Cyclone ultra-light composite brake disc and manufacturing method thereof

Abstract

The application discloses a cyclone ultra-light composite brake disc and a manufacturing method thereof, and solves the problem of large brake disc mass and easy wear in the prior art. The brake disc comprises a disc body and a connecting disc, the connecting disc comprises a connecting body and a connecting flange, the disc body and the connecting disc are formed by melting and casting, and the disc body is provided with an inner air duct and an outer cyclone air duct in the radial direction. The disc body comprises an upper disc body and a lower disc body, a radial reinforcing rib is arranged between the upper disc body and the lower disc body, and the inner air duct is formed between two adjacent radial reinforcing ribs. The connecting disc adopts a steel structure, the disc body adopts gray cast iron, has high strength and rigidity, the connecting body and the disc body are fused in liquid state, then the connecting body is welded with the connecting flange, and the melting and casting forms a composite brake disc whole body, and the strength is effectively guaranteed. In the braking process, the deformation is small, the disc body is uniformly stressed, the brake disc has good wear resistance and high strength, and the service life is prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of brake disc, in particular to a cyclone ultra-light composite brake disc and a manufacturing method thereof. BACKGROUND

[0002] The brake disc, also known as brake disc, is a metal disc made of alloy steel and fixed on the wheel, rotating with the wheel. When the vehicle is running, the brake caliper clamps the brake disc to slow down or stop the vehicle. Generally, the brake disc has a circular hole, which serves to reduce weight and increase friction. Brake discs are of various types, characterized by thin walls, and the disc body and center are formed by sand cores. Different types of brake discs differ in disc diameter, disc thickness and gap size between the two pieces, and the thickness and height of the hub are different. Currently, both the main machine manufacturers and the axle manufacturers are gradually paying attention to the light weight of automobile parts. The existing brake disc is heavy, and due to the different installation directions, the air duct not only causes the airflow to be not smooth, affecting the passability of the airflow, but also limits the heat carried away by the airflow under the condition of a certain airflow, reducing the heat dissipation effect. SUMMARY

[0003] In view of the deficiencies in the above background art, the present application provides a cyclone ultra-light composite brake disc and a manufacturing method thereof, which solves the problems of large mass and easy wear of the brake disc in the prior art.

[0004] The technical scheme of the present application is as follows: a cyclone ultra-light composite brake disc, comprising a disc body and a connecting disc, the disc body and the connecting disc are formed by casting, and the disc body is provided with an inner air duct and an outer cyclone air duct in the radial direction.

[0005] The disc body comprises a disc body upper part and a disc body lower part, and a radial reinforcing rib is arranged between the disc body upper part and the disc body lower part, and the inner air duct is formed between the adjacent two radial reinforcing ribs.

[0006] The disc body upper part, the disc body lower part and the radial reinforcing rib are integrally formed by casting; the radial reinforcing rib is arranged at equal angles in the radial direction between the disc body upper part and the disc body lower part.

[0007] The radial reinforcing rib is a cylindrical rib body, a cuboid rib body, a square rib body or a trapezoidal rib body.

[0008] The disc body upper part and the disc body lower part are provided with axial ventilation holes, and the axial ventilation holes are arranged alternately with the radial reinforcing ribs.

[0009] The upper surface of the disc body upper part and the lower surface of the disc body lower part are uniformly provided with the outer cyclone air duct.

[0010] The outer cyclone air duct is a curved cyclone groove.

[0011] The outer cyclone air duct is a herringbone air duct, which is arranged on the outer surface of the disc body along the center of the disc body.

[0012] The connecting disc comprises a connecting body and a connecting flange, which are coaxially arranged, and the lower part of the connecting body is provided with petal-shaped protrusions; the inner part of the disc body is provided with an insertion slot, which is arranged in cross with the inner air duct, and the petal-shaped protrusions are matched with the insertion slot.

[0013] The connecting body and the connecting flange are integrally pressed or matched and welded. The connecting flange is a straight outward flange, a straight inward flange, an oblique outward flange or an oblique inward flange. The connecting part of the connecting flange is a circular ring or a petal shape.

[0014] A manufacturing method of a cyclone ultra-light composite brake disc, comprising the following steps:

[0015] S1: manufacturing a connecting body: stamping a steel plate or a steel pipe into a half product of a flange-shaped connecting body; then stamping or cold working to make a plurality of bosses around the half product of the flange-shaped connecting body to form a petal-shaped protrusion connecting body;

[0016] S2: manufacturing a connecting flange: using high-quality carbon steel or alloy steel with good welding performance to stamp or spin or roll into a connecting flange;

[0017] S3: manufacturing a disc body sand core: reserving space for placing the connecting body in step S1 when manufacturing a core box of a disc body sand core; placing the connecting body in step S1 into the core box to make the connecting body into the disc body sand core, and covering a layer of sand on the surface of the petal-shaped protrusion of the connecting body which does not fuse with the disc body to ensure isolation from liquid iron during pouring;

[0018] S4: pouring the brake disc: after the disc body sand core is manufactured, smelting the iron, adding a pearlite inoculant before pouring to ensure that the metallographic and mechanical properties of the brake disc meet the requirements; then adopting stack pouring with a pouring temperature of 1360-1500℃ to pour the brake disc;

[0019] S5: welding the connecting flange and the connecting body: nesting the connecting flange in step S2 on the connecting body in step S4 to ensure that the connecting flange and the connecting body are coaxially arranged, and then welding;

[0020] S6: machining: after the welding in step S5 is completed, machining the brake disc to ensure the process requirements of the brake disc, and performing dynamic balancing and coating after inspection; completing the production and manufacturing of the brake disc.

[0021] The connecting disc of the application adopts steel structure, the disc body adopts gray cast iron, has very high strength and rigidity, the connecting body and the disc body are fused in liquid state, then the connecting body is welded with the connecting flange, and the connecting body and the connecting flange are fused and cast into a composite brake disc whole body, the strength is effectively guaranteed. In the braking process, the deformation is small, the disc body is uniformly stressed, and the brake disc has good wear resistance and high strength, prolonging the service life. The cooperation of the inner wind channel and the outer cyclone wind channel minimizes the weight of the brake disc, reduces the weight of the brake disc by 20-30% compared with the traditional ordinary brake disc, and makes the brake disc light weight to the extreme. In addition, the cooperation of the inner wind channel and the outer cyclone wind channel makes the ventilation of the brake disc better, greatly improves the heat dissipation of the brake disc, and ensures that the disc body can be rapidly cooled after braking, and the braking performance of the vehicle is best. The application has good process performance, adopts separate forming and then welding, the effective utilization rate of the material can reach more than 90%, and the production cost is low; the production process is simple, and mass production is facilitated. BRIEF DESCRIPTION OF DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the application, the drawings needed in the following embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0023] Figure 1 It is a front three-dimensional schematic view of the application.

[0024] Figure 2 It is a back three-dimensional schematic view of the application.

[0025] Figure 3 It is a sectional view of the connecting body and the disc body connecting structure of the application.

[0026] Figure 4 It is a front view of the application.

[0027] Figure 5 It is a view of the connecting body and the connecting flange in the separate welding state Figure 4 A-A direction.

[0028] Figure 6 It is a connecting body structure schematic view.

[0029] Figure 7 It is a connecting flange straight inward flange structure schematic view.

[0030] Figure 8 It is a connecting flange first inclined outward flange structure schematic view.

[0031] Figure 9 It is a connecting flange second inclined outward flange structure schematic view.

[0032] Figure 10 This is a schematic diagram of a circular flange structure for connection.

[0033] Figure 11 This is a schematic diagram of a petal-shaped flange structure for connection. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] like Figure 1 As shown in Example 1, a cyclone ultralight composite brake disc includes a disc body 1 and a connecting disc 2. The connecting disc includes a connecting body 201 and a connecting flange 202. The connecting body 201 of the disc body 1 and the connecting disc 2 is fused together, meaning the lower part of the connecting disc is located inside the disc body. The connecting disc and the disc body are arranged along the same central axis and then fused together using liquid fusion. For tires of the same size, the bearing positions and threaded holes of the brake disc may differ slightly depending on the axle type. Since the connecting body and the disc body are fused together, only the different connecting discs need to be replaced when switching products. This invention can connect connecting discs of different diameters, shapes, and heights. As long as the axle is of the same tonnage and uses the same friction pads, it can be switched. Unlike traditional one-piece brake discs, it does not require the creation of new molds. Product switching is convenient and quick. It can save a lot of mold costs and facilitate production site management. The disc body 1 is provided with an inner air duct 3 and an outer cyclone air duct 4 along the radial direction. The combined use of internal and external air ducts minimizes the weight of the brake disc, reducing it by 20-30% compared to traditional brake discs, achieving the ultimate in lightweight design. Furthermore, the combination of internal and external air ducts improves the brake disc's ventilation, significantly enhancing heat dissipation and allowing the disc to cool down rapidly after braking, ensuring optimal braking performance and ultimately protecting the safety of the driver and passengers. The disc body is made of gray cast iron or vermicular graphite cast iron, while the connecting disc is made of high-quality carbon steel or similar materials, guaranteeing overall strength.

[0036] Furthermore, such as Figure 2As shown, the disc body 1 comprises a disc body upper part 101 and a disc body lower part 102 with the same diameter and arranged in parallel, and a radial reinforcing rib 103 is arranged between the disc body upper part 101 and the disc body lower part 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 square rib or a trapezoidal rib. When the radial reinforcing rib 103 is a cylindrical rib, a cuboid rib or a square rib, the inner air duct is an air duct with the same width; when the radial reinforcing rib 103 is a trapezoidal rib, the inner air duct is an air duct with gradually decreasing or gradually increasing width.

[0037] Further, the disc body upper part 101, the disc body lower part 102 and the radial reinforcing rib 103 are integrally formed by casting; the radial reinforcing rib 103 is arranged at equal angles in the radial direction between the disc body upper part 101 and the disc body lower part 102. The upper surface of the disc body upper part 101 and the lower surface of the disc body lower part 102 are both provided with outer cyclone air ducts 4. The disc body upper part 101 and the disc body lower part 102 are both provided with outer cyclone air ducts, which not only enhance the ventilation and heat dissipation effect, but also reduce the weight of the brake disc.

[0038] In embodiment 2, a cyclone ultra-light composite brake disc, in order to further reduce the weight of the brake disc, an axial ventilation hole can be arranged on the disc body upper part 101 and the disc body lower part 102. When the axial ventilation hole is arranged, the outer cyclone air duct can not be arranged. The axial ventilation hole and the radial reinforcing rib 103 are arranged alternately, that is, the ventilation hole is punched on the friction surface of the disc body, and the position of the ventilation hole and the position of the radial reinforcing rib are staggered, so as to ensure the permeability and not damage the strength of the radial reinforcing rib.

[0039] Further, the outer cyclone air duct 4 is a curved cyclone groove. When the brake disc is viewed from one direction, whether it rotates clockwise or counterclockwise, the effect is the same, and a 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 in an array along the center of the disc body 1. Two or three adjacent herringbone ventilation grooves intersect, which increases the number of air ducts and improves the heat dissipation efficiency.

[0040] Further, as shown in Figure 3 , 6 , the connecting disc 2 comprises a connecting body 201 and a connecting flange 202. The connecting flange can be divided into four types according to the connection mode, including a straight outward flange (as shown in Figure 5 ), a straight inward flange (as shown in Figure 7 ), an oblique outward flange (as shown in Figure 8 , 9 ) and an oblique inward flange. The connecting part of the connecting flange can be divided into a circular ring type flange (as shown in Figure 10 ) or a petal type flange (as shown in Figure 11 ) according to the shape of the flange. The circular ring type flange (as shown in Figure 10The petal-shaped flange can be combined with a straight outward flange (as shown in Figure 5 ), a straight inward flange (as shown in Figure 7 ), and an oblique outward flange (as shown in Figure 8 , 9 ), an oblique inward flange, as needed, in any two combinations. The oblique outward flange (as shown in Figure 8 , 9 ) and the oblique inward flange can be provided with weight-reducing holes on the circumferential wall to reduce the overall weight. The connecting body 201 and the connecting flange 202 are coaxially arranged, and the materials of the connecting body and the connecting flange are high-quality carbon steel or the like. The lower part of the connecting body 201 is provided with an integrally formed petal-shaped protrusion 203; the inside of the disc body 1 is provided with a slot 5, and the slot 5 is arranged in cross with the inner air duct 3. The petal-shaped protrusion 203 is matched with the slot 5, facilitating the positioning of the connecting body and the fusion casting of the disc body, so that the strength is effectively guaranteed.

[0041] 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 Figure 5 ), the connecting flange can also be provided with a 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 two are nested (or interference fit) for welding. When the interference fit is used, a press is used for press fitting, and then welding is performed. The separate forming is then welded, which has good process performance, and the effective utilization rate of the material can reach more than 90% or even 100%, the production cost is low, the production process is simple, and mass production is facilitated.

[0042] Embodiment 3: A manufacturing method of a cyclone ultra-light composite brake disc, the steps are as follows:

[0043] S1: manufacturing a connecting body: a steel plate or a steel pipe with a thickness of 6-15 mm is punched into a half-finished product of a flange-shaped connecting body, and the specific thickness can be determined according to the bridge type; then, a plurality of bosses are made on the periphery of the half-finished product of the flange-shaped connecting body by punching or cold working, to form a petal-shaped protruding connecting body. The connecting body can also be made by precision casting to form a cast steel part.

[0044] S2: manufacturing a connecting flange: high-quality carbon steel or alloy steel with good welding performance is used to make a connecting flange by punching or spinning or rolling forming; for example, high-quality carbon steel such as Q235 / Q345 / 45 / 20 with good welding performance.

[0045] S3: making the disc body sand core: when making the core box of the disc body sand core, a space for placing the connecting body in step S1 is reserved; when making the disc body sand core by using a core shooter, the connecting body in step S1 is placed into the core box, the connecting body is made into the disc body sand core, a layer of sand is covered on the surface of the petal protrusion of the connecting body which is not fused with the disc body, so as to ensure that the petal protrusion is isolated from the liquid iron during pouring; the part of the petal protrusion of the connecting body which needs to be fused with the disc body is exposed, so as to facilitate the fusion casting with the disc body.

[0046] S4: pouring the disc: after the disc body sand core is made, the molten iron is smelted, and the liquid is inoculated before pouring, and the pearlite inoculant is added, so as to ensure that the metallographic and mechanical properties of the disc meet the requirements; then, the disc is poured by using the stacking box, and the pouring temperature is kept at 1360-1500 DEG C, and the disc (and the liquid fusion process of the connecting body and the disc body) is poured. The disc body is made of gray cast iron, and the chemical composition of the gray cast iron is as follows: C: 3.1-3.6%; Si: 1.7-2.5%; Mn: 0.6-0.9%; S≤0.12%; P≤0.15%. According to actual needs, a proper amount of trace elements such as Cu, Cr, Sn, Mo, Nb, Ni and Bi can be added for adjustment. The performance is as follows: hardness: 180-255 HBW; tensile strength≥220 Mpa. The proportion of A type graphite is more than 90%, the graphite length is 2-6, the uniform fine flake eutectoid is presented, the content of ferrite is not more than 5%, and there is no ledeburite. The content of carbide and phosphorus eutectic is not more than 2%.

[0047] S5: welding the connecting flange and the connecting body: the connecting flange in step S2 is nested on the connecting body in step S4, the connecting flange and the connecting body are concentrically arranged, and then welding is performed. Since the connecting body and the connecting flange are both made of steel, they have high strength and rigidity, the connecting disc and the disc body are fused in liquid state, and are fused into one whole, so that the strength is effectively guaranteed. During braking, the deformation is small, and the disc body is uniformly stressed. The disc has good wear resistance, high strength and long service life.

[0048] S6: machining: after the welding in step S5 is completed, the disc is machined, the disc process requirements are guaranteed, and after the disc is inspected and qualified, dynamic balance and coating are performed; the production and manufacturing of the disc are completed. The structure of the disc after machining is the same as that of the disc in embodiment 2.

[0049] The above only describes the preferred embodiments of the present application, and is not used to limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A method for manufacturing a cyclone ultra-light composite brake disc, the cyclone ultra-light composite brake disc comprising a disc body (1) and a connecting disc (2), characterized in that: The disc body (1) and the connecting disc (2) are formed by casting, the disc body (1) is provided with an inner air duct (3) and an outer cyclone air duct (4) in the radial direction, the outer cyclone air duct (4) is a curved cyclone groove, the outer cyclone air duct (4) is a herringbone type ventilation groove, and the herringbone type ventilation grooves are arranged in an array on the outer surface of the disc body (1) along the center of the disc body (1); two or three adjacent herringbone type ventilation grooves intersect with each other. The disc body (1) comprises a disc body upper portion (101) and a disc body lower portion (102), and a radial reinforcing rib (103) is arranged between the disc body upper portion (101) and the disc body lower portion (102), and the inner air duct (3) is formed between two adjacent radial reinforcing ribs (103); the disc body upper portion (101), the disc body lower portion (102) and the radial reinforcing rib (103) are integrally formed by casting. 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 the lower portion of the connecting body (201) is provided with petal-shaped protrusions (203); the inner portion of the disc body (1) is provided with a slot (5), the slot (5) is arranged in cross with the inner air duct (3), and the petal-shaped protrusions (203) are matched with the slot (5). The manufacturing method of the cyclone ultra-light composite brake disc comprises the following steps: S1: manufacturing the connecting body: a steel plate or a steel pipe is punched into a half product of a flange-shaped connecting body; then a plurality of bosses are manufactured around the half product of the flange-shaped connecting body by punching or cold working, so as to form the connecting body with petal-shaped protrusions; S2: manufacturing the connecting flange: high-quality carbon steel or alloy steel with good welding performance is used to manufacture the connecting flange by punching or spinning or roll forming; S3: manufacturing the disc body sand core: when a core box of the disc body sand core is manufactured, a space for placing the connecting body in step S1 is reserved; when the disc body sand core is manufactured, the connecting body in step S1 is placed into the core box, the connecting body is placed into the disc body sand core, and a layer of sand is coated on the surface of the part of the petal-shaped protrusions of the connecting body which is not fused with the disc body, so as to ensure that the part is isolated from liquid molten iron during pouring; S4: pouring the brake disc: after the disc body sand core is manufactured, the molten iron is smelted, and the liquid is inoculated before pouring, and pearlite inoculant is added, so as to ensure that the metallographic and mechanical properties of the brake disc meet the requirements; then the brake disc is poured by stacking the boxes, and the pouring temperature is kept at 1360-1500℃; S5: welding the connecting flange and the connecting body: the connecting flange in step S2 is nested on the connecting body in step S4, the connecting flange and the connecting body are coaxially arranged, and then welding is performed; S6： Machining: after the welding in step S5 is completed, the brake disc is machined, the process requirements of the brake disc are ensured, and the brake disc is balanced and painted after inspection; the production and manufacturing of the brake disc are completed.

2. The method of manufacturing a cyclonic ultra-lightweight composite brake disc according to claim 1, wherein: The radial reinforcing ribs (103) are arranged at equal angles in the radial direction between the disc body upper portion (101) and the disc body lower portion (102).

3. The method of manufacturing a cyclonic ultra-lightweight composite brake disc according to claim 1 or 2, characterized in that: The radial reinforcing ribs (103) are cylindrical rib bodies, cuboid rib bodies, square rib bodies or trapezoidal rib bodies.

4. The method of manufacturing a cyclonic ultra-lightweight composite brake disc of claim 1, wherein: The upper portion (101) and the lower portion (102) of the disc body are provided with axial ventilation holes, and the axial ventilation holes are staggered with the radial reinforcing ribs (103); the upper surface of the upper portion (101) and the lower surface of the lower portion (102) are uniformly provided with outer cyclone air ducts (4).

5. The method of manufacturing a cyclonic ultra-lightweight composite brake disc of claim 1, wherein: The connecting body (201) and the connecting flange (202) are matched and welded and fixed; the connecting flange (202) is a straight outward flange or a straight inward flange or an oblique outward flange or an oblique inward flange; the connecting part of the connecting flange (202) is a circular ring type or a petal type.

Images