Method for manufacturing a brake disc, brake disc and disc brake

Abstract

The application provides a manufacturing method of a brake disc, the brake disc and a disc brake. The manufacturing method of the brake disc comprises the following steps: embedding a friction ring and a disc cap of the brake disc; placing the friction ring and the disc cap on a welding fixing clamp; and welding the friction ring and the disc cap. The application solves the problem of complex manufacturing process of the brake disc in the prior art.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of brake disc processing, in particular to a brake disc manufacturing method, a brake disc and a disc brake. BACKGROUND

[0002] The brake disc is an important component of the automobile braking system. The existing brake disc manufacturing process mainly includes: 1) a stamping type connection steel cap scheme: a disc cap and a friction ring are respectively manufactured by using the principle of gear meshing, and finally a steel cap composite disc is obtained by mechanical assembly. The stamping assembly equipment in this process is complex and extremely expensive; 2) a composite structure scheme for connecting and fixing the friction ring and the disc cap by using bolts and nuts. This scheme has a large number of supporting parts, a complex assembly process, a long working time, and a high weight of the brake disc after assembly; 3) a composite casting scheme of combining a disc cap made of steel or other materials with a friction ring made of gray cast iron. This composite casting scheme has a high requirement for the casting process, and it is difficult to ensure the yield rate.

[0003] As known from the above, the existing technology has the problem of complex brake disc manufacturing process. SUMMARY

[0004] The main purpose of the present application is to provide a brake disc manufacturing method, a brake disc and a disc brake to solve the problem of complex brake disc manufacturing process in the prior art.

[0005] In order to achieve the above-mentioned purpose, according to one aspect of the present application, a brake disc manufacturing method is provided, which comprises: nesting a friction ring and a disc cap of a brake disc; placing the friction ring and the disc cap on a welding fixture; and welding the friction ring and the disc cap.

[0006] Further, in the process of welding the friction ring and the disc cap, the friction ring and the disc cap are welded by using induction welding or laser welding.

[0007] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by using induction welding, placing welding material in a welding material storage groove of the friction ring before welding the friction ring and the disc cap; using an induction welding device to heat the welding area between the friction ring and the disc cap to melt the welding material; and completing the welding after the welding material fills the welding area.

[0008] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by using induction welding, removing the welding material storage groove after completing the welding.

[0009] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by laser welding, locally laser heating the friction ring and the disc cap respectively before embedding the friction ring and the disc cap of the brake disc, so as to ablate the chemical particles which have influence on welding.

[0010] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by laser welding, locally laser heating the friction ring and the disc cap respectively after the local laser heating and before embedding the friction ring and the disc cap of the brake disc, for a preset time; and welding the friction ring and the disc cap by using a laser welding device during the welding of the friction ring and the disc cap.

[0011] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by induction welding, measuring the welding gap between the friction ring and the disc cap after placing the friction ring and the disc cap on the welding fixture; and welding the friction ring and the disc cap again if the welding gap is less than 0.1 mm.

[0012] Further, the manufacturing method further comprises: in the case of welding the friction ring and the disc cap by laser welding, measuring the welding gap between the friction ring and the disc cap after placing the friction ring and the disc cap on the welding fixture; and welding the friction ring and the disc cap again if the welding gap is less than 0.8 mm.

[0013] Further, the manufacturing method further comprises: after the welding, using an induction heating device to heat and keep warm the welding area between the friction ring and the disc cap for a preset time, so as to eliminate or reduce the accumulated thermal stress during welding.

[0014] According to another aspect of the present application, a brake disc is provided, which is manufactured by the above-mentioned manufacturing method of a brake disc, and comprises: a friction ring; and a disc cap, which is welded with the friction ring, wherein the friction ring is embedded in the disc cap, or the disc cap is embedded in the friction ring.

[0015] Further, the friction ring is provided with a solder storage groove at the welding position of the friction ring and the disc cap.

[0016] Further, the disc cap is in the shape of a cap or a flat plate.

[0017] Further, the material of the friction ring is any one of gray cast iron and aluminum alloy.

[0018] Further, the material of the disc cap is any one of aluminum, aluminum alloy and carbon steel.

[0019] According to another aspect of the present application, a disc brake is provided, which comprises the above-mentioned brake disc.

[0020] The manufacturing method of the brake disc comprises the following steps: embedding a friction ring and a disc cap of the brake disc; placing the friction ring and the disc cap on a welding fixing clamp; and welding the friction ring and the disc cap. The friction ring and the disc cap are connected and fixed by welding, without other auxiliary parts, so that the process difficulty and assembly time of the manufacturing process are reduced, the manufacturing process of the brake disc is simplified, the manufacturing cost is reduced, and the problem of complex manufacturing process of the brake disc in the prior art is solved. BRIEF DESCRIPTION OF DRAWINGS

[0021] The drawings constituting a part of the specification illustrate the present application and, together with the description, serve to explain the principles of the application. In the drawings:

[0022] Figure 1 A flow chart of the manufacturing method of the brake disc in one embodiment of the present application is shown; and

[0023] Figure 2 A structure schematic diagram of the brake disc in one embodiment of the present application is shown;

[0024] Figure 3 A structure schematic diagram of the brake disc in another embodiment of the present application is shown;

[0025] Figure 4 A structure schematic diagram of the brake disc in another embodiment of the present application is shown;

[0026] Figure 5 A welding schematic diagram when the welding mode is induction welding in another embodiment of the present application is shown.

[0027] The above drawings comprise the following reference signs:

[0028] 10, friction ring; 11, solder storage groove; 20, disc cap. DETAILED DESCRIPTION

[0029] It should be noted that the embodiments and the features in the embodiments in the present application can be combined with each other without conflict. The present application will be described in detail below with reference to the drawings and in combination with the embodiments.

[0030] It should be noted that, unless otherwise specified, all the technical and scientific terms used in the present application have the same meaning as that generally understood by the ordinary skilled in the art to which the present application belongs.

[0031] In this invention, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" are generally used in relation to the direction shown in the accompanying drawings, or in relation to the vertical, perpendicular, or gravitational direction of the component itself; similarly, for ease of understanding and description, "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit this invention.

[0032] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0033] To address the problem of complex manufacturing processes for brake discs in existing technologies, this invention provides a method for manufacturing a brake disc, a brake disc itself, and a disc brake. The brake disc described below is manufactured using the method described below. The disc brake described below includes the brake disc described below.

[0034] like Figure 1 As shown, the manufacturing method of the brake disc includes: nesting the friction ring 10 and the disc cap 20 of the brake disc; placing the friction ring 10 and the disc cap 20 on a welding fixture; and welding the friction ring 10 and the disc cap 20.

[0035] The manufacturing method of the brake disc includes: nesting the friction ring 10 and the disc cap 20 of the brake disc; placing the friction ring 10 and the disc cap 20 on a welding fixture; and welding the friction ring 10 and the disc cap 20. In this way, the friction ring 10 and the disc cap 20 are connected and fixed by welding, without the need for other auxiliary parts, which reduces the process difficulty and assembly time of the manufacturing process, thereby simplifying the manufacturing process of the brake disc and reducing the manufacturing cost.

[0036] In one specific embodiment, induction welding is used to weld the friction ring 10 and the disc cap 20. This welding method results in a better weld between the friction ring 10 and the disc cap 20, ensuring a strong connection.

[0037] like Figure 5As shown, in the present embodiment, in the case of welding the friction ring 10 and the disc cap 20 by means of induction welding, the solder is placed in the solder storage groove 11 of the friction ring 10 before the friction ring 10 and the disc cap 20 are welded; the welding area between the friction ring 10 and the disc cap 20 is heated by using the induction welding equipment to melt the solder; and the welding is completed after the solder fills the welding area. Specifically, the welding area is the connecting position of the friction ring 10 and the disc cap 20, and the solder after being heated and melted fills the welding area under the capillary action, and the friction ring 10 and the disc cap 20 are rigidly connected together after the solder is cooled.

[0038] Further, in the case of welding the friction ring 10 and the disc cap 20 by means of induction welding, the solder storage groove 11 is removed after the welding is completed. In this way, the appearance of the product is ensured to be beautiful, the weight of the brake disc product is reduced, and the solder storage groove 11 does not affect the normal connection between the friction ring 10 and other components of the brake disc.

[0039] Specifically, in the case of welding the friction ring 10 and the disc cap 20 by means of induction welding, after the friction ring 10 and the disc cap 20 are placed on the welding fixing clamp, the welding gap between the friction ring 10 and the disc cap 20 is measured; and if the welding gap is less than 0.1 mm, the friction ring 10 and the disc cap 20 are welded again. That is, the induction welding has certain requirements for the welding gap between the friction ring 10 and the disc cap 20, and if the welding gap is too large, the welding effect will be poor, thereby affecting the connection firmness between the friction ring 10 and the disc cap 20.

[0040] In an optional embodiment, in the process of welding the friction ring 10 and the disc cap 20, the friction ring 10 and the disc cap 20 are welded by means of laser welding. The above welding method can make the friction ring 10 and the disc cap 20 have better welding effect and ensure the connection firmness.

[0041] Specifically, in the case of welding the friction ring 10 and the disc cap 20 by means of laser welding, before the friction ring 10 and the disc cap 20 of the brake disc are nested, the friction ring 10 and the disc cap 20 are respectively subjected to local laser heating to ablate the chemical particles that affect welding. In this way, the welding effect between the friction ring 10 and the disc cap 20 can be ensured.

[0042] Further, in the case of welding the friction ring 10 and the disc cap 20 by means of laser welding, after the local laser heating and before the friction ring 10 and the disc cap 20 of the brake disc are nested, the friction ring 10 and the disc cap 20 are respectively subjected to induction heating for a predetermined time. In this way, the friction ring 10 and the disc cap 20 are preheated, which can improve the welding effect. In the process of welding the friction ring 10 and the disc cap 20, the friction ring 10 and the disc cap 20 are welded by using the laser welding equipment.

[0043] Specifically, in the case of welding the friction ring 10 and the disc cap 20 by laser welding, after the friction ring 10 and the disc cap 20 are placed on the welding fixture, the welding gap between the friction ring 10 and the disc cap 20 is measured; if the welding gap is less than 0.8 mm, the friction ring 10 and the disc cap 20 are welded again. That is, laser welding has certain requirements for the welding gap between the friction ring 10 and the disc cap 20. If the welding gap is too large, the welding effect will be poor, which will affect the connection firmness between the friction ring 10 and the disc cap 20.

[0044] Of course, the friction ring 10 and the disc cap 20 can also be welded by ordinary welding, which can be selected according to actual needs. When ordinary welding is used, the positions of the friction ring 10 and the disc cap 20 to be welded are fixed and appropriate clamping measures are taken, and then the welding area at the connection between the two components is directly welded.

[0045] It should be noted that when laser welding or ordinary welding is used, the welding surface also needs to be processed to remove excess welding material.

[0046] In this embodiment, whether induction welding or laser welding is used, after welding is completed, the welding area between the friction ring 10 and the disc cap 20 is heated and kept warm for a predetermined time using an induction heating device to eliminate or reduce the thermal stress accumulated during welding.

[0047] As shown in Figures 2 to 5 The application also provides a brake disc manufactured by the above-mentioned manufacturing method of a brake disc, which comprises a friction ring 10 and a disc cap 20. The friction ring 10 and the disc cap 20 are welded and connected.

[0048] As shown in Figure 2 In this embodiment, the friction ring 10 is nested on the disc cap 20. Specifically, the inner wall of the connecting portion of the friction ring 10 is provided with a connecting groove, and at least a portion of the disc cap 20 extends into the connecting portion of the friction ring 10 and abuts against the connecting groove. In this way, the welding area between the friction ring 10 and the disc cap 20 is an inwardly bent L-shaped.

[0049] As shown in Figure 3 In an alternative embodiment, the disc cap 20 is nested on the friction ring 10. Specifically, the outer wall of the connecting portion of the friction ring 10 is provided with a connecting groove, and at least a portion of the disc cap 20 is sleeved on the outer wall of the connecting portion of the friction ring 10 and abuts against the connecting groove. In this way, the welding area between the friction ring 10 and the disc cap 20 is an outwardly bent L-shaped.

[0050] As shown in Figure 5As shown, the friction ring 10 is provided with a solder storage groove 11 at the welding position of the friction ring 10 and the disc cap 20. Specifically, the solder storage groove 11 is provided on the top surface of the connecting portion of the friction ring 10, so as to be removed after welding.

[0051] As shown in the drawings, Figures 2 to 3 As shown, the disc cap 20 is in the shape of a cap. Specifically, the cap edge of the disc cap 20 is bent to be connected with the friction ring 10.

[0052] As shown in the drawings, Figure 4 As shown in an optional embodiment, the disc cap 20 is in the shape of a flat plate. It can be understood that the friction ring 10 is nested on the disc cap 20 at this time. Specifically, the edge of the disc cap 20 abuts against the connecting groove. Further, the top surface of the disc cap 20 is flush with the top surface of the connecting portion of the friction ring 10.

[0053] In the embodiment, the material of the friction ring 10 is any one of gray cast iron and aluminum alloy.

[0054] In the embodiment, the material of the disc cap 20 is any one of aluminum, aluminum alloy and carbon steel. Preferably, the material of the disc cap 20 is aluminum alloy or carbon steel. Compared with gray cast iron, aluminum alloy has smaller density, thereby reducing the weight of the disc cap 20 and further reducing the weight of the brake disc, so as to meet the demand of lightening the vehicle. In addition, although the density of carbon steel is close to that of gray cast iron, the strength of carbon steel can reach more than 500 MPa, which is greater than the strength of gray cast iron and other materials. Therefore, when the material of the disc cap 20 is carbon steel, the thickness of the mounting surface of the brake disc can be greatly reduced under the premise of ensuring the strength, so as to meet the demand of the vehicle model whose thickness of the mounting surface of the brake disc is strictly limited.

[0055] In an optional embodiment, the material of the disc cap 20 is at least two of aluminum, aluminum alloy and carbon steel. Preferably, the material of the disc cap 20 is gray cast iron and aluminum alloy, or gray cast iron and carbon steel. That is, a part of the disc cap 20 is made of gray cast iron, and another part is made of aluminum alloy or carbon steel. In this way, using aluminum alloy or carbon steel instead of a part of gray cast iron can also achieve the effect of reducing the weight of the brake disc and reducing the thickness of the mounting surface of the brake disc.

[0056] The application further provides a disc brake comprising the above brake disc.

[0057] From the above description, it can be seen that the above-mentioned embodiments of the present application achieve the following technical effects: the manufacturing method of the brake disc includes: embedding the friction ring 10 and the disc cap 20 of the brake disc; placing the friction ring 10 and the disc cap 20 on the welding fixing clamp; and welding the friction ring 10 and the disc cap 20, so that the friction ring 10 and the disc cap 20 are connected and fixed by welding, without other auxiliary parts, thereby reducing the process difficulty and assembly time of the manufacturing process, so that the manufacturing process of the brake disc is simplified, and the manufacturing cost is reduced.

[0058] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments in accordance with the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0059] It should be noted that the terms "first", "second", and the like, as used in the specification and in the claims, are intended to modify a particular aspect of the subject matter described in the specification and claims, but do not specifically limit the order or sequence of steps of the method practices, but are used to distinguish between similar aspects of examples. It will be understood by those within the art that, in some aspects of the application, subsets of the operations and / or devices can be implemented to accomplish the stated purposes, and that the exclusive use of those described is not required. In other instances, well-known structures have not been shown or described in order to not obscure the application.

[0060] The preferred embodiments of the present application have been described above with the specific details. Obviously, the present application can be modified and altered in various ways by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the scope of protection of the present application.

Claims

1. A method of manufacturing a brake disc, characterized by, The manufacturing method comprises the following steps: nesting a friction ring (10) and a disc cap (20) of the brake disc; placing the friction ring (10) and the disc cap (20) on a welding fixture; welding the friction ring (10) and the disc cap (20); a welding area is formed at the joint of the friction ring (10) and the disc cap (20); a connecting groove is formed on the inner wall or the outer wall of the connecting part of the friction ring (10), and at least a part of the disc cap (20) extends into the connecting part of the friction ring (10) and abuts against the connecting groove or at least a part of the disc cap (20) is sleeved on the outer wall of the connecting part of the friction ring (10) and abuts against the connecting groove; in the process of welding the friction ring (10) and the disc cap (20), the friction ring (10) and the disc cap (20) are welded by induction welding or laser welding; in the case of welding the friction ring (10) and the disc cap (20) by induction welding, before welding the friction ring (10) and the disc cap (20), welding material is placed in the welding material storage groove (11) of the friction ring (10); after welding is completed, the welding material storage groove (11) is removed; the welding material storage groove (11) is formed on the top surface of the connecting part of the friction ring (10); the connecting part of the friction ring (10) is bent, the disc cap (20) is cap-shaped, and the cap edge of the disc cap (20) is bent and connected to the connecting part.

2. The manufacturing method of a brake disc according to claim 1, characterized in that, The manufacturing method further comprises: in the case of welding the friction ring (10) and the disc cap (20) by induction welding, the welding area between the friction ring (10) and the disc cap (20) is heated by an induction welding device to melt the welding material; welding is completed after the welding material fills the welding area.

3. The manufacturing method of a brake disc according to claim 1, characterized in that, The manufacturing method further comprises: in the case of welding the friction ring (10) and the disc cap (20) by laser welding, before nesting the friction ring (10) and the disc cap (20) of the brake disc, the friction ring (10) and the disc cap (20) are respectively subjected to local laser heating to ablate chemical particles that affect welding.

4. The manufacturing method of a brake disc according to claim 3, characterized in that, The manufacturing method further comprises: in the case of welding the friction ring (10) and the disc cap (20) by laser welding, after the local laser heating and before nesting the friction ring (10) and the disc cap (20) of the brake disc, the friction ring (10) and the disc cap (20) are respectively subjected to induction heating for a preset time; in the process of welding the friction ring (10) and the disc cap (20), the friction ring (10) and the disc cap (20) are welded by a laser welding device.

5. The manufacturing method of a brake disc according to claim 1, characterized in that, The manufacturing method further comprises: in the case of welding the friction ring (10) and the disc cap (20) by induction welding, After placing the friction ring (10) and the disc cap (20) on a welding fixture, the welding gap between the friction ring (10) and the disc cap (20) is measured. If the welding gap is less than 0.1 mm, the friction ring (10) and the disc cap (20) are welded again.

6. The manufacturing method of a brake disc according to claim 1, characterized in that, The manufacturing method further comprises: In the case of welding the friction ring (10) and the disc cap (20) by means of laser welding, After placing the friction ring (10) and the disc cap (20) on a welding fixture, the welding gap between the friction ring (10) and the disc cap (20) is measured. If the welding gap is less than 0.8 mm, the friction ring (10) and the disc cap (20) are welded again.

7. The manufacturing method of a brake disc according to any one of claims 1 to 6, characterized in that, The manufacturing method further comprises: After welding, the welding area between the friction ring (10) and the disc cap (20) is heated and kept warm for a preset time using an induction heating device to eliminate or reduce the thermal stress accumulated during welding.

8. A brake disc, characterized in that The brake disc is manufactured by the manufacturing method of the brake disc according to any one of claims 1 to 7, and comprises: a friction ring (10); a disc cap (20) welded with the friction ring (10), wherein the friction ring (10) is nested on the disc cap (20), and the inner wall of the connecting part of the friction ring (10) is provided with a connecting groove; or the disc cap (20) is nested on the friction ring (10), and the outer wall of the connecting part of the friction ring (10) is provided with a connecting groove.

9. The brake disc of claim 8, wherein, The friction ring (10) is provided with a solder storage groove (11) at the welding position of the friction ring (10) and the disc cap (20).

10. The brake disc of claim 8, wherein, The material of the friction ring (10) is any one of gray cast iron and aluminum alloy.

11. The brake disc of claim 8, wherein, The material of the disc cap (20) is any one of aluminum, aluminum alloy and carbon steel.

12. A disc brake, characterized by The brake disc comprises the brake disc according to any one of claims 8 to 11.

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