High-molecular special rubber hot die forging press friction block and manufacturing method thereof

Abstract

The invention discloses a manufacturing method of a macromolecular special rubber hot die forging press friction block, which comprises the following steps: mixing the following components: 25-35% of rubber, 2-8% of tungsten carbide cobalt powder, 8-15% of red copper powder, 5-15% of molybdenum disulfide, 2-8% of carbon fiber, 2-6% of aramid fiber, 4-6% of sulfur, 6-15% of high-wear-resistant carbon black, 8-15% of high-temperature resin and 8-12% of glass fiber powder, synthesizing by a high-temperature and high-pressure kneading internal mixer, crushing, adding into a mold, pressing at high pressure and high temperature, and cooling to obtain the macromolecular special rubber hot die forging press friction block. Automatically cooling after mold stripping; through detection, the friction coefficient of the obtained finished product can reach more than 0.45, the surface pressure is more than 100mPA, the temperature resistance is 100-300 DEG C, the wear rate is 0.06-0.08, and the hardness is more than 95 degrees. According to the product, the friction coefficient of the friction block is increased, the abrasion loss is reduced, the surface pressure is increased, the surface processing is pollution-free, the service life is prolonged, and the maintenance cost of equipment is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of friction materials, in particular to a method for manufacturing a friction block of a high-molecular special rubber hot die forging press. Background Art

[0002] As is known to all, friction blocks are used to increase friction in the lifting device of friction presses. These blocks are mainly used on the clutches and brakes of domestic and imported hot die forging presses. Traditional friction blocks are usually made of phenolic resin and asbestos materials through high-temperature and high-pressure thermosetting and surface processing processes. They have a friction coefficient of 0.36-0.38, an impact strength of 3-4 kg, a temperature resistance of 100-160°C, a wear rate of 0.2-1.0, and a hardness of 115 degrees. Friction blocks made of this material and process have the following disadvantages: 1. When phenolic resin friction blocks are used in hot die presses and large-scale 10,000-ton line forging equipment, they wear quickly and have a short replacement cycle, which increases the company's maintenance costs. They are also prone to breakage and can damage the clutch and brake external tooth discs of the main equipment, causing economic losses to the company. 2. Because phenolic resin contains asbestos materials, as the friction blocks wear, they produce small dust containing asbestos, which can easily cause respiratory diseases and endanger the health of production personnel.

[0003] As a technician in this field, there is currently a need to design a press friction block and a manufacturing method thereof, the purpose of which is to improve the wear resistance and high temperature resistance of such products, avoid the release of harmful dust that harms the environment during use, and improve equipment stability. Summary of the Invention

[0004] In order to solve the above technical problems, the present invention discloses a high-polymer special rubber hot die forging press friction block and a manufacturing method thereof. The purpose is to provide a high-temperature resistant friction block with a long service life, good wear resistance, asbestos-free, safe and environmentally friendly. The friction block has high stability of the friction coefficient and low wear rate at high and normal temperatures, and has good comprehensive performance, and is particularly suitable for use on hot die forging presses.

[0005] A high molecular weight special rubber hot die forging press friction block comprises the following raw material components in percentage by weight: 25-35% rubber, 2-8% tungsten carbide cobalt powder, 8-15% copper powder, 5-15% molybdenum disulfide, 2-8% carbon fiber, 2-6% aramid fiber, 4-6% sulfur, 6-15% high wear-resistant carbon black, 8-15% high temperature resin, and 8-12% glass fiber powder.

[0006] The rubber is selected from fluororubber, polysulfide rubber, epichlorohydrin rubber, nitrile rubber, polyacrylate rubber, polyurethane rubber and high-temperature resistant silicone rubber. The high-temperature resin is selected from polyimide or polyetheretherketone.

[0007] A method for manufacturing a high polymer special rubber hot die forging press friction block, the production process of which is as follows: (1) Prepare all raw materials according to the component formula; (2) putting the prepared rubber into a mixing mill and mixing it for 5-20 minutes; adding the prepared tungsten carbide cobalt powder, copper powder, molybdenum disulfide, carbon fiber, aramid fiber, sulfur, high wear-resistant carbon black, high temperature resin, and glass fiber powder to the mixing mill in step (1), and rolling the mixture for 5-7 minutes. After the mixture is evenly mixed in the mixing mill to form a film structure, the film is discharged; (3) placing the mixture after hot pressing and curing in step (2) into a heat treatment device, heating it from room temperature to 195° C., and keeping it at a temperature of 195-200° C. for 20 minutes, maintaining a high pressure state during the insulation process, and controlling the pressure at 5-8 MPa; (4) Cool naturally to room temperature along with the heat treatment device; (5) Take out the cooling product and grind it to obtain a friction block.

[0008] Furthermore, in the step (3), the material obtained in the step (2) can be filled into a pre-made mold and pressurized to form a friction block semi-finished product, and then placed together with the mold into a high-pressure and high-heat equipment for heating, and vulcanized to obtain a finished product.

[0009] The beneficial effects of the present invention are as follows: 25-35% rubber, 2-8% tungsten carbide cobalt powder, 8-15% copper powder, 5-15% molybdenum disulfide, 2-8% carbon fiber, 2-6% aramid fiber, 4-6% sulfur, 6-15% high-wear-resistant carbon black, 8-15% high-temperature resin, and 8-12% glass fiber powder are mixed, synthesized and pulverized in a high-temperature and high-pressure kneading internal mixer, and then placed in a mold for high-pressure and high-temperature pressing, and automatically cooled after being ejected from the mold. The resulting finished product has been tested to have a friction coefficient of over 0.45, a surface pressure of over 100 mPA, a temperature resistance of 100° to 300°, a wear rate of 0.06-0.08, and a hardness of over 95 degrees. The above product increases the friction coefficient of the friction block, reduces wear, increases surface pressure, and has a pollution-free surface processing, which increases service life and reduces equipment maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 This is the original record sheet of the compressive strength test of the present invention; Figure 2 The product quality inspection report of the present invention; DETAILED DESCRIPTION In order to make the objects, technical solutions and advantages of the present application clearer, the present application will be further described in detail below through specific examples. It should be understood that the specific implementation described herein is only used to explain the present application and does not limit the present application.

[0011] Example 1 A high polymer special rubber hot die forging press friction block comprises the following raw material components by weight percentage: Rubber 30%, tungsten cobalt carbide powder 5%, red copper powder 10%, molybdenum disulfide 10%, carbon fiber 5%, aramid fiber 5%, sulfur 5%, high wear-resistant carbon black 10%, high temperature resin 10%, glass fiber powder 10%.

[0012] The rubber adopts fluorine rubber; The high temperature resin adopts polyether ether ketone, which belongs to aromatic crystalline thermoplastic polymer material, and its melting point is 334℃. It has high mechanical strength, high temperature resistance, impact resistance, flame resistance, acid and alkali resistance, hydrolysis resistance, wear resistance, fatigue resistance, radiation resistance and excellent electrical properties, and can replace metal, alloy, ceramic and other materials in most cases. Although it is a composite material, it does not produce toxic gas at high temperature.

[0013] The production process of the above-mentioned high polymer special rubber hot die forging press friction block is as follows: (1) Prepare each raw material according to the component formula; (2) Put the prepared rubber into the mixer and mix it for 10 minutes. Add the prepared tungsten cobalt carbide powder, red copper powder, molybdenum disulfide, carbon fiber, aramid fiber, sulfur, high wear-resistant carbon black, high temperature resin and glass fiber powder into the mixer in step (1) and mix them for 6 minutes. After mixing uniformly in the mixer to form a rubber sheet structure, the rubber sheet is discharged; (3) Fill the material obtained in step (2) into the previously prepared mold to form a friction block semi-finished product, and then put the mold and the friction block semi-finished product into a heat treatment device. Start heating from room temperature to 195℃, and keep the temperature at 195-200℃ for 20 minutes. Keep high pressure during the heat preservation process, and control the pressure at 7Mpa; (4) Then naturally cool the heat treatment device to room temperature; (5) Take out the cooled product and grind it to obtain a high polymer special rubber hot die forging press friction block.

[0014] The physical product obtained above is tested, and the friction coefficient can reach 0.45-0.5, the surface pressure is 105Mpa, the temperature resistance is 100°-300°, the wear rate is 0.06-0.08, and the hardness is 95-103 degrees.

[0015] Example 2: A high molecular weight special rubber hot die forging press friction block comprises the following raw material components in percentage by weight: 30% rubber, 6% tungsten carbide cobalt powder, 12% copper powder, 8% molybdenum disulfide, 4% carbon fiber, 2% aramid fiber, 4% sulfur, 14% high wear-resistant carbon black, 12% high temperature resin, and 8% glass fiber powder.

[0016] The rubber is made of high-temperature resistant silicone rubber, which generally has a temperature resistance range of -60°C to +300°C and has excellent high-temperature resistance, excellent electrical insulation performance, chemical resistance and aging resistance, as well as good tensile strength and wear resistance.

[0017] The high temperature resin is polyimide, which is a type of polymer containing an imide ring on the main chain. It has excellent high temperature resistance, can withstand temperatures above 400°C, and remains stable within a temperature range of -200 to 300°C.

[0018] Nano-tungsten cobalt carbide exhibits excellent hardness and wear resistance. During frictional use, the high temperatures and high pressures generated by friction often lead to wear and thermal stress on the surface of friction products. The high hardness and wear resistance of nano-tungsten cobalt carbide effectively reduce wear and extend the service life of friction products. Nano-tungsten cobalt carbide also exhibits excellent heat resistance. Its excellent thermal stability and high melting point allow it to withstand high temperatures, preventing deformation or failure of friction products. Furthermore, nano-tungsten cobalt carbide exhibits excellent mechanical properties. Its high strength and toughness enable friction products to withstand significant rolling pressure and impact.

[0019] The above components can be used to make clutch and brake friction blocks required by hot die forging presses. The production process is as follows: (1) Prepare all raw materials according to the component formula; (2) Put the prepared rubber into a mixer and mix it for 10 minutes; add the prepared tungsten carbide cobalt powder, copper powder, molybdenum disulfide, carbon fiber, aramid fiber, sulfur, high wear-resistant carbon black, high temperature resin, and glass fiber powder into the mixer in step (1), and mix and roll for 6 minutes. After the rubber is evenly mixed in the mixer to form a film structure, the film is discharged; (3) The material obtained in step (2) is filled into a pre-made mold and pressurized to form a friction block semi-finished product, which is then placed in a heat treatment device together with the mold, heated from room temperature to 195°C, and kept at a temperature of 195-200°C for 20 minutes. During the heat preservation process, the high pressure state is maintained and the pressure is controlled at 7 MPa; (4) Then naturally cool to room temperature along with the heat treatment device; (5) The cooling product is taken out and ground to obtain a clutch and brake friction block required for a hot forging press made of a polymer special rubber.

[0020] After testing, the friction coefficient of the finished product is 0.45-0.5, the surface pressure is 100MPa, the temperature resistance is 300 degrees, the wear rate is 0.06-0.08, and the hardness is 105-110 degrees.

[0021] The resulting products have been field-tested by dozens of users, including 4000T hot forging presses at Guilin Fuda Forging Co., Ltd., 8000T hot forging presses at Chongqing Dajiang Forging Co., Ltd., 12500T hot forging presses at China Second Heavy Industries, 2000T hot forging presses at China First Heavy Industries, and Dongfeng Motor Forging Co., Ltd., receiving unanimous praise. These products are expected to have a service life of three years or more, or 20,000 hours. This design improves production efficiency, reduces maintenance costs, and conserves resources.

Claims

1. A high polymer special rubber hot die forging press friction block, characterized by: Contains the following raw material components in percentage by weight: 25-35% rubber, 2-8% tungsten carbide cobalt powder, 8-15% copper powder, 5-15% molybdenum disulfide, 2-8% carbon fiber, 2-6% aramid fiber, 4-6% sulfur, 6-15% high wear-resistant carbon black, 8-15% high temperature resin, and 8-12% glass fiber powder.

2. The high polymer special rubber hot die forging press friction block according to claim 1, characterized in that: The rubber is one of fluororubber, polysulfide rubber, epichlorohydrin rubber, nitrile rubber, polyacrylate rubber, polyurethane rubber and high-temperature resistant silicone rubber.

3. The high polymer special rubber hot die forging press friction block according to claim 1, characterized in that: The high temperature resin is polyimide or polyetheretherketone.

4. The method for producing a high molecular special rubber hot die forging press friction block according to any one of claims 1 to 3, characterized in that: The production process is as follows: (1) Prepare all raw materials according to the component formula; (2) The prepared rubber is put into a mixing mill and mixed for 5-20 minutes; the prepared tungsten carbide cobalt powder, copper powder, molybdenum disulfide, carbon fiber, aramid fiber, sulfur, high wear-resistant carbon black, high temperature resin, and glass fiber powder are added to the mixing mill in step (1) and mixed and rolled for 5-7 minutes. After the rubber is evenly mixed in the mixing mill to form a rubber sheet structure, the sheet is discharged; (3) placing the mixture after hot pressing and curing in step (2) into a heat treatment device, heating it from room temperature to 195°C, and keeping it at a temperature of 195-200°C for 20 minutes, maintaining a high pressure state during the insulation process, and controlling the pressure at 5-8 MPa; (4) Cool naturally to room temperature along with the heat treatment device; (5) Take out the cooling product and grind it to obtain a friction block.

5. The method for producing a high polymer special rubber hot die forging press friction block according to claim 4, characterized in that: In the step (3), the material obtained in the step (2) can be filled into a pre-made mold and pressurized to form a friction block semi-finished product, and then placed together with the mold into a high-pressure and high-heat equipment for heating, and vulcanized to obtain a finished product.

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