TWI448561B - Aluminum alloy composition for brake caliper for vechicles - Google Patents

Description

Aluminum alloy brake caliper composition for vehicles

The invention relates to a composition for an aluminum alloy brake caliper for a vehicle, in particular to a brake caliper made of an aluminum alloy material containing copper, magnesium, manganese, cerium, zirconium and silver, which is made at 150 degrees Celsius. At high temperatures, the tensile strength and the strength of the fall have characteristics of more than 350 MPa and more than 300 MPa, respectively, which can avoid the problem of rapid deterioration of mechanical strength when the temperature is increased, so as to ensure that the brake calipers can be normally operated under the environment of frequent high temperature.

Press, in the process of driving a car, it is often necessary to step on the brakes to facilitate the vehicle to stop; the general hydraulic disc brake system is composed of a disc and a caliper, the disc is set on the wheel and rotates coaxially with the wheel, and the caliper is fixed and not rotated. It straddles the two sides of the disc. The caliper is provided with two shovel shoes (strips) on opposite sides of the disc; when the driver steps on the brake pedal or presses the brake handle, hydraulically drives and pushes the brake The piston in the caliper forces the piston to push against the shovel clip to the disc, causing the smashing of the shovel and the disc to generate friction to slow down or stop the wheel; therefore, the shovel and the disc are often continuously at high speed. Friction generates a large amount of heat, which causes the brake calipers to have the property of resisting high temperatures and maintaining their strength to ensure proper operation of the brake system.

In addition, in response to the global trend of energy conservation and carbon reduction, the electric vehicle industry is also booming. Currently, electric vehicles are mostly modified with passenger cars. The brake calipers must use floating calipers; The caliper body is still dominated by high-strength cast iron materials (for example: FCD 500 ductile iron, etc.), but the cast iron calipers have a considerable weight (about 4.3kg / piece), if an electric vehicle has 4 brake calipers, The weight generated will not be underestimated; in addition, the current electric vehicle is limited by the battery's endurance, and it is imperative to reduce the weight and requirements of the overall body weight to reduce the energy consumption of the battery.

Therefore, cast iron calipers are gradually being replaced by lightweight materials (such as aluminum, magnesium, etc.), among which the development of aluminum alloys is the most; and aluminum alloys are also available in various models, such as 6000 series aluminum alloy series with good ductility, often made For fixed-size calipers with large volume; however, for electric vehicles based on passenger vehicles, floating calipers that require over-moving movements have insufficient mechanical strength and fatigue resistance; in addition, 7XXX or 2XXX series Although the aluminum alloy has excellent mechanical strength at room temperature, the mechanical strength is rapidly degraded when the temperature is increased, so that the brake caliper cannot ensure normal operation in a frequently high temperature environment, which is significant for driving vehicles and driving safety. The threat; in addition, the caliper application is often in the body of the vibration environment, therefore, the design of the caliper material also needs to consider its vibration-resistant life.

Nowadays, the inventor is still in the light of the lack of practicality in the implementation of the existing brake calipers. It is a tireless spirit and is improved by its rich professional knowledge and years of practical experience. And based on this, the present invention was developed.

The main object of the present invention is to provide an aluminum alloy brake caliper composition for a vehicle and a manufacturing method thereof, in particular to a brake caliper made of an aluminum alloy material containing copper, magnesium, manganese, cerium, zirconium and silver, so that At a high temperature of 150 degrees Celsius, the tensile strength and the strength of the fall have characteristics of more than 350 MPa and more than 300 MPa, respectively, which can avoid the problem of rapid deterioration of mechanical strength when the temperature is increased, so as to ensure that the brake calipers can be used in a frequently hot environment. Normal operator.

In order to achieve the above-mentioned implementation object, the inventors propose a composition for an aluminum alloy brake caliper for a vehicle, which is made of an aluminum alloy material and is calculated by weight percentage of 100% of the total composition, and the aluminum alloy material includes 4.0 to 8.0 wt. % copper, 0.3-0.5 wt% magnesium, 0.3-0.5 wt% manganese, 0.2-0.3 wt% bismuth, 0.2-0.3 wt% zirconium, 0.1-0.4 wt% silver, and remaining weight percent aluminum .

Furthermore, the brake caliper formed according to the above aluminum alloy material has a Brinell hardness of more than 120 HB and an elongation (EL) of more than 8%; in addition, the brake caliper of the present invention has a tensile strength (UTS) in the chamber. The lower temperature system is greater than 450 MPa, and the system is greater than 350 MPa at 150 degrees Celsius; and its lodging strength (YS) is greater than 400 MPa at room temperature, and greater than 300 MPa at 150 degrees Celsius, demonstrating that the brake caliper of the present invention has high mechanical strength. And it retains the characteristics of excellent mechanical strength at high temperatures.

In addition, the weight of the brake caliper formed by the above aluminum alloy material It is about 1.4kg/piece. Compared with the weight of traditional cast iron calipers of 4.3kg/piece, it can reduce the weight of about 11.6kg on one electric vehicle, which is in line with the trend of light weight, energy saving and carbon saving.

Furthermore, the brake caliper of the present invention performs the compressive strength test and the high-temperature actuation endurance test under the JASO C448 caliper test specification, and the test results show that there is no hydraulic leakage and damage or breakage or harmful deformation.

The object of the present invention and its structural and functional advantages will be explained in conjunction with the specific embodiments according to the structure shown in the following drawings, so that the reviewing committee can have a more in-depth and specific understanding of the present invention.

First, the aluminum alloy brake caliper composition for a vehicle of the present invention can be promoted for a disc brake assembly mounted on a wheel, such as a motorcycle, a bicycle, a car, a bus, a truck, a golf cart, etc., and is particularly suitable for The electric vehicle brake system used for the floating calipers is required to reduce the overall weight of the vehicle to reduce the energy consumption of the battery because the electric vehicle is limited by the battery life, and the brake caliper described in the description of the present invention meets the above requirements.

Please refer to the following table, which is a composition component composition of the aluminum alloy brake caliper for vehicles of the present invention. As shown in the table, the aluminum alloy material includes 4.0 to 8.0 wt%, calculated as 100% of the total component weight percentage. Copper, 0.3~0.5wt% magnesium, 0.3~0.5wt% manganese, 0.2~0.3wt% bismuth, 0.2~0.3wt% zirconium, 0.1~ 0.4 wt% silver, and the remaining weight percent aluminum.

Furthermore, the aluminum alloy using the above composition is sequentially processed by extrusion processing, hot forging, etc. to form a brake caliper excellent in high temperature strength; wherein the extrusion processing system is used to fine grain structure and The dispersion is uniform, and the hot forging process eliminates internal defects by high pressure, so that the structure has the advantages of high density and miniaturization; thereby, the brake caliper after molding has a Brinell (HB) system of more than 120 HB, And the elongation (EL) is greater than 8%; in addition, the tensile strength (UTS) of the brake caliper of the present invention is greater than 450 MPa at room temperature, greater than 350 MPa at 150 degrees Celsius; and its lodging strength (YS) is At room temperature, the system is greater than 400 MPa, and at 150 degrees Celsius, the system is greater than 300 MPa, which proves that the brake caliper of the present invention has high mechanical strength and can maintain excellent mechanical strength at high temperatures; the following table shows the brake caliper of the present invention at room temperature. Compare with the strength of other materials at high temperatures.

Furthermore, since the vehicle is mostly in a vibrating environment during travel, the caliper material needs to be evaluated for its excellent mechanical strength in addition to its high mechanical strength. The following table is the brake caliper of the present invention and other application materials. The test results of the resonance lifetime of the open V-groove test piece at the resonance frequency; it is known from the experimental data that the brake caliper of the present invention has excellent properties at both normal temperature and high temperature.

At the same time, the brake caliper of the present invention performs the compressive strength test and the high temperature actuation endurance test under the JASO C448 caliper test specification respectively; the compressive strength test is performed under the hydraulic pressure of 140±5 MPa (13.72±0.49 kgf/cm ² ), and the operation is performed 10,000 times. After that, there is no hydraulic leakage and damage to breakage or harmful deformation; and the high temperature actuation endurance test is performed at a temperature of 120 ± 5 ° C and a hydraulic pressure of 6.86 ± 0.29 MPa (70 ± 3 kgf / cm ² ), and the test results are 70,000 times. There are also no hydraulic leaks and damage to broken or harmful deformation.

It can be seen from the above description that the present invention has the following advantages compared with the prior art:

1. The brake caliper of the present invention can have a tensile strength greater than 450 MPa and greater than 350 MPa at room temperature and 150 degrees Celsius, respectively, and the fall strength can be greater than 400 MPa and greater than 300 MPa, respectively, which proves that the brake caliper of the present invention has high mechanical strength and It can maintain the characteristics of excellent mechanical strength at high temperature, and improve the problem that the traditional aluminum alloy material (such as 7XXX; 2XXX) causes the mechanical strength to deteriorate rapidly when the temperature is raised, so as to ensure that the brake caliper of the present invention can be used in a frequently high temperature environment. working normally.

2. The weight of the aluminum alloy brake caliper of the invention is about 1.4kg/piece, which is equivalent to the weight of the conventional cast iron caliper of 4.3kg/piece, and can reduce the weight of about 11.6kg on one electric vehicle, which is light weight and energy saving. The trend of saving carbon.

In summary, the aluminum alloy brake caliper composition for a vehicle of the present invention can achieve the intended use efficiency by the above disclosed embodiments, and the present invention has not been disclosed before the application, and has been fully complied with. The provisions and requirements of the Patent Law.爰Issuing an application for a patent for invention in accordance with the law, and asking for a review, and granting a patent, is truly sensible.

The illustrations and descriptions of the present invention are merely preferred embodiments of the present invention, and are not intended to limit the scope of the present invention; those skilled in the art, which are characterized by the scope of the present invention, Equivalent variations or modifications are considered to be within the scope of the design of the invention.

Claims (6)

The utility model relates to an aluminum alloy brake caliper composition for a vehicle, which is made of an aluminum alloy material and is calculated by weight percentage of 100% of the total composition. The aluminum alloy material comprises 4.0 to 8.0 wt% of copper and 0.3 to 0.5 wt%. Magnesium, 0.3 to 0.5 wt% of manganese, 0.2 to 0.3 wt% of niobium, 0.2 to 0.3 wt% of zirconium, 0.1 to 0.4 wt% of silver, and residual weight percent of aluminum, wherein the aluminum alloy is formed after molding Brake calipers have an elongation (EL) of greater than 8%. The aluminum alloy brake caliper composition for a vehicle according to claim 1, wherein the aluminum alloy material has a Brinell hardness of more than 120 HB after the molding. The aluminum alloy brake caliper composition for a vehicle according to claim 1, wherein the aluminum alloy material has a tensile strength (UTS) of more than 450 MPa at room temperature after forming the brake caliper. The aluminum alloy brake caliper composition for a vehicle according to claim 3, wherein the aluminum alloy material has a tensile strength (UTS) of more than 350 MPa at 150 degrees Celsius after the forming of the brake caliper. The aluminum alloy brake caliper composition for a vehicle according to claim 1, wherein the aluminum alloy material has a relief strength (YS) of more than 400 MPa at room temperature after molding. The aluminum alloy brake caliper composition for a vehicle according to the fifth aspect of the invention, wherein the aluminum alloy material is made of After the type of brake calipers, the drop strength (YS) is greater than 300 MPa at 150 degrees Celsius.