Riveting and cladding technology for automobile brake disc machining

Abstract

The invention discloses a riveting and cladding technology for automobile brake disc machining, relates to the technical field of brake disc machining, and solves the problems that in the existing brake disc riveting process, the brake disc riveting quality and the brake disc rotating balance are inconvenient to maintain, and in the laser cladding treatment process, the brake disc riveting quality and the brake disc rotating balance are not convenient to maintain. And the unstable laser power is easy to cause bubbles and cracks on the brake surface of the brake disc. A riveting cladding technology for automobile brake disc machining comprises the following steps that S1, a casting ring and an aluminum cap are clamped on a numerical control machine tool and roughly machined to be in a finished product state, and the hub outer diameter, the hub outer circle height and the stop face thickness size of the casting ring are controlled; and then the casting rings and the aluminum caps are conveyed and fed through the ring feeding position and the aluminum cap feeding position of the pressing machine correspondingly. By means of balance detection and laser power control in the brake disc machining treatment process, the machining quality can be effectively guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of brake disc processing, and particularly to a riveting and cladding process for automobile brake disc processing. Background Art

[0002] Brakes are braking devices for automobile braking and emergency braking. Brakes can be divided into disc brakes and drum brakes. Disc brakes have better heat dissipation than drum brakes, and are not prone to heat fade under high-speed braking conditions, so their high-speed braking effect is good. Disc brakes are mainly composed of a brake caliper and a brake disc. The brake disc is a circular plate and is the key to braking. With the development of the automobile industry, the performance requirements for brake discs are getting higher and higher. Automobile brake discs need to be successively subjected to riveting and laser cladding assembly processing operations. During the laser cladding process, laser coating treatment needs to be carried out on the surface of the brake disc to form a metal coating to reduce braking dust, increase service life and improve safety.

[0003] During the existing riveting process of brake discs, it is not convenient to maintain the riveting quality of the brake discs and the rotational balance of the brake discs, and during the laser cladding treatment, unstable laser power is likely to cause bubbles and cracks on the braking surface of the brake discs; therefore, it does not meet the existing requirements, and for this reason, we propose a riveting and cladding process for automobile brake disc processing. Summary of the Invention

[0004] The purpose of the present invention is to provide a riveting and cladding process for automobile brake disc processing, so as to solve the problems mentioned in the above background art that during the existing riveting process of brake discs, it is not convenient to maintain the riveting quality of the brake discs and the rotational balance of the brake discs, and during the laser cladding treatment, unstable laser power is likely to cause bubbles and cracks on the braking surface of the brake discs.

[0005] To achieve the above purpose, the present invention provides the following technical solution: A riveting and cladding process for automobile brake disc processing, including the following steps: S1: Clamp the casting ring and the aluminum cap on the numerically controlled machine tool respectively and perform rough machining to the finished state. Control the hub outer diameter, hub outer circle height and stop surface thickness dimensions of the casting ring. Then, use the ring loading position and the aluminum cap loading position of the press to convey and load the casting ring and the aluminum cap respectively. Synchronously grab the casting ring and the aluminum cap by the press and transfer them to the pressing position of the press. Keep the aluminum cap directly above the casting ring and coaxial with the casting ring. Then, press down the aluminum cap by the punching head of the press to realize the pressing operation of the casting ring and the aluminum cap and form a brake disc; S2: Pick up the brake disc from the material picking position of the press-fitting machine and clamp it on the numerical control machine again. Use the drill bit of the numerical control machine to process multiple riveting holes on the surface of the brake disc. After drilling, place the brake disc at the riveting position of the riveting machine, and at the same time place multiple rivets in the vibrating bowl of the riveting machine. During the process of the vibrating bowl automatically feeding the rivets, the riveting machine presses the rivets into the inner side of the riveting holes, and internally and externally punches the rivets to make their tails expand to form a head to achieve the function of fixing the casting ring and the aluminum cap. Collect and identify the picture of the rivets placed in the riveting holes through the built-in camera of the riveting machine to avoid the situation of deviation in rivet feeding; S3: After the riveting operation, use the numerical control machine again to process the positioning holes on the surface of the aluminum cap. Then, the dynamic balancing machine uses the positioning holes to accurately position the brake disc and automatically measure the unbalance of the brake disc, and remove the excess mass by milling to achieve a balanced state; S4: Clamp the brake disc on the processing position of the laser cladding machine, so that the laser cladding machine melts the metal powder through a high-energy laser beam and combines it with the base material of the brake disc to realize the laser cladding operation of the transition layer and the wear-resistant layer on the two braking surfaces of the casting ring in an alternating manner; S5: After the cladding treatment, use the grinding machine to perform multiple grinding operations with different precisions on the two braking surfaces of the casting ring, and measure the flatness of the braking surfaces and the thickness dimensions of the casting ring after grinding. At the same time, use an ultrasonic flaw detector to detect whether there are bubbles and cracks on the surface and inside of the casting ring. After the brake disc is qualified, it is packaged and transported.

[0006] Preferably, the brake disc is composed of a casting ring, an aluminum cap and multiple rivets. The casting ring and the aluminum cap are fixedly connected by multiple rivets. The multiple rivets are arranged in a circumferential pattern relative to the axis of the casting ring. The end face of the aluminum cap is provided with positioning holes and multiple mounting holes.

[0007] Preferably, the clamping pressure of the numerical control machine for rough machining the casting ring in S1 is 8 - 12 MPa.

[0008] Preferably, the pressing pressure of the press-fitting machine in S2 is 7.5 - 13.5 KN, and the brake disc is coaxial with the center of the press-fitting position of the press-fitting machine.

[0009] Preferably, the diameter size of the riveting holes in S2 is 5.1 - 5.15 mm, the processing speed of the numerical control machine for the riveting holes is 3000 - 3600 r / min, the clamping pressure of the numerical control machine for processing the riveting holes on the brake disc is 2 - 4 MPa, and the riveting pressure of the riveting machine is 30 - 42 KN.

[0010] Preferably, the clamping pressure of the grinding tool of the grinding machine for grinding the brake disc in S5 is 2 - 4 MPa, and the grinding speed of the grinding machine for the brake disc is 800 - 1200 r / min.

[0011] Preferably, the laser cladding machine in S4 is composed of a laser, a powder feeding system, a dust removal system, a cooling system, a processing system, and an electric control system.

[0012] Preferably, when the laser cladding machine clads the transition layer on the braking surface, the linear velocity is 3000 - 4000 mm / min, the coating spacing is 0.2 - 0.9 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.1 - 0.28 mm, the height of the laser lens of the laser is 12 - 36 mm, the protective gas flow rate is 10 - 50 L / min, and the powder feeding gas flow rate is 2 - 6 L / min.

[0013] Preferably, when the laser cladding machine clads the wear-resistant layer on the braking surface, the linear velocity is 2000 - 5200 mm / min, the coating spacing is 0.1 - 0.75 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.2 - 0.5 mm, the height of the laser lens of the laser is 20 - 30 mm, the protective gas flow rate is 10 - 50 L / min, and the powder feeding gas flow rate is 1 - 5 L / min. Preferably, the axial runout of the tooling of the grinding machine is not more than 0.002 mm, and the end face runout of the tooling of the grinding machine is not more than 0.002 mm.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: During the rough machining of the casting ring of the present invention, the height of the outer circle of the hub and the thickness of the braking surface of the casting ring are controlled to achieve one-time machining and forming. At the same time, during the press-fitting, the center of the press-fitting position of the brake disc and the press-fitting machine is coaxially aligned to maintain high-quality press-fitting operation of the brake disc. During the riveting process, the surfaces of the riveting holes and rivets are detected to improve the riveting quality. The dynamic balancing machine is used to automatically measure the unbalance of the brake disc, and the excess mass is removed by milling to achieve a balanced state, ensuring that the brake disc can maintain stability during high-speed rotation, reducing vibration and noise, improving the braking effect, driving comfort, and the service life of the braking system. The laser cladding operation of the transition layer and the wear-resistant layer on the two braking surfaces of the casting ring in an alternating manner can change the surface strength of the brake disc, increase the wear resistance, reduce dust emissions, and significantly avoid the appearance of bubbles and cracks on the brake disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic structural diagram of the brake disc of the present invention; Figure 2 It is a schematic installation structure diagram of the aluminum cap of the present invention; Figure 3 It is a schematic flow diagram of the whole of the present invention; Figure 4Schematic diagram for comparison of qualified and unqualified laser cladding on the braking surface of the present invention; Figure 5 Schematic diagram of the structure of the press-fitting machine of the present invention; Figure 6 Schematic diagram of the structure of the riveting machine of the present invention; Figure 7 Flow chart of the riveting and cladding steps of the whole of the present invention.

[0016] In the figure: 1, casting ring; 2, aluminum cap; 3, rivet; 4, mounting hole; 5, positioning hole. Detailed implementation mode

[0017] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments.

[0018] Please refer to Figure 1 , Figure 2 , Figure 3 , Figure 5 , Figure 6 and Figure 7 , an embodiment provided by the present invention: a riveting and cladding process for machining an automotive brake disc, including the following steps: S1: Clamp the casting ring 1 and the aluminum cap 2 on the numerically controlled machine tool respectively and perform rough machining to the finished product state. Among them, the hub outer diameter, hub outer circle height and stop surface thickness dimensions of the casting ring 1 are controlled. The clamping pressure of the numerically controlled machine tool for rough machining of the casting ring 1 is 8-12 MPa. Then, use the ring loading position and the aluminum cap loading position of the press-fitting machine to convey and load the casting ring 1 and the aluminum cap 2 respectively. Synchronously grab the casting ring 1 and the aluminum cap 2 through the press-fitting machine and transfer them to the press-fitting position of the press-fitting machine. Keep the aluminum cap 2 directly above the casting ring 1 and coaxial with the casting ring 1. Then, press down the aluminum cap 2 through the punching head of the press-fitting machine to realize the press-fitting operation of the casting ring 1 and the aluminum cap 2 and form a brake disc; S2: Take the brake disc from the material taking position of the press-fitting machine and clamp it on the numerically controlled machine tool again. Use the drill bit of the numerically controlled machine tool to process multiple riveting holes on the surface of the brake disc. After drilling, place the brake disc at the riveting position of the riveting machine, and at the same time place multiple rivets 3 in the vibrating disk of the riveting machine. During the automatic feeding of the rivets 3 by the vibrating disk of the riveting machine, press the rivets 3 into the inner side of the riveting holes, and punch the rivets 3 inside and outside to make the tail expand to form a head to achieve the function of fixing the casting ring 1 and the aluminum cap 2. Collect and identify the picture of the rivets 3 placed in the riveting holes through the built-in camera of the riveting machine to avoid the situation of deviation in the feeding of the rivets 3; S3: After the riveting operation, the CNC machine tool is used again to machine the positioning holes 5 on the surface of the aluminum cap 2. Then, the dynamic balancing machine uses the positioning holes 5 to accurately position the brake disc and automatically measure the unbalance of the brake disc, and removes the excess mass by milling to achieve a balanced state. S4: The brake disc is clamped to the processing position of the laser cladding machine, so that the laser cladding machine melts the metal powder through a high-energy laser beam and combines it with the base material of the brake disc to realize the laser cladding operation of the transition layer and the wear-resistant layer on the two braking surfaces of the casting ring 1 in an alternating manner. S5: After the cladding treatment, the grinding machine is used to perform multiple grinding operations with different precisions on the two braking surfaces of the casting ring 1. After grinding, the flatness of the braking surface and the thickness dimension of the casting ring 1 are measured. At the same time, an ultrasonic flaw detector is used to detect whether there are bubbles and cracks on the surface and inside of the casting ring 1. After the brake disc is qualified, it is packaged and transported.

[0019] Please refer to Figure 1 and Figure 2 , the brake disc is composed of a casting ring 1, an aluminum cap 2 and a plurality of rivets 3. The casting ring 1 and the aluminum cap 2 are fixedly connected by a plurality of rivets 3. The plurality of rivets 3 are arranged in a circumference relative to the axis of the casting ring 1. The end face of the aluminum cap 2 is provided with positioning holes 5 and a plurality of mounting holes 4, which is convenient for the dynamic balancing machine to achieve accurate positioning when measuring the unbalance of the brake disc by using the positioning holes 5.

[0020] Please refer to Figure 5 and Figure 6 , the pressing force of the press is 9.5 - 11.5 KN. The brake disc is coaxially centered with the pressing position of the press. The diameter dimension of the riveting hole is 5.1 - 5.15 mm. The machining speed of the CNC machine tool for the riveting hole is 3000 - 3600 r / min. The clamping pressure of the CNC machine tool for machining the riveting hole of the brake disc is 2 - 4 MPa. The riveting pressure of the riveting machine is 30 - 42 KN. By controlling the parameters of the machining of the riveting hole and the riveting of the rivets, it is convenient to improve the riveting quality.

[0021] Please refer to Figure 4 , the laser cladding machine in S4 is composed of a laser, a powder feeding system, a dust removal system, a cooling system, a processing system and an electric control system. The linear speed of the laser cladding machine for cladding the transition layer on the braking surface is 3000 - 4000 mm / min, the coating spacing is 0.2 - 0.9 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.1 - 0.28 mm, the height of the laser lens of the laser is 12 - 36 mm, the protective gas flow rate is 10 - 50 L / min and the powder feeding gas flow rate is 2 - 6 L / min. The linear velocity of the laser cladding machine for cladding the wear-resistant layer on the brake surface is 2000 - 5200 mm / min, the coating spacing is 0.1 - 0.75 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.2 - 0.5 mm, the height of the laser lens of the laser is 20 - 30 mm, the protective gas flow rate is 10 - 50 L / min, and the powder feeding gas flow rate is 1 - 5 L / min. By sequentially treating the transition layer and the wear-resistant layer on the brake surface, the bonding degree between the substrate and the metal powder can be effectively enhanced, and the generation of bubbles and cracks can be avoided.

[0022] Among them, the clamping pressure of the grinding tool of the grinding machine for grinding the brake disc is 2 - 4 MPa, the rotational speed of the grinding machine for grinding the brake disc is 800 - 1200 r / min, the axial runout of the grinding tool of the grinding machine is not more than 0.002 mm, and the end face runout of the grinding tool of the grinding machine is not more than 0.002 mm. By controlling the grinding parameters of the brake disc, the quality of the brake surface of the brake disc can be effectively improved.

[0023] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

Claims

1. A riveting and cladding process for machining automotive brake discs, characterized in that, It includes the following steps: S1: Clamp the casting ring (1) and the aluminum cap (2) on the numerical control machine tool respectively and rough machine them to the finished state. Control the hub outer diameter, hub outer circle height and stop surface thickness dimensions of the casting ring (1). Then, use the ring loading position and aluminum cap loading position of the press-fitting machine to convey and load the casting ring (1) and the aluminum cap (2) respectively. Synchronously grasp the casting ring (1) and the aluminum cap (2) by the press-fitting machine and transfer them to the press-fitting position of the press-fitting machine. Keep the aluminum cap (2) directly above the casting ring (1) and coaxial with the casting ring (1). Then, press down the aluminum cap (2) by the punch head of the press-fitting machine to realize the press-fitting operation of the casting ring (1) and the aluminum cap (2) and form a brake disc. S2: Take the brake disc from the material taking position of the press-fitting machine and clamp it on the numerical control machine tool again. Use the drill bit of the numerical control machine tool to process multiple riveting holes on the surface of the brake disc. After drilling, place the brake disc at the riveting position of the riveting machine, and at the same time place multiple rivets (3) in the vibrating disc of the riveting machine. During the process of the vibrating disc automatically feeding the rivets (3), the riveting machine presses the rivets (3) into the inner side of the riveting holes, and internally and externally punches the rivets (3) to make their tails expand to form a head to play the role of fixing the casting ring (1) and the aluminum cap (2). Collect and identify the picture of the rivets (3) placed in the riveting holes through the built-in camera of the riveting machine to avoid the deviation of the rivet (3) feeding. S3: After the riveting operation, use the numerical control machine tool again to process the positioning holes (5) on the surface of the aluminum cap (2). Then, the dynamic balancing machine uses the positioning holes (5) to accurately position the brake disc and automatically measure the unbalance amount of the brake disc, and removes the excess mass by milling to achieve a balanced state. S4: Clamp the brake disc on the processing position of the laser cladding machine, so that the laser cladding machine melts the metal powder through a high-energy laser beam and combines it with the base material of the brake disc to realize the laser cladding operation of the transition layer and wear-resistant layer on the two braking surfaces of the casting ring (1) in an alternating manner. S5: After the cladding treatment, use a grinding machine to perform multiple grinding operations with different precisions on the two braking surfaces of the casting ring (1). After grinding, measure the flatness of the braking surface and the thickness dimension of the casting ring (1). At the same time, use an ultrasonic flaw detector to detect whether there are bubbles and cracks on the surface and inside of the casting ring (1). After the brake disc is qualified, it is packaged and transported.

2. The riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The brake disc is composed of a casting ring (1), an aluminum cap (2) and multiple rivets (3). The casting ring (1) and the aluminum cap (2) are fixedly connected by multiple rivets (3). The multiple rivets (3) are arranged in a circumferential pattern relative to the axis of the casting ring (1). The end face of the aluminum cap (2) is provided with positioning holes (5) and multiple mounting holes (4).

3. The riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The clamping pressure of the numerical control machine tool for rough machining the casting ring (1) in S1 is 8 - 12 MPa.

4. The riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The press-fitting pressure of the press-fitting machine in S2 is 7.5 - 13.5 KN, and the brake disc is coaxial with the center of the press-fitting position of the press-fitting machine.

5. A riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The diameter size of the riveting hole in S2 is 5.1 - 5.15 mm, the machining speed of the CNC machine tool for the riveting hole is 3000 - 3600 r / min, the clamping pressure of the CNC machine tool for machining the riveting hole of the brake disc is 2 - 4 MPa, and the riveting pressure of the riveting machine is 30 - 42 KN.

6. The riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The clamping pressure of the grinding tool of the grinding machine in S5 for grinding the brake disc is 2 - 4 MPa, and the grinding speed of the grinding machine for the brake disc is 800 - 1200 r / min.

7. A riveting and cladding process for machining an automotive brake disc according to claim 1, characterized in that: The laser cladding machine in S4 consists of a laser, a powder feeding system, a dust removal system, a cooling system, a processing system, and an electric control system.

8. A riveting and cladding process for machining an automotive brake disc according to claim 7, characterized in that: The linear velocity of the laser cladding machine for cladding the transition layer on the braking surface is 3000 - 4000 mm / min, the coating spacing is 0.2 - 0.9 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.1 - 0.28 mm, the height of the laser lens of the laser is 12 - 36 mm, the protective gas flow rate is 10 - 50 L / min, and the powder feeding gas flow rate is 2 - 6 L / min.

9. A riveting and cladding process for machining an automotive brake disc according to claim 8, characterized in that: The linear velocity of the laser cladding machine for cladding the wear-resistant layer on the braking surface is 2000 - 5200 mm / min, the coating spacing is 0.1 - 0.75 mm, the power is 12 KW - 30 KW, the powder feeding amount is 60 - 150 g, the coating thickness is 0.2 - 0.5 mm, the height of the laser lens of the laser is 20 - 30 mm, the protective gas flow rate is 10 - 50 L / min, and the powder feeding gas flow rate is 1 - 5 L / min.

10. A riveting and cladding process for machining an automotive brake disc according to claim 6, characterized in that: The axial runout of the grinding tool of the grinding machine is not more than 0.002 mm, and the end face runout of the grinding tool of the grinding machine is not more than 0.002 mm.

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