Manufacturing method and manufacturing device of hard alloy coating brake disc

Abstract

The invention discloses a manufacturing method and a manufacturing device of a hard alloy coating brake disc, and relates to the technical field of brake discs. The manufacturing device for the super-hard alloy coating brake disc based on the gray cast iron base material through high velocity oxy-fuel spraying comprises an A-face spraying completion conveying line and a B-face spraying completion conveying line, and the A-face spraying completion conveying line is located on the left side of the B-face spraying completion conveying line; the effective directions of the A face spraying completion conveying line and the B face spraying completion conveying line are parallel to each other, and an A face spraying area is arranged on the left side of the A face spraying completion conveying line. According to the manufacturing method of the hard alloy coating brake disc and the manufacturing device of the hard alloy coating brake disc, through improvement of technological parameters, on the premise that the manufacturing cost and the strength are guaranteed, the abrasion resistance of a product is greatly improved, and it can be well guaranteed that the brake disc does not need to be replaced all the year round under the non-special condition.

Description

Technical Field

[0001] The present invention relates to the technical field of brake discs, and in particular to a method and a device for manufacturing a hard alloy coated brake disc. Background Art

[0002] The brake disc is the braking device used for braking and emergency braking of a car. The braking methods of a car can be divided into disc brakes and drum brakes. Disc brakes have better heat dissipation than drum brakes, and are not prone to thermal decay under high-speed braking conditions, so their high-speed braking effect is good. Disc brakes are mainly composed of brake calipers and brake discs. The brake disc is a round plate and is the key to braking.

[0003] In the existing technology, as vehicle performance improves, the performance requirements for brake discs also increase accordingly. The requirements for the strength, plasticity, toughness and wear resistance of brake discs gradually increase. The parameters used in brake disc manufacturing largely determine the performance of the brake disc. Summary of the Invention

[0004] (1) Technical problems solved In view of the deficiencies in the prior art, the present invention provides a method for manufacturing a cemented carbide coated brake disc and a manufacturing device thereof, which solve the problems existing in the prior art.

[0005] (2) Technical solution To achieve the above objectives, the present invention is implemented through the following technical solutions: a manufacturing device for a supersonic flame sprayed superhard carbide coated brake disc based on a gray cast iron substrate, comprising an A-side spraying completion conveyor line and a B-side spraying completion conveyor line, wherein the A-side spraying completion conveyor line is located on the left side of the B-side spraying completion conveyor line, and the effective directions of the A-side spraying completion conveyor line and the B-side spraying completion conveyor line are parallel to each other, an A-side spraying area is provided on the left side of the A-side spraying completion conveyor line, an AB-side flipping mechanism is provided at the end of the A-side spraying completion conveyor line, a loading and exchange workbench is provided at the starting end of the A-side spraying completion conveyor line, a B-side spraying area is provided on the right side of the B-side spraying completion conveyor line, and supersonic flame spraying mechanisms are provided in both the A-side spraying area and the B-side spraying area. A method for manufacturing a super-hard carbide-coated brake disc using a supersonic flame spraying method based on a gray cast iron substrate comprises the above-mentioned manufacturing device for a super-hard carbide-coated brake disc using a supersonic flame spraying method based on a gray cast iron substrate, and the specific operations are as follows: Step S1: machining the gray cast iron blank casting to obtain a semi-finished brake disc; Step S2: induction heating the semi-finished brake disc at a temperature range of 200-350°C; Step S3: using a high-energy laser beam to melt-clad 430L stainless steel powder onto the braking surface of the brake disc, with a coating thickness of 70-200 μm, thereby obtaining a semi-finished brake disc with a transition layer; Step S4: Grinding the brake disc with the stainless steel cladding layer on a dedicated double-end surface grinder to obtain a semi-finished brake disc with a smooth braking surface (runout less than 0.02 mm, DTV less than 5 μm, and parallelism less than 0.02 mm); Step S5: sandblasting the brake surface of the ground brake disc using sand particles of 0.5-1 mm to obtain a semi-finished brake disc with a rough braking surface; Step S6: mixing pure tungsten carbide powder with other carbide powders in a ratio of 70%-90% to obtain premixed tungsten carbide powder; Step S7: using a supersonic flame spraying process, adjusting the flame speed to Mach 7-9, spraying the tungsten carbide premixed powder onto the 430L stainless steel surface layer, with a coating thickness of 100-350 μm, thereby obtaining a brake disc semi-finished product with a superhard cemented carbide coating; Step S8: Cooling the carbide coated brake disc to 30-50° C. using an air cooling device; Step S9: Grind the cooled carbide coated brake disc using a dedicated double-end grinding device to obtain a finished super-hard carbide coated brake disc with a coating bonding strength greater than 70 MPa, a porosity less than 0.8%, and a surface hardness of 1000 hv0.3-1300 hv0.3.

[0006] Preferably, in step S7, a supersonic flame spraying process is used to melt the tungsten carbide powder and spray it onto the surface of the brake disc.

[0007] Preferably, in step S6, spherical tungsten carbide powder is sprayed on a 430L stainless steel surface layer using a supersonic flame spraying process with other carbide powders (CrC, NiC) in proportion, thereby obtaining a brake disc semi-finished product with an ultra-hard cemented carbide coating; wherein the weight proportion of the tungsten carbide powder is 70%-90%.

[0008] Preferably, in step S7, the product is processed using a manufacturing device for supersonic flame spraying superhard carbide coated brake discs based on a gray cast iron substrate, the linear speed is set to 150-300 m / min, the powder feeding flow rate is adjusted to 60-150 g / min, the powder feeding gas flow rate is set to 2-5 L / min, the spray gun movement speed is adjusted to 50 m / min, the fuel flow rate is set to 0.8-2 L / min, and the spray gun height is adjusted to 400-450 mm.

[0009] (3) Beneficial effects The present invention provides a method and device for manufacturing a carbide-coated brake disc, which has the following beneficial effects: (1) The manufacturing method and manufacturing device of the carbide coated brake disc, by improving the process parameters, greatly enhances the wear resistance of the product while ensuring the manufacturing cost and strength, and can well ensure that the brake disc does not need to be replaced throughout its life unless under special circumstances.

[0010] (2) The manufacturing method and manufacturing device of the cemented carbide coated brake disc and the equipment required for improvement are all based on existing equipment and are a combination of existing equipment, thereby greatly reducing the cost of improvement and being suitable for large-scale improvement. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 A metallographic photograph of the product of the present invention; Figure 3 A metallographic photograph of a product in the prior art; Figure 4 This is a schematic diagram for comparing product parameters. DETAILED DESCRIPTION

[0012] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0013] See also Figure 1-4 The present invention provides a technical solution: a manufacturing device for a supersonic flame sprayed super-hard carbide coated brake disc based on a gray cast iron substrate, comprising an A-side spraying completion conveyor line and a B-side spraying completion conveyor line, wherein the A-side spraying completion conveyor line is located on the left side of the B-side spraying completion conveyor line, and the effective directions of the A-side spraying completion conveyor line and the B-side spraying completion conveyor line are parallel to each other, an A-side spraying area is provided on the left side of the A-side spraying completion conveyor line, an AB-side flipping mechanism is provided at the end of the A-side spraying completion conveyor line, a loading and exchanging workbench is provided at the starting end of the A-side spraying completion conveyor line, a B-side spraying area is provided on the right side of the B-side spraying completion conveyor line, and supersonic flame spraying mechanisms are provided in both the A-side spraying area and the B-side spraying area. A manufacturing method for a supersonic flame sprayed super-hard carbide coated brake disc based on a gray cast iron substrate, comprising the above-mentioned manufacturing device for a supersonic flame sprayed super-hard carbide coated brake disc based on a gray cast iron substrate, and the specific operations are as follows: Step S1: machining the gray cast iron blank casting to obtain a semi-finished brake disc; Step S2: induction heating the semi-finished brake disc at a temperature range of 200-350°C; Step S3: using a high-energy laser beam to melt-clad 430L stainless steel powder onto the braking surface of the brake disc, with a coating thickness of 70-200 μm, thereby obtaining a semi-finished brake disc with a transition layer; Step S4: Grinding the brake disc with the stainless steel cladding layer on a dedicated double-end surface grinder to obtain a semi-finished brake disc with a smooth braking surface (runout less than 0.02 mm, DTV less than 5 μm, and parallelism less than 0.02 mm); Step S5: sandblasting the brake surface of the ground brake disc using sand particles of 0.5-1 mm to obtain a semi-finished brake disc with a rough braking surface; Step S6: Pure tungsten carbide powder is mixed with other carbide powders in a ratio of 70% to 90% to obtain premixed tungsten carbide powder, and the spherical tungsten carbide powder is sprayed onto a 430L stainless steel surface layer using a supersonic flame spraying process, thereby obtaining a semi-finished brake disc with an ultra-hard cemented carbide coating; wherein the weight proportion of the tungsten carbide powder is 70% to 90%; Step S7: Using a supersonic flame spraying process, adjusting the flame speed to Mach 7-9, spraying the tungsten carbide premixed powder on the 430L stainless steel surface layer, with a coating thickness of 100-350 μm, thereby obtaining a brake disc semi-finished product with a superhard cemented carbide coating, using a supersonic flame spraying process to melt the tungsten carbide powder and spray it on the brake disc surface, and using a manufacturing device for supersonic flame spraying superhard cemented carbide coated brake disc based on a gray cast iron substrate to process the product, setting the line speed to 150-300 m / min, adjusting the powder feed flow rate to 60-150 g / min, setting the powder feed gas flow rate to 2-5 L / min, adjusting the spray gun movement speed to 50 m / min, setting the fuel flow rate to 0.8-2 L / min, and adjusting the spray gun height to 400-450 mm; Step S8: Cooling the carbide coated brake disc to 30-50° C. using an air cooling device; Step S9: Grind the cooled carbide coated brake disc using a dedicated double-end grinding device to obtain a finished super-hard carbide coated brake disc with a coating bonding strength greater than 70 MPa, a porosity less than 0.8%, and a surface hardness of 1000 hv0.3-1300 hv0.3.

[0014] In summary, the manufacturing method and manufacturing device of the carbide coated brake disc, through the improvement of process parameters, greatly enhance the wear resistance of the product while ensuring manufacturing cost and strength, and can well ensure that the brake disc does not need to be replaced throughout its life unless under special circumstances.

[0015] The manufacturing method and manufacturing device of the cemented carbide coated brake disc and the equipment required for improvement are all based on existing equipment and are a combination of existing equipment, thereby greatly reducing the cost of improvement and being suitable for large-scale improvement.

[0016] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0017] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing apparatus for a gray cast iron-based supersonic flame sprayed superhard carbide-coated brake disc, comprising a conveyor line for spraying a side A and a conveyor line for spraying a side B, wherein the conveyor line for spraying a side A is located to the left of the conveyor line for spraying a side B, and the effective directions of the conveyor lines for spraying a side A and B are parallel to each other, and characterized by: An A-side spraying area is provided on the left side of the A-side spraying completion conveying line, an AB-side flipping mechanism is provided at the end of the A-side spraying completion conveying line, a loading and exchange workbench is provided at the starting end of the A-side spraying completion conveying line, a B-side spraying area is provided on the right side of the B-side spraying completion conveying line, and supersonic flame spraying mechanisms are provided in both the A-side spraying area and the B-side spraying area.

2. A method for manufacturing a super-hard carbide coated brake disc by supersonic flame spraying based on a gray cast iron substrate, characterized in that: The manufacturing device of the supersonic flame sprayed superhard carbide coated brake disc based on the gray cast iron substrate according to claim 1 is specifically operated as follows: Step S1: machining the gray cast iron blank casting to obtain a semi-finished brake disc; Step S2: induction heating the semi-finished brake disc at a temperature range of 200-350°C; Step S3: using a high-energy laser beam to melt-clad 430L stainless steel powder onto the braking surface of the brake disc, with a coating thickness of 70-200 μm, thereby obtaining a semi-finished brake disc with a transition layer; Step S4: Grinding the brake disc with the stainless steel cladding layer on a dedicated double-end surface grinder to obtain a semi-finished brake disc with a smooth braking surface (runout less than 0.02 mm, DTV less than 5 μm, and parallelism less than 0.02 mm); Step S5: sandblasting the brake surface of the ground brake disc using sand particles of 0.5-1 mm to obtain a semi-finished brake disc with a rough brake surface; Step S6: mixing pure tungsten carbide powder with other carbide powders in a ratio of 70%-90% to obtain premixed tungsten carbide powder; Step S7: using a supersonic flame spraying process, adjusting the flame speed to Mach 7-9, spraying the tungsten carbide premixed powder onto the 430L stainless steel surface layer, with a coating thickness of 100-350 μm, thereby obtaining a brake disc semi-finished product with a superhard cemented carbide coating; Step S8: Cooling the carbide coated brake disc to 30-50° C. using an air cooling device; Step S9: Grind the cooled carbide coated brake disc using a dedicated double-end grinding device to obtain a finished super-hard carbide coated brake disc with a coating bonding strength greater than 70 MPa, a porosity less than 0.8%, and a surface hardness of 1000 hv0.3-1300 hv0.

3.

3. The method for manufacturing a super-hard cemented carbide coating brake disc based on a gray cast iron substrate by high velocity flame spraying according to claim 2, characterized in that: In step S7 , the tungsten carbide powder is melted and sprayed onto the surface of the brake disc using a supersonic flame spraying process.

4. The method for manufacturing a brake disc with a supersonic flame sprayed superhard carbide coating based on a gray cast iron substrate according to claim 2, characterized in that: In step S6, spherical tungsten carbide powder is sprayed onto a 430L stainless steel surface layer using a supersonic flame spraying process along with other carbide powders (CrC, NiC) in proportion, thereby obtaining a brake disc semi-finished product with an ultra-hard cemented carbide coating; wherein the weight proportion of the tungsten carbide powder is 70%-90%.

5. The method for manufacturing a super-hard cemented carbide coating brake disc based on a gray cast iron substrate by high velocity flame spraying according to claim 2, characterized in that: In step S7, the product is processed using a manufacturing device for supersonic flame spraying superhard carbide coated brake discs based on a gray cast iron substrate, the linear speed is set to 150-300 m / min, the powder feeding flow rate is adjusted to 60-150 g / min, the powder feeding gas flow rate is set to 2-5 L / min, the spray gun movement speed is adjusted to 50 m / min, the fuel flow rate is set to 0.8-2 L / min, and the spray gun height is adjusted to 400-450 mm.

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