Brake disc and manufacturing method

Abstract

A brake disc, comprising: a disc body (10) and a connecting disc (20), wherein the disc body (10) comprises two disc surfaces (110) spaced apart from each other, the connecting disc (20) is of an annular disc configuration and is connected to the sides of the two disc surfaces (110) facing each other by means of metallurgical bonding, and the two disc surfaces (110) are fixedly connected to each other via a plurality of stand columns (30); a flange (40) fixedly connected to an inner ring of the connecting disc (20); and connecting claws (50) cast-formed on an outer wall of a petal-shaped fusion plate (210) in the circumferential direction of the connecting disc (20), wherein the connecting claw (50) and the disc body (10) are integrally cast and formed. By means of arranging the connecting disc (20) to connect the two disc surfaces (110) from a symmetrical plane of the two disc surfaces (110) of the disc body (10), and the flange (40) being fixed to the connecting disc (20), the two disc surfaces (110) can independently deform outwards to avoid excessive internal stress on a single side; a plurality of air ducts are provided by connecting the two disc surfaces via the stand columns (30) for heat dissipation; and the cast-formed connecting claws (50) are connected to the petal-shaped fusion plate (210) to form an integrated structure, thereby improving the structural strength, and prolonging the service life of the brake disc. Further disclosed is a method for manufacturing a brake disc.

Description

Brake disc and manufacturing method

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on January 31, 2024, with application number 202410138119.9 and invention name “A brake disc and its manufacturing method”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present invention relates to the technical field of brake disc equipment, and in particular to a brake disc and a manufacturing method thereof. Background Art

[0003] The brake disc is a friction component on a disc brake that rotates with the wheels as the vehicle moves. When the vehicle brakes, the caliper clamps the brake disc to apply friction brakes, slowing or stopping the vehicle. Currently, commercial vehicle brake discs on the market are mainly made of gray cast iron. The connecting flange of the brake disc is directly connected to the single-sided friction surface of the disc body. During the braking process, a large amount of heat is generated at the disc body, causing the disc body to expand due to heat. During this process, the friction surface on the side of the disc body without a connecting flange can expand freely, while the friction surface on the side with a connecting flange is restricted by the connecting flange and cannot expand. During the cooling stage after braking, the friction surfaces on both sides of the disc body will shrink inward. Repeated internal stress will occur on the friction surface on the side connected to the connecting flange, making it easy to crack. In severe cases, this will affect the service life.

[0004] Therefore, how to improve the service life of the brake disc is an urgent problem that needs to be solved by those skilled in the art. Summary of the Invention

[0005] In view of this, an object of the present invention is to provide a brake disc with high structural strength and long service life.

[0006] Another object of the present invention is to provide a method for manufacturing the brake disc.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A brake disc comprising:

[0009] The disc body and the connecting disc, the disc body includes two disc surfaces spaced apart, the connecting disc is an annular disc configuration and is metallurgically connected to the two disc surfaces on one side facing each other, and the two disc surfaces are fixedly connected by a plurality of columns;

[0010] A flange fixedly connected to the inner ring of the connecting plate;

[0011] The connecting claw is cast on the outer wall of the petal-shaped fusion plate in the circumferential direction of the connecting disk and covers the fusion plate. The connecting claw is cast integrally with the disk body.

[0012] Preferably, in the above brake disc, a single connecting claw extends with a width b on a plane parallel to the disc surface. z , the depth of the connecting claw is L z , then b z conform to:

[0013] L z conform to:

[0014] in:

[0015] d is the diameter of the inner circle of the disk;

[0016] n is the number of the fusion plates;

[0017] D is the outer diameter of the disk.

[0018] Preferably, in the above brake disc, the height coefficient of the connecting disc is i h , the height coefficient And i h ≤1;

[0019] in:

[0020] A is the total width distance between the two outer edges of the disk;

[0021] H is the axial height of the connecting disk.

[0022] Preferably, in the above brake disc, the width of the fusion plate is b r The depth of the fusion plate inserted into the disc is L r , then b r conform to:

[0023] L r conform to:

[0024] Preferably, in the above brake disc, thicknesses of both sides of a single connecting claw in a width direction of a single fusion plate are equal.

[0025] Preferably, in the above brake disc, the pillar has a circular, elliptical, cashew-shaped, diamond-shaped or trapezoidal shape after being cut in a plane direction parallel to the disc surface.

[0026] Preferably, in the above brake disc, the pillars are sequentially sectioned along a plane parallel to the disc surface, and each section is equivalent to a circle with equal area, and the diameter of the circle with the smallest area is defined as d0, then d0 meets the following conditions:

[0027] Preferably, in the above brake disc, the columns are arranged 2-6 times around the center of the connecting disc.

[0028] Preferably, in the above brake disc, the material of the connecting disc and the flange is Q355 or ZG230-450, and the material of the disc body is HT200, HT250 or HT300.

[0029] A manufacturing method for producing a brake disc according to any of the above embodiments, the manufacturing method comprising at least the following steps:

[0030] Forging: heating a steel pipe to 800° C.-950° C. and forging the flange and the connecting plate;

[0031] Mold placement: embed the connecting disc into the brake disc core, assemble the brake disc core and place the brake disc core into a sand box, and lay steel shots in the sand box;

[0032] Casting the brake disc: pouring molten iron, after completion, the resin in the core coating sand is burned and scrapped, and the connecting disc and the disc body are fused into an integrated structure;

[0033] Welding: The flange and the connecting plate are welded by lap welding with an overlap length of 5mm-20mm, and reinforced welding is performed by submerged arc welding after press-fitting.

[0034] It can be seen from the above technical solution that the brake disc provided by the present invention includes a disc body, a connecting disc, a flange and a connecting claw, wherein the disc body includes two disc surfaces arranged at intervals for friction braking, and the connecting disc is arranged between the two disc surfaces. The connecting disc is an annular disc configuration and is connected to the sides facing the two disc surfaces by metallurgical bonding. At the same time, in order to ensure structural stability, the two disc surfaces are fixedly connected by a plurality of spaced columns. The columns can make each disc body evenly have connection points, and at the same time, an air duct is formed through the gaps between the columns to dissipate the heat generated in the disc body. It is discharged in time through the air duct; the flange is fixedly connected to the inner ring position of the connecting disc, that is, the flange is indirectly connected to the disc body, thereby avoiding its influence on the expansion and contraction state of the two disc surfaces, thereby improving the service life of the brake disc. At the same time, the circumferential direction of the connecting disc is a petal-shaped fusion plate, and the connecting claws are cast on the outer wall of the fusion plate and cover the fusion plate setting. The connecting claws are formed by integral casting with the disc body to stably connect the two disc surfaces, and through its extended structure based on the connecting disc, the disc surfaces are connected over a larger area, thereby enhancing the structural strength and service life of the brake disc. The brake disc provided by the present invention connects the two disc surfaces at the symmetrical plane position of the disc body through a connecting disc, and at the same time, the disc body is indirectly connected to the flange through the connecting disc, so that both disc surfaces can be deformed freely, and avoid the generation of large internal stress in the disc body and affecting the service life of the brake disc. At the same time, a plurality of connecting claws are cast on the outer wall in the circumferential direction of the connecting disc, so that the connecting claws can achieve a stable connection between the two disc surfaces through an integral casting manner, and then the integrity of the brake disc is improved by the column, so as to improve the structural stability of the brake disc while providing ventilation and heat dissipation through the gap between the columns, thereby reducing the impact of the high temperature environment on the service life of the brake disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0036] FIG1 is a schematic diagram of a cross-sectional structure of a brake disc provided by an embodiment of the present invention;

[0037] FIG2 is a schematic diagram of a top cross-sectional structure of a brake disc provided by an embodiment of the present invention;

[0038] FIG3 is a schematic diagram of the structure of the connecting claw in the covering state according to an embodiment of the present invention;

[0039] Among them, 10 is the disk body; 110 is the disk surface; 20 is the connecting disk; 210 is the fusion plate; 30 is the column; 40 is the flange; and 50 is the connecting claw. DETAILED DESCRIPTION

[0040] The core of the present invention is to disclose a brake disc with high structural strength and long service life.

[0041] Another object of the present invention is to disclose a method for manufacturing the brake disc.

[0042] To help those skilled in the art better understand the present invention, embodiments of the present invention are described below with reference to the accompanying drawings. The embodiments described below do not limit the invention as set forth in the claims. Furthermore, the entire contents of the configurations shown in the embodiments below are not necessarily required to serve as the solution to the invention as set forth in the claims.

[0043] As shown in Figures 1, 2 and 3, the brake disc provided by the embodiment of the present invention includes a disc body 10, a connecting disc 20, a flange 40 and a connecting claw 50, wherein the disc body 10 includes two disc surfaces 110 arranged at intervals for friction braking, and the connecting disc 20 is arranged between the two disc surfaces 110. The connecting disc 20 has an annular disc configuration and is connected to the two disc surfaces 110 on the side facing each other by metallurgical bonding. At the same time, in order to ensure structural stability, the two disc surfaces 110 are fixedly connected by a plurality of spaced columns 30. The columns 30 can ensure that each disc body 10 has a uniform connection point, and at the same time, an air duct is formed through the gaps between the columns 30, so that the heat generated in the disc body 10 can be discharged in time through the air duct.

[0044] The flange 40 is fixedly connected to the inner ring position of the connecting disk 20, that is, the flange 40 is indirectly connected to the disk body 10. Since the flange 40 is connected to the disk body 10 through the connecting disk 20, the connecting disk 20 is arranged in the middle position of the two disk surfaces 110 on the disk body 10, so that the expansion and contraction states of the two disk surfaces 110 are the same, and the setting structure of the flange 40 is irrelevant, thereby improving the service life of the brake disk. At the same time, the circumferential direction of the connecting disk 20 is a petal-shaped fusion plate 210, and the connecting claw 50 is cast on the outer wall of the fusion plate 210 and covers the fusion plate 210. The molding method of the connecting claw 50 is to cast it integrally with the disk body 10 to stably connect the two disk surfaces 110, and through its extended structure based on the connecting disk 20, the disk surface 110 is connected to a larger area, thereby enhancing the structural strength and service life of the brake disk.

[0045] The brake disc provided in an embodiment of the present invention connects the two disc surfaces 110 through the symmetrical plane position of the disc body 10 in the connecting disc 20, and at the same time, the disc body 10 is indirectly connected to the flange 40 through the connecting disc 20, so that both disc surfaces 110 can be deformed freely, and avoid the generation of large internal stress in the disc body 10 to affect the service life of the brake disc. At the same time, a plurality of connecting claws 50 are cast on the outer wall in the circumferential direction of the connecting disc 20, so that the connecting claws 50 can achieve a stable connection between the two disc surfaces 110 through an integral casting manner, and then the integrity of the brake disc is improved by the column 30, so as to provide ventilation and heat dissipation through the gap between the columns 30 while improving the structural stability of the brake disc, thereby reducing the impact of high temperature environment on the service life of the brake disc.

[0046] It should be noted that, compared with traditional brake discs, the brake disc provided in the embodiment of the present invention is used for heat dissipation ducts in two directions, that is, through a plurality of spaced columns 30, the heat generated in the disc body 10 can be dissipated outward along the outer circle of the disc surface 110, and can also be dissipated along the inner circle of the disc surface 110 to the internal flange 40 position.

[0047] Furthermore, in the brake disc provided in the embodiment of the present invention, the flange 40 of the brake disc is connected to the wheel hub and rotates with the wheel. During the braking process, the torque generated by the friction between the disc surface 110 and the brake pad will be borne entirely by the connecting claw 50 and the fusion plate 210. Therefore, in order to ensure the structural strength of the disc body 10 during the braking process, the connecting claw 50 and the fusion plate 210 need to have a certain width and thickness. Here, the width of a single connecting claw 50 extending in a plane parallel to the disc surface 110 is defined as b. z , which represents the connection area between the connecting claw 50 and the disk body 10, and the depth of a single connecting claw 50 is L z , then b z and L z conform to:

[0048] in:

[0049] d is the diameter of the inner circle of the disc body 10;

[0050] n is the number of fusion plates 210;

[0051] D is the outer diameter of the disc body 10.

[0052] In the above embodiment, b z In the corresponding range, it can meet the basic connection strength requirements and will not affect the heat dissipation due to excessive width. However, it should be noted that for L z The purpose of limiting the value range is that if L zIf the depth of the fusion plate 210 inserted into the disc body 10 is too shallow, the disc body 10 will be subjected to a large stress at the connecting claw 50 during the braking process, and the shallow connection depth will lead to insufficient strength of the connecting claw 50 and crack failure. On the other hand, if L z If the L is too large, the depth of the fusion plate 210 inserted into the disc body 10 will be too deep. For a brake disc with a certain specification, the inner diameter and outer diameter of the disc surface 110 are certain. z If the number or cross-sectional area of ​​the columns 30 is too large, it will occupy the space on the disc 110 where the columns 30 are set. If the number or cross-sectional area of ​​the columns 30 is not reduced, the heat dissipation performance of the air duct between the two discs 110 will be affected, that is, the air duct will become very narrow, and ventilation and heat dissipation will be poor. If the number or cross-sectional area of ​​the columns 30 is reduced, although the position of the connecting claws 50 is very strong, the columns 30 between the two disc bodies 10 will become the weakest position, affecting the strength of the brake disc. Under the action of strong friction, the columns 30 may break, posing a serious safety hazard. In addition, if the cross-sectional area of ​​the columns 30 is too small, it is not conducive to the implementation of the casting process, and it is easy to form defects such as looseness and shrinkage.

[0053] Furthermore, in a specific embodiment of the present invention, the height coefficient of the connection plate 20 is i h , the height coefficient And i h ≤1,

[0054] in:

[0055] A is the total width spacing between the two disks 110;

[0056] H is the axial height of the connecting disk 20;

[0057] It should be noted that if the height of the connecting plate 20 is too high, it is not convenient for pouring, and stacking box pouring cannot be performed, which affects production efficiency. h If the value is less than 1, the production efficiency can be improved by stacking boxes for casting.

[0058] In order to further optimize the above technical solution, in the brake disc provided in the embodiment of the present invention, the width b of the fusion plate 210 is r conform to:

[0059] That is, the width of the connecting claw 50 is 20 mm larger than the width of the corresponding fusion plate 210, and based on the present embodiment, it is preferred that the thickness of a single connecting claw 50 on both sides of its corresponding fusion plate 210 in the width direction is equal, that is, the thickness of the connecting claw 50 covered on one side of the fusion plate 210 is 10 mm, so that the covering effect of the connecting claw 50 is more uniform, and both sides of the fusion plate 210 have the same ventilation space to ensure balanced heat dissipation effect on both sides.

[0060] The depth L of the fusion plate 210 inserted into the disc 10 is r Then it meets the following conditions:

[0061] It is necessary to explain here that L r The corresponding interval is to meet the connection depth requirement, and when in the corresponding interval, the area of ​​the connecting claw 50 accounts for 10%-30% of the total area of ​​the disk body 10 to meet the connection strength requirement without wasting materials and providing sufficient air duct space for heat dissipation.

[0062] Furthermore, in the brake disc provided by the embodiment of the present invention, the configuration of the pillar 30 after being cut in a plane direction parallel to the disc surface 110 can be circular, elliptical, cashew-shaped, diamond-shaped or trapezoidal.

[0063] Based on the above embodiment, the pillar 30 is sequentially sectioned along a plane parallel to the disk surface 110, and each section is equivalent to a circle with equal area. The diameter of the circle with the smallest area is defined as d0, and d0 meets the following conditions:

[0064] Here, the equivalent diameter of the position with the smallest cross-sectional area on the column 30 is limited. If d0 is too small, the column 30 between the two disc bodies 10 will become the weakest position, affecting the strength of the brake disc. If d0 is too large, it will affect the gap between the columns 30, causing the air duct to become very narrow and the ventilation to be poor.

[0065] Furthermore, in the brake disc provided in an embodiment of the present invention, the column 30 is arranged 2-6 times around the center of the connecting disc 20. Specifically, when the single-side thickness of the disc body 10 in any radial direction is between 70mm and 100mm, the column 30 is arranged 2-4 times, and when the single-side thickness of the disc body 10 in any radial direction is greater than 100mm, the column 30 is arranged 5-6 times.

[0066] Furthermore, the brake disc provided in the embodiment of the present invention is a bimetallic composite brake disc. Specifically, the material of the connecting disc 20 and the flange 40 is Q355 or ZG230-450. Taking Q355 as an example, the yield strength of Q355 is ≥355MPa, the tensile strength is 450-630MPa, and the elongation is ≥21%. The flange 40 and the connecting disc 20 are made of Q355, which has high material strength and high yield strength, so that the flange 40 and the connecting disc 20 can withstand large external forces without failure. At the same time, Q355 has high elongation and will not produce defects such as cracks during forging or stamping. It is easy to produce and manufacture. At the same time, Q355 is easily available on the market and the price is reasonable. The material of the disc body 10 is HT200, HT250 or HT300, that is, gray cast iron. The above-mentioned different materials can make the brake disc have strong structural strength while meeting the braking requirements of the friction surface.

[0067] An embodiment of the present invention further provides a manufacturing method for manufacturing the brake disc provided in any of the above embodiments, and the manufacturing method comprises at least the following steps:

[0068] S01: Forging: Using a steel pipe, heat it to 800°C-950°C and forge it into a flange 40 and a connecting plate 20;

[0069] S02: Mold placement: embed the connecting disc 20 into the brake disc core, assemble the brake disc core and place the brake disc core into a sand box, and lay steel shots in the sand box;

[0070] S03: Casting the brake disc: pouring molten iron, after which the resin in the core coating sand is burned and scrapped, and the connecting disc 20 and the disc body 10 are fused into an integrated structure;

[0071] S04: Welding: The flange 40 and the connecting plate 20 are welded by lap welding, with an overlap length of 5 mm to 20 mm. After the press-fitting is completed, the welding is reinforced by submerged arc welding.

[0072] It should be noted that in step S02, steel shots with a thickness of at least 10 cm are also pressed on the upper portion of the brake disc core to prevent the size of the blank from increasing due to expansion of the box.

[0073] It should be further explained that in step S04, in order to improve the concentricity of the flange 40 and the disk body 10, the cylindrical diameter of the flange 40 and the connecting disk 20 are interference fit. Before welding, a press is required to press the flange 40 into the connecting disk 20 to ensure the connection effect.

[0074] The terms "first," "second," "left," and "right," etc., in the specification and claims of the present invention and the accompanying drawings are used to distinguish between different objects, not to describe a specific order. Furthermore, the terms "including," "having," and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus comprising a series of steps or elements is not limited to the listed steps or elements and may include steps or elements that are not listed.

[0075] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A brake disc, characterized in that: include: A disk body (10) and a connecting disk (20), wherein the disk body (10) includes two disk surfaces (110) spaced apart from each other, the connecting disk (20) is in the form of an annular disk and is connected to the two disk surfaces (110) on one side facing each other by metallurgical bonding, and the two disk surfaces (110) are fixedly connected by a plurality of columns (30); A flange (40) fixedly connected to the inner ring of the connecting plate (20); The connecting claw (50) is cast on the outer wall of the petal-shaped fusion plate (210) in the circumferential direction of the connecting disk (20) and covers the fusion plate (210). The connecting claw (50) and the disk body (10) are integrally cast.

2. The brake disc according to claim 1, wherein The width of a single connecting claw (50) extending on a plane parallel to the disk surface (110) is b. z The depth of the connecting claw (50) is L z , then b z conform to: L z conform to: in: d is the diameter of the inner circle of the disk (10); n is the number of the fusion plates (210); D is the outer diameter of the disk (10).

3. The brake disc according to claim 1, wherein The height coefficient of the connecting plate (20) is i h , the height coefficient And i h ≤1; in: A is the total width distance between the outer edges of the two disk surfaces (110); H is the axial height of the connecting disk (20).

4. The brake disc according to claim 2, wherein The width of the fusion plate (210) is b r The depth of the fusion plate (210) inserted into the disc (10) is L r , then b r conform to: L r conform to:

5. The brake disc according to claim 4, characterized in that The thickness of both sides of a single connection claw (50) in the width direction of a single fusion plate (210) is equal.

6. The brake disc according to claim 2, wherein: The configuration of the pillar (30) after being cut in a plane direction parallel to the disk surface (110) is circular, elliptical, cashew-shaped, diamond-shaped or trapezoidal.

7. The brake disc according to claim 6, characterized in that The pillar (30) is sequentially cut along a plane direction parallel to the disk surface (110), and each cut surface is equivalent to a circle with equal area, and the diameter of the circle with the smallest area is defined as d0, then d0 meets the following conditions:

8. The brake disc according to claim 6, wherein The upright posts (30) are arranged around the center of the connecting plate (20) in 2-6 circles.

9. The brake disc according to claim 1, wherein The material of the connecting disk (20) and the flange (40) is Q355 or ZG230-450, and the material of the disk body (10) is HT200, HT250 or HT300.

10. A production method, characterized in that: For producing the brake disc according to any one of claims 1 to 9, the manufacturing method comprises at least the following steps: Forging: using a steel pipe heated to 800° C.-950° C. and forging to form the flange (40) and the connecting plate (20); Mold placement: embedding the connecting disc (20) into the interior of the brake disc core, assembling the brake disc core and placing the brake disc core into a sand box, and laying steel shots in the sand box; Casting the brake disc: pouring molten iron, after which the resin in the core's coated sand is burned and discarded, and the connecting disc (20) and the disc body (10) are fused into an integrated structure; Welding: The flange (40) and the connecting plate (20) are welded by lap welding, with the lap length being 5mm-20mm, and reinforced welding is performed by submerged arc welding after the press-fitting is completed.

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