JP2676456B2 - Brake disc material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a brake disc material having excellent wear resistance and heat crack resistance.

[0002]

2. Description of the Related Art Conventionally, flake graphite cast iron has been used as a brake disc material for railway vehicles and the like, and in order to improve wear resistance and the like, various types of cast iron brake disc materials are listed below. It is known that the alloy disk is added and a heat-treated cast iron brake disc material is used. (1) Japanese Patent Publication No. 59-22780 discloses that cast iron has M
o, Cu, Ni, etc. are contained and 677 ° C or higher (760 ° C
It is made of wear-resistant cast iron with increased hardness (Brinell hardness HB: 302 to 415) and improved wear resistance by performing mold release in the vicinity) and making most of it a martensite structure and a bainite structure. A vehicle braking system member is described. However, although it is similar to the present invention in that it is released from the mold at a high temperature, the mold release temperature is different, and the chemical composition range and strain relief annealing are also different.

(2) Japanese Patent Application Laid-Open No. 60-157528 discloses a motorcycle in which Ni: 7 to 20%, Cr, Cu: 1 to 5% or the like is added to form an austenite structure or bainite structure to improve corrosion resistance. Brake discs for vehicles such as However, the present invention means that Ni, Cr,
The addition amount of Cu and the like is different. (3) Japanese Unexamined Patent Publication No. 64-62412 discloses a vehicle brake disc material having a bainite structure obtained by subjecting flake graphite cast iron having a specific composition to an austempering treatment. However, this is different from the present invention in that it is a bainite structure obtained by heat treatment without adding any alloying element. (4) JP-A-61-153256 describes a flake graphite cast iron having a specific composition and a cast iron for brake shoes having a bainite structure as a base. However, this is cast iron having a bainite structure to which no alloying element is added, and there is no description of a specific means (method) for forming bainite.

[0004]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention
The vehicle braking system member described in Japanese Patent No. 22780, which contains Mo, Cu, Ni, and the like and contains mostly martensite and bainite, has improved strength and wear resistance, but is resistant to heat cracking. The characteristics are not always good. Further, in the wear-resistant cast iron described in this publication, the hardness is increased to HB302 to 415 with an emphasis on wear resistance, but when the hardness is HB300 or more, the current vehicle lining has a hardness of 0.3. Since it is difficult to achieve the above friction coefficient, it is not suitable for use as a brake disc material. Further, since the hardness is high, the workability is significantly impaired. In addition, the method of forming the flake graphite cast iron into a bainite structure without adding alloy elements (Mo, Cu, Ni, etc.) requires a new heat treatment called austempering, which increases the number of extra steps and increases the cost. Become. The present invention has been made in view of the above points, and an object of the present invention is to provide a method for manufacturing a brake disc material that is endowed with heat resistance and crack resistance at the same time.

[0005]

In order to achieve the above object, the method for producing a brake disc material of the present invention has a chemical composition of C: 3.
3 to 3.7% by weight, Si: 1.3 to 2.4% by weight, M
n: 0.6 to 1.1% by weight, P: 0.16% by weight or less,
S: 0.12 wt% or less, with the balance being flake graphite cast iron consisting essentially of Fe, Ni: 1.0-3.0 wt% and M
O: 0.2-0.6 wt% is contained , and further Cr:
For the molten metal containing 0.1 to 0.3% by weight , select the mold with appropriate cooling capacity and the conditions for releasing the mold, and set the cooling speed.
Temperature and time after casting while adjusting the degree of casting
It is characterized in that the matrix structure is controlled by managing and removing the mold, and then strain relief annealing is performed.
In another manufacturing method of the brake disc material of the present invention, the chemical composition is C: 3.3 to 3.7% by weight, Si: 1.3 to 2.
4% by weight, Mn: 0.6 to 1.1% by weight, P: 0.16
Weight% or less, S: 0.12% by weight or less, and the balance of flake graphite cast iron consisting essentially of Fe, Ni: 1.0 to 3.0% by weight and Mo: 0.2 to 0.6% by weight In addition, Cu: 0.3 to 0.7 wt% and Cr: 0.1
For the molten metal containing 0.3 % by weight , the cooling rate is adjusted by selecting the mold with appropriate cooling capacity and the conditions for releasing the mold.
And casting , and controlling the temperature and time after casting.
It is characterized in that the matrix structure is controlled by removing the mold and then strain relief annealing is performed.

Still another method for producing the brake disc material of the present invention has a chemical composition of C: 3.3 to 3.7% by weight,
Si: 1.3 to 2.4% by weight, Mn: 0.6 to 1.1% by weight, P: 0.16% by weight or less, S: 0.12% by weight or less, and the balance being substantially Fe. Flake graphite cast iron, N
i: 1.0 to 3.0% by weight and Mo: 0.2 to 0.6% by weight, and V: 0.10 to 0.20% by weight and Cr: 0.1 to 0.3% by weight. After casting the molten metal containing wt %, after selecting the mold with appropriate cooling capacity and the conditions for releasing the mold , adjusting the cooling rate and casting
It is characterized in that the matrix structure is controlled by controlling the temperature and time of the above and releasing the mold, and then the strain relief annealing is performed. In the above manufacturing method, as a step of controlling the matrix structure, casting is performed in a mold having a high cooling capacity, and the temperature of the cast brake disc material is 770 to 950 ° C.
Desirably, when the temperature is 800 to 900 ° C., mold release is performed to make the matrix structure a martensite structure, or as a step of controlling the matrix structure, casting is performed with a mold having a low cooling capacity, and the temperature is kept in the mold up to around room temperature. After holding, the mold release is performed to make the base structure a pearlite structure. That is, a mold having an appropriate cooling capacity is selected, and the mold releasing conditions after casting (mold releasing time, cooling method, etc.) are controlled.

As described above, in order to improve the heat crack resistance and wear resistance, alloy elements such as Ni, Mo , Cr, ( V, Cu) are added, and a mold having an appropriate cooling ability and a mold thereof are provided. select a mold shakeout conditions, casting then by adjusting the cooling rate
In both cases, by controlling the temperature and time after casting, the matrix structure can be arbitrarily controlled such as martensite structure or pearlite structure. Then, as a concrete control method of the base structure, (1) When it is desired to increase the cooling rate to obtain a martensite structure, for example, at the same time when casting is performed with a mold having a high cooling capacity such as a green automatic molding line. , The temperature of the cast brake disc material is 770 to 950 ° C, preferably 800 ° C to
The mold is removed at a high temperature of 900 ° C. If the cast product is unmolded when the temperature is lower than 770 ° C., the cast iron is unmolded at or below the A1 transformation temperature of the cast iron or in the very vicinity of the transformation temperature, and there is a disadvantage that a predetermined metal structure cannot be obtained.
On the other hand, if the mold is unmolded when the temperature of the casting exceeds 950 ° C., extra residual stress is generated in the casting, and the work is performed at a high temperature, so that workability is slightly deteriorated. (2) When it is desired to reduce the cooling rate to form a pearlite structure, casting is performed in a mold having a low cooling capacity such as a furan mold, and at the same time, the mold is unmolded after being kept at around room temperature.

When the matrix structure is a martensite structure, the subsequent strain relief annealing temperature should be higher than the normal temperature (about 550 ° C.) in consideration of braking performance (holding an appropriate friction coefficient) and wear resistance. The sorbite (tempered martensite) structure is raised to a high temperature (about 640 ° C.), and hardness and mechanical properties are adjusted to appropriate states so that a predetermined disk material can be obtained. When the base organization is a solvite organization, it has the following characteristics. (1) The hardness is about HB190 to 230, and an appropriate friction coefficient and wear resistance can be obtained. (2) The tensile strength is about 30 kgf / mm ^2, which is higher than ordinary flake graphite cast iron. (3) Young's modulus is 1.0 × 10 kgf for high strength
/ Mm ² and low, the thermal stress generated during use is small,
Excellent heat crack resistance. Further, when the matrix structure is a pearlite structure, it can be used as a disk material by the usual ordinary strain relief annealing (heat treatment temperature is about 550 ° C.).

[0010]

Examples of the present invention will be described below. Example 1 A CO ₂ mold (a mold in which silica silicate was mixed with sodium silicate for molding and CO ₂ gas was aerated to cure the mold) was used to cast a round bar test piece having a diameter of 30 mm. Examined the relationship. Table 1 shows the chemical composition of the test piece.

[0011]

[Table 1]

The round bar test pieces were treated under the heat treatment conditions and cooling rates shown in Table 2 to measure the hardness (Brinell hardness (HB). The results are shown in Table 2.
The hardness is measured three times, and the average value thereof is shown. Further, FIGS. 1 to 6 show micrographs (magnification: 500 times) of the metal structures of the sample materials of to.

[0013]

[Table 2]

Example 2 Tests were carried out on a test piece taken from a brake disc prototyped on a green automatic molding line. Table 3 shows the chemical composition of the test piece.

[0015]

[Table 3]

Further, as a test material, a material disc cut out from a prototype disk produced on a green automatic forming line was used, and after 1 hour of casting, the mold was released, and a test piece was cut out.
The material was investigated by strain relief annealing (furnace cooling) at 40 ° C. The microstructure was a sorbite (tempered martensite) structure. The tensile test results were as shown in Table 4.

[0017]

[Table 4]

Example 3 A test was carried out by using a real brake disc (having a shape of KIHA) prototyped on a raw automatic molding line as a test piece. The chemical composition is shown in Table 5.

[0019]

[Table 5]

Further, as a sample material, a solid disk (shape is Kiha type) prototyped in a green automatic forming line was used, and after 1 hour of casting, the mold was released and strain relief annealing (furnace cooling) was performed at 640 ° C. The microstructure was sorbite (tempered martensite structure). Also, as a mechanical property,
The results of the brake disc tensile test (8 tests) are shown in Table 6, and the hardness of the disc cross section is shown in Table 7. The hardness of the sliding wall of the disk cross section is HB217-
231 (average HB225).

[0021]

[Table 6]

[0022]

[Table 7]

The tensile strength, hardness and Young's modulus of FC (gray cast iron (FC280)), FCM-A (alloy gray cast iron), test pieces and actual discs as comparative materials were measured. The results were as shown in FIGS. 7, 8 and 9. As is clear from FIG. 7, the tensile strength [σ _B
(Kgf / mm 2)] is about 25.0 for the comparative material, but about 30.0 for the present invention.
Further, as is clear from FIG. 9, Young's modulus [E (× 10
⁴ kgf / mm ² )] is about 1.15 for the comparative material, but is about 1.00 for the invention.
Further, the thermal cracking coefficient (K) is expressed by Equation 1, and from this value, it is expected that the thermal cracking resistance will be improved by 30 to 40%.

[0024]

(Equation 1)

Example 4 A test was carried out using a brake disc (Kiha type disc) prototyped with a Flan mold as a test material. The chemical composition is shown in Table 8.

[0026]

[Table 8]

This test material was an A-type flake graphite and had an all-perlite structure. Further, after 24 hours of casting, the mold was removed and strain relief annealing (furnace cooling) was performed at 550 ° C. The results of the brake disc tensile test are shown in Table 9, and the hardness of the disc cross section is shown in Table 10. The hardness of the sliding wall in the cross section of the disk in the width direction was HB207 to 217 (average HB211).

[0028]

[Table 9]

[0029]

[Table 10]

Example 5 A test was carried out using a brake disc (205 type disc) prototyped with a furan mold as a test material. Table 1 shows the chemical composition
1

[0031]

[Table 11]

This test material was A-type flake graphite and had an all-perlite structure. Further, after 24 hours of casting, the mold was removed and strain relief annealing (furnace cooling) was performed at 550 ° C. The results of the brake disc tensile test are shown in Table 12, and the hardness of the disc cross section is shown in Table 13. The hardness of the sliding wall was HB187 to 201 (average HB192).

[0033]

[Table 12]

[0034]

[Table 13]

[0035]

As described above, the present invention has the following effects. (1) Flake graphite cast iron with Ni and Mo, and further C
By adding r, Cu and Cr, or V and Cr, wear resistance and heat crack resistance can be improved. (2) By selecting a mold having an appropriate cooling capacity, controlling the mold release conditions after casting (mold release time, cooling method, etc.), and selecting the microstructure control step, the base structure is martensite structure or It can be controlled arbitrarily such as pearlite structure. Therefore, the quality is stable and the target braking performance (friction coefficient, disc temperature during braking,
Wear resistance, heat crack resistance, etc.) can be stably obtained.

[Brief description of the drawings]

FIG. 1 is a micrograph (magnification: 500 times) showing a metal structure of a test material under heat treatment conditions in Example 1.

2 is a micrograph (magnification: 500 times) showing a microstructure of a test material under heat treatment conditions in Example 1. FIG.

FIG. 3 is a micrograph (magnification: 500 times) showing a microstructure of a test material under heat treatment conditions in Example 1.

FIG. 4 is a micrograph (magnification: 500 times) showing a microstructure of a test material under heat treatment conditions in Example 1.

5 is a micrograph (magnification: 500 times) showing a microstructure of a test material under heat treatment conditions in Example 1. FIG.

FIG. 6 is a micrograph (magnification: 500 times) showing a microstructure of a test material under heat treatment conditions in Example 1.

FIG. 7 is a graph showing the results of measuring tensile strengths of a comparative material, a test piece and a physical disk in Example 3.

FIG. 8 is a graph showing the results of measuring the hardness of a comparative material, a test piece, and a physical disk in Example 3.

9 is a graph showing the results of measuring Young's modulus of a comparative material, a test piece, and a physical disk in Example 3. FIG.

Claims (5)

(57) [Claims] 1. The chemical composition of C: 3.3 to 3.7% by weight, Si: 1.3 to 2.4% by weight, Mn: 0.6 to 1.
1% by weight, P: 0.16% by weight or less, S: 0.12% by weight or less, and flake graphite cast iron whose balance is substantially Fe,
Ni: 1.0-3.0 wt% and Mo: 0.2-0.6
% By weight , and Cr: 0.1 to 0.3 weight
% Of molten metal is cast by adjusting the cooling rate by selecting the mold with appropriate cooling capacity and the conditions for releasing the mold .
In addition, by controlling the temperature and time after casting and releasing the mold, the matrix structure is controlled, and then strain relief annealing is performed. 2. The chemical composition is C: 3.3 to 3.7% by weight, Si: 1.3 to 2.4% by weight, Mn: 0.6 to 1.
1% by weight, P: 0.16% by weight or less, S: 0.12% by weight or less, and flake graphite cast iron whose balance is substantially Fe,
Ni: 1.0-3.0 wt% and Mo: 0.2-0.6
By weight, and a molten metal containing Cu: 0.3 to 0.7% by weight and Cr: 0.1 to 0.3 % by weight, a mold having an appropriate cooling capacity, and conditions for releasing the mold. After casting , adjusting the cooling rate and casting
A method for producing a brake disc material, which comprises controlling the matrix structure by controlling the temperature and time of the step (3) to release the mold, and then performing stress relief annealing. 3. The chemical composition is C: 3.3 to 3.7% by weight, Si: 1.3 to 2.4% by weight, Mn: 0.6 to 1.
1% by weight, P: 0.16% by weight or less, S: 0.12% by weight or less, and flake graphite cast iron whose balance is substantially Fe,
Ni: 1.0-3.0 wt% and Mo: 0.2-0.6
Wt%, and further, V: 0.10 to 0.20 wt% and Cr: 0.1 to 0.3 wt % of a molten metal, a mold having an appropriate cooling capacity, and conditions for releasing the mold. After casting , adjusting the cooling rate and casting
A method for producing a brake disc material, which comprises controlling the matrix structure by controlling the temperature and time of the step (3) to release the mold, and then performing stress relief annealing. 4. The step of controlling the matrix structure is carried out by casting with a mold having a high cooling capacity, and when the temperature of the cast brake disc material is 770 to 950 ° C., the mold is released to make the matrix structure a martensite structure. The method of manufacturing a brake disc material according to claim 1, 2 or 3, wherein 5. The step of controlling the matrix structure is a step of casting in a mold having a low cooling capacity, holding the mold in the mold to a temperature close to room temperature, and then releasing the mold to make the matrix structure a pearlite structure. The method for manufacturing a brake disc material according to claim 1, 2 or 3, characterized in that.