阅读说明：本技术 熔铸式制动盘及其制作方法 (Fusion casting type brake disc and manufacturing method thereof ) 是由 王春轩 李晓成 于 2020-12-11 设计创作，主要内容包括：本发明提供一种熔铸式制动盘及其制作方法,熔铸式制动盘包括盘体(10)和帽(20),所述盘体(10)呈具有中孔的圆盘状,所述盘体(10)的内周形成盘结合部(12),所述盘结合部(12)的表面具有凹部,所述帽(20)的外周形成帽结合部(21),所述帽(20)通过熔铸的方式形成于所述盘体(10)的内周侧,且所述帽结合部(21)部分地伸入所述凹部。根据本发明的熔铸式制动盘结构简单、可靠性高。(The invention provides a fusion-cast brake disc and a manufacturing method thereof, the fusion-cast brake disc comprises a disc body (10) and a cap (20), the disc body (10) is in a disc shape with a central hole, a disc combining part (12) is formed on the inner periphery of the disc body (10), a concave part is formed on the surface of the disc combining part (12), a cap combining part (21) is formed on the outer periphery of the cap (20), the cap (20) is formed on the inner periphery side of the disc body (10) in a fusion-cast mode, and the cap combining part (21) partially extends into the concave part. The fusion-cast brake disc disclosed by the invention is simple in structure and high in reliability.)

1. A fusion cast brake disc comprising a disc body (10) and a cap (20), said disc body (10) being disc-shaped with a central hole, characterized in that,

the inner periphery of the tray body (10) forms a tray bonding portion (12), the surface of the tray bonding portion (12) has a concave portion,

the outer periphery of the cap (20) forms a cap bonding portion (21), the cap (20) is formed on the inner peripheral side of the tray body (10) by means of fusion casting, and the cap bonding portion (21) partially protrudes into the recessed portion.

2. Fusion-cast brake disc according to claim 1, characterized in that the recess is a through hole (120) through the disc joint (12).

3. Fusion-cast brake disc according to claim 1, characterized in that the disc bond (12) is at least partially embedded within the cap bond (21).

4. Fusion-cast brake disc according to claim 1, wherein the disc joining portion (12) is tubular and extends in the axial direction (a) of the brake disc, and the cap joining portion (21) wraps the disc joining portion (12) at the inner and outer circumferential sides of the disc joining portion (12).

5. Fusion-cast brake disc according to claim 1, wherein the disc joining portion (12) is disc-shaped and extends in a radial direction (R) of the brake disc toward an inner circumferential side of the brake disc, and the cap joining portion (21) wraps the disc joining portion (12) on both sides in an axial direction (a) of the disc joining portion (12).

6. Fusion cast brake disc according to any of claims 1 to 5, characterized in that the disc body (10) is made of a material comprising cast iron.

7. Fused cast brake disc according to any of claims 1 to 5, wherein the cap (20) is made of a material comprising an aluminium alloy.

8. Fusion-cast brake disc according to any one of claims 1 to 5, characterized in that the interior of the peripherally located body (11) of the disc body (10) forms several heat dissipation grooves (14).

9. Method for manufacturing a fusion-cast brake disc, wherein the brake disc is a fusion-cast brake disc according to any one of claims 1 to 8, the method comprising:

providing a tray body (10);

the cap (20) connected to the tray (10) is formed by means of fusion casting.

10. Method for manufacturing a fusion-cast brake disc according to claim 9, wherein the providing of the disc (10) comprises: the disk bonding portion (12) is subjected to a sand blast treatment.

Technical Field

The invention relates to the field of brake discs, in particular to a fusion-cast brake disc and a manufacturing method thereof.

Background

For a brake disc for a motor vehicle, for example, it is common to include a disc body for engaging a friction plate at the time of braking and a cap provided on an inner peripheral side of the disc body for non-rotatably connecting with a transmission portion (e.g., a hub) of the vehicle.

Generally, the disc body and the cap are coupled together by riveting, the coupling strength of the two is not ideal, and the riveting coupling member increases the overall weight of the brake disc.

Disclosure of Invention

The present invention aims to overcome or at least alleviate the above-mentioned deficiencies of the prior art and to provide a light-weight, high-strength fusion-cast brake disc and a method for manufacturing the same.

According to a first aspect of the present invention, there is provided a fusion-cast brake disc comprising a disc body having a disc shape with a central hole, and a cap, wherein,

the inner periphery of the tray body forms a tray bonding portion, the surface of the tray bonding portion has a concave portion,

the outer periphery of the cap forms a cap coupling portion, the cap is formed on the inner peripheral side of the tray body by fusion casting, and the cap coupling portion partially protrudes into the recess.

In at least one embodiment, the recess is a through hole that penetrates the disc engaging portion.

In at least one embodiment, the disk bond is at least partially embedded within the cap bond.

In at least one embodiment, the disc bonding portion has a tubular shape and extends in an axial direction of the brake disc, and the cap bonding portion wraps the disc bonding portion on an inner circumferential side and an outer circumferential side of the disc bonding portion.

In at least one embodiment, the disc bonding portion is disc-shaped and extends toward an inner peripheral side of the brake disc in a radial direction of the brake disc, and the cap bonding portion wraps the disc bonding portion on both sides in an axial direction of the disc bonding portion.

In at least one embodiment, the material from which the disk is made comprises cast iron.

In at least one embodiment, the cap is made of a material comprising an aluminum alloy.

In at least one embodiment, the body of the tray body at the outer periphery has a plurality of heat dissipation grooves formed therein.

According to a second aspect of the present invention, there is provided a method of manufacturing a fusion-cast brake disc, wherein the brake disc is a fusion-cast brake disc according to the present invention, the method comprising:

providing a tray body;

the cap connected to the tray body is formed by fusion casting.

In at least one embodiment, the providing a tray comprises: the disk bonding portion is subjected to sand blasting.

The fusion-cast brake disc disclosed by the invention is simple in structure and high in reliability.

Drawings

Fig. 1 is a sectional view of a disc body according to a first embodiment of the present invention in an axial direction.

Fig. 2 is a sectional view of a brake disc according to a first embodiment of the present invention in an axial direction.

Fig. 3 is a perspective sectional view of a brake disc according to a first embodiment of the present invention.

Fig. 4 is a sectional view of a disk body according to a second embodiment of the present invention in the axial direction.

Fig. 5 is a sectional view of a brake disc according to a second embodiment of the present invention in an axial direction.

Fig. 6 is a perspective sectional view of a brake disc according to a second embodiment of the present invention.

Description of reference numerals:

10, a tray body; 11a main body; 11a end plate; 11b a blade; 12 a disc engaging portion; 120 through holes; 13 a yielding groove; 14 heat dissipation grooves; 20 a cap; 21 a cap joint; r is radial; a axial direction.

Detailed Description

Exemplary embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the detailed description is intended only to teach one skilled in the art how to practice the invention, and is not intended to be exhaustive or to limit the scope of the invention.

Referring to fig. 1, 2, 4 and 5, unless otherwise specified, a indicates the axial direction of the brake disc, which is coincident with the axial direction of the disc body 10 and the cap 20; r denotes a radial direction of the brake disk, which coincides with the radial direction of the disk body 10 and the cap 20.

Referring to fig. 1 to 6, a fusion-cast brake disc and a method for manufacturing the same according to the present invention will be described, taking a brake disc of a motor vehicle as an example.

(first embodiment)

First, referring to fig. 1 to 3, a brake disc according to a first embodiment of the present invention will be described. The brake disc includes a disc body 10 and a cap 20.

The tray body 10 has a disk shape with a central hole. The outer peripheral portion of the disc 10 is a main body 11, and the main body 11 is used to engage the friction plates during braking. The main body 11 includes two disk-shaped end plates 11a arranged opposite to each other in the axial direction a, a plurality of circumferentially spaced blades 11b connecting the two end plates 11a are provided between the two end plates 11a, and heat dissipation grooves 14 for dissipating heat are formed between the adjacent blades 11 b. During the rotation of the brake disk, air can flow through the heat dissipation grooves 14 to dissipate heat from the disk body 10.

The inner circumferential portion of the tray body 10 forms a tray coupling portion 12 for coupling with the cap 20. In the present embodiment, the disc joint portion 12 is formed in a short pipe shape and extends outward away from the main body 11 in the axial direction a.

A region of the disk coupling portion 12 near the distal end portion (an axial end portion distant from the disk body 10) in the axial direction a is provided with a plurality of through holes 120 penetrating the disk coupling portion 12 in the radial direction R, the through holes 120 being arranged in the circumferential direction of the disk coupling portion 12. The through-hole 120 serves to enable the cap coupling portion 21 of the cap 20 described below to be more firmly coupled with the disk coupling portion 12.

Alternatively, the through-holes 120 may be replaced by a plurality of pits or grooves formed in the disc bonding portion 12, for example, each pit or groove is formed as a pit or groove on the inner or outer circumferential wall of the disc bonding portion 12, which does not penetrate the disc bonding portion 12 in the radial direction R.

In the present application, the above-described pits, grooves, and through-holes are also referred to as recesses.

Preferably, an inner circumferential region of the main body 11 adjacent to an outer circumference of the disc coupling portion 12 is partially recessed to form a relief groove 13 surrounding the disc coupling portion 12. The cap coupling portion 21 described below can partially protrude into the escape groove 13.

Optionally, the material of construction of the tray 10 includes cast iron, and is preferably gray cast iron.

The cap 20 is intended to be connected non-rotatably to a transmission part of the vehicle, such as a wheel hub. The cap 20 projects in the axial direction a beyond the disk 10.

The outer peripheral wall of the cap 20 forms a cap coupling portion 21, and the cap coupling portion 21 is adapted to be coupled to the tray coupling portion 12.

Next, the connection structure of the cap 20 and the disc body 10 will be described with reference to the manufacturing method of the brake disc.

First, the tray 10 described above is prepared. Preferably, the disc bonding portions 12 of the disc body 10 are sand blasted to provide the disc bonding portions 12 with high cleanliness and appropriate surface roughness to ensure a cast bonding rate of the caps 20 to the disc body 10.

Next, the cap 20 is formed by fusion casting. The cap 20 is made of, for example, an aluminum alloy, and a molten liquid of the aluminum alloy is cast into the cavity (the tray 10 is also located in the cavity at this time), and the molten liquid is solidified to form the cap 20 connected to the tray 10. Due to the fluidity of the liquid, the cap coupling portion 21 will partially pass through the through-holes 120 at the tray coupling portion 12, increasing the coupling strength of the cap 20 to the tray body 10.

In the present embodiment, the thickness of the cap joint portion 21 is larger than the thickness of the disk joint portion 12 in the radial direction R, and the cap joint portion 21 wraps the disk joint portion 12 on the inner circumferential side, the outer circumferential side, and the axially outer side (the left side in fig. 2) of the disk joint portion 12.

(second embodiment)

Next, referring to fig. 4 to 6, a brake disc according to a second embodiment of the present invention will be described.

The second embodiment is a modification of the first embodiment, and the same or similar parts as those of the first embodiment are given the same reference numerals, and detailed description thereof is omitted.

In the first embodiment, the disk body 10 and the cap 20 are combined in the axial direction a; in the present embodiment, the tray body 10 and the cap 20 are combined in the radial direction R.

The disc bonding portion 12 has an annular disc shape and extends in the radial direction R toward the inner peripheral side of the disc body 10. The through hole 120 penetrates the disc coupling portion 12 in the axial direction a.

The cap coupling portion 21 forms a flange-like edge in the outer peripheral region of the cap 20.

In the present embodiment, the thickness of the cap bonding portion 21 is larger than the thickness of the disk bonding portion 12 in the axial direction a, and the cap bonding portion 21 wraps the disk bonding portion 12 on both sides in the axial direction and on the radially inner side of the disk bonding portion 12.

In the axial direction a, the disc engaging portion 12 is recessed in the surface of the main body 11, and the recessed portion forms a relief groove 13. Preferably, one axial end face (left end face in fig. 5) of the cap coupling portion 21 is in the same plane as a corresponding axial end face (left end face in fig. 5) of the main body 11.

The invention has at least one of the following advantages:

(i) the connection of the disc body 10 and the cap 20 of the brake disc according to the present invention is completed in a fusion casting process without using other connecting members, and the mosaic type connection manner has a high bonding strength.

(ii) The tray body 10 and the cap 20 are bonded by both the structural inlay (the cap bonding portion 21 is extended into the through-hole 120) and the chemical infiltration (infiltration in the fusion casting process), and the contact area of the connection portion is large and the heat conduction performance is good.

(iii) The disc bonding portion 12 subjected to, for example, sand blasting has high surface cleanliness and is not likely to have an oxide layer remaining, so that the cast bonding rate of the disc body 10 and the cap 20 is high.

(iv) The thermal expansion coefficients of the materials of the cast iron disc 10 and the aluminum alloy cap 20 are close, so that the brake disc is not easy to be cracked due to temperature change in the use process.

Of course, the present invention is not limited to the above-described embodiments, and those skilled in the art can make various modifications to the above-described embodiments of the present invention without departing from the scope of the present invention under the teaching of the present invention. For example:

(i) in addition to the sand blast treatment, other surface treatments may be applied to the disc bonding portion 12 to clean the surface thereof and increase the surface area of the bonding surface (for example, providing grooves on the surface of the disc bonding portion 12).

(ii) The tray 10 and cap 20 may be made of other materials having similar coefficients of thermal expansion.