CN111623060A - Cyclone ultralight composite brake disc and manufacturing method thereof - Google Patents

Abstract

The invention discloses a cyclone ultralight composite brake disc and a manufacturing method thereof, and solves the problems of large mass and easy abrasion of the brake disc in the prior art. The brake disc comprises a disc body and a connecting disc, wherein the connecting disc comprises a connecting body and a connecting flange, the disc body and the connecting disc are formed by casting, and an inner air duct and an outer cyclone air duct are arranged on the disc body along the radial direction. The tray body includes tray body upper portion and tray body lower part, is equipped with radial strengthening rib between tray body upper portion and the tray body lower part, forms interior wind channel between two adjacent radial strengthening ribs. The connecting disc is made of a steel structure, the disc body is made of gray cast iron, the connecting disc has high strength and rigidity, the connecting body and the disc body are fused in a liquid state, then the connecting body is welded with the connecting flange, and the composite brake disc is cast into a whole, so that the strength of the composite brake disc is effectively guaranteed. In the braking process, the deformation is small, the stress of the disc body is uniform, the abrasion resistance of the brake disc is good, the strength is high, and the service life is prolonged.

Description

Cyclone ultralight composite brake disc and manufacturing method thereof

Technical Field

The invention relates to the technical field of brake discs, in particular to a cyclone ultralight composite brake disc and a manufacturing method thereof.

Background

The brake disc is a metal disc, is made of alloy steel, is fixed on a wheel and rotates along with the wheel. When a vehicle steps on the brake in the running process, the brake calipers clamp the brake disc to play the role of speed reduction or parking. The brake disc is generally provided with a round hole, and the round hole has the functions of reducing weight and increasing friction force. The brake disc has various types and is characterized in that the wall is thin, and the disc body and the center are formed by sand cores. Different types of brake discs have differences in disc diameter, disc thickness and size of a gap between two discs, and the thickness and the height of a disc hub are different. At present, each host machine factory is good, and light weight of automobile parts is gradually emphasized in axle factories. The existing brake disc is large in mass, and in the braking process, due to the fact that the installation directions are different, the air channel not only causes unsmooth air flow and influences the air flow passing performance, but also under the condition that the air flow is constant, the heat taken away by the air flow is limited, and the heat dissipation effect is reduced.

Disclosure of Invention

Aiming at the defects in the background technology, the invention provides a cyclone ultralight composite brake disc and a manufacturing method thereof, and solves the problems of large mass and easy abrasion of the brake disc in the prior art.

The technical scheme of the invention is realized as follows: the cyclone ultralight composite brake disc comprises a disc body and a connecting disc, wherein the disc body and the connecting disc are formed by casting, and an inner air duct and an outer cyclone air duct are arranged on the disc body along the radial direction.

The tray body includes tray body upper portion and tray body lower part, is equipped with radial strengthening rib between tray body upper portion and the tray body lower part, forms interior wind channel between two adjacent radial strengthening ribs.

The upper part of the tray body, the lower part of the tray body and the radial reinforcing ribs are cast and integrally formed; the radial reinforcing ribs are arranged between the upper part of the tray body and the lower part of the tray body at equal angles along the radial direction.

The radial reinforcing ribs are cylindrical ribs, cuboid ribs, cubic ribs or trapezoidal reinforcing ribs.

And axial ventilation holes are formed in the upper part of the tray body and the lower part of the tray body and are arranged in a staggered mode with the radial reinforcing ribs.

And outer cyclone air channels are uniformly distributed on the upper surface of the upper part of the tray body and the lower surface of the lower part of the tray body.

The outer cyclone air duct is a curved cyclone groove.

The outer cyclone air duct is a herringbone ventilation groove which is arranged on the outer surface of the tray body along the center of the tray body in an array mode.

The connecting disc comprises a connecting body and a connecting flange, the connecting body and the connecting flange are coaxially arranged, and petal bulges are arranged at the lower part of the connecting body; the inside of disk body is equipped with the slot, and slot and interior wind channel are alternately arranged, and the petal is protruding to cooperate with the slot.

The connector and the connecting flange are integrally pressed and formed or the connector and the connecting flange are matched and welded and fixed. The connecting flange is a straight outward-turning flange or a straight inward-turning flange or an oblique outward-turning flange or an oblique inward-turning flange. The connecting part of the connecting flange is of a circular ring type or a petal type.

A manufacturing method of a cyclone ultralight composite brake disc comprises the following steps:

s1: manufacturing a connector: punching a steel plate or a steel pipe into a semi-finished product of the convex edge-shaped connector; then punching or cold processing is adopted, and a plurality of bosses are manufactured on the periphery of the half-finished product of the camberline-shaped connector to form a connector with petal bulges;

s2: manufacturing a connecting flange: high-quality carbon steel or alloy steel with good welding performance is used for manufacturing the connecting flange by stamping, spinning or roll forming;

s3: manufacturing a disk body sand core: when a core box of the tray body sand core is manufactured, a space for placing the connecting body in the step S1 is reserved; when the disk body sand core is used, the connecting body in the step S1 is placed in the core box, the connecting body is arranged in the disk body sand core, and a layer of sand is coated on the surface of the part, which is not fused with the disk body, of the petal bulge of the connecting body, so that the separation from liquid molten iron is ensured during pouring;

s4: pouring a brake disc: smelting molten iron after the sand core of the disc body is manufactured, inoculating along with the stream before pouring, and adding a pearlite inoculant to ensure that the metallographic phase and the mechanical property of the brake disc meet the requirements; then, pouring by adopting a stack box, keeping the pouring temperature at 1360-1500 ℃, and pouring the brake disc;

s5: welding a connecting flange and a connecting body: nesting the connecting flange in the step S2 on the connecting body in the step S4 to ensure that the connecting flange and the connecting body are concentrically arranged, and then welding;

s6: machining: step S5, machining the brake disc after welding, ensuring the technological requirements of the brake disc, and performing action balance and coating after the brake disc is qualified; and finishing the production and manufacture of the brake disc.

The connecting disc is made of a steel structure, the disc body is made of gray cast iron, the connecting disc has high strength and rigidity, the connecting body and the disc body are fused in a liquid state, then the connecting body is welded with the connecting flange, and the composite brake disc is cast into a whole, so that the strength of the composite brake disc is effectively guaranteed. In the braking process, the deformation is small, the stress of the disc body is uniform, the abrasion resistance of the brake disc is good, the strength is high, and the service life is prolonged. The weight of the brake disc is minimized by the matching use of the inner air duct and the outer cyclone air duct, and is reduced by 20-30% compared with the weight of the traditional common brake disc, and the light weight of the brake disc is extremely achieved. In addition, the cooperation in interior wind channel and outer whirlwind wind channel makes the air permeability of brake disc better, improves the thermal diffusivity of brake disc greatly, makes the brake back disk body can cool down rapidly, ensures that vehicle brake performance is best. The invention has good process performance, adopts the split independent forming and then welding, has the effective utilization rate of the material reaching more than 90 percent and lower production cost; the production process is simple, and large-scale and batch production is facilitated.

Drawings

In order to illustrate the embodiments of the invention more clearly, the drawings that are needed in the description of the embodiments will be briefly described below, it being apparent that the drawings in the following description are only some embodiments of the invention, and that other drawings may be derived from those drawings by a person skilled in the art without inventive effort.

FIG. 1 is a front three-dimensional schematic view of the present invention.

FIG. 2 is a schematic representation of the reverse side of the present invention in three dimensions.

FIG. 3 is a cross-sectional view of the connection structure of the connection body and the tray body according to the present invention.

FIG. 4 is a schematic front view of the present invention.

Fig. 5 is a view from a-a in fig. 4 in a state where the coupling body and the coupling flange are separately welded.

FIG. 6 is a schematic view of a linker structure.

Fig. 7 is a schematic structural view of a flange with a straight inward-turning type connecting flange.

Fig. 8 is a schematic structural view of a first obliquely outward-turned flange of the connecting flange.

Fig. 9 is a schematic structural view of a second obliquely outward-turned flange of the connecting flange.

Fig. 10 is a schematic structural view of a connecting flange being a circular ring type flange.

Fig. 11 is a schematic structural view of a connecting flange being a petal-shaped flange.

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 obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.

As shown in fig. 1, in embodiment 1, a cyclone ultralight composite brake disc includes a disc body 1 and a connection disc 2, the connection disc includes a connection body 201 and a connection flange 202, the connection body 201 of the disc body 1 and the connection disc 2 is formed by fusion casting, that is, the lower part of the connection disc is located in the disc body, the connection disc and the disc body are arranged on the same central axis and then are fused in a liquid state, and the connection disc and the disc body are fused into a whole. The tires of the same size are slightly different from the tires of different bridge types and brake discs in terms of bearing positions and threaded holes, the connecting bodies and the brake discs are cast, and when products are switched, only different connecting discs need to be replaced. The invention can be connected with connecting discs with different diameters, different shapes and different heights. The bridges with the same tonnage can be switched by using the same friction plates. There is no need to remake the mold like a conventional one-piece brake disc. The switching of products is convenient and fast. Can save a large amount of mould expenses, also be convenient for the production field management. An inner air duct 3 and an outer cyclone air duct 4 are arranged on the tray body 1 along the radial direction. The weight of the brake disc is minimized by the matching use of the inner air duct and the outer cyclone air duct, and is reduced by 20-30% compared with the weight of the traditional common brake disc, and the light weight of the brake disc is extremely achieved. In addition, the cooperation in interior wind channel and outer whirlwind wind channel makes the air permeability of brake disc better, improves the thermal diffusivity of brake disc greatly, makes the brake back disk body can cool down rapidly, ensures that car brake performance is best, and then ensures car owner's personal safety. The disk body is made of gray cast iron or vermicular cast iron, and the connecting disk is made of high-quality carbon steel or the like, so that the integral strength is ensured.

Further, as shown in fig. 2, the tray body 1 includes a tray body upper portion 101 and a tray body lower portion 102 which have the same diameter and are arranged in parallel, a radial reinforcing rib 103 is arranged between the tray body upper portion 101 and the tray body lower portion 102, and an inner air duct 3 is formed between two adjacent radial reinforcing ribs 103. Preferably, the radial reinforcing rib 103 is a cylindrical rib, a cuboid rib, a cube rib or a trapezoidal reinforcing rib. When the radial reinforcing ribs 103 are cylindrical ribs, cuboid ribs or cubic ribs, the inner air channels are air channels with the same channel width; when the radial reinforcing rib 103 is a trapezoidal rib body, the inner air duct is an air duct with a gradually decreasing or increasing track width.

Further, the upper tray body part 101, the lower tray body part 102 and the radial reinforcing ribs 103 are integrally molded by casting; the radial reinforcing ribs 103 are radially arranged between the disc upper part 101 and the disc lower part 102 at equal angles. The upper surface of the upper part 101 of the tray body and the lower surface of the lower part 102 of the tray body are uniformly provided with outer cyclone air ducts 4. And outer cyclone air ducts are arranged on the upper part 101 and the lower part 102 of the disc body, so that the ventilation and heat dissipation effects are enhanced, and the weight of the brake disc is reduced.

Embodiment 2, a cyclone ultra-light composite brake disc, wherein axial vents may be provided on the disc body upper portion 101 and the disc body lower portion 102 to further reduce the weight of the brake disc. And when the axial vent hole is arranged, the external cyclone air duct can be omitted. The axial ventilation holes and the radial reinforcing ribs 103 are arranged in a staggered mode, namely, ventilation holes are formed in the friction surfaces of the disc body, the positions of the ventilation holes and the positions of the radial reinforcing ribs are staggered, and the strength of the radial reinforcing ribs cannot be damaged by the ventilation.

Further, the outer cyclone air duct 4 is a curved cyclone duct. The effect is the same whether the brake disc rotates clockwise or anticlockwise when the brake disc is seen from one direction, and the cyclone can be formed. The outer cyclone air duct 4 is a herringbone ventilation groove which is arranged on the outer surface of the disc body 1 along the center of the disc body 1 in an array mode. Two or three adjacent herringbone ventilation grooves are crossed, the number of air channels is increased, and the heat dissipation efficiency is improved.

Further, as shown in fig. 3 and 6, the connecting disc 2 includes a connecting body 201 and a connecting flange 202, and the connecting flange is divided into four types, namely a straight outward-turning flange (as shown in fig. 5), a straight inward-turning flange (as shown in fig. 7), an oblique outward-turning flange (as shown in fig. 8 and 9), and an oblique inward-turning flange, according to the connecting manner. The connecting portion of the connecting flange is divided into flange shapes, and can be divided into a circular ring type flange (as shown in fig. 10) or a petal type flange (as shown in fig. 11). The circular ring type flange (as shown in fig. 10) or the petal type flange can be combined with a straight outward turning type flange (as shown in fig. 5), a straight inward turning type flange (as shown in fig. 7), an oblique outward turning type flange (as shown in fig. 8 and 9) and an oblique inward turning type flange in any pairs according to requirements. The inclined outward-turning type flange (as shown in figures 8 and 9) and the inclined inward-turning type flange can be provided with lightening holes on the circumferential wall, so that the overall mass is reduced. The connecting body 201 and the connecting flange 202 are coaxially arranged, and the connecting body and the connecting flange are made of high-quality carbon steel or the like. The lower part of the connecting body 201 is provided with an integrally formed petal bulge 203; the inside of disk body 1 is equipped with slot 5, and slot 5 and interior wind channel 3 cross arrangement, the protruding 203 of petal cooperatees with slot 5, the location of the connector of being convenient for and the founding shaping with the disk body, make its intensity obtain effectual assurance.

Further, the connecting body 201 and the connecting flange 202 are matched and welded. When the connecting body and the connecting flange are welded together (as shown in fig. 5), the connecting flange can also be provided with a section of neck pipe, the outer diameter of the neck pipe of the connecting flange is slightly smaller than the inner diameter of the neck pipe of the connecting body, or the inner diameter of the neck pipe of the connecting flange is slightly larger than the outer diameter of the neck pipe of the connecting body, and the connecting body and the connecting flange are nested one section (or are in interference fit) for welding. And press mounting by a press machine during over-hard matching, and then welding. The split type single-body forming is adopted, and then welding is carried out, so that the process performance is good, the effective utilization rate of materials can reach more than 90% and even 100%, the production cost is low, the production process is simple, and large-scale and batch production is facilitated.

Example 3: a manufacturing method of a cyclone ultralight composite brake disc comprises the following steps:

s1: manufacturing a connector: punching a steel plate or a steel pipe with the thickness of 6-15mm into a semi-finished product of the convex edge-shaped connector, wherein the specific thickness can be determined according to the bridge shape; then stamping or cold processing is adopted, and a plurality of bosses are manufactured on the periphery of the half-finished product of the brim-shaped connector to form the connector with the convex petals. The connector can also be made into a steel casting by adopting precision casting and is formed by casting once.

S2: manufacturing a connecting flange: high-quality carbon steel or alloy steel with good welding performance is used for manufacturing the connecting flange by stamping, spinning or roll forming; such as high quality carbon steel with good weldability such as Q235/Q345/45/20.

S3: manufacturing a disk body sand core: when a core box of the tray body sand core is manufactured, a space for placing the connecting body in the step S1 is reserved; when a core shooter is used for manufacturing the sand core of the tray body, the connecting body in the step S1 is placed in the core box, the connecting body is arranged in the sand core of the tray body, a layer of sand is coated on the surface of the part, fused with the tray body, of the petal bulge of the connecting body, and the separation from liquid molten iron is ensured during pouring; the part of the petal bulge of the connector, which needs to be fused with the disc body in a liquid state, needs to be exposed, so that the petal bulge and the disc body can be conveniently fused and cast.

S4: pouring a brake disc: smelting molten iron after the sand core of the disc body is manufactured, inoculating along with the stream before pouring, and adding a pearlite inoculant to ensure that the metallographic phase and the mechanical property of the brake disc meet the requirements; and then, a stack box is adopted for pouring, the pouring temperature is kept at 1360-1500 ℃, and the brake disc (and the liquid fusion process of the connecting body and the disc body) is poured. Wherein the disk body adopts grey cast iron, the chemical composition of grey cast iron: c: 3.1 to 3.6 percent; si: 1.7-2.5%; mn: 0.6-0.9%; s is less than or equal to 0.12 percent; p is less than or equal to 0.15 percent. According to the actual requirement, a proper amount of trace elements such as Cu, Cr, Sn, Mo, Nb, Ni, Bi and the like can be added for blending. Performance: hardness: 180-255 HBW; the tensile strength is more than or equal to 220 Mpa. The A-type graphite accounts for more than 90 percent, and the graphite length is 2-6 grades. Uniform fine lamellar pearlite is presented, the ferrite content is not more than 5%, and no ledeburite is present. The content of eutectic of carbide and phosphorus is not more than 2%.

S5: welding a connecting flange and a connecting body: and (4) nesting the connecting flange in the step S2 on the connecting body in the step S4 to ensure that the connecting flange and the connecting body are arranged concentrically, and then welding. Because the connecting body and the connecting flange are both made of steel, the connecting body and the connecting flange have high strength and rigidity, the connecting disk and the disk body are fused in a liquid state and are cast into a whole, and the strength of the connecting body and the connecting flange is effectively ensured. In the braking process, the deformation is small, and the stress of the disc body is uniform. The brake disc has good wear resistance, high strength and long service life.

S6: machining: step S5, machining the brake disc after welding, ensuring the technological requirements of the brake disc, and performing action balance and coating after the brake disc is qualified; and finishing the production and manufacture of the brake disc. The brake disc structure after machining is the same as that of embodiment 2.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.

Claims (10)

1. The utility model provides a super light composite brake disc of whirlwind, includes disk body (1) and connection pad (2), its characterized in that: the tray body (1) and the connecting tray (2) are formed by fusion casting, and an inner air duct (3) and an outer cyclone air duct (4) are arranged on the tray body (1) along the radial direction.

2. The cyclonic ultralight composite brake disc of claim 1, wherein: the tray body (1) comprises a tray body upper part (101) and a tray body lower part (102), radial reinforcing ribs (103) are arranged between the tray body upper part (101) and the tray body lower part (102), and an inner air duct (3) is formed between every two adjacent radial reinforcing ribs (103).

3. The cyclonic ultralight composite brake disc of claim 2, wherein: the upper part (101) of the tray body, the lower part (102) of the tray body and the radial reinforcing ribs (103) are cast and integrally formed; the radial reinforcing ribs (103) are arranged between the upper part (101) of the tray body and the lower part (102) of the tray body at equal angles along the radial direction.

4. The ultra-light composite brake disc of claim 2 or 3, wherein: the radial reinforcing ribs (103) are cylindrical ribs, cuboid ribs, cubic ribs or trapezoidal reinforcing ribs.

5. The composite brake disc of claim 4, wherein: axial vent holes are formed in the upper part (101) and the lower part (102) of the tray body, and the axial vent holes and the radial reinforcing ribs (103) are arranged in a staggered mode; outer cyclone air ducts (4) are uniformly distributed on the upper surface of the upper part (101) of the tray body and the lower surface of the lower part (102) of the tray body.

6. The cyclone ultralight composite brake disc as claimed in any one of claims 1 to 3 and 5, wherein: the outer cyclone air duct (4) is a curved cyclone air duct.

7. The composite brake disc of claim 6, wherein: the outer cyclone air duct (4) is a herringbone ventilation groove which is arranged on the outer surface of the disc body (1) along the center array of the disc body (1).

8. The cyclone ultra-light composite brake disc as claimed in any one of claims 1 to 3, 5, 6 and 7, wherein: the connecting disc (2) comprises a connecting body (201) and a connecting flange (202), the connecting body (201) and the connecting flange (202) are coaxially arranged, and petal bulges (203) are arranged at the lower part of the connecting body (201); the inside of disk body (1) is equipped with slot (5), and slot (5) and interior wind channel (3) cross arrangement, and the petal is protruding (203) and is cooperated with slot (5).

9. The cyclonic ultralight composite brake disc of claim 8, wherein: the connecting body (201) is matched with the connecting flange (202) and is welded and fixed; the connecting flange (202) is a straight outward-turning flange or a straight inward-turning flange or an oblique outward-turning flange or an oblique inward-turning flange; the connecting part of the connecting flange (202) is of a circular ring type or a petal type.

10. A manufacturing method of a cyclone ultralight composite brake disc is characterized by comprising the following steps: the method comprises the following steps:

s1: manufacturing a connector: punching a steel plate or a steel pipe into a semi-finished product of the convex edge-shaped connector; then punching or cold processing is adopted, and a plurality of bosses are manufactured on the periphery of the half-finished product of the camberline-shaped connector to form a connector with petal bulges;

s2: manufacturing a connecting flange: high-quality carbon steel or alloy steel with good welding performance is used for manufacturing the connecting flange by stamping, spinning or roll forming;

s3: manufacturing a disk body sand core: when a core box of the tray body sand core is manufactured, a space for placing the connecting body in the step S1 is reserved; when the tray body sand core is manufactured, the connecting body in the step S1 is placed in the core box, the connecting body is arranged in the tray body sand core, and a layer of sand is coated on the surface of the part, which is not fused with the tray body, of the petal bulge of the connecting body, so that the separation from liquid molten iron is ensured during pouring;

s4: pouring a brake disc: smelting molten iron after the sand core of the disc body is manufactured, inoculating along with the stream before pouring, and adding a pearlite inoculant to ensure that the metallographic phase and the mechanical property of the brake disc meet the requirements; then, pouring by adopting a stack box, keeping the pouring temperature at 1360-1500 ℃, and pouring the brake disc;

s5: welding a connecting flange and a connecting body: nesting the connecting flange in the step S2 on the connecting body in the step S4 to ensure that the connecting flange and the connecting body are concentrically arranged, and then welding;

s6: machining: step S5, machining the brake disc after welding, ensuring the technological requirements of the brake disc, and performing action balance and coating after the brake disc is qualified; and finishing the production and manufacture of the brake disc.

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