A method and device for manufacturing a laser cladding disk

Abstract

The present invention proposes a method for manufacturing a laser cladding disc and a manufacturing device thereof, which belong to the technical field of brake disc manufacturing. The manufacturing method comprises the following steps: pouring a gray cast iron solution into a brake disc manufacturing mold to obtain a blank casting of the brake disc, and sequentially heat treating and semi-finishing the blank casting; fully and evenly mixing 316 stainless steel powder and nickel-based powder, and then laser cladding the blank casting on the friction surface of the brake disc; metallizing TiC powder by vapor deposition; laser cladding the TiC powder after the metallization treatment in step S3 on the 316 stainless steel surface layer; laser cold cutting the outer side of the TiC cladding layer in the brake disc; grinding the TiC cladding layer after laser cold cutting to obtain a finished brake disc. The manufacturing method for the laser cladding disc and the manufacturing device thereof provided by the present invention have developed a new low-cost high-performance brake disc, which meets the requirements of strength, plasticity and wear resistance, has low cost, and a simple preparation process.

Description

Technical Field

[0001] The present invention belongs to the technical field of brake disc manufacturing, and in particular relates to a manufacturing method and a manufacturing device of a laser cladding disc. Background Art

[0002] The brake disc is an essential component of all vehicle braking systems. It is fixed on the axle and rotates with the wheel. When braking, the brake pad is pushed onto the brake disc by the clamp piston, and the friction between the brake pad and the brake disc is used to reduce the wheel speed, thereby achieving the purpose of vehicle deceleration and braking. Under such working conditions, the brake disc will bear the pressure and friction of the brake pad, and will wear out in the relative movement with the brake pad. Especially when there are sand and other debris on the working surface, the wear is more serious, greatly shortening the service life of the brake disc. Therefore, the material used to make the brake disc must have both high mechanical strength and good wear resistance.

[0003] At present, common brake discs are made of single materials such as malleable cast iron, gray cast iron, and ductile iron. Although the strength meets the working conditions, the wear resistance is too poor. Thermal cracking often occurs during use. Some even cause brake failure and traffic accidents due to insufficient thickness after long-term wear of the brake disc. Cr, Ni, and Mo are often added in the production of low-alloy gray cast iron. Although the tensile strength, wear resistance, and heat fatigue resistance are improved, the addition of precious metals such as Ni and Mo makes its production cost higher. In addition, carbon fiber ceramic composite brake discs have good heat dissipation, ultra-light weight, and excellent wear resistance, but their preparation process is delicate and complex, and the price is high.

[0004] For a very popular consumable like automobile, how to develop new cheap high-performance brake discs that can not only meet the requirements of strength, plasticity and wear resistance, but also be low-cost, simple in preparation process, and suitable for large-scale standardized production has become the key technical problem to be solved in this program. Summary of the invention

[0005] The purpose of the present invention is to provide a method and a device for manufacturing a laser cladding disc, which solves the technical problem of how to develop a new low-cost high-performance brake disc, meets the requirements of strength, plasticity and wear resistance, has low cost and simple preparation process.

[0006] A method for manufacturing a laser cladding disk comprises the following steps:

[0007] Step S1: pouring the gray cast iron solution into a brake disc manufacturing mold to obtain a blank casting of the brake disc, and sequentially performing heat treatment and semi-finish turning on the blank casting;

[0008] Step S2: 316 stainless steel powder and nickel-based powder are fully and evenly mixed so that the mass fraction ratio of the two is (97%-100%): (0-3%), and then laser clad on the friction surface of the brake disc;

[0009] Step S3: metallizing the TiC powder by vapor deposition;

[0010] Step S4: laser cladding the TiC powder after metallization treatment in step S3 on the 316 stainless steel surface layer;

[0011] Step S5: performing laser cold cutting on the outer side of the TiC cladding layer in the brake disc to remove a thin layer of 0.5-1 mm;

[0012] Step S6: grinding the TiC cladding layer after laser cold cutting to obtain a finished brake disc.

[0013] In the step S3, nickel powder is vapor-deposited on the TiC powder to obtain metallized TiC powder.

[0014] In the step S4, the nickel-chromium powder and the metallized TiC powder are fully mixed according to the mass fraction ratio of (0-2%): (98%-100%);

[0015] Among them, the mass ratio of nickel-based powder to nickel-chromium powder is 1.5-2.2.

[0016] In the step S3, copper powder is vapor-deposited on the TiC powder to obtain metallized TiC powder.

[0017] In the step S3, the copper powder, titanium powder and metallized TiC powder are fully mixed according to the mass fraction ratio of (0-1%): (0-2.0%): (97%-100%) respectively;

[0018] Wherein, in step S3, by mass, nickel-chromium powder / (copper powder+titanium powder)=0.5-1.2.

[0019] In the step S3, SiC powder is uniformly mixed in the TiC powder, and the mass percentage of SiC powder in the mixed powder is 0-0.5%.

[0020] A manufacturing device for a laser cladding disc comprises a conveying structure and a plurality of brake discs positioned at equal intervals on the conveying structure, wherein a cladding structure 1 for a 316 stainless steel powder layer, a cladding structure 2 for a TiC powder layer, and a grinding structure for cutting a TiC cladding layer are sequentially arranged in the conveying structure along its movement direction, and the structures of the cladding structure 1 and the cladding structure 2 are consistent.

[0021] The cladding structure 1 includes an outer protective cover, an inner protective cover coaxially arranged inside the outer protective cover, a laser cladding head connected to the end of the outer protective cover through a bellows, a lifting cylinder 1 connected to the end of the outer protective cover at a free end, a vacuum tube 1 connected to the outer protective cover at one end, a camera 1 arranged inside the outer protective cover, and a video line 1 connected to the camera 1 at one end, the inner side of the outer protective cover is clamped on the outer side of the friction part of the brake disc, and the outer side of the inner protective cover is clamped on the inner side of the friction part of the brake disc;

[0022] The mounting portion of the brake disc is movably connected to a limiting structure, and the limiting structure is arranged below the conveying structure.

[0023] The grinding structure includes a protective cover, a laser cutting machine connected to the outside of the protective cover, a lifting cylinder with a free end connected to the end of the protective cover, a vacuum tube with one end connected to the protective cover, a camera arranged inside the protective cover, and a video line with one end connected to the camera. The inner side of the protective cover is clamped on the outer side of the friction part of the brake disc.

[0024] The mounting portion of the brake disc is movably connected to a limiting structure, and the limiting structure is arranged below the conveying structure.

[0025] The limiting structure includes a vertically arranged supporting cylinder, a rotating cylinder fixed on the top of the supporting cylinder, an embedded column with a bottom end fixed on the rotating cylinder, and a camera assembly arranged on the top of the rotating cylinder, wherein the camera assembly is arranged between a plurality of the embedded columns.

[0026] The beneficial effects of the present invention are as follows:

[0027] (1) Due to the large difference in the chemical properties of titanium and stainless steel, direct welding is likely to cause chemical reactions, resulting in reduced strength of the weld and hydrogen embrittlement. Since the melting point of copper is very close to that of stainless steel and titanium alloy, copper is used as a transition material for the intermediate layer to play a buffering role.

[0028] (2) TiC can be deposited with a variety of metal materials to form composite materials or coatings to improve the performance of the materials. For example, nickel-based titanium carbide composite materials (Ni-TiC) have good high-temperature strength and oxidation resistance, dense microstructure, and copper-based titanium carbide composite materials (Cu-TiC) have good wear resistance.

[0029] In addition, by mixing nickel-chromium powder with metallized TiC powder, the diffusion interface between chromium and carbon materials is relatively stable, and the connection strength is higher;

[0030] (3) The physical and chemical properties of gray cast iron and stainless steel are quite different. The linear expansion coefficient and thermal conductivity of gray cast iron are lower than those of stainless steel, which leads to large thermal stress during welding, thus causing cracks. Therefore, nickel powder is added to stainless steel to improve its plasticity and toughness, which promotes graphitization in the semi-melted zone of cast iron. Nickel can reduce or eliminate the white cast layer, and the cladding temperature does not exceed 900°C.

[0031] (4) In this manufacturing device, an outer protective cover and an inner protective cover are provided, which has the following technical effects:

[0032] First, a sealed environment is formed at the friction part of the brake disc, which is convenient for vacuuming by using the vacuum tube 1, so that the cladding is carried out in a vacuum environment to avoid oxidation. At the same time, the existence of the vacuum tube 1 also helps to ensure the balance of internal and external air pressure;

[0033] The second is to ensure the cleanliness of the environment, prevent metal dust from escaping into the air, and prevent metal dust from entering the inner side of the brake disc;

[0034] Third, the inner and outer sides of the friction surface of the friction part are blocked by the inner protective cover and the outer protective cover respectively, which limits the size and position of the cladding layer and helps to level the inner and outer sides of the cladding layer;

[0035] (5) Setting a limited position structure has the following technical effects:

[0036] First, the mounting hole of the brake disc is limited by the embedded column, and the brake disc is rotated with the rotary cylinder, while the position of the laser cladding head remains unchanged, so as to achieve cladding of the brake disc in the circumference;

[0037] Secondly, a camera component is provided to take a picture of the position of the mounting hole and upload it to the PLC controller. The PLC controller is connected to the host computer, and the relative position of the embedded column and the mounting hole is determined through the image comparison module, and the rotating cylinder is adjusted so that the embedded column is embedded in the mounting hole.

[0038] (6) The bellows not only helps the sealing effect, but also enables the laser cladding head to be adjusted up, down, left and right according to the actual situation. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a front view of the manufacturing device in the present invention.

[0040] Figure 2 It is a schematic diagram of the structure of the manufacturing device in the present invention.

[0041] Figure 3 It is a schematic structural diagram of the cladding structure 1 in the present invention.

[0042] Figure 4It is a schematic diagram of the connection structure of the protection component in the present invention.

[0043] Figure 5 It is a structural schematic diagram of the grinding structure in the present invention.

[0044] Figure 6 It is a schematic diagram of the connection structure of the protective cover in the present invention.

[0045] Figure 7 It is a schematic diagram of the structure of the brake disc in the present invention.

[0046] Figure 8 It is a schematic diagram of the structure of the conveyor belt in the present invention.

[0047] Fig. 9 It is the metallographic diagram of the slices of gray cast iron, stainless steel cladding and TiC cladding in the present invention.

[0048] Among them, the accompanying drawings are marked as: 1. laser cladding head; 2. outer protective cover; 21. video line one; 22. vacuum tube one; 23. inner protective cover; 3. conveyor belt; 31. positioning hole; 4. support plate; 7. grinding disc; 8. protective cover; 81. laser cutting machine; 82. through hole; 83. camera assembly; 84. video line two; 85. vacuum tube two; 9. lifting cylinder two; 10. telescopic cylinder; 12. lifting cylinder one; 13. supporting cylinder; 131. rotating cylinder; 133. embedded column; 14. brake disc; 141. mounting hole. DETAILED DESCRIPTION

[0049] In order to more clearly illustrate the technical features of this solution, this solution is described below through specific implementation methods.

[0050] Embodiment 1:

[0051] See also Fig. 9 , a method for manufacturing a laser cladding disk, specifically comprising the following steps:

[0052] Step S1: pouring a gray cast iron solution into a brake disc 14 manufacturing mold to obtain a blank casting of the brake disc 14, and sequentially performing heat treatment and semi-finish turning on the blank casting;

[0053] Step S2: 316 stainless steel powder and nickel-based powder are fully and evenly mixed so that the mass fraction ratio of the two is (97%-100%): (0-3%), and then laser clad on the friction surface of the brake disc 14;

[0054] Step S3: metallizing the TiC powder by vapor deposition;

[0055] Step S4: laser cladding the TiC powder after metallization treatment in step S3 on the 316 stainless steel surface layer;

[0056] Step S5: performing laser cold cutting on the outer side of the TiC cladding layer in the brake disc 14 to remove a thin layer of 0.5-1 mm;

[0057] Step S6: grinding the TiC cladding layer after laser cold cutting to obtain a finished brake disc 14.

[0058] In step S3, nickel powder is vapor-deposited on the TiC powder to obtain metallized TiC powder. The metallization process of TiC powder belongs to the prior art, and various parameters in the process refer to the prior art and will not be described in detail here.

[0059] In step S4, nickel-chromium powder and metallized TiC powder are fully mixed according to a mass fraction ratio of (0-2%): (98%-100%);

[0060] Among them, the mass ratio of nickel-based powder to nickel-chromium powder is 1.5-2.2.

[0061] In step S3, SiC powder is uniformly mixed in the TiC powder, and the mass percentage of SiC powder in the mixed powder is 0-0.5%.

[0062] Design of experimental group 1: The mass percentages of 316 stainless steel powder and nickel-based powder are 98% and 2% respectively; the mass percentages of nickel-chromium powder and TiC powder (metallization) are 1.5% and 98.5% respectively;

[0063] Design of experimental group 2: The mass percentages of 316 stainless steel powder and nickel-based powder are 97% and 3% respectively; the mass percentages of nickel-chromium powder and TiC powder (metallization) are 2% and 98% respectively;

[0064] Design experiment group three: gray cast iron, stainless steel cladding and TiC cladding.

[0065] Control group: gray cast iron and TiC cladding, no stainless steel;

[0066] Table 1 is a table showing the performance of the experimental group and the control group in Example 1.

[0067] Example 1 Compressive strength / MPa Hardness / HV Experimental Group 1 3295 2310 Experimental Group 2 3356 2346 Experimental Group 3 3110 2153 Control group 3012 2021

[0068] As can be seen from Table 1, the stainless steel cladding layer is set between the gray cast iron and the TiC cladding layer, which greatly improves the compressive strength and hardness compared with simply cladding TiC on the surface of the gray cast iron; the performance of experimental groups 1 and 2 is further improved.

[0069] Embodiment 2:

[0070] In step S3, copper powder is vapor-deposited on the TiC powder to obtain metallized TiC powder.

[0071] In step S3, the copper powder, titanium powder and metallized TiC powder are fully mixed according to the mass fraction ratio of (0-1%): (0-2.0%): (97%-100%);

[0072] Wherein, in step S3, the mass ratio of nickel-chromium powder to (copper powder+titanium powder) is 0.5-1.2.

[0073] Design of experimental group 1: The mass percentages of 316 stainless steel powder and nickel-based powder are 98% and 2% respectively; copper powder, titanium powder and metallized TiC powder are fully mixed in the ratio of 0.5%:1.5%:98% respectively;

[0074] Experimental group 2: The mass percentages of 316 stainless steel powder and nickel-based powder were 97% and 3% respectively; copper powder, titanium powder and metallized TiC powder were fully mixed in the ratio of 1%:2.0%:100% respectively;

[0075] Design experiment group three: gray cast iron, stainless steel cladding and TiC cladding.

[0076] Control group: gray cast iron and TiC cladding, no stainless steel;

[0077] Table 2 is the performance table of the experimental group and the control group in this embodiment 2

[0078] Example 2 Compressive strength / MPa Hardness / HV Experimental Group 1 3315 2350 Experimental Group 2 3397 2394 Experimental Group 3 3169 2185 Control group 3042 2043

[0079] By analyzing the data in Table 2 above, it can be concluded that compared with the control group, adding stainless steel cladding in experimental group 3, that is, cladding a stainless steel layer between the gray cast iron and TiC cladding, helps to improve the compressive strength and hardness of the overall brake disc; adding nickel-based powder to 316 stainless steel powder, metallizing TiC powder, and adding copper powder and titanium powder can help to further improve the overall compressive strength and hardness of the brake disc. It can be seen that the optimization of the processing technology is of great significance to improving the comprehensive mechanical properties of the brake disc. At the same time, this also brings inspiration to people. By optimizing the proportion of each component, the performance of the brake disc can be optimized.

[0080] Embodiment 3:

[0081] See also Figure 1-Figure 9 A manufacturing device for a laser cladding disk includes a conveying structure and a plurality of brake disks 14 positioned at equal intervals on the conveying structure. The conveying structure has a cladding structure 1 for a 316 stainless steel powder layer, a cladding structure 2 for a TiC powder layer, and a grinding structure for cutting a TiC cladding layer, and the structures of the cladding structure 1 and the cladding structure 2 are consistent.

[0082] The cladding structure 1 includes an outer protective cover 2, an inner protective cover 23 coaxially arranged inside the outer protective cover 2, a laser cladding head 1 connected to the end of the outer protective cover 2 through a bellows, a lifting cylinder 12 connected to the end of the outer protective cover 2 at a free end, a vacuum tube 22 connected to the outer protective cover 2 at one end, a camera 1 arranged inside the outer protective cover 2, and a video line 21 connected to the camera 1 at one end, the inner side of the outer protective cover 2 is clamped on the outer side of the friction part of the brake disc 14, and the outer side of the inner protective cover 23 is clamped on the inner side of the friction part of the brake disc 14;

[0083] The mounting portion of the brake disc 14 is movably connected to the limiting structure, and the limiting structure is arranged below the conveying structure.

[0084] The grinding structure includes a protective cover 8, a laser cutting machine 81 connected to a through hole 82 on the outer side of the protective cover 8, a lifting cylinder 9 whose free end is connected to the end of the protective cover 8, a vacuum tube 85 whose one end is connected to the protective cover 8, a camera 2 arranged inside the protective cover 8, a video line 84 whose one end is connected to the camera 2, a driving shaft fixedly connected to the bottom end of the lifting cylinder 29, a driving motor connected to the driving shaft, a telescopic cylinder 10 whose bottom end is fixed on the driving shaft, and a grinding disc 7 connected to the free end of the telescopic cylinder 10. The inner side of the protective cover 8 is clamped on the outer side of the friction part of the brake disc 14.

[0085] The mounting portion of the brake disc 14 is movably connected to the limiting structure, and the limiting structure is arranged below the conveying structure.

[0086] The limiting structure includes a vertically arranged supporting cylinder 13, a rotating cylinder 131 fixed at the top of the supporting cylinder 13, an embedded column 133 whose bottom end is fixed on the rotating cylinder 131, and a camera assembly 83 arranged at the top of the rotating cylinder 131, and the camera assembly 83 is arranged between multiple embedded columns 133.

[0087] Among them, the conveying structure includes a conveyor belt 3, a power driving structure connected to the conveyor belt 3, and a support plate 4 arranged in the conveyor belt 3. A plurality of positioning holes 31 are arranged at equal intervals on the conveyor belt 3. The mounting part of the brake disc 14 is inserted into the positioning hole 31 for limiting the position, and the friction part of the brake disc is supported on the support plate 4.

[0088] The specific working process of the present invention is as follows:

[0089] In the manufacturing device, under the action of the conveyor belt 3, when the brake disc 14 is driven to the bottom of the outer protective cover 2 and the inner protective cover 23, the outer protective cover 2 and the inner protective cover 23 are lowered under the drive of the lifting cylinder 12, and are clamped on the friction part of the brake disc 14, so that a sealed environment is formed at the friction part of the brake disc 14, which is convenient for vacuuming by using the vacuum tube 22, so that the cladding is carried out in a vacuum environment to avoid oxidation. At the same time, the existence of the vacuum tube 22 also helps to ensure the balance of internal and external air pressure;

[0090] Ensure the cleanliness of the environment, prevent metal dust from escaping into the air, and prevent metal dust from entering the inner side of the brake disc 14; the inner and outer sides of the friction surface of the friction part are blocked by the inner protective cover 23 and the outer protective cover 2 respectively, and the size and position of the cladding layer are limited, which is conducive to the flatness of the inner and outer sides of the cladding layer;

[0091] A limiting structure is provided, and the mounting hole 141 of the brake disc 14 is limited by the embedded column 133, and the brake disc 14 is rotated by cooperating with the rotating cylinder 131, and the position of the laser cladding head 1 does not move, so as to achieve cladding of the brake disc 14 in the circumferential direction;

[0092] A camera assembly 83 is provided to take a picture of the position of the mounting hole 141 and upload it to the PLC controller. The PLC controller is connected to the host computer, and through the image comparison module, the relative position of the embedded column 133 and the mounting hole 141 is determined, and the rotating cylinder 131 is adjusted so that the embedded column 133 is embedded in the mounting hole 141.

[0093] The provision of the bellows not only helps to achieve a sealing effect, but also enables the laser cladding head 1 to be adjusted up, down, left, and right according to actual circumstances.

[0094] Technical features not described in the present invention can be achieved through or by adopting existing technologies and will not be described in detail here. Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Changes, modifications, additions or substitutions made by ordinary technicians in this technical field within the essential scope of the present invention should also fall within the scope of protection of the present invention.

Claims

1. A method for manufacturing a laser cladding disk, characterized in that: The specific steps include: Step S1: pouring a grey cast iron solution into a brake disc (14) manufacturing mold to obtain a blank casting of the brake disc (14), and sequentially performing heat treatment and semi-finish turning on the blank casting; Step S2: 316 stainless steel powder and nickel-based powder are fully and evenly mixed so that the mass fraction ratio of the two is (97%-98%):(2%-3%), and then laser-clad on the friction surface of the brake disc (14); Step S3: metallizing the TiC powder by vapor deposition; In the step S3, nickel powder is vapor-deposited on the TiC powder to obtain metallized TiC powder; Step S4: laser cladding the TiC powder after metallization treatment in step S3 on the 316 stainless steel surface layer; In the step S4, the nickel-chromium powder and the metallized TiC powder are fully mixed according to the mass fraction ratio of (1.5%-2%): (98%-98.5%); Among them, the mass ratio of nickel-based powder to nickel-chromium powder is 1.5-2.2; Step S5: performing laser cold cutting on the outer side of the TiC cladding layer in the brake disc (14) to remove a thin layer of 0.5-1 mm; Step S6: grinding the TiC cladding layer after laser cold cutting to obtain a finished brake disc (14).

2. A manufacturing device for a laser cladding disk, using a manufacturing method for a laser cladding disk as claimed in claim 1, comprising a conveying structure, and a plurality of brake disks (14) positioned at equal intervals on the conveying structure, characterized in that: The conveying structure is sequentially arranged along its moving direction with a cladding structure 1 for 316 stainless steel powder cladding layer, a cladding structure 2 for TiC powder cladding layer, and a grinding structure for cutting the TiC cladding layer, and the cladding structure 1 and the cladding structure 2 have the same structure; The cladding structure comprises an outer protective cover (2), an inner protective cover (23) coaxially arranged inside the outer protective cover (2), a laser cladding head (1) connected to the end of the outer protective cover (2) via a bellows, a lifting cylinder (12) having a free end connected to the end of the outer protective cover (2), a vacuum tube (22) having one end connected to the outer protective cover (2), a camera (1) arranged inside the outer protective cover (2), and a video cable (21) having one end connected to the camera (1), the inner side of the outer protective cover (2) being clamped on the outer side of the friction portion of the brake disc (14), and the outer side of the inner protective cover (23) being clamped on the inner side of the friction portion of the brake disc (14); The mounting portion of the brake disc (14) is movably connected to a limiting structure, and the limiting structure is arranged below the conveying structure; The grinding structure comprises a protective cover (8), a laser cutting machine (81) connected to the outside of the protective cover (8), a lifting cylinder (9) having a free end connected to the end of the protective cover (8), a vacuum tube (85) having one end connected to the protective cover (8), a camera (2) arranged inside the protective cover (8), and a video cable (84) having one end connected to the camera (2), wherein the inner side of the protective cover (8) is clamped on the outer side of the friction portion of the brake disc (14); The mounting portion of the brake disc (14) is movably connected to a limiting structure, and the limiting structure is arranged below the conveying structure.

3. The manufacturing device of a laser cladding disk according to claim 2, characterized in that: The limiting structure comprises a vertically arranged supporting cylinder (13), a rotating cylinder (131) fixed to the top of the supporting cylinder (13), an embedded column (133) whose bottom end is fixed to the rotating cylinder (131), and a camera assembly (83) arranged at the top of the rotating cylinder (131), wherein the camera assembly (83) is arranged between a plurality of the embedded columns (133).

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