Smelting process for increasing addition amount of waste steel and steel cuttings for wear-resistant brake disc

Abstract

The invention relates to a smelting process for increasing the addition amount of waste steel and steel cuttings for a wear-resistant brake disc, and relates to the technical field of casting and spraying of brake discs. The smelting process comprises the steps that the waste steel and the steel cuttings are conveyed into a crusher to be pretreated and then conveyed into a smelting furnace and a grinding machine; the pretreated waste steel and steel cuttings conveyed into the smelting furnace are melted, alloy elements in a preset proportion are added, and the melted metal liquid is subjected to refining treatment and then cast into a brake disc base body; the pretreated waste steel and steel cuttings conveyed into the grinding machine are ground into waste steel powder and screened, the waste steel powder which does not meet the spraying process requirement is conveyed into a smelting furnace, the waste steel powder suitable for spraying is mixed with a binding agent, then the mixture is sprayed to the surface of the brake disc base body, and a waste steel powder coating is formed; and the brake disc base body with the waste steel powder coating is put into a heating furnace to be subjected to tempering treatment, and then surface polishing is conducted. The method has the advantages that the production cost is reduced, high-added-value components in the waste steel are effectively utilized, and resource waste is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of casting and spraying of brake discs, and in particular to a smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips. Background Art

[0002] With the development of the automobile industry, the performance requirements for automobile brake discs are getting higher and higher. Traditional brake discs are mostly made of cast iron materials. Due to their low cost and convenient processing, they are widely used in low-end models. However, cast iron brake discs have poor wear resistance and heat resistance, and are prone to severe wear under high-intensity use environments, resulting in a shortened service life. In recent years, in order to improve the performance of brake discs, many studies have focused on the application of new materials, such as composite materials and powder metallurgy materials. Although these new materials have improved the performance of brake discs to a certain extent, they are expensive and difficult to promote and apply on a large scale. At the same time, the treatment of a large amount of scrap steel and steel chips generated in the steel industry has become an important issue of environmental protection and resource recycling. At present, most scrap steel is reused through simple classification and remelting, but this simple method fails to make full use of the high value-added components in scrap steel, resulting in a waste of resources.

[0003] In the prior art, in order to solve the problem of insufficient brake disc performance, the following methods are usually used: First, continue to use traditional cast iron brake discs. Although they are low in cost, they have poor wear resistance and heat resistance, are prone to high-temperature cracks and wear, and result in a short service life. Second, use composite brake discs. This type of brake disc has high strength and wear resistance and is suitable for high-performance vehicles, but its production process is complex and costly, which limits its popularity in ordinary passenger cars. Third, scrap steel and steel chips are sorted and sent to an electric arc furnace or converter for remelting, and then made into new steel. Although this method can achieve basic recycling of scrap steel, it fails to fully extract and utilize the high value-added components therein, resulting in a waste of resources.

[0004] The above existing technical means have obvious defects: cast iron brake discs have poor wear resistance and heat resistance, short service life, and cannot meet the needs of high-performance vehicles; composite brake discs have superior performance, but high cost and complex production process, making them difficult to promote on a large scale; the high value-added components in scrap steel cannot be effectively extracted and utilized during the remelting process, resulting in a waste of resources. Therefore, there is an urgent need for a new technology that can improve the wear resistance and heat resistance of brake discs, extend service life, reduce costs, and effectively utilize the high value-added components in scrap steel. Summary of the invention

[0005] In order to reduce production costs, achieve effective utilization of high value-added components in scrap steel, and reduce resource waste, the present application provides a smelting process for wear-resistant brake discs by increasing the amount of scrap steel and steel chips added.

[0006] The present application provides a smelting process for wear-resistant brake discs by increasing the amount of scrap steel and steel chips added, which adopts the following technical solution: A smelting process for increasing the amount of scrap steel and steel chips added to a wear-resistant brake disc comprises the following steps: S1 conveys the scrap steel and steel chips to the crusher and pre-treats the scrap steel and steel chips to a predetermined particle size; S2 transports the pre-treated scrap steel and steel chips to the furnace and grinder respectively according to a predetermined ratio; S3 melts the pre-treated scrap steel and steel scraps transported to the melting furnace and adds a predetermined proportion of alloying elements; further grinds the pre-treated scrap steel and steel scraps transported to the grinder into scrap steel powder; S4 refines the molten metal to remove impurities; screens the ground scrap steel powder to remove oversized or undersized particles to ensure that the particle size of the final powder is suitable for the spraying process. Scrap steel powder that does not meet the requirements of the spraying process is transported to the furnace; S5 casts the refined molten metal into a brake disc matrix; mixes scrap steel powder suitable for spraying with a binder; S6 sprays the mixture of scrap steel powder and binder on the surface of the brake disc substrate to form a uniform scrap steel powder coating; S7 puts the brake disc substrate with scrap steel powder coating into a heating furnace for tempering treatment, heats it to 700°C, and keeps it warm for 2 hours, so that the scrap steel powder and the brake disc substrate material are closely combined to form a firm composite layer; S8 polishes the surface of the brake disc after tempering to ensure its smooth surface and improve its friction performance and heat dissipation performance.

[0007] By adopting the above technical scheme, the utilization rate of scrap steel and steel chips can be effectively improved, the waste of raw materials can be reduced, and at the same time, by accurately controlling each processing step, it is ensured that the brake disc produced in the end has excellent wear resistance and good heat dissipation performance. By pre-treating the scrap steel and steel chips to reach the predetermined particle size, it is helpful to smoothly carry out the subsequent melting and grinding process and improve production efficiency. The pre-treated scrap steel and steel chips are respectively transported to the furnace and the grinder according to the predetermined proportion, which ensures the stability and consistency of the melting and grinding process. The addition of a predetermined proportion of alloy elements during the melting process improves the performance of the molten metal, while the grinding process ensures the fineness and uniformity of the scrap steel powder, which is suitable for the spraying process. The refining treatment removes impurities in the molten metal and improves the quality of the brake disc matrix, and the screening treatment ensures that the particle size of the scrap steel powder is uniform, which meets the requirements of the spraying process. Casting the refined molten metal into the brake disc matrix ensures the strength and stability of the matrix, and the mixing of the scrap steel powder and the binder provides a good foundation for subsequent spraying. The mixture of scrap steel powder and binder is sprayed on the surface of the brake disc substrate to form a uniform coating, which not only reduces production costs, but also realizes the effective utilization of high value-added components in scrap steel, reduces resource waste, and enhances the wear resistance and heat dissipation performance of the brake disc. The tempering treatment makes the scrap steel powder and the brake disc substrate material closely combined to form a strong composite layer, further improving the overall performance of the brake disc. Surface polishing ensures the smoothness and flatness of the brake disc surface, improving its friction performance and heat dissipation performance.

[0008] Optionally, the crusher includes a box, a screen and two crushing rollers, the two crushing rollers are rotatably connected to the box inside the box, the screen is located below the crushing rollers, the screen is inclined, a discharge port is provided on the side wall of the box near the lowest end of the screen, the lowest end of the screen passes through the discharge port and is flush with the outer wall of the box body, the upper and lower ends of the box are open, and the lower end of the box is provided with a first baffle and a second baffle for sealing the opening at the lower end of the box, one end of the first baffle near the discharge port is hinged to the box, and the end of the second baffle away from the discharge port is hinged to the box, and the side of the first baffle away from the discharge port abuts against the side of the second baffle near the discharge port.

[0009] By adopting the above technical solution, the structural design of the crusher enables efficient pre-processing of scrap steel and steel chips. The two crushing rollers installed in the box can effectively crush large pieces of scrap steel and steel chips into small pieces of predetermined particle size. The tilt setting and position design of the screen ensure that the crushed materials can be discharged from the discharge port and the lower end opening according to their own size. The design of the first baffle and the second baffle allows the lower end opening of the box to be blocked when necessary to prevent material leakage, thereby improving the safety and reliability of the equipment. This structure not only improves the crushing efficiency, but also ensures the uniformity of the material, providing high-quality raw materials for subsequent smelting and grinding processes.

[0010] Optionally, a partition plate that slides in a vertical direction is provided at the opening at the lower end of the box body, and the first baffle plate and the second baffle plate are both slidably connected to the partition plate.

[0011] By adopting the above technical solution, the partition slides upward to divide the material in the box into two parts, and the two parts of material are stacked on the first baffle and the second baffle respectively. The first baffle or the second baffle can be opened separately to discharge the material stacked above it, thereby improving the convenience of the equipment.

[0012] Optionally, a first conveyor belt and a second conveyor belt are provided under the box body, the first conveyor belt conveys a molten material box, the molten material box is used to collect the crushed steel materials falling from the discharge port and the first baffle, the second conveyor belt conveys an abrasive box, the abrasive box is used to collect the crushed steel materials falling from the second baffle, the partition is located between the first conveyor belt and the second conveyor belt, a fixed platform is provided under the first conveyor belt and the second conveyor belt, and support plates fixedly connected to the fixed platform are provided on both sides of the box body.

[0013] By adopting the above technical solution, the crushed steel can be effectively separated to ensure that steel for different purposes can be accurately collected. The steel falling from the discharge port and the first baffle can be collected by the melt box, while the steel falling from the second baffle is collected by the abrasive box, avoiding material mixing and improving production efficiency. At the same time, the setting of the partition further ensures the accurate diversion of materials, and the structure of the fixed platform and the support plate enhances the overall stability of the equipment, ensuring the smooth progress of the entire crushing and collection process.

[0014] Optionally, a material guide trough is provided at the material outlet, and the opening at the lower end of the material guide trough is located directly above the melt box.

[0015] By adopting the above technical solution, the setting of the guide chute can effectively guide the crushed steel material to fall accurately into the melting box, avoid material scattering, and improve production efficiency and safety. At the same time, the design of the guide chute can also reduce the loss of steel material during the transmission process, ensuring the smooth progress of subsequent processes.

[0016] Optionally, the partition is provided with buffer grooves on both sides close to the melt box and the abrasive box, respectively, and the buffer grooves are used to guide the steel material sliding down from the first baffle and the second baffle into the melt box and the abrasive box respectively.

[0017] By adopting the above technical solution, the splashing phenomenon of steel during the sliding process can be effectively reduced, and the steel can be prevented from scattering outside the equipment, thereby improving the safety and efficiency of production. At the same time, the design of the buffer tank allows the steel to fall accurately into the designated container, ensuring the smooth progress of subsequent processes. This design not only optimizes the material transmission process, but also reduces the workload of operators and improves the stability and reliability of the entire system.

[0018] Optionally, a reinforcing plate is provided under the partition, the lower end surface of the reinforcing plate is arranged horizontally, the two buffer grooves are fixedly connected to the reinforcing plate on one side away from the box body, and a lifting cylinder is fixedly provided on the lower end surface of the reinforcing plate, and the lower end of the lifting cylinder is fixedly connected to the workbench.

[0019] By adopting the above technical solution, the additional reinforcement plate under the partition can effectively improve the structural strength of the buffer grooves on both sides of the partition to prevent deformation due to gravity during long-term use, thereby ensuring that the crushed steel can be smoothly introduced into the melt box and abrasive box. The setting of the lifting cylinder can flexibly adjust the height of the partition to meet the needs of different working conditions, improving the convenience and flexibility of operation.

[0020] Optionally, the four corners of the lower end surface of the screen are provided with elastic parts fixedly connected to the side walls of the box body, the lower end surface of the screen is provided with a disc cam, and the outer side wall of the box body is provided with a driving motor that drives the disc cam to rotate.

[0021] By adopting the above technical solution, fatigue damage of the screen caused by long-term vibration can be effectively reduced, and the service life of the screen can be extended. At the same time, the rotation of the disc cam can periodically change the vibration frequency and amplitude of the screen, thereby improving the screening efficiency of the screen, ensuring that the particle size of scrap steel and steel chips is uniform, and meeting the requirements of subsequent smelting and grinding.

[0022] Optionally, each side of the first baffle plate is fixedly provided with a first side plate on a side perpendicular to its own rotation axis, and each side of the second baffle plate is fixedly provided with a second side plate on a side perpendicular to its own rotation axis, the two first side plates and the two second side plates are both in contact with the outer wall of the box body on one side close to the box body, and the first side plate and the second side plate are both rotatably connected to a flip cylinder on one side away from the box body, the telescopic end of the flip cylinder is located at the end of the first side plate and the second side plate away from their own rotation axis, and the cylinder body of the flip cylinder is rotatably connected to the box body.

[0023] By adopting the above technical solution, the setting of the first side plate and the second side plate can effectively prevent the leakage of materials during the rotation of the first baffle and the second baffle, reduce the splashing phenomenon of steel materials during the sliding process, and ensure the integrity and purity of the materials. At the same time, the rotating connection design of the flip cylinder makes the opening and closing of the baffle more flexible and controllable, easy to adjust and maintain, and improves the reliability and operational convenience of the equipment. These improvement measures work together to not only improve the working efficiency of the crusher, but also ensure the smooth progress of the subsequent smelting and grinding processes, and ultimately improve the quality and performance of the wear-resistant brake disc.

[0024] In summary, the present application includes at least one of the following beneficial technical effects: 1. It can effectively improve the utilization rate of scrap steel and steel chips, reduce the waste of raw materials, and at the same time, through precise control of each processing step, ensure that the final brake disc has excellent wear resistance and good heat dissipation performance; by pre-treating the scrap steel and steel chips to reach the predetermined particle size, it is helpful for the subsequent melting and grinding process to proceed smoothly and improve production efficiency. The pre-treated scrap steel and steel chips are respectively transported to the furnace and grinder according to the predetermined proportion, which ensures the stability and consistency of the melting and grinding processes; the addition of a predetermined proportion of alloy elements during the melting process improves the performance of the molten metal, and the grinding process ensures the fineness and uniformity of the scrap steel powder, which is suitable for the spraying process; the refining treatment removes impurities in the molten metal and improves the quality of the brake disc matrix, and the screening treatment ensures that the particle size of the scrap steel powder is uniform and meets the requirements of the spraying process; the refined molten metal is cast into the brake disc matrix, which ensures the strength and stability of the matrix, and The mixture of scrap steel powder and binder provides a good foundation for subsequent spraying; spraying the mixture of scrap steel powder and binder on the surface of the brake disc substrate forms a uniform coating, which not only reduces production costs, but also realizes the effective utilization of high value-added components in scrap steel, reduces resource waste, and enhances the wear resistance and heat dissipation performance of the brake disc; tempering treatment makes the scrap steel powder and the brake disc substrate material closely combined to form a strong composite layer, further improving the overall performance of the brake disc; surface polishing ensures the smoothness and flatness of the brake disc surface, and improves its friction performance and heat dissipation performance; 2. The structural design of the crusher enables efficient pre-processing of scrap steel and steel chips; the two crushing rollers installed in the box can effectively crush large pieces of scrap steel and steel chips into small pieces of predetermined particle size, and the tilt setting and position design of the screen ensure that the crushed materials can be discharged from the discharge port and the lower end opening according to their own size; the design of the first baffle and the second baffle enables the lower end opening of the box to be blocked when necessary to prevent material leakage, thereby improving the safety and reliability of the equipment; this structure not only improves the crushing efficiency, but also ensures the uniformity of the material, providing high-quality raw materials for subsequent smelting and grinding processes; 3. After the partition slides upward, the materials in the box are divided into two parts. The two parts of materials are stacked on the first baffle and the second baffle respectively. The first baffle or the second baffle can be opened separately to discharge the materials stacked above them, which improves the convenience of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 The present invention is a process flow chart of a smelting process for wear-resistant brake discs with increased amounts of scrap steel and steel chips.

[0026] Figure 2 It is a schematic diagram of the overall structure of the process production equipment.

[0027] Figure 3 yes Figure 2Schematic cross-section diagram of .

[0028] Explanation of the reference numerals in the accompanying drawings: 1. Crusher; 11. Box body; 111. Discharge port; 12. Screen; 13. Crushing roller; 14. Guide trough; 15. Elastic member; 16. Disc cam; 17. Driving motor; 18. Flip cylinder; 19. Support plate; 2. First baffle plate; 21. First side plate; 3. Second baffle plate; 31. Second side plate; 4. Partition plate; 41. Buffer trough; 42. Reinforcement plate; 43. Lifting cylinder; 5. First conveyor belt; 51. Melt box; 6. Second conveyor belt; 61. Abrasive box; 7. Fixed table. DETAILED DESCRIPTION

[0029] The present application is further described in detail below in conjunction with all the accompanying drawings.

[0030] The embodiment of the present application discloses a smelting process for wear-resistant brake discs by increasing the amount of scrap steel and steel chips added.

[0031] Reference Figure 1 A smelting process for wear-resistant brake discs with increased scrap steel and steel chips, comprising the following steps: S1 transports the scrap steel and steel chips to the crusher 1, and pre-treats the scrap steel and steel chips to a predetermined particle size, which helps the subsequent melting and grinding process to proceed smoothly and improve production efficiency. The crusher 1 can be used to crush the scrap steel and steel chips to a particle size range of 1-5mm. The crusher 1 can be a jaw crusher 1 or a hammer crusher 1, both of which can effectively crush large pieces of scrap steel and steel chips into the required small particles. The crushed scrap steel and steel chips can be further screened to ensure that their particle size is uniform, which helps the subsequent smelting process to be smoother.

[0032] S2 transports the pre-treated scrap steel and steel chips to the furnace and grinder respectively according to the predetermined ratio. The furnace is used to melt the scrap steel and steel chips, and the grinder is used to further grind them into scrap steel powder. This process ensures the uniformity and purity of the scrap steel and steel chips in subsequent processes. The pre-treated scrap steel and steel chips are added to the furnace in a predetermined ratio, with the scrap steel accounting for 60%-80% of the total weight and the steel chips accounting for 20%-40% of the total weight. The furnace can be selected as an electric arc furnace or an induction furnace, both of which have high melting efficiency and temperature control accuracy.

[0033] S3 melts the pre-treated scrap steel and steel chips transported to the furnace and adds a predetermined proportion of alloying elements; the pre-treated scrap steel and steel chips transported to the grinder are further ground into scrap steel powder. The scrap steel and steel chips in the furnace are melted at high temperature, and a predetermined proportion of alloying elements are added to improve the comprehensive performance of the molten metal. The grinder further grinds the pre-treated scrap steel and steel chips into fine scrap steel powder to ensure that its particle size is suitable for the spraying process. In the furnace, the scrap steel and steel chips are heated to 1600 degrees Celsius to completely melt them. In order to improve the fluidity and chemical stability of the melt, appropriate amounts of alloying elements such as chromium, nickel and molybdenum can be added during the melting process. The mass fraction of chromium is 1.0%, the mass fraction of nickel is 0.6%, and the mass fraction of molybdenum is 0.3%. The addition of these alloying elements can not only improve the wear resistance and corrosion resistance of the brake disc, but also enhance its mechanical properties.

[0034] S4 refines the molten metal to remove impurities. Specific refining treatments include oxygen blowing desulfurization and vacuum degassing. Oxygen blowing desulfurization can be carried out by introducing oxygen into the melt to oxidize and volatilize harmful elements such as sulfur. Vacuum degassing is carried out in a vacuum environment to remove gases in the melt and prevent the formation of pores. These two steps of refining can significantly improve the purity of the molten metal, thereby ensuring the quality of the final product. The ground scrap steel powder is screened to remove particles that are too large or too small to ensure that the particle size of the final powder is suitable for the spraying process. The scrap steel powder that does not meet the requirements of the spraying process is transported to the furnace. The molten metal removes impurities during the refining process to ensure its purity. The ground scrap steel powder is screened to remove particles that do not meet the requirements of the spraying process to ensure that the particle size of the final powder is uniform. The scrap steel powder that does not meet the requirements of the spraying process can be transported back to the furnace for reuse.

[0035] S5 casts the refined molten metal into the brake disc matrix to ensure that its shape and size meet the requirements; mixes the scrap steel powder suitable for spraying with the binder to form a uniform spraying material. The casting method can be gravity casting or pressure casting. Gravity casting is suitable for smaller-scale production, while pressure casting is suitable for large-scale production because pressure casting can better control the filling speed and solidification process of the molten metal, thereby obtaining a denser organizational structure. No matter which casting method is chosen, it is necessary to ensure that the mold is clean and preheated to avoid cracks or other defects during the cooling of the molten metal.

[0036] S6 sprays a mixture of ground scrap steel powder and binder on the surface of the brake disc substrate to form a uniform scrap steel powder coating. The wear resistance and heat dissipation performance of the brake disc surface are improved. The particle size range of the scrap steel powder is 50-100μm, and the purity is greater than 98% to ensure the uniformity and stability of the coating. The binder is an epoxy resin binder with good adhesion and high temperature resistance. In addition to epoxy resin binders, other types of resins or glues, such as polyurethane resins, phenolic resins, etc., can also be selected to meet the requirements of different process conditions. For example, polyurethane resins have better flexibility in low temperature environments, while phenolic resins are more stable in high temperature environments.

[0037] S7 puts the brake disc substrate with scrap steel powder coating into a high-temperature furnace for tempering treatment, heats it to 700℃, and keeps it warm for 2 hours, so that the scrap steel powder and the brake disc substrate material are closely combined to form a strong composite layer. The overall strength and durability of the brake disc are improved. The purpose of tempering treatment is to make the scrap steel powder and the substrate material react chemically through high temperature to form a strong composite layer and improve the comprehensive performance of the brake disc. In addition, the brake disc substrate can also be cold deformed before tempering treatment to improve its strength and toughness through plastic deformation, and further enhance the performance of the brake disc. The cold deformation treatment method can be rolling, hammering, etc. Through appropriate deformation, a small plastic deformation is generated inside the brake disc substrate, thereby improving its strength and toughness.

[0038] S8 performs surface polishing on the tempered brake disc, using a 600-mesh diamond grinding wheel to ensure a smooth and flat surface, improving its friction and heat dissipation performance. This process further improves the performance of the brake disc. The purpose of surface polishing is to remove the rough parts of the surface, make the surface of the brake disc smoother and flatter, and improve its friction and heat dissipation performance. In addition to the 600-mesh diamond grinding wheel, you can also choose grinding wheels with different grits, such as 400 mesh, 800 mesh, etc., to obtain different surface effects. For example, a 400-mesh grinding wheel is suitable for rough polishing, while an 800-mesh grinding wheel is suitable for fine polishing to achieve a higher surface finish.

[0039] Reference Figure 2 and Figure 3The crusher 1 includes a box body 11, a screen 12 and two crushing rollers 13. The box body 11 is open at the upper and lower ends, and scrap steel and steel chips are input from the upper opening of the box body 11. The two crushing rollers 13 are rotatably connected to the box body 11 inside the box body 11, and the crushing rollers 13 can effectively crush large pieces of scrap steel and steel chips into small pieces of predetermined particle sizes. The screen 12 is located below the crushing rollers 13, and the four corners of the lower end surface of the screen 12 are provided with elastic members 15 fixedly connected to the side wall of the box body 11. The elastic member 15 can be a spring or a rubber pad to reduce the wear of the screen 12 during vibration. A disc cam 16 is provided on the lower end surface of the screen 12, and the disc cam 16 is driven by a driving motor 17 to make the screen 12 vibrate periodically, which is helpful for the screening and discharge of materials.

[0040] Reference Figure 3 A discharge port 111 is provided on the side wall of the box 11 near the lowest end of the screen 12. The lowest end of the screen 12 passes through the discharge port 111 and is flush with the outer wall of the box 11. The screen 12 is tilted so that the material on the screen 12 can be discharged from the discharge port 111 along the screen 12. A guide trough 14 is provided at the discharge port 111. The lower end opening of the guide trough 14 is located directly above the melt box 51. The guide trough 14 blocks the material sliding off the screen 12, ensuring that the material accurately falls into the melt box 51 from the discharge port 111 along the guide trough 14.

[0041] Reference Figure 2 and Figure 3 The lower end of the box body 11 is provided with a first baffle 2 and a second baffle 3 for blocking the lower end opening of the box body 11, and the side of the first baffle 2 away from the discharge port 111 abuts against the side of the second baffle 3 close to the discharge port 111. The design of the first baffle 2 and the second baffle 3 allows the lower end opening of the box body 11 to be blocked when necessary to prevent material leakage, thereby improving the safety and reliability of the equipment.

[0042] Reference Figure 2The first baffle plate 2 is hinged to the box body 11 at one end close to the discharge port 111, and a first side panel 21 is fixedly provided on the side perpendicular to its own rotation axis, and the two first side panels 21 are in contact with the outer side wall of the box body 11 on one side close to the box body 11; the second baffle plate 3 is hinged to the box body 11 at one end away from the discharge port 111, and a second side panel 31 is fixedly provided on the side perpendicular to its own rotation axis, and the two second side panels 31 are in contact with the outer side wall of the box body 11 on one side close to the box body 11. The setting of the first side panel 21 and the second side panel 31 can effectively prevent the leakage of materials during the rotation of the first baffle plate 2 and the second baffle plate 3, reduce the splashing phenomenon of steel materials during the sliding process, and ensure the integrity and purity of the materials. The first side plate 21 and the second side plate 31 are both rotatably connected to the side away from the box body 11 with a flip cylinder 18. The telescopic end of the flip cylinder 18 is located at the end of the first side plate 21 and the second side plate 31 away from their own rotation axis. The cylinder body of the flip cylinder 18 is rotatably connected to the box body 11, which is convenient for controlling the opening and closing of the first baffle 2 and the second baffle 3.

[0043] Reference Figure 2 , a partition 4 that slides in the vertical direction is provided at the opening of the lower end of the box body 11, and the first baffle 2 and the second baffle 3 are both slidably connected to the partition 4. Buffer grooves 41 are fixedly provided on both sides of the partition 4 close to the melt box 51 and the abrasive box 61, respectively. The buffer grooves 41 are used to guide the steel materials sliding down from the first baffle 2 and the second baffle 3 into the melt box 51 and the abrasive box 61, respectively, which can effectively reduce the splashing phenomenon of the steel materials during the sliding process, prevent the steel materials from scattering to the outside of the equipment, and improve the safety and efficiency of production. A reinforcing plate 42 is provided below the partition 4, and the lower end surface of the reinforcing plate 42 is horizontally arranged. The two buffer grooves 41 are fixedly connected to the reinforcing plate 42 on one side away from the box body 11. The reinforcing plate 42 can effectively improve the structural strength of the buffer grooves 41 on both sides of the partition 4 to prevent deformation due to gravity during long-term use. A lifting cylinder 43 is fixedly provided on the lower end surface of the reinforcing plate 42, and the lower end of the lifting cylinder 43 is fixedly connected to the workbench. The lifting cylinder 43 drives the reinforcing plate 42 to rise and fall, thereby driving the partition 4 to slide upward to divide the material in the box 11 into two parts. The two parts of material are stacked on the first baffle 2 and the second baffle 3 respectively. The first baffle 2 or the second baffle 3 can be opened separately to discharge the materials stacked above them, thereby improving the convenience of the equipment.

[0044] Reference Figure 2A first conveyor belt 5 and a second conveyor belt 6 are provided below the box body 11. A molten material box 51 is conveyed on the first conveyor belt 5. The molten material box 51 is used to collect the crushed steel materials falling from the discharge port 111 and the first baffle 2. An abrasive box 61 is conveyed on the second conveyor belt 6. The abrasive box 61 is used to collect the crushed steel materials falling from the second baffle 3. The partition 4 is located between the first conveyor belt 5 and the second conveyor belt 6. A fixed platform 7 is provided below the first conveyor belt 5 and the second conveyor belt 6. Support plates 19 fixedly connected to the fixed platform 7 are provided on both sides of the box body 11, thereby enhancing the stability of the entire device.

[0045] The specific working process of the crushing box is as follows: pour scrap steel and steel chips from the opening at the upper end of the box body 11, and the crushing roller 13 crushes the scrap steel and steel chips; the crushed slag with a size larger than the mesh of the screen 12 falls from the discharge port 111 into the melt box 51, and the crushed slag with a size smaller than the mesh of the screen 12 falls onto the first baffle 2 and the second baffle 3; the lifting cylinder 43 drives the partition 4 to rise upward, and divides the slag on the first baffle 2 and the second baffle 3 into two parts; open the first baffle 2, and the slag on the first baffle 2 falls onto the buffer groove 41 of the partition 4 close to the first baffle 2, and then falls into the melt box 51, and the first conveyor belt 5 sends the melt box 51 to the direction of the furnace; open the second baffle 3, and the slag on the second baffle 3 falls onto the buffer groove 41 of the partition 4 close to the second baffle 3, and then falls into the abrasive box 61, and the second conveyor belt 6 sends the abrasive box 61 to the direction of the grinder. The area of ​​the first baffle 2 is not less than that of the second baffle 3. The steel required for smelting is more than that required for spraying. Weighing devices can be installed on both the first baffle 2 and the second baffle 3. When the weight reaches the amount required for production, the first baffle 2 and the second baffle 3 are opened respectively to discharge the slag.

[0046] The implementation principle of the melting process of a wear-resistant brake disc with increased scrap steel and steel chips in the embodiment of the present application is: it can effectively improve the utilization rate of scrap steel and steel chips, reduce the waste of raw materials, and ensure that the final brake disc has excellent wear resistance and good heat dissipation performance by accurately controlling each processing step. By pre-treating the scrap steel and steel chips to reach a predetermined particle size, it is helpful to smoothly carry out the subsequent melting and grinding process and improve production efficiency. The pre-treated scrap steel and steel chips are respectively transported to the furnace and the grinder according to a predetermined ratio, ensuring the stability and consistency of the melting and grinding process. The addition of a predetermined proportion of alloy elements during the melting process improves the performance of the molten metal, while the grinding process ensures the fineness and uniformity of the scrap steel powder, which is suitable for the spraying process. The refining treatment removes impurities in the molten metal and improves the quality of the brake disc matrix, and the screening treatment ensures that the particle size of the scrap steel powder is uniform, which meets the requirements of the spraying process. The refined molten metal is cast into the brake disc matrix to ensure the strength and stability of the matrix, and the mixing of the scrap steel powder and the binder provides a good foundation for subsequent spraying. The mixture of scrap steel powder and binder is sprayed on the surface of the brake disc substrate to form a uniform coating, which not only reduces production costs, but also realizes the effective utilization of high value-added components in scrap steel, reduces resource waste, and enhances the wear resistance and heat dissipation performance of the brake disc. The tempering treatment makes the scrap steel powder and the brake disc substrate material closely combined to form a strong composite layer, further improving the overall performance of the brake disc. Surface polishing ensures the smoothness and flatness of the brake disc surface, improving its friction performance and heat dissipation performance.

[0047] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A smelting process for wear-resistant brake discs with increased scrap steel and steel chips, characterized in that: The steps include: S1 conveys the scrap steel and steel chips to the crusher (1) and pre-treats the scrap steel and steel chips to a predetermined particle size; S2 transports the pre-treated scrap steel and steel chips to the furnace and grinder respectively according to a predetermined ratio; S3 melts the pre-treated scrap steel and steel scraps transported to the melting furnace and adds a predetermined proportion of alloying elements; further grinds the pre-treated scrap steel and steel scraps transported to the grinder into scrap steel powder; S4 refines the molten metal to remove impurities; screens the ground scrap steel powder to remove oversized or undersized particles to ensure that the particle size of the final powder is suitable for the spraying process. Scrap steel powder that does not meet the requirements of the spraying process is transported to the furnace; S5 casts the refined molten metal into a brake disc matrix; mixes scrap steel powder suitable for spraying with a binder; S6 sprays the mixture of scrap steel powder and binder on the surface of the brake disc substrate to form a uniform scrap steel powder coating; S7 puts the brake disc substrate with scrap steel powder coating into a heating furnace for tempering treatment, heats it to 700°C, and keeps it warm for 2 hours, so that the scrap steel powder and the brake disc substrate material are closely combined to form a firm composite layer; S8 polishes the surface of the brake disc after tempering to ensure its smooth surface and improve its friction performance and heat dissipation performance.

2. The smelting process for wear-resistant brake discs with increased scrap steel and steel chips according to claim 1, characterized in that: The crusher (1) comprises a housing (11), a screen (12) and two crushing rollers (13), wherein the two crushing rollers (13) are rotatably connected to the housing (11) inside the housing (11), the screen (12) is located below the crushing rollers (13), the screen (12) is arranged at an angle, a discharge port (111) is provided on a side wall of the housing (11) near the lowest end of the screen (12), the lowest end of the screen (12) passes through the discharge port (111) and is flush with the outer wall of the housing (11), and the housing (11) is provided with a plurality of crushing rollers (13). The upper and lower ends of the box body (11) are open, and the lower end of the box body (11) is provided with a first baffle (2) and a second baffle (3) for blocking the lower end opening of the box body (11), an end of the first baffle (2) close to the discharge port (111) is hinged to the box body (11), an end of the second baffle (3) away from the discharge port (111) is hinged to the box body (11), and a side of the first baffle (2) away from the discharge port (111) abuts against a side of the second baffle (3) close to the discharge port (111).

3. The smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips according to claim 2, characterized in that: A partition plate (4) which slides in a vertical direction is provided at the lower opening of the box body (11), and both the first baffle plate (2) and the second baffle plate (3) are slidably connected to the partition plate (4).

4. The smelting process for wear-resistant brake discs with increased scrap steel and steel chips according to claim 3 is characterized in that: A first conveyor belt (5) and a second conveyor belt (6) are provided below the box body (11). A molten material box (51) is conveyed on the first conveyor belt (5). The molten material box (51) is used to collect the crushed steel material falling from the discharge port (111) and the first baffle plate (2). An abrasive material box (61) is conveyed on the second conveyor belt (6). The abrasive material box (61) is used to collect the crushed steel material falling from the second baffle plate (3). The partition plate (4) is located between the first conveyor belt (5) and the second conveyor belt (6). A fixed platform (7) is provided below the first conveyor belt (5) and the second conveyor belt (6). Support plates (19) fixedly connected to the fixed platform (7) are fixedly provided on both sides of the box body (11).

5. The smelting process for wear-resistant brake discs with increased scrap steel and steel chips according to claim 4, characterized in that: A material guide trough (14) is provided at the material outlet (111), and the lower end opening of the material guide trough (14) is located directly above the molten material box (51).

6. The smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips according to claim 4, characterized in that: The partition plate (4) is provided with buffer grooves (41) on both sides close to the melt box (51) and the abrasive box (61), respectively. The buffer grooves (41) are used to guide the steel material sliding down from the first baffle plate (2) and the second baffle plate (3) into the melt box (51) and the abrasive box (61), respectively.

7. The smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips according to claim 6, characterized in that: A reinforcing plate (42) is provided below the partition (4), the lower end surface of the reinforcing plate (42) is arranged horizontally, the two buffer grooves (41) are fixedly connected to the reinforcing plate (42) on one side away from the box body (11), and a lifting cylinder (43) is fixedly provided on the lower end surface of the reinforcing plate (42), and the lower end of the lifting cylinder (43) is fixedly connected to the workbench.

8. The smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips according to claim 2, characterized in that: The four corners of the lower end surface of the screen (12) are provided with elastic members (15) fixedly connected to the side wall of the box body (11), the lower end surface of the screen (12) is provided with a disc cam (16), and the outer side wall of the box body (11) is provided with a driving motor (17) for driving the disc cam (16) to rotate.

9. The smelting process for wear-resistant brake discs with increased addition of scrap steel and steel chips according to claim 2, characterized in that: A first side plate (21) is fixedly provided on each side of the first baffle plate (2) perpendicular to its own rotation axis, and a second side plate (31) is fixedly provided on each side of the second baffle plate (3) perpendicular to its own rotation axis. The two first side plates (21) and the two second side plates (31) are both in contact with the outer wall of the box body (11) on one side close to the box body (11), and the first side plate (21) and the second side plate (31) are both rotatably connected to a flip cylinder (18) on one side away from the box body (11). The telescopic end of the flip cylinder (18) is located at one end of the first side plate (21) and the second side plate (31) away from their own rotation axis, and the cylinder body of the flip cylinder (18) is rotatably connected to the box body (11).

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