CN113606270A - Multi-metal composite brake drum and manufacturing method thereof - Google Patents
Multi-metal composite brake drum and manufacturing method thereof Download PDFInfo
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- CN113606270A CN113606270A CN202110953525.7A CN202110953525A CN113606270A CN 113606270 A CN113606270 A CN 113606270A CN 202110953525 A CN202110953525 A CN 202110953525A CN 113606270 A CN113606270 A CN 113606270A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 22
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/10—Drums for externally- or internally-engaging brakes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/04—Centrifugal casting; Casting by using centrifugal force of shallow solid or hollow bodies, e.g. wheels or rings, in moulds rotating around their axis of symmetry
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
Abstract
The invention discloses a multi-metal composite brake drum and a manufacturing method thereof, wherein the outer layer of the multi-metal composite brake drum is a flexible layer, and high-strength and high-toughness brake drum steel or wheel steel is adopted, so that the multi-metal composite brake drum is easy to spin; the middle layer is a rigidity strengthening layer and adopts white cast iron/high-strength ductile iron/high-strength vermicular cast iron, and the inner layer is a wear-resistant layer and adopts high-alloy cast iron HT200 or HT 250. Placing the spinning steel-tapping shell on a centrifugal casting machine, and compounding a layer of high-grade vermicular graphite cast iron, ductile iron or white cast iron on the inner layer of the steel shell; and after the rigidity reinforcing layer is poured, centrifugal pouring is continuously adopted, and a layer of wear-resistant gray cast iron is compounded on the inner side of the rigidity reinforcing layer. The middle rigidity strengthening layer solves the problem that the rigidity of the common gray iron or steel composite brake drum is insufficient, and the outer steel shell also solves the problems that the yield strength of the wear-resistant gray iron layer and the vermicular iron, ductile iron and white cast iron is low, the elongation rate is low and the brake drum is easy to crack. The multi-metal composite brake drum has the characteristics of no cracking, no top falling and longer service life. The production equipment of the technical scheme is simple, and the production investment is low.
Description
Technical Field
The invention belongs to the technical field of brake drums, and particularly relates to a multi-metal composite brake drum and a manufacturing method thereof.
Background
The strength and rigidity of the brake drum determine the service life of the brake drum, and the brake drum is well known in the industry. In order to improve the strength and rigidity of the brake drum, the material of the traditional pure gray iron brake drum is improved from HT200 to HT250, but the requirement of working conditions cannot be met. Since the strength and hardness of metal have a certain correspondence, if the strength of the material is further improved, the hardness is too high, and the processing is difficult. The development of brake drums has thus far met a technical bottleneck.
Although the bimetal steel composite brake drum has great breakthrough, the problem of cracking cannot be thoroughly solved, and the fundamental reasons are that the rigidity is insufficient, the brake drum is easy to deform and crack during braking, and small cracks generated at the initial stage gradually extend into large cracks to cause the brake drum to lose efficacy. Technicians in the industry have been searching for ways to improve rigidity for a long time so as to thoroughly solve the problems of insufficient rigidity and easy cracking of the brake drum.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the multi-metal composite brake drum and the manufacturing method thereof, the multi-metal composite brake drum is not cracked, the service life is longer, the production equipment is simple, and the production investment is less.
In order to solve the technical problems, the invention adopts the following technical scheme:
a multi-metal composite brake drum is composed of a flexible layer, a rigidity reinforcing layer and a wear-resistant layer from outside to inside in sequence;
the flexible layer is formed by spinning high-strength and high-toughness brake drum steel or wheel steel and is positioned on the outermost layer of the brake drum;
the rigidity reinforcing layer is formed by centrifugally casting high-grade vermicular cast iron, high-grade ductile iron and white cast iron with high hardness and high strength and is positioned in the middle layer of the brake drum;
the wear-resistant layer is formed by centrifugal casting of high-alloy cast iron HT200 or HT250 and is positioned on the innermost layer of the brake drum;
the thickness of the outer flexible layer is set to be 4-7mm, the thickness of the middle rigidity reinforcing layer is set to be 4-13mm, and the thickness of the inner wear-resistant layer is set to be 4-6 mm.
The invention relates to a manufacturing method of a multi-metal composite brake drum, which comprises the following steps:
(1) preparing an outer steel shell; manufacturing an outermost layer steel shell by adopting wheel special steel T380CL or brake drum special steel ZDG380 and ZDG400 through the procedures of blanking, punching, spinning and grooving;
(2) pouring a rigidity reinforcing layer: placing the spun steel shell, namely the outer steel shell, on a centrifugal casting machine, and compounding a layer of high-grade vermicular cast iron, ductile iron or white cast iron on the inner layer of the steel shell;
(3) casting a wear-resistant layer: and after the rigidity reinforcing layer is poured, centrifugal pouring is continuously adopted, and a layer of wear-resistant gray cast iron is compounded on the inner side of the rigidity reinforcing layer.
Further, the molten iron needs to be subjected to sufficient creeping treatment, spheroidizing treatment or whitening treatment before the rigid reinforcing layer is poured in the step (2).
Further, wire feeding and creeping inoculation are adopted in the creeping treatment, rare earth magnesium calcium silicon alloy is used for creeping, the creeping treatment temperature is 1400-1450 ℃, the carbon equivalent is controlled to be 4.3-4.7%, the quantity of vermicular graphite is 80-90%, the length-thickness ratio of graphite is 5-10, and the content of pearlite is 80-90%.
Further, the spheroidizing treatment adopts wire feeding spheroidizing inoculation treatment, and high-magnesium alloy spheroidizing wires are used for spheroidizing, wherein the spheroidizing rate is not lower than 80%, the spheroidizing grade is superior to grade 2, the content of pearlite is more than 80%, and the spheroidizing temperature is 1400-grade 1450 ℃.
Further, the white-mouth treatment is to add 1% of rare earth alterant into the foundry ladle, then add 1% -1.4% of Cr, complete the alteration after stirring and full melting, and the added alterant and the chromium can promote the formation of cementite and prevent the formation of graphite.
And further, after the rigid reinforcing layer is poured for 1-2 minutes, and when the reinforcing layer is solidified and is not hardened, the inner wear-resistant layer is poured.
Further, the semi-finished blank, namely the outer steel shell behind the composite rigidity strengthening layer, needs to be preheated before the inner wear-resistant layer is poured, the temperature is increased to 700-.
The outer layer of the multi-metal composite brake drum is a flexible layer, and high-strength and high-toughness brake drum steel or wheel steel is adopted, so that the multi-metal composite brake drum is easy to spin; the middle layer is a rigidity reinforcing layer and is made of white cast iron/high-strength ductile iron/high-strength vermicular cast iron, the hardness is more than or equal to 300HBW, and the strength is more than or equal to 700 Mpa; the inner layer is a wear-resistant layer made of high-alloy cast iron HT200 or HT 250.
Compared with the prior art, the invention has the beneficial effects that:
1. the middle rigidity strengthening layer solves the problem that the rigidity of the common gray iron or steel composite brake drum is insufficient, and the outer steel shell also solves the problems that the yield strength of the wear-resistant gray iron layer and the vermicular iron, ductile iron and white cast iron is low, the elongation is low and the brake drum is easy to crack.
2. The production equipment of the technical scheme is simple, and the production investment is low.
3. Because the strength and the rigidity of the brake drum are higher, the wall thickness of the brake drum can be properly reduced, the weight of the brake drum is reduced, and the weight of the brake drum is reduced by 15 to 20 percent compared with that of a common brake drum and is reduced by about 10 percent compared with that of a steel bimetal composite brake drum.
4. The multi-metal composite brake drum disclosed by the invention is not cracked or topped, and is long in service life.
Drawings
FIG. 1 is a schematic structural view of a multi-metal composite brake drum according to the present invention.
FIG. 2 is a schematic structural diagram of an outer steel shell of the multi-metal composite brake drum of the present invention.
FIG. 3 is a schematic view of the spheroidizing casting process in example 1.
FIG. 4 is a schematic diagram of the vermicular casting process of example 2.
Fig. 5 is a schematic diagram of the insertion depth in the spheroidizing and creeping processes.
FIG. 6 is a schematic drawing of centrifugal casting.
The method comprises the following steps of 1-a flexible layer, 2-a rigidity reinforcing layer, 3-a wear-resistant layer, 4-a transition arc position, 5-a middle section, 6-a large opening, 7-a smelting furnace, 8-a spectrum analyzer, 9-a wire feeding treatment station, 10-a guide frame, 11-a spheroidizing wire, 12-a creeping wire, 13-a inoculation wire, 14-a wire feeding machine, 15-a pouring small bag, 16-a self-centering clamping jaw, 17-a centrifugal pouring machine and 18-a pouring cup.
Detailed Description
The present invention will be further described with reference to the following examples. It is to be understood that the following examples are illustrative only and are not intended to limit the scope of the invention, which is to be given numerous insubstantial modifications and adaptations by those skilled in the art based on the teachings set forth above.
Example 1
The multi-metal composite brake drum of the embodiment sequentially comprises a flexible layer 1, a rigidity reinforcing layer 2 and a wear-resistant layer 3 from outside to inside; the flexible layer 1 is formed by spinning high-strength and high-toughness brake drum steel or wheel steel and is positioned on the outermost layer of the brake drum; the rigidity reinforcing layer 2 is formed by high-grade vermicular cast iron, high-grade ductile iron and white cast iron with high hardness and high strength through centrifugal casting and is positioned in the middle layer of the brake drum; the wear-resistant layer 3 is formed by centrifugal casting of high alloy HT200 or HT250 and is positioned on the innermost layer of the brake drum;
the thickness of the outer flexible layer is set to be 4-7mm, the thickness of the middle rigidity reinforcing layer is set to be 4-13mm, and the thickness of the inner wear-resistant layer is set to be 4-6 mm.
The manufacturing method of the multi-metal composite brake drum of the embodiment is as follows:
firstly, preparing an outer layer steel shell
(1) The outermost layer steel shell is manufactured by adopting the special steel T380CL for wheels or the special steel ZDG380 and ZDG400 for brake drums through the working procedures of blanking, punching, spinning, grooving and the like.
(2) The requirements on the material performance are as follows: the tensile strength is more than or equal to 500MPa, the yield strength is more than or equal to 420MPa, and the elongation is more than or equal to 30%.
(3) According to the main failure mode of the brake drum, (a, the brake drum falls off, namely the transition arc of the brake drum is cracked, the flange falls off, b, the brake drum is cracked in a large opening, and the crack penetrates through the brake drum) is provided with the spinning wall thickness requirement (as shown in figure 2): the transition arc 4 (corresponding to the height h 1) is not less than 9mm, the middle section 5 (corresponding to the height h 2) is 3-5mm, and the large opening 6 (corresponding to the height h 3) is 5-7 mm.
(4) In the spinning process, the spinning speed of the transition arc and the large opening is reduced and set to be 3-5mm/s, and the spinning speed of the middle section is set to be 5-10 mm/s. So as to increase the extrusion time at the position, refine the crystal grains at the position and improve the strength.
(5) And in the rolling groove procedure, a groove in the middle section of the steel shell is rolled, so that the weight can be reduced, and the strength can be improved.
Second, compound rigidity reinforcing layer
1. Smelting molten iron: the chemical composition is controlled as follows, C: 3.0% -3.6% Si: 0.8% -1.8% of Mn: 0.4 to 0.8 percent of S is less than or equal to 0.12 percent, and P is less than or equal to 0.3 percent; the smelting temperature is controlled between 1500 ℃ and 1550 ℃. The temperature is properly raised before discharging, and the discharging temperature is ensured to be 1550-1600 ℃.
2. Spheroidizing (as shown in fig. 3): the wire feeding spheroidization inoculation treatment is adopted, the high magnesium alloy spheroidization wire is used for spheroidization, the height-diameter ratio of a molten iron treatment ladle is set to be 1.8, a phi 13 core-spun wire is used, the thickness of the steel strip of the core-spun wire is 0.35mm, and the spheroidization temperature is 1400-1450 ℃.
The treatment process comprises the following steps: before 7 molten irons of smelting furnace, need make chemical composition inspection test block, spectral analysis appearance 8 detects chemical composition, detects qualified back, sends the testing result to feeding line processing station 9, by processing station intelligent analysis, calculates automatically that feeding line handles the parameter (including parameters such as feeding length, feeding line speed, balling time, length of moving back), and intelligence overhead traveling crane will handle the package and transport to the assigned position, and automatic processing station handles, and accurate control adds the magnesium volume.
The carbon equivalent of the treated molten iron is controlled to be 4.1-4.7 percent, the nodularity is not lower than 80 percent, the nodularity grade is better than 2 grade, and the content of pearlite is more than 80 percent.
In order to avoid degradation of spheroidization, the spheroidization station is arranged beside the casting station, so that the time for transferring molten iron is reduced.
The middle rigidity reinforcing layer is made of QT500-7, QT600-3 and QT 700-2.
3. The steel shell is assembled on a centrifugal casting machine 17, the steel shell rotates at the rotating speed of 500-600r/min, and qualified molten iron is cast into the steel shell.
Three, composite wear-resistant layer
After the pouring is finished, waiting for 1-2 minutes, pouring a layer of wear-resistant gray cast iron on the inner surface under the condition that the inner surface of the rigidity strengthening layer begins to solidify and is not hardened, at the moment, preheating the finished product blank (the outer layer steel shell behind the composite rigidity strengthening layer) to 700-800 ℃ by using a medium-frequency induction heater, adding 0.06-0.09% of silicon-barium inoculant into the pouring small bag 15, and inoculating with flow. In order to improve the inoculation effect, the inoculant is added and then slowly stirred for 2-3 circles by an automatic stirring device, and the pouring temperature is controlled at 1450-1500 ℃.
The material of the gray cast iron can adopt HT200, HT250 and the like.
Fourthly, shot blasting, machining, permanent mark marking, dynamic balancing, paint spraying, packaging and warehousing.
Example 2
Compared with the embodiment 1, the method only differs in the composite rigidity reinforcing layer, and other steps are the same as the embodiment 1. The method comprises the following specific steps:
1. smelting molten iron: the chemical composition is controlled as follows, C: 3.0% -3.6% Si: 0.8% -1.4% of Mn: 0.4-0.8% of S is less than or equal to 0.1%, and P is less than or equal to 0.0.07%; the smelting temperature is controlled between 1500 ℃ and 1550 ℃. The temperature is properly raised before discharging, and the discharging temperature is ensured to be 1550-1600 ℃.
2. Vermicular treatment (as shown in fig. 4): the wire feeding vermicularizing inoculation treatment is adopted, the method has the characteristics of small using amount of a vermicularizing agent and low vermicularizing cost, the treatment result is stable, the content of residual magnesium in molten iron is low, and the vermicularizing quality is good.
The treatment process comprises the following steps: before 7 smelting furnaces go out the molten iron, need make chemical composition inspection test block, spectral analysis appearance 8 detects qualified back, sends the testing result to feeding line and handles station 9, by processing station intelligent analysis, calculates automatically that the line is fed and handles parameters (including feeding length, line feeding speed, creep time, back line length isoparametric), and intelligent overhead traveling crane will handle the package and transport to the position of formulating, and automatic processing station handles.
The rare earth Mg-Ca-Si alloy vermicular wire is used for vermicular, a phi 13 core-spun wire is used, the thickness of the steel strip of the core-spun wire is 0.35mm, and the vermicular treatment temperature is 1400-1450 ℃. The carbon equivalent of the treated molten iron is controlled to be 4.3-4.7%, the molten iron eutectic degree Sc =1, the quantity of vermicular graphite is 80-90%, the length-thickness ratio of the graphite is 5-10, and the content of pearlite is 80-90%.
Note that:
A. sufficient alloy is added during smelting, and the alloy cannot be supplemented by using a flushing method during molten iron discharging so as to avoid the influence on the core quantity control precision of the vermicular molten iron due to chilling type cores during flushing of the alloy.
B. During the vermicular reaction, the higher the magnesium content in the vermicular agent is, the larger the insertion depth is (as shown in fig. 5), so as to prevent the magnesium vapor from being absorbed by the molten iron completely during the upward floating process and escaping.
C. In order to prevent white spots from being generated and increase the number of eutectic clusters, inoculation treatment is required while creeping, 75% of silicon is added according to the carbon equivalent for inoculation, and a small amount of silicon-calcium alloy is added before pouring for secondary inoculation.
The middle rigidity reinforcing layer is made of RT350, RT550 and the like.
3. The steel shell 1 is assembled on a centrifugal casting machine 17, the steel shell rotates at the rotating speed of 500-600r/min, and qualified molten iron is cast into the steel shell.
Example 3
Compared with the embodiment 1, the method only differs in the composite rigidity reinforcing layer, and other steps are the same as the embodiment 1. The method comprises the following specific steps:
1. smelting molten iron: the chemical composition is controlled as follows, C: 2.5% -3.0% Si: 0.5% -1.1% of Mn: 0.4 to 0.8 percent of S is less than or equal to 0.2 percent, and P is less than or equal to 0.2 percent; cr: 0.6 percent to 1.2 percent, and the smelting temperature is controlled between 1500 ℃ and 1550 ℃. The temperature is properly raised before discharging, and the discharging temperature is ensured to be 1550-1600 ℃.
2. White-skinning treatment: adding 1% of rare earth alterant into the ladle, adding 1% of Cr, stirring, and fully melting to complete the alteration.
3. Assembling the steel shell on a centrifugal casting machine, preheating to 800 ℃ at 700-.
4. And meanwhile, in the casting process, the atomizing nozzle is used for spraying water mist on the outer surface of the steel shell, so that the temperature of molten iron is reduced, and the solidification speed of the molten iron is increased.
The tensile strength of the finished multi-metal composite brake drum prepared in the embodiment 1-3 is more than or equal to 380MPa, and the hardness is 210-240 HBW.
The foregoing shows and describes the general principles and features of the present invention, together with the advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (8)
1. A multi-metal composite brake drum is characterized in that: the multi-metal composite brake drum is sequentially composed of a flexible layer (1), a rigidity reinforcing layer (2) and a wear-resistant layer (3) from outside to inside;
the flexible layer (1) is formed by spinning high-strength and high-toughness brake drum steel or wheel steel and is positioned on the outermost layer of the brake drum;
the rigidity reinforcing layer (2) is formed by centrifugally casting high-grade vermicular cast iron, high-grade ductile iron and white cast iron with high hardness and high strength and is positioned in the middle layer of the brake drum;
the wear-resistant layer (3) is formed by centrifugal casting of high-alloy cast iron HT200 or HT250 and is positioned on the innermost layer of the brake drum;
the thickness of the outer flexible layer is set to be 4-7mm, the thickness of the middle rigidity reinforcing layer is set to be 4-13mm, and the thickness of the inner wear-resistant layer is set to be 4-6 mm.
2. The method of manufacturing a multi-metal composite brake drum according to claim 1, comprising the steps of:
(1) preparing an outer steel shell; manufacturing an outermost layer steel shell by adopting wheel special steel T380CL or brake drum special steel ZDG380 and ZDG400 through the procedures of blanking, punching, spinning and grooving;
(2) pouring a rigidity reinforcing layer: placing the spun steel shell, namely the outer steel shell, on a centrifugal casting machine, and compounding a layer of high-grade vermicular cast iron, ductile iron or white cast iron on the inner layer of the steel shell;
(3) casting a wear-resistant layer: and after the rigidity reinforcing layer is poured, centrifugal pouring is continuously adopted, and a layer of wear-resistant gray cast iron is compounded on the inner side of the rigidity reinforcing layer.
3. The method of manufacturing a multi-metal composite brake drum according to claim 2, wherein: and (3) before the rigid reinforcing layer is poured in the step (2), the molten iron needs to be subjected to sufficient creeping treatment, spheroidizing treatment or white melting treatment.
4. The method of manufacturing a multi-metal composite brake drum according to claim 3, wherein: the vermicular treatment adopts wire feeding vermicular inoculation treatment, the rare earth magnesium calcium silicon alloy is used for vermicular treatment, the vermicular treatment temperature is 1400-1450 ℃, the carbon equivalent is controlled to be 4.3-4.7%, the quantity of vermicular graphite is 80-90%, the length-thickness ratio of the graphite is 5-10, and the content of pearlite is 80-90%.
5. The method of manufacturing a multi-metal composite brake drum according to claim 3, wherein: the spheroidization adopts the wire feeding spheroidization inoculation treatment, and the spheroidization is carried out by using a high-magnesium alloy spheroidization wire, wherein the spheroidization rate is not lower than 80 percent, the spheroidization grade is better than grade 2, the content of pearlite is more than 80 percent, and the spheroidization temperature is 1400-plus 1450 ℃.
6. The method of manufacturing a multi-metal composite brake drum according to claim 3, wherein: the white-mouth treatment is to add 1 percent of rare earth alterant into the foundry ladle, then add 1 to 1.4 percent of Cr, complete the alteration after stirring and full melting, and the added alterant and the chromium can promote the formation of cementite and prevent the formation of graphite.
7. The method of manufacturing a multi-metal composite brake drum according to claim 3, wherein: and after the rigid reinforcing layer is poured for 1-2 minutes, and when the reinforcing layer is solidified and is not hardened, the inner wear-resistant layer is poured.
8. The method of manufacturing a multi-metal composite brake drum according to claim 3 or 7, wherein: before the inner wear-resistant layer is poured, the semi-finished blank, namely the outer steel shell with the composite rigidity reinforcing layer, needs to be preheated to 700-800 ℃, and then 0.06% -0.09% of silicon-barium inoculant is added for stream inoculation when the inner wear-resistant layer is poured.
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| CN114318035A (en) * | 2021-12-29 | 2022-04-12 | 山西汤荣机械制造股份有限公司 | Preparation method of lightweight composite brake drum |
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