阅读说明：本技术 防翘曲变形的轮装制动盘的生产方法 (Production method of wheel-mounted brake disc capable of preventing buckling deformation ) 是由 陈国贤 于 2019-08-29 设计创作，主要内容包括：本发明涉及一种防翘曲变形的轮装制动盘的生产方法,在轮装制动盘的铸造过程中,在制动盘散热面的散热筋顶面增加一整体的环状筋板,环状筋板与制动盘一次铸造成型,将散热筋顶面逐一联接起来,形成一个稳固的、上下面双环设置的环状框架结构,完成浇铸后的冷却凝固过程中,散热筋顶面的环状筋板先凝固,用于固定散热筋,使得铸件冷却时收缩率明显均匀,避免因铸件几何尺寸不对称产生翘曲变形；同时将制动盘的摩擦面的加工余量顶设计成锥面,增大了铸件变形的阻力,使铸件保持稳定收缩,冷却成型后通过机加工去除环状筋板,并将摩擦面的加工余量顶加工成平面,对铸件结构形状没有任何影响,大幅提升了产品动平衡检测通过率。(The invention relates to a production method of a wheel-mounted brake disc capable of preventing warping and deformation, wherein in the casting process of the wheel-mounted brake disc, an integral annular rib plate is added on the top surface of a heat dissipation rib of a heat dissipation surface of the brake disc, the annular rib plate and the brake disc are cast and formed at one time, the top surfaces of the heat dissipation ribs are connected one by one to form a stable annular frame structure with upper and lower double rings, and in the cooling and solidification process after casting, the annular rib plate on the top surface of the heat dissipation rib is solidified first and is used for fixing the heat dissipation rib, so that the shrinkage rate is obviously uniform when a casting is cooled, and warping and deformation caused by asymmetric geometric dimension of the casting is; meanwhile, the machining allowance top of the friction surface of the brake disc is designed into a conical surface, so that the deformation resistance of the casting is increased, the casting is kept to be stably contracted, the annular rib plate is removed through machining after cooling forming, the machining allowance top of the friction surface is machined into a plane, the structural shape of the casting is not affected, and the dynamic balance detection passing rate of the product is greatly improved.)

1. A production method of a wheel-mounted brake disc is characterized in that in the casting process, an annular rib plate (3) is added on the top surface (12) of a heat dissipation rib of a heat dissipation surface (1) of the brake disc, and the top surfaces of the heat dissipation ribs are connected one by one;

the annular rib plate (3) and the brake disc are cast and formed at one time to form a stable annular frame structure with double rings on the upper surface and the lower surface; designing the machining allowance top of the friction surface of the brake disc into a conical surface;

and (3) keeping the casting to shrink stably, removing the annular rib plate (3) after cooling is finished, and processing the machining allowance top of the friction surface of the brake disc into a plane.

2. A method for producing a brake disc for a wheel according to claim 1, further comprising designing a machining allowance top (21) of the friction surface (2) of the brake disc to be a tapered surface at the time of casting;

and after casting, machining the machining allowance top (21) of the friction surface (2) of the brake disc into a plane.

Technical Field

The invention relates to a production method of a wheel-mounted brake disc and the wheel-mounted brake disc using the same, in particular to a production method of a wheel-mounted brake disc preventing warping and deformation.

Background

At present, the basic brake of urban fast rail trains, railway passenger trains and high-speed motor train unit trains adopts a disc brake device, and the disc brake device has the function that when the vehicles brake, a brake pad vertically compresses a friction surface of a wheel-mounted or shaft-mounted brake disc to generate friction force, so that brake torque is generated, kinetic energy and potential energy generated when the vehicles move are converted into heat energy, and the purpose of decelerating or stopping the vehicles is achieved. Brake discs are therefore critical components for converting kinetic and potential energy of a train into thermal energy by friction.

The invention patent with publication number CN102069148A discloses a casting method of a brake disc for a high-speed locomotive, which comprises the following steps: the invention relates to solidification simulation, design of a sand core and core box manufacturing, core making, core assembly, smelting casting, box beating and sand shakeout and cleaning.

Disclosure of Invention

In order to overcome the problems in the prior art, the invention provides a production method of a wheel-mounted brake disc which is easy to realize and avoids buckling deformation, and the wheel-mounted brake disc manufactured by the method.

The technical scheme of the invention is as follows: a production method of a wheel-mounted brake disc is characterized in that in the casting process of the wheel-mounted brake disc, an integral annular rib plate (the thickness of the annular rib plate is 10mm, or 5mm, or 6mm, or 7mm, or 8mm, or 9 mm) is added on the top surface of a heat dissipation rib of a heat dissipation surface of the brake disc, the top surfaces of the heat dissipation ribs are connected one by one, the annular rib plate and the brake disc are cast and formed at one time to form a stable annular frame structure with upper and lower faces arranged in a double ring mode, the cooling uniformity of a casting is improved, the casting is prevented from warping and deforming in the cooling process, the machining allowance of the friction surface of the brake disc is designed to be a conical surface, the deformation resistance of the casting is increased, the casting keeps stable shrinkage, after cooling is completed, the annular rib plate on the top surface of the heat dissipation rib plate is removed.

The production method of the wheel-mounted brake disc comprises the following specific steps:

A. performing simulation analysis on the casting process and the casting mold of the brake disc through computer simulation software to determine the size of the annular rib plate on the top surface of the heat dissipation rib, and designing the machining allowance top of the friction surface of the brake disc into a conical surface to change the section of the conical surface from a rectangle into a triangle, so that the deformation resistance of the casting is increased, the casting keeps stable shrinkage, and the deformation is prevented;

B. establishing a casting process of the brake disc, and performing bottom pouring by adopting a bottom return introducing mode, wherein the molten metal enters a cavity from the bottom of the rectification filtering device;

C. b, manufacturing a casting mold according to the simulation analysis result of the step A, wherein the machining allowance of the annular rib plate and the friction surface of the casting mold accords with the simulation analysis result of the step A; wherein the thickness of the annular rib plate is 10mm, or 5mm, or 6mm, or 7mm, or 8mm, or 9mm

D. Manufacturing a mold core, closing the mold, smelting and casting, cooling and solidifying, and molding and shakeout;

E. performing rough machining and heat treatment on the casting, and removing machining allowance tops of the annular rib plate and the friction surface;

F. and (4) carrying out quenching and tempering and fine machining on the casting.

Before simulation analysis is carried out, the technical requirements which need to be met by a casting are analyzed, and the casting process and the casting mold of the brake disc are simulated according to the technical requirements. The simulation software selected by the invention comprises any simulation software suitable for the material processing engineering and manufacturing field, such as Magma, ProCast, Novacat, AnyCast, Flow3D, Hua cast CAE, Ansys, Abaqus, Marc and the like.

Opening simulation software, establishing a solid model, dividing grids on the model, setting parameters, and performing simulation analysis; debugging parameters according to the simulation result, and then performing simulation analysis again by using new parameters; and obtaining a casting process and a casting mold which can meet the technical requirements of castings through continuously debugging parameters.

According to the invention, on the premise of meeting the requirement that the normal sequential solidification of the casting is not influenced and the process thermal section is not increased, the annular rib plates on the top surfaces of the radiating ribs are solidified first in the cooling and solidifying process after casting, and a plurality of radiating ribs in different shapes are fixed, so that the defect that the warping deformation of the friction surfaces forms wavy surfaces is overcome, the parallelism of the two annular surfaces is completely in the process requirement range, the machined product can form uniform friction ring thickness, and the dynamic balance test is completely passed.

Furthermore, the thickness of the annular rib plate is not more than 10mm, the requirement of uniform cooling is met, and the waste of raw materials is reduced as much as possible.

A wheel-mounted brake disc, the brake disc being made by any of the above methods. The shrinkage rate of the prepared brake disc in the cooling process is obviously uniform, the conical machining allowance top is used for the friction surface, the deformation resistance of the casting is increased, the casting keeps stable shrinkage, the buckling deformation is prevented, the wavy friction surface does not appear any more, and the passing rate of the dynamic balance detection of the wheel pair is greatly improved.

The invention has the technical effects that: (1) compared with the prior art, the production method of the wheel-mounted brake disc has the advantages that the integral annular rib plate is added on the top surface of the heat dissipation rib of the heat dissipation surface of the brake disc in the manufacturing process, and the annular rib plate and the brake disc are cast and formed at one time, so that the shrinkage rate is obviously uniform when a casting is cooled, and the warping deformation caused by the asymmetric geometric dimension of the casting is avoided; (2) the machining allowance top of the friction surface of the brake disc is designed into a conical surface from a plane, so that the deformation resistance of the casting is increased, and the casting is kept to shrink stably; (3) and after cooling forming, the annular rib plate is removed through machining, the machining allowance of the friction surface of the brake disc is processed into a plane, the structural shape of the casting is not affected, only a small amount of machining time needs to be added in the machining process, and the dynamic balance detection passing rate of the product is greatly improved.

Drawings

The invention is described in further detail below with reference to the drawings of the specification:

FIG. 1 is a schematic view of a conventional wheel-mounted brake disc;

FIG. 2 is a schematic sectional view taken along line A-A of FIG. 1;

FIG. 3 is a process flow diagram of a method of producing a wheel mounted brake rotor according to the present invention;

FIG. 4 is a schematic diagram of a blank structure of the wheel-mounted brake disc of the present invention;

fig. 5 is a schematic sectional view taken along line a-a of fig. 4.

In the figure: the heat dissipation surface 1, the heat dissipation rib 11, the heat dissipation rib top surface 12, the friction surface 2, the machining allowance top 21 and the annular rib plate 3.

Detailed Description

Example 1

Taking a high-speed train steel casting wheel-mounted brake disc (with the outer diameter of 620mm and the inner diameter of 260 mm) with the speed of 250km/h as an example, the process flow of the casting method is shown in figure 3, and the casting method comprises the following steps in sequence:

A. the casting process and the casting mold of the brake disc are simulated and analyzed through computer simulation software, the thickness of the annular rib plate on the top surface of the radiating rib is determined to be 10mm (in other embodiments, the thickness can be 5mm, 6mm, 7mm, 8mm, 9mm and the like), meanwhile, the machining allowance top of the friction surface of the brake disc is designed to be a conical surface, the machining allowance is 10mm, the section of the conical surface is changed from a rectangle to a triangle, the deformation resistance of a casting is increased, the casting is kept to be stably contracted, and deformation is prevented.

B. And establishing a casting process of the brake disc, and performing bottom pouring by adopting a mode of introducing molten metal from bottom to bottom, wherein the molten metal enters the cavity from the bottom of the rectifying and filtering device.

C. And C, manufacturing a casting mould according to the simulation analysis result of the step A, wherein the machining allowance of the annular rib plate and the friction surface of the casting mould accords with the simulation analysis result of the step A.

D. Manufacturing a mold core, closing the mold, smelting and casting, cooling and solidifying, and molding and shakeout.

E. And performing rough machining and heat treatment on the brake disc, and removing machining allowance tops of the annular rib plate and the friction surface.

F. And (4) carrying out quenching and tempering and finish machining on the brake disc.

And (4) selecting ProCast simulation software to perform simulation analysis on the casting process and the casting mold. And (4) according to the optimal simulation result, establishing an actual casting process flow and an actual casting mold. In the casting process of the brake disc, all parameters such as the mode, the position, the flow rate and the like of the molten metal entering the cavity are in accordance with the simulation result; the position, shape, size, feeder head number and shape of the casting system and feeding system in the casting mould are all in accordance with the simulation result.

The thickness of the annular rib plate 3 of the heat dissipation rib top surface 12 of the heat dissipation surface 1 is set to be 10mm (in other embodiments, the thickness can be 5mm, 6mm, 7mm, 8mm, 9mm and the like), the machining allowance of the machining allowance top 21 of the friction surface 2 is set to be 10mm (in other embodiments, the thickness can be 5mm, 6mm, 7mm, 8mm, 9mm and the like), a mold core is manufactured, mold closing is completed, after the smelting and casting processes are carried out, the annular rib plate 3 is firstly solidified in the cooling and solidifying processes and is used for fixing the heat dissipation ribs 11 of various shapes, the situation that the friction surface 2 is warped and deformed to form a wavy surface due to deformation in the cooling process of the heat dissipation ribs 11 is avoided, the parallelism of the two annular surfaces is completely within the technological requirement range, the brake disc is machined after the mold is beaten and the sand is dropped, the annular.

The casting is subjected to nondestructive testing, the testing requirements of X-ray flaw detection I level, ultrasonic flaw detection II level and magnetic particle flaw detection I level are met, the brake discs qualified in detection are paired for wheel pair dynamic balance testing, and the testing qualification rate is 100%.

It should be understood that the above examples are only for clearly illustrating the present invention and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And such obvious variations or modifications which fall within the spirit of the invention are intended to be covered by the scope of the present invention.