DE102022202786A1 - Method for reconditioning a brake disc for a vehicle that has been worn out due to abrasion and brake disc - Google Patents

Abstract

The invention relates to a method for reconditioning a brake disc (2) for a vehicle that has been worn out due to abrasion, wherein the worn brake disc (2) comprises at least one base body (4) and at least one worn friction layer (8) fixed to the base body (4). Steps:a. Removing the abrasion-worn friction layer (8) of the brake disc (2) using a removal tool until a flat application surface is produced, which is formed by a surface of the partially removed friction layer (8) when a basic friction layer thickness is reached or by a surface of the base body without a friction layer (4) is formed when the friction layer (8) arranged thereon is completely removed.b. Applying at least one friction layer (10) to the application surface until a predetermined or predetermined friction layer thickness is reached.

Description

The invention relates to a method for reconditioning a brake disc for a vehicle that has been worn out due to abrasion, and to a brake disc that is produced using such a method.

In order to reduce particle emissions during braking and the tendency of brake discs to corrode, brake discs can be coated with various metallic or non-metallic materials, for example stainless steel, oxides or carbides.

It is known from the prior art to have such a friction layer, e.g. B. can be applied using laser deposition welding, also known as laser cladding, EHLA, etc.

These friction layers usually have a thickness of approx. 100-250 µm. Depending on the application, the friction layer can also be thicker. After a life cycle of the brake disc, the friction layer is worn and removed, so that the brake disc must be replaced in order to continue to ensure the road safety of the vehicle. Replacing the brake disc results in an increased amount of scrap due to the disposal of the old brake disc.

An object of an exemplary embodiment of the invention is to propose a method for reconditioning an abrasion-worn brake disc for a vehicle as well as a brake disc which is produced according to such a method, in which a service life of a brake disc is increased.

1. a. Abtragendes Bearbeiten der durch Abrieb abgenutzten Reibschicht der Bremsscheibe durch ein Abtragwerkzeug, bis Herstellen einer planen Auftragsoberfläche, die durch eine Oberfläche der teilweise abgetragenen Reibschicht bei Erreichen einer Grundreibschichtdicke gebildet ist oder die durch eine reibschichtfreie Oberfläche des Grundkörpers bei Erreichen eines vollständigen Abtrags der daran angeordneten Reibschicht gebildet ist.
2. b. Auftragen mindestens einer Reibschicht auf die Auftragsoberfläche, bis Erreichen einer vorgebbaren oder vorgegebenen Reibschichtdicke.

This object is achieved by a method for reconditioning a brake disc for a vehicle that has been worn out due to abrasion, the worn brake disc comprising at least one base body and at least one worn friction layer fixed to the base body, with the steps:

1. a. Abrasive processing of the friction layer of the brake disc worn by abrasion using a removal tool until production of a flat application surface, which is formed by a surface of the partially removed friction layer when a basic friction layer thickness is reached or which is formed by a friction layer-free surface of the base body when the friction layer arranged thereon is completely removed is formed.
2. b. Applying at least one friction layer to the application surface until a predetermined or predetermined friction layer thickness is reached.

Using the method according to the invention, a worn, worn brake disc can be reconditioned by first removing the worn friction layer and applying a new friction layer. As a result, the brake disc can be given at least a second life cycle, in particular further life cycles.

Depending on the material of the friction layer, the basic friction layer thickness can be ten µm.

The application surface can be formed by a surface of the friction layer that is completely or only partially removed to the base friction layer thickness or by a surface of the base body that is completely or only partially free of friction layer.

In addition, the process allows brake discs originally made exclusively of gray cast iron, i.e. brake discs in which the base body and friction layer form a common one-piece component, to be reused by applying the new friction layer, as well as coated brake discs, i.e. brake discs in which the base body and friction layer form separate components or Layers are joined together.

The method according to the invention can also be used to reduce maintenance costs, especially for large brake discs that are used, for example, in trucks, rail vehicles and aircraft, which are complex and expensive to produce.

In principle, it is conceivable that the brake disc is processed by the removal tool in such a way that the entire surface of the base body is freed from the friction layer worn away by abrasion. In addition, the brake disc can also be made free of a friction layer in only one section by machining and this section can be provided with a new applied friction layer. This can be useful, for example, if the brake disc is worn unevenly and does not need to be reconditioned in some areas.

In one embodiment of the method, it is provided that the abrasive machining of the friction layer of the brake disc worn by abrasion using a removal tool includes turning, in particular fine turning, milling or grinding.

In such a case, the removal tool can comprise a turning tool, a milling tool or a grinding tool.

In addition, it proves to be advantageous if the application of the friction layer to the application surface involves arc spraying or laser deposition welding until a predetermined friction layer thickness is reached.

In addition, in a further development of the method, it is provided that the applied or to be applied friction layer is a stainless steel, an oxide, such as a ceramic-metal composite material, or a carbide with a friction layer thickness of 100 µm to 300 µm or a stainless steel with a friction layer thickness of 100 µm to 1.5 mm.

If the friction layer comprises a stainless steel or a gray cast iron, the predetermined friction layer thickness can range from 100 µm to 1.5 mm. If the friction layer comprises a stainless steel, an oxide such as a ceramic-metal composite material, or a carbide, the friction layer thickness can range from 100 to 100 μm. 300 µm.

By using a hard material, such as a ceramic-metal composite or stainless steel, the brake disc can have small layer thicknesses. This allows the brake disc to be made compact.

The quality of the brake disc can be further improved if, before applying the friction layer to the application surface, the application surface of the brake disc is cleaned with a cleaning tool, in particular if corrosion and contamination are removed.

Cleaning the application surface of the brake disc can eliminate corrosion or contamination. By eliminating corrosion and contamination, the service life of the brake disc can be increased. By applying the friction layer to the cleaned application surface, the base body and/or the friction layer is protected against environmental influences, in particular against contamination and moisture.

In order to keep the traffic safety of the motor vehicle high, it proves to be advantageous if, before applying the friction layer to the application surface and in particular after cleaning the application surface, the base body of the brake disc is checked for damage, in particular for cracks, by a sensor means.

When operating the motor vehicle and when removing the friction layer worn by abrasion using a removal tool, it can never be completely avoided that the forces or heat input acting on the brake disc or the base body can lead to damage, such as cracks. Because the base body is checked for damage by the sensor means, the desired braking behavior can be guaranteed.

The sensor means can, for example, comprise an optical means with which the surface is checked for cracks, for example, and/or include an X-ray with which invisible structures of the base body can also be detected.

In addition, embodiments of the method are conceivable in which several different friction layers are applied to the base body or to a friction layer, in particular materials forming several different friction layers are removed from one another.

In a further development of the method, it proves to be advantageous if, before the friction layer is applied to the base body, an intermediate layer, in particular an elastic adhesive layer, is applied to the free surface of the base body of the brake disc, to which the friction layer is applied.

If, before applying the friction layer to the base body, an intermediate layer, in particular an elastic adhesive layer, is applied to the application surface to which the friction layer is applied, the risk of damage to the brake disc is reduced.

In a further development of the last-mentioned embodiment of the method, it is provided that during laser deposition welding, a laser beam is moved over a stainless steel powder applied to the application surface and the friction layer is created on the intermediate layer, which is formed from a stainless steel matrix with hard material particles embedded therein.

This makes it easy to arrange the friction layer on the adhesive layer.

In a further development of the last-mentioned embodiment of the method, parameters prove to be advantageous in which, when producing the friction layer, the laser beam with a laser intensity of 0.1 - 2.5 kW/mm ² is directed onto the stainless steel powder applied to the intermediate layer, that the spot in which the laser beam hits the applied stainless steel powder and in which the stainless steel powder is melted into a melt pool has a diameter of 2.5 mm to 15 mm, and that hard material particles are added to the melt pool thus formed, their average grain diameter 15 µm to 135 µm.

In principle, it is conceivable that the intermediate layer and/or the friction layer are applied to the base body at ambient temperature. However, it proves to be advantageous if the base body is preheated to a preheating temperature of 100 ° C - 700 ° C before applying an intermediate layer and / or friction layer to the base body.

This makes it possible to further improve the joining of the base body and the intermediate layer, or of the base body, the intermediate layer and the friction layer.

In a further development of the last-mentioned embodiment, it is provided that the base body is preheated to the preheating temperature in a locally limited manner in its entirety or on the section of the base body without a friction layer, and then the friction layer is applied to the application surface of the base body, in particular by melting the stainless steel powder using the laser beam.

In principle, it is conceivable that the entire base body is preheated to the preheating temperature. However, if the base body is only free of friction layers in one or more sections, it can prove to be advantageous if the base body is only preheated to the preheating temperature in a locally limited manner. This allows the process to be carried out energy-efficiently.

The heating of the base body, or of locally limited sections of the base body, can be technically implemented in any desired manner. This can be done, for example, by heat conduction or heat radiation. In one embodiment of the method it is provided that the preheating includes inductive heating.

Furthermore, embodiments of the method are conceivable in which the abrasive machining of the friction layer of the brake disc worn by abrasion and the application of the at least one friction layer to the friction layer-free base body or to the friction layer-free section of the base body on a single surface of the base body or on two, in particular opposite, surfaces , surfaces of the base body takes place.

In this case, the brake disc can be refinished on one or both sides.

Finally, the task is solved by a brake disc for a vehicle, which is manufactured using a process with the aforementioned features.

By reprocessing the brake disc, it can be given another life cycle. This is advantageous not least for environmental reasons. In addition, the process allows brake discs that no longer meet current regulations to be remanufactured in accordance with regulations and used again.

Further features, details and advantages of the invention result from the attached patent claims, from the graphic representation and subsequent description of a preferred embodiment of the brake disc and the method.

• 1 Eine geschnittene Ansicht durch eine durch Abrieb abgenutzte Bremsscheibe;
• 2 Eine Bremsscheibe mit aufgetragener Reibschicht;
• 3 Ein schematisches Ablaufdiagramm eines erfindungsgemäßen Verfahrens.

In the drawing shows:

• 1 A sectioned view through a brake disc worn by abrasion;
• 2 A brake disc with an applied friction layer;
• 3 A schematic flow diagram of a method according to the invention.

1 shows a brake disc for a vehicle, provided overall with the reference number 2. The brake disc 2 comprises a base body 4, in which a worn friction layer 8 is arranged on a surface 6 of the base body 4.

2 shows a brake disc 2 in which the worn friction layer 8 has been removed from the base body 4 by abrasive machining and a new friction layer 10 has been applied to the surface 6 of the base body 4.

• In einem ersten Schritt 100 erfolgt ein abtragendes Bearbeiten der durch Abrieb abgenutzten Reibschicht 8 der Bremsscheibe 2 durch ein Abtragwerkzeug, bis Herstellen einer planen Auftragsoberfläche, die bei dem in den Figuren ersichtlichen Ausführungsbeispiel durch die reibschichtfreie Oberfläche 6 des Grundkörpers 4 bei Erreichen eines vollständigen Abtrags der daran angeordneten Reibschicht (8) gebildet ist.

Based 3 the method according to the invention is described. With the help of the in 1 and 2 Brake discs 2 shown, the method is explained below as follows:

• In a first step 100, the abrasion-worn friction layer 8 of the brake disc 2 is removed using a removal tool until a flat application surface is produced, which in the exemplary embodiment shown in the figures is achieved by the friction-layer-free surface 6 of the base body 4 when complete removal of the brake disc is achieved friction layer (8) arranged thereon is formed.

Removing machining can include turning, milling or grinding.

In principle, it is conceivable that in a step 104 immediately following this, a friction is applied to the application surface formed by the base body 4 of the brake disc 2 without a friction layer Layer 10 is applied until a predetermined or predetermined friction layer thickness is reached. The predeterminable or predetermined friction layer thickness can be, for example, 100 μm to 250 μm.

The at least one friction layer 10 can be applied using arc spraying or laser deposition welding.

In addition, a method step 101 can be provided between steps 100 and 104, in which the surface 6 of the base body 4 of the brake disc 2 is cleaned by a cleaning tool before the friction layer 10 is applied to the application surface.

Following this, in a step 102, before applying a friction layer 10 to the application surface and in particular after cleaning the application surface formed by the surface 6 of the base body 4, the base body 4 of the brake disc 2 can be checked for damage by a sensor means.

In a subsequent step 103, before the friction layer 10 is applied to the application surface, an intermediate layer, in particular an elastic adhesive layer, can be applied to the application surface formed by the free surface 6 of the base body 4.

The features of the invention disclosed in the above description, in the claims and in the drawing can be essential both individually and in any combination in the implementation of the invention in its various embodiments.

Reference symbol list

2

worn brake disc

4

Basic body

6

surface

8th

worn friction layer

10

friction layer

100 - 104

Procedural steps

Claims (14)

Method for reconditioning a brake disc (2) for a vehicle that has been worn out due to abrasion, the worn brake disc (2) comprising at least one base body (4) and at least one worn friction layer (8) fixed to the base body (4), with the steps: a. Removing the abrasion-worn friction layer (8) of the brake disc (2) using a removal tool until a flat application surface is produced, which is formed by a surface of the partially removed friction layer (8) when a basic friction layer thickness is reached or which is formed by a surface free of friction layer (6 ) of the base body (4) is formed when the friction layer (8) arranged thereon is completely removed. b. Applying at least one friction layer (10) to the application surface until a predetermined or predetermined friction layer thickness is reached. Procedure according to Claim 1 , characterized in that the abrasive machining of the friction layer (8) of the brake disc (2) worn by abrasion using a removal tool includes turning, in particular fine turning, milling or grinding. Procedure according to Claim 1 or 2 , characterized in that the application of the friction layer (10) to the application surface until a predetermined friction layer thickness is reached includes arc spraying or laser deposition welding. Method according to one of the preceding claims, characterized in that the applied or to be applied friction layer (10) comprises a stainless steel, an oxide, such as a ceramic-metal composite material, or a carbide with a friction layer thickness of 100 µm to 300 µm or a stainless steel a friction layer thickness of 100 µm to 1.5 mm. Method according to one of the preceding claims, characterized in that before the friction layer (10) is applied to the application surface, the application surface is cleaned by a cleaning tool, in particular corrosion and contamination are removed. Method according to one of the preceding claims, characterized in that before applying the friction layer (10) to the application surface and in particular after cleaning the application surface, the base body (4) of the brake disc (2) is checked for damage, in particular for cracks, by a sensor means. is checked. Method according to one of the preceding claims, characterized in that before the friction layer (10) is applied to the application surface, an intermediate layer, in particular an elastic adhesive layer, is applied to the application surface, to or on which the friction layer (10) is applied . Procedure according to Claim 7 , characterized in that during laser deposition welding a laser beam is directed onto the free surface Stainless steel powder applied to the base body (4) is moved and the friction layer (10) is created on the intermediate layer, which is formed from a stainless steel matrix with hard material particles embedded therein. Procedure according to Claim 8 , characterized in that when producing the friction layer (10), the laser beam with a laser intensity of 0.1 - 2.5 kW/mm2 is directed onto the stainless steel powder applied to the intermediate layer, that is, the spot in which the laser beam meets the applied stainless steel powder and in which the stainless steel powder is melted into a melt pool, has a diameter of 2.5 mm to 15 mm, and that hard material particles are added to the melt pool thus formed, the average grain diameter of which is 15 µm to 135 µm. Method according to one of the preceding claims, characterized in that the base body (4) is preheated to a preheating temperature of 100°C - 700°C before applying an intermediate layer and/or friction layer (10) to the application surface. Procedure according to Claim 10 , characterized in that the base body (4) is preheated to the preheating temperature in a locally limited manner in its entirety or on a friction layer-free section of the base body (4), and then the friction layer (10) is applied to the application surface, in particular by melting the stainless steel powder through the Laser beam. Procedure according to Claim 10 or 11 , characterized in that the preheating includes inductive heating. Method according to one of the preceding claims, characterized in that the abrasion-worn friction layer (8) of the brake disc (2) and the application of the at least one friction layer (10) to the application surface on a single side of the base body (4) or takes place on two, in particular opposite, opposite sides of the base body (4). Brake disc (2) for a vehicle, which uses a method of Claims 1 until 13 is manufactured.

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