, characterized by: the brake hub shell is made by melting and casting scrap steel serving as an original material to form an annular casting blank, cooling the annular casting blank, performing shot blasting, heating and adjusting the temperature to 1180-1320 ℃, extruding the annular casting blank on an extruder by using a die to form a pot-shaped intermediate, and spinning, thinning and rounding the pot-shaped intermediate.
2. The bi-metallic brake hub shell of claim 1, wherein: the brake hub shell comprises a flange part and a rim part, and the flange part and the rim part are integrally bent and transitionally connected; the thickness of the flange part is between 10 and 20 millimeters, and the metallographic grain size grade of the material of the flange part is 8-9 grades; the mechanical properties of the material are as follows: the tensile strength is not less than 400MPa, the yield strength is not less than 300MPa, and the elongation is not less than 22%; the thickness of the rim part is 3.5 mm to 6 mm, the metallographic grain size grade of the material of the rim part is 10-11 grades, and the mechanical properties of the material are as follows: the tensile strength is not less than 650MPa, the yield strength is not less than 500MPa, and the elongation is not less than 8%.
3. The bi-metallic brake hub shell of claim 2, wherein: the flange part is provided with a screw hole and a pit; the opening part of rim portion is provided with the receipts limit of inside buckling, and the barrel body position of rim portion sets up wavy annular bulge.
4. A method of manufacturing a bi-metallic brake hub shell as defined in claims 1-3, wherein: the method comprises the following steps:
a: casting: melting waste steel materials, casting the waste steel materials into a circular casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, then sending the casting blank into a temperature regulating box for heating and regulating the temperature to be higher than the recrystallization temperature and reach the uniform temperature inside and outside the casting blank, and extruding the casting blank on an extruder by using a die to prepare an intermediate body of a flange part and a rim part with an integral structure;
c: spinning: and spinning, thinning and rounding the rim part of the intermediate body to form the cylindrical brake hub shell.
5. The method of manufacturing a bi-metallic brake hub shell of claim 4, wherein: and the shot blasting treatment process is also included after the casting blank is cooled, and before the temperature adjustment and heat preservation, so that casting sand, an oxide layer and impurities on the surface of the casting blank are removed.
6. The method of manufacturing a bi-metallic brake hub shell of claim 4, wherein: after the spinning, thinning and rounding treatment is finished, the rolling process is also included, and the wavy annular bulge of the wheel ring part and the edge of the opening are formed by rolling; the centrifugal casting temperature is controlled to be 1520-1680 ℃, and the casting rotating speed is controlled to be 450-550.
7. A metal wheel, characterized by: the metal wheel takes waste metal as an original material, and a circular casting blank is formed by melting and casting; cooling the annular casting blank to surface hardening, and then preserving heat and adjusting temperature to be above the metal recrystallization temperature; then, extruding an intermediate body with a flange part and a rim part on an extruder by a mould; spinning, thinning and rounding to obtain the metal wheel; the metal wheel structure comprises a flange part and a rim part, and the flange part and the rim part are integrally bent and transitionally connected; the wheel flange part is formed by extrusion after casting, the material gold of the flange part conforms to the metallographic characteristics of the extrusion, and the material performance numerical value conforms to the numerical characteristics formed by extrusion; the wheel rim part is formed by extrusion and spinning after casting, the metallographic phase of the material of the wheel rim part accords with the metallographic phase characteristic of spinning forming, and the material performance numerical value accords with the numerical value characteristic of spinning forming.
8. A method of manufacturing a metal wheel according to claim 7, comprising the steps of:
a: casting: melting waste metal materials, casting into a circular casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, conveying the casting blank into a temperature regulating box, keeping the temperature and regulating the temperature to be higher than the metal recrystallization temperature to reach the internal and external uniform temperature, and extruding the casting blank on an extruder by using a die to prepare an intermediate body of a flange part and a rim part with an integral structure;
c: spinning: and spinning, thinning and rounding the rim part of the intermediate body to form the cylindrical wheel.
9. A cylindrical metal component, characterized by: the metal cylindrical component takes waste metal as an original material, and is melted and cast to form a circular ring-shaped or circular ring-shaped casting blank; cooling the casting blank to surface hardening, and then preserving heat and adjusting temperature to be above the metal recrystallization temperature; then, extruding the mixture on an extruder by using a die to form an intermediate body with a barrel body part and a barrel bottom part; spinning, thinning and rounding to obtain a metal cylinder body; the cylindrical metal part structure comprises a cylinder body part and a cylinder bottom part, and the cylinder body part and the cylinder bottom part are integrally bent and transitionally connected; the barrel bottom of the part is formed by extrusion after casting, the metallographic phase of a material at the barrel bottom accords with the metallographic phase characteristic of the extrusion, and the material performance numerical value accords with the numerical value characteristic formed by extrusion; the barrel part is formed by extrusion and spinning after casting, the metallographic phase of the material of the barrel part accords with the metallographic characteristic of spinning forming, and the performance numerical value of the material accords with the numerical characteristic of spinning forming.
10. A method of manufacturing a tubular metal component as set forth in claim 9, comprising the steps of:
a: casting: melting waste metal materials, casting into a circular or round cake-shaped casting blank by adopting a centrifugal casting process, and naturally cooling;
b: hot extrusion: naturally cooling the casting blank, sending the casting blank into a temperature regulating box, preserving heat, regulating temperature to be higher than the metal recrystallization temperature to reach the internal and external uniform temperature, and extruding the casting blank on an extruder by using a die to prepare an intermediate body with an integral structure, namely a barrel body part and a barrel bottom part;
c: spinning: and spinning, thinning and rounding the cylinder body part of the intermediate body to form the cylindrical part.
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