CN111318861A - Automobile brake caliper blank machining process - Google Patents
Automobile brake caliper blank machining process Download PDFInfo
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- CN111318861A CN111318861A CN202010266869.6A CN202010266869A CN111318861A CN 111318861 A CN111318861 A CN 111318861A CN 202010266869 A CN202010266869 A CN 202010266869A CN 111318861 A CN111318861 A CN 111318861A
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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
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/04—Making ferrous alloys by melting
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/04—Anodisation of aluminium or alloys based thereon
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Abstract
The invention discloses a processing technology of a blank of an automobile brake caliper, belonging to the technical field of automobiles and comprising the following steps: s1: a caliper blank: s2: cutting: s3: and (3) heat treatment: s4: rough machining and finish machining: s5: anodic oxidation: s6: hole site cleaning: s7: and (6) checking. The invention provides a processing technology of a vehicle brake caliper blank, the caliper blank is cut into a plurality of single caliper blanks under the work of a cutting knife of a metallographic cutting machine, the single caliper blanks are sent into heat treatment equipment for heat treatment, the microstructure change is caused to occur, so that the mechanical property is improved, a layer of oxidation film with higher hardness is formed on the surface of aluminum alloy under the action of electrolyte and impressed current, the anodic oxidation can be colorless, the oxidation layer can be dyed, the processing technology can be realized by spraying paint on calipers with more colors, the performance of the blanks is improved by utilizing increased metal, the hardness of the oxidation film is improved, and the service life of the brake caliper blanks is prolonged.
Description
Technical Field
The invention relates to the technical field of automobiles, in particular to a machining process for an automobile brake caliper blank.
Background
The automobile safety is closely related to the life of each person, and the most basic active safety equipment on the automobile needs a braking system. The brake is a main component of a brake system of an automobile and is one of main safety parts of the automobile. With the continuous improvement of vehicle performance and the continuous improvement of vehicle speed, higher requirements are also put forward on a braking system of a vehicle, and thus a disc brake with a better braking effect is more and more widely applied to cars and commercial vehicles. The disc brake for automobile has friction surface as the middle end surface, and the friction plate and metal disc constitute the brake unit.
The existing brake caliper blank processing needs to be carried out for many times, from an iron ingot to a casting, cutting, heat treatment, shot blasting and machining, the machining comprises face milling, grooving, drilling and thread drilling, the processing technology is complex, the production efficiency is low, the production cost is high, a preliminary detection function is not provided in the processing process, whether the brake caliper is processed perfectly or not cannot be judged, and if the brake caliper blank is not processed perfectly, the brake caliper blank processing method is reduced.
Disclosure of Invention
The invention aims to provide a processing technology of a blank of an automobile brake caliper, wherein a layer of oxide film with higher hardness is formed on the surface of an aluminum alloy by anodic oxidation under the action of electrolyte and impressed current, the anodic oxidation can be colorless and can also dye the oxide layer, the anodic oxidation can be realized by spraying paint on calipers with more colors, the performance of the blank is improved by utilizing added metal, the hardness of the blank is improved by the oxide film, and the service life of the blank of the brake caliper is prolonged, so that the problems in the background technology are solved.
In order to achieve the purpose, the invention provides the following technical scheme: a processing technology for a blank of an automobile brake caliper comprises the following steps:
s1: a caliper blank: mixing wear-resistant high-strength carbon steel, iron, silicon, manganese, phosphorus, strontium, titanium and magnesium materials according to a ratio, pouring the mixture into a smelting furnace with the temperature of 1200 ℃ to be melted into molten iron, casting the molten iron into a sand core die, reducing the temperature in the sand core die to 700-800 ℃ by adopting a step cooling mode of reducing the temperature by 100 ℃ every 5min, forming the molten iron in the sand core die, opening the sand core die, taking out a caliper blank well, performing water cooling, and cooling to a normal temperature state to obtain a caliper blank;
s2: cutting: the cooled caliper blank is placed on a working table of a metallographic cutting machine, a cutting line on the caliper blank is aligned with a cutter of the cutting machine, the caliper blank is clamped and fixed by a clamping block which slides on the cutting machine, the cutting line on the caliper blank is cut by the cutter of the cutting machine in a rotating and descending manner, the caliper blank is driven by the sliding clamping block to travel along the path of the cutting line, and the caliper blank is cut into a plurality of single caliper blanks under the work of the cutter of the metallographic cutting machine;
s3: and (3) heat treatment: placing the cut caliper blank in a furnace, heating to 1200-1300 ℃ for quenching treatment, preserving heat for 30-50min, cooling to room temperature within 30min, placing the caliper blank in the furnace at 720-740 ℃ for tempering treatment, preserving heat for 30-60min, then placing the caliper blank in the furnace at the speed of more than 70 ℃/min to room temperature again, and carrying out secondary tempering to obtain the caliper blank after heat treatment;
s4: rough machining and finish machining: carrying out rough turning on the caliper blank subjected to heat treatment, wherein the caliper blank is conveyed by a following fixture, clamping a plurality of caliper blanks at the front end and the rear end of the fixture, milling an R angle at the opening position of the caliper blank by using a disc milling cutter, milling and drilling guide pin mounting holes, air relief holes, oil holes and piston mounting holes on the two sides of the caliper blank, reserving finish machining allowance, and polishing the outer surface of the caliper blank;
s5: anodic oxidation: after the surface is polished, the caliper blank is placed in an electrolyte solution taking aluminum as an anode, when current passes through the caliper blank, the aluminum on the anode is oxidized by the separated oxygen to form an anhydrous aluminum oxide film which is coated on the surface of the caliper blank so that a layer of oxide film with higher hardness is formed on the surface of the aluminum alloy;
s6: hole site cleaning: fixing the caliper blank with the oxidized surface in a clamping tool, rotating around the clamping tool, flushing hole positions of the caliper blank by using alcohol solution with the purity of 99%, removing scrap iron in the holes through a high-pressure air port at each hole position, and cleaning each hole position;
s7: and (4) checking: and taking down the brake caliper blank from the hydraulic fixture, and inspecting the processed brake caliper by a vision industrial camera.
Further, with respect to step S2, the cutter blade of the cutting machine cuts the brake caliper blank in the lateral-to-vertical direction, and the cut surface of the caliper blank after cutting is polished.
Further, for the finish machining in step S4, a tap is used, the tap is aligned with the guide pin mounting position hole and the boring piston mounting hole, the rotation speed of the tap is 1200R/min, and internal threads are machined in the guide pin mounting position hole and the boring piston mounting hole.
Further, in step S4, a sealing ring groove and a joint surface are machined on the finish-machined milling-drilling air-bleeding hole and oil hole, and a sealing rubber ring is sleeved on the sealing ring groove and the joint surface.
Further, in step S5, the maximum thickness of the oxide film can be 150 μm, the micro-hardness of the film formed on pure aluminum is 13000-14000MPa, the general hardness of the alloy is 4100-6200MPa, and the porosity of the hard film is 18-20%.
Further, in step S7, the vision industrial camera converts the object captured on the surface of the blank of the brake caliper of the automobile into an image signal by the machine vision product, transmits the image signal to a dedicated image processing system, converts the image signal into a digital signal according to the information such as pixel distribution, brightness and color, and the image system performs various calculations on the signal to extract the feature of the object, and controls the operation of the equipment on site according to the result of the determination.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the processing technology of the automobile brake caliper blank, strontium, titanium and magnesium metals are added in the smelting process to improve the performance of the cast blank, a cutting machine cutter rotates to descend to cut a cutting line on the caliper blank, a sliding clamping block drives the caliper blank to travel along the path of the cutting line, the cutting machine cutter transversely and vertically cuts the brake caliper blank, the surface of the cut section of the cut caliper blank is polished, the caliper blank is cut into a plurality of single caliper blanks under the work of the metallographic cutting machine cutter, and the single caliper blanks are sent into heat treatment equipment to be subjected to heat treatment, so that the microstructure change of the single caliper blanks is generated to improve the mechanical performance.
2. The processing of the automobile brake caliper blank is an indispensable process, the anodic oxidation is to form an oxidation film with higher hardness on the surface of the aluminum alloy under the action of electrolyte and impressed current, the anodic oxidation can be colorless and can also dye the oxidation layer, the anodic oxidation can be realized by spraying paint on calipers with more colors, the performance of the blank is improved by utilizing increased metal, the hardness of the blank is improved by the oxidation film, and the service life of the brake caliper blank is prolonged.
3. According to the processing technology of the automobile brake caliper blank, the vision industrial camera is converted into digital signals according to information such as pixel distribution, brightness and color, the image system performs various operations on the signals to extract the characteristics of a target, and the field equipment action is controlled according to the judgment result.
Drawings
FIG. 1 is a process flow diagram of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, a process for machining a blank of an automobile brake caliper includes the following steps:
the method comprises the following steps: a caliper blank: mixing wear-resistant high-strength carbon steel, iron, silicon, manganese, phosphorus, strontium, titanium and magnesium materials according to a proportion, pouring the mixture into a smelting furnace with the temperature of 1200 ℃ to be molten into molten iron, casting the molten iron into a sand core die, in order to ensure the strength, the light weight and the high-temperature stability of the calipers, adding strontium, titanium and magnesium metals in the smelting process to improve the performance of a cast blank, reducing the temperature in the sand core die to 700-800 ℃ by adopting a step cooling mode of reducing the temperature by 100 ℃ every 5min, forming the molten iron in the sand core die, opening the sand core die, taking out a caliper blank well, performing water cooling, and cooling to a normal temperature state to obtain the caliper blank;
step two: cutting: the cooled caliper blank is placed on a working table of a metallographic cutting machine, a cutting line on the caliper blank is aligned with a cutter of the cutting machine, the caliper blank is clamped and fixed by a clamping block which slides on the cutting machine, the cutting line on the caliper blank is cut by the cutter of the cutting machine in a rotating and descending manner, the caliper blank is driven by the sliding clamping block to travel along the path of the cutting line, the brake caliper blank is cut by the cutter of the cutting machine in a transverse and vertical direction, the surface of the section of the cut caliper blank is polished, and the caliper blank is cut into a plurality of single caliper blanks under the operation of the cutter of the;
step three: and (3) heat treatment: placing the cut caliper blank in a furnace, heating to 1200-1300 ℃ for quenching treatment, preserving heat for 30-50min, cooling to room temperature within 30min, placing the caliper blank in the furnace at 720-740 ℃ for tempering treatment, preserving heat for 30-60min, then, cooling to room temperature at a speed of more than 70 ℃/min, placing the caliper blank in the furnace at 720-740 ℃ again for secondary tempering to obtain the caliper blank after heat treatment, wherein the appearance shape of the caliper blank is obtained, and the single caliper blank is sent into heat treatment equipment for heat treatment to generate microstructure change so as to improve the mechanical property;
step four: rough machining and finish machining: carrying out rough turning on the caliper blank subjected to heat treatment, wherein the caliper blank is conveyed by a following fixture, a plurality of caliper blanks are clamped by the front end and the rear end of the fixture, an R angle at the position where the caliper blank is opened is milled by using a disc milling cutter, guide pin mounting position holes at two sides of the caliper blank are milled and drilled, air bleeding holes are milled and drilled, oil holes and a boring piston mounting hole, finish machining allowance is reserved, a screw tap is used for finish machining, the screw tap is aligned with the guide pin mounting position holes and the boring piston mounting hole, the rotating speed of the screw tap is 1200R/min, internal threads are machined in the guide pin mounting position holes and the boring piston mounting holes, sealing ring grooves and joint surfaces are machined in the air bleeding holes and the oil holes after finish machining, sealing rubber rings are sleeved on the sealing ring grooves and the joint surfaces;
step five: anodic oxidation: after the surface is polished, the caliper blank is placed in an electrolyte solution taking aluminum as an anode, when current passes through, the aluminum on the anode is oxidized by the separated oxygen to form an anhydrous aluminum oxide film to cover the surface of the caliper blank so as to form an oxide film with higher hardness on the surface of the aluminum alloy, the maximum thickness of the formed oxide film can be 150 mu m, the microhardness of a film layer formed on pure aluminum is 13000-14000MPa, the alloy is generally 4100-6200MPa, and the porosity of a hard film is 18-20 percent, the treatment is an indispensable process, the anodic oxidation is a process of forming an oxide film with higher hardness on the surface of the aluminum alloy under the action of the electrolyte and the applied current, the anodic oxidation can be colorless, can also dye an oxide layer, and can also be realized by painting calipers with more colors;
step six: hole site cleaning: fixing the caliper blank with the oxidized surface on a clamping tool, rotating around the clamping tool, flushing hole positions of the caliper blank by using alcohol solution with the purity of 99%, removing scrap iron in the holes through a high-pressure air port in each hole position, cleaning each hole position, blowing the scrap iron in the hole positions by air flow generated by high pressure, and completely removing the scrap iron in the holes;
step seven: and (4) checking: the method comprises the steps of taking a brake caliper blank from a hydraulic clamp, inspecting the processed brake caliper by a vision industrial camera, converting a target shot on the surface of the automobile brake caliper blank into an image signal by the vision industrial camera through a machine vision product, transmitting the image signal to a special image processing system, converting the image signal into a digital signal according to information such as pixel distribution, brightness and color, and carrying out various operations on the signal by the image system to extract the characteristics of the target.
In summary, the following steps: according to the automobile brake caliper blank processing technology, strontium, titanium and magnesium metals are added in the smelting process to improve the performance of a cast blank, a cutting machine cutter rotates to descend to cut a cutting line on the caliper blank, a sliding clamping block drives the caliper blank to travel along the path of the cutting line, the cutting machine cutter transversely and vertically cuts the brake caliper blank, the surface of the cut section of the cut caliper blank is polished, the caliper blank is cut into a plurality of single caliper blanks under the work of the metallographic cutting machine cutter, and the single caliper blanks are sent into heat treatment equipment to be subjected to heat treatment, so that the microstructure change of the single caliper blanks is generated to improve the mechanical performance; the treatment is an indispensable process, the anodic oxidation is to form an oxidation film with higher hardness on the surface of the aluminum alloy under the action of electrolyte and impressed current, the anodic oxidation can be colorless and can also dye the oxidation layer, calipers with more colors can also be realized by painting, the performance of blanks is improved by utilizing added metal, the hardness of the blanks is improved through the oxidation film, the service life of the brake caliper blanks is prolonged, a vision industrial camera converts the signals into digital signals according to the information of pixel distribution, brightness, color and the like, an image system carries out various operations on the signals to extract the characteristics of targets, and the field equipment action is controlled according to the result of the judgment.
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 able to cover the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.
Claims (6)
1. The automobile brake caliper blank machining process is characterized by comprising the following steps of:
s1: a caliper blank: mixing wear-resistant high-strength carbon steel, iron, silicon, manganese, phosphorus, strontium, titanium and magnesium materials according to a ratio, pouring the mixture into a smelting furnace with the temperature of 1200 ℃ to be melted into molten iron, casting the molten iron into a sand core die, reducing the temperature in the sand core die to 700-800 ℃ by adopting a step cooling mode of reducing the temperature by 100 ℃ every 5min, forming the molten iron in the sand core die, opening the sand core die, taking out a caliper blank well, performing water cooling, and cooling to a normal temperature state to obtain a caliper blank;
s2: cutting: the cooled caliper blank is placed on a working table of a metallographic cutting machine, a cutting line on the caliper blank is aligned with a cutter of the cutting machine, the caliper blank is clamped and fixed by a clamping block which slides on the cutting machine, the cutting line on the caliper blank is cut by the cutter of the cutting machine in a rotating and descending manner, the caliper blank is driven by the sliding clamping block to travel along the path of the cutting line, and the caliper blank is cut into a plurality of single caliper blanks under the work of the cutter of the metallographic cutting machine;
s3: and (3) heat treatment: placing the cut caliper blank in a furnace, heating to 1200-1300 ℃ for quenching treatment, preserving heat for 30-50min, cooling to room temperature within 30min, placing the caliper blank in the furnace at 720-740 ℃ for tempering treatment, preserving heat for 30-60min, then placing the caliper blank in the furnace at the speed of more than 70 ℃/min to room temperature again, and carrying out secondary tempering to obtain the caliper blank after heat treatment;
s4: rough machining and finish machining: carrying out rough turning on the caliper blank subjected to heat treatment, wherein the caliper blank is conveyed by a following fixture, clamping a plurality of caliper blanks at the front end and the rear end of the fixture, milling an R angle at the opening position of the caliper blank by using a disc milling cutter, milling and drilling guide pin mounting holes, air relief holes, oil holes and piston mounting holes on the two sides of the caliper blank, reserving finish machining allowance, and polishing the outer surface of the caliper blank;
s5: anodic oxidation: after the surface is polished, the caliper blank is placed in an electrolyte solution taking aluminum as an anode, when current passes through the caliper blank, the aluminum on the anode is oxidized by the separated oxygen to form an anhydrous aluminum oxide film which is coated on the surface of the caliper blank so that a layer of oxide film with higher hardness is formed on the surface of the aluminum alloy;
s6: hole site cleaning: fixing the caliper blank with the oxidized surface in a clamping tool, rotating around the clamping tool, flushing hole positions of the caliper blank by using alcohol solution with the purity of 99%, removing scrap iron in the holes through a high-pressure air port at each hole position, and cleaning each hole position;
s7: and (4) checking: and taking down the brake caliper blank from the hydraulic fixture, and inspecting the processed brake caliper by a vision industrial camera.
2. The automobile brake caliper blank machining process according to claim 1, wherein the brake caliper blank is cut transversely and vertically by a cutter of a cutting machine and the cut surface of the cut caliper blank is polished in step S2.
3. The automotive brake caliper blank machining process according to claim 1, wherein a tap is used for finish machining in step S4, the tap is aligned with the guide pin mounting hole and the boring piston mounting hole, the rotation speed of the tap is 1200R/min, and internal threads are machined in the guide pin mounting hole and the boring piston mounting hole.
4. The process for machining a blank of an automobile brake caliper according to claim 1, wherein in step S4, a sealing ring groove and a joint surface are machined on a milling-drilled air bleed hole and an oil hole after finish machining, and a sealing rubber ring is sleeved on the sealing ring groove and the joint surface.
5. The automobile brake caliper blank machining process as claimed in claim 1, wherein in step S5, the maximum thickness of the formed oxide film is 150 μm, the microhardness of the film formed on the pure aluminum is 13000-14000MPa, the general alloy is 4100-6200MPa, and the porosity of the hard film is 18-20%.
6. The automobile brake caliper blank machining process according to claim 1, wherein in step S7, the vision industry camera converts the object captured on the surface of the automobile brake caliper blank into image signals through the machine vision product, transmits the image signals to a dedicated image processing system, converts the image signals into digital signals according to information such as pixel distribution, brightness and color, the image system performs various operations on the signals to extract the characteristics of the object, and controls the on-site equipment operation according to the result of the determination.
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| CN202010266869.6A CN111318861A (en) | 2020-04-07 | 2020-04-07 | Automobile brake caliper blank machining process |
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| CN202010266869.6A CN111318861A (en) | 2020-04-07 | 2020-04-07 | Automobile brake caliper blank machining process |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112719818A (en) * | 2020-12-17 | 2021-04-30 | 昆山育源精密机械制造有限公司 | Method for processing automobile brake calipers |
| CN112984124A (en) * | 2021-03-01 | 2021-06-18 | 安徽斯瑞尔阀门有限公司 | Backflow type oil-liquid separation valve for hydraulic leveling and machining process thereof |
| CN116252111A (en) * | 2023-05-15 | 2023-06-13 | 深圳市玉沣科技有限公司 | Precise machining method of semiconductor wafer sucker |
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| KR20160123712A (en) * | 2015-04-17 | 2016-10-26 | 주식회사 에스이케이 | Method for Treating the Surface of Disk Brake Caliper |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112719818A (en) * | 2020-12-17 | 2021-04-30 | 昆山育源精密机械制造有限公司 | Method for processing automobile brake calipers |
| CN112984124A (en) * | 2021-03-01 | 2021-06-18 | 安徽斯瑞尔阀门有限公司 | Backflow type oil-liquid separation valve for hydraulic leveling and machining process thereof |
| CN112984124B (en) * | 2021-03-01 | 2022-12-06 | 安徽斯瑞尔阀门有限公司 | Backflow type oil-liquid separation valve for hydraulic leveling and machining process thereof |
| CN116252111A (en) * | 2023-05-15 | 2023-06-13 | 深圳市玉沣科技有限公司 | Precise machining method of semiconductor wafer sucker |
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Application publication date: 20200623 |