TWI488765B - Wear-resistance brake piston of aluminum alloys and method thereof - Google Patents
Wear-resistance brake piston of aluminum alloys and method thereof Download PDFInfo
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Description
本發明係有關於一種耐磨耗鋁合金剎車活塞及其製造方法，尤其是指一種將鋁合金材質加熱成熔融狀態，令其可均勻地充分攪拌，使得鋁合金材質所析出之矽結晶粒不僅分佈較為均勻，且平均粒徑更小於80μm，並藉助第二相介在物的強化效應以達到提升剎車活塞之強度以及耐磨耗性，並改善剎車活塞於頻繁地往覆位移作動後易產生裂縫，甚而發生裂斷情形之耐磨耗鋁合金剎車活塞及其製造方法。 The invention relates to a wear-resistant aluminum alloy brake piston and a manufacturing method thereof, in particular to a method for heating an aluminum alloy material into a molten state so that it can be uniformly stirred uniformly, so that the crystal grains of the aluminum alloy material are not only precipitated. The distribution is relatively uniform, and the average particle size is less than 80 μm, and the strengthening effect of the brake piston is improved by the strengthening effect of the second phase medium, and the brake piston is easily cracked after frequent displacement. , wear-resistant aluminum alloy brake piston and its manufacturing method even in the case of cracking.
按，一般汽車之剎車系統係主要包括一剎車分泵，該剎車分泵通常具有兩支液壓起動之剎車活塞，該剎車活塞連接至對應之剎車塊上；當駕駛人施以一力量踩踏剎車踏板後，經由一真空動力輔助器利用真空壓力差的原理將力量放大，以推動剎車總泵；然後，剎車總泵再藉由液壓動力推動剎車分泵的剎車活塞，剎車活塞從剎車分泵本體分別以相反的方向向外伸張，使得剎車塊向外移動以摩擦剎車碟盤使其進行剎車的動作。 Press, the brake system of a general automobile mainly includes a brake sub-pump, which usually has two hydraulically-activated brake pistons, which are connected to the corresponding brake blocks; when the driver applies a force to step on the brake pedal Afterwards, the vacuum booster is used to amplify the force by the principle of vacuum pressure difference to push the brake master cylinder; then, the brake master cylinder pushes the brake piston of the brake cylinder by hydraulic power, and the brake piston is respectively separated from the brake cylinder body Extending outward in the opposite direction causes the brake block to move outward to rub the brake disc to brake.
傳統的鑄鐵活塞雖具有較佳之耐磨性以承受來自剎車塊的摩擦力量；然，因近年來國際油價居高不下，使得對於減輕整體車體重量以降低燃料消耗量之輕量化趨勢與要求日益增加，因此，傳統的鑄鐵活塞漸漸被鋁合金活塞所取代，而為使鋁合金活塞具有較高強度與較高之耐磨耗性，一般係藉由含有矽成分較多之鋁合金作為剎車活塞之用；惟，含有較多矽之鋁合金鑄造性較差，導致模鑄量產上較為困難。 Although the traditional cast iron piston has better wear resistance to withstand the frictional force from the brake block; however, due to the high international oil price in recent years, the light weight trend and demand for reducing the overall body weight to reduce fuel consumption are increasing. Therefore, the traditional cast iron piston is gradually replaced by the aluminum alloy piston, and in order to make the aluminum alloy piston have higher strength and higher wear resistance, generally the aluminum alloy containing the bismuth component is used as the brake piston. However, the aluminum alloy containing more bismuth has poor castability, which makes it difficult to produce the mold.
目前，一般傳統之鋁合金剎車活塞之製造方法係主要藉由鋁擠型成型加工方式，依所需之剎車活塞之斷面形狀，先製作出鋁擠型板，並經由固定模具、活動模具之擠壓加工，以成型一剎車活塞；接著，將成型之剎車活塞經由熱處理後，再置入到機具內做二次的機械加工處理，以符合實際使用時需要；然，利用鋁擠型方式所成型之剎車活塞其所析出之初晶矽結晶粒不僅平均粒徑過大(大約為300μm)，且分佈相當不均，導致剎車活塞於頻繁地往覆位移作動後極易產生裂縫，甚而發生裂斷之情形，進而造成剎車油漏洩之問題發生，對行駛中的車輛與駕駛安全造成重大的威脅。 At present, the manufacturing method of the conventional aluminum alloy brake piston is mainly by the aluminum extrusion molding process, according to the required cross-sectional shape of the brake piston, the aluminum extrusion plate is first made, and the fixed mold and the movable mold are adopted. Extrusion processing to form a brake piston; then, the formed brake piston is subjected to heat treatment, and then placed into the machine for secondary mechanical processing to meet the needs of actual use; The formed brake piston has not only the average grain size of the primary crystal grains (about 300 μm), but also the uneven distribution. As a result, the brake piston is prone to cracks after frequent displacement and even cracking. In this case, the problem of leakage of brake oil occurs, which poses a major threat to the running vehicle and driving safety.
今，發明人即是鑑於上述現有之鋁合金剎車活塞及其製造方法在實際實施上仍具有多處之缺失，於是乃一本孜孜不倦之精神，並藉由其豐富之專業知識及多年之實務經驗所輔佐，而加以改善，並據此研創出本發明。 Nowadays, the inventor is in view of the above-mentioned existing aluminum alloy brake piston and its manufacturing method, which still has many defects in practical implementation, so it is a tireless spirit, and with its rich professional knowledge and years of practical experience. The invention was assisted and improved, and the present invention was developed based on this.
本發明主要目的為提供一種耐磨耗鋁合金剎車活塞及其製造方法，尤其是指一種將鋁合金材質加熱成熔融狀態，令其可均勻地充分攪拌，使得鋁合金材質所析出之矽結晶粒不僅分佈較為均勻，且平均粒徑更小於80μm，以達到提升剎車活塞之強度以及耐磨耗性，並改善剎車活塞於頻繁地往覆 位移作動後易產生裂縫，甚而發生裂斷情形之耐磨耗鋁合金剎車活塞及其製造方法。 The main object of the present invention is to provide a wear-resistant aluminum alloy brake piston and a manufacturing method thereof, in particular to a method for heating an aluminum alloy material into a molten state so that it can be uniformly stirred uniformly, so that the aluminum alloy material is precipitated and crystallized. Not only the distribution is relatively uniform, but also the average particle size is less than 80μm, in order to improve the strength and wear resistance of the brake piston, and to improve the brake piston frequently A wear-resistant aluminum alloy brake piston that is prone to cracks after displacement and even a cracking condition and a manufacturing method thereof.
為了達到上述實施目的，本發明人提出一種耐磨耗鋁合金剎車活塞之製造方法，係至少包括下列步驟：首先，準備包括有10~20wt%的矽、1~5wt%的鐵、1~5wt%的錳、1~5wt%的銅，以及剩餘重量百分比的鋁之鋁合金材質；接著，將鋁合金材質加熱使其成為熔融狀態；再將熔融狀態之鋁合金材質均勻地充分攪拌；然後，將熔融狀態之鋁合金材質鑄入鑄模中，並使熔融狀態鋁合金材質凝固過程中受到壓縮應力，以成型剎車活塞；接著，將成型之剎車活塞依序經由T4與T6熱處理；最後，將熱處理後之剎車活塞置入機具內做二次機械加工處理，以符合實際使用之需要；其中，T4熱處理係於攝氏約510度持續3個小時後，再予以水冷處理，而T6熱處理係於攝氏約200度持續2個小時後，再予以空冷處理。 In order to achieve the above-mentioned implementation object, the inventors propose a method for manufacturing a wear-resistant aluminum alloy brake piston, which comprises at least the following steps: First, preparation includes 10-20 wt% of niobium, 1 to 5 wt% of iron, and 1 to 5 wt. % manganese, 1 to 5 wt% of copper, and aluminum alloy material of the remaining weight percentage; then, the aluminum alloy material is heated to be in a molten state; and the molten aluminum alloy material is uniformly stirred uniformly; The molten aluminum alloy material is cast into the mold, and the aluminum alloy material in the molten state is subjected to compressive stress during solidification to form the brake piston; then, the formed brake piston is sequentially heat-treated through T4 and T6; finally, the heat treatment is performed The brake piston is placed in the machine for secondary machining to meet the needs of actual use. Among them, the T4 heat treatment is about 510 degrees Celsius for 3 hours, then water-cooled, and the T6 heat treatment is about Celsius. After 200 hours for 2 hours, it is air-cooled.
此外，根據本發明之耐磨耗鋁合金剎車活塞其製造方法所製作成型之剎車活塞，其鋁合金材質所析出之矽結晶粒不僅分佈較為均勻，且平均粒徑更遠小於傳統之300μm，約介於30μm~80μm之間，並藉助第二相介在物(inclusion)的分散強化效應，使其具有較優異之強度以及耐磨耗性；藉此，即可改善剎車活塞於頻繁地往覆位移作動後易產生裂縫，甚而發生裂斷之情形，以減少剎車分泵中因剎車活塞的磨損而形成剎車油洩漏之情形發生。 In addition, according to the brake piston of the wear-resistant aluminum alloy brake piston of the present invention, the brake crystals formed by the aluminum alloy material are not only uniformly distributed, but the average particle diameter is further smaller than the conventional 300 μm. Between 30μm and 80μm, and with the dispersion strengthening effect of the second phase in the inclusion, it has better strength and wear resistance; thereby, the brake piston can be frequently displaced. Cracks may occur after actuation, and even cracks may occur to reduce the occurrence of brake oil leakage due to wear of the brake piston in the brake cylinder.
再者，本發明將成型之剎車活塞依序經由T4與T6熱處理，經實驗能使最大抗拉强度達到300MPa以上，而洛氏硬度可至70以上，伸長率則大於5%，且於攝氏60度之高溫下經測試作動18萬次後並無剎車油 洩漏之情形發生，大幅超越14萬次的合格車輛認證規範標準。 Furthermore, the brake pedal of the invention is heat-treated by T4 and T6 in sequence, and the maximum tensile strength can reach 300 MPa or more through experiments, and the Rockwell hardness can be above 70, the elongation is more than 5%, and 60 degrees Celsius. There is no brake oil after 180,000 times of test at high temperature. The situation of the leak occurred, significantly exceeding the 140,000 qualifying vehicle certification standards.
(S1)‧‧‧步驟一 (S1)‧‧‧Step one
(S2)‧‧‧步驟二 (S2)‧‧‧Step 2
(S3)‧‧‧步驟三 (S3) ‧ ‧ Step 3
(S4)‧‧‧步驟四 (S4)‧‧‧Step four
(S5)‧‧‧步驟五 (S5) ‧ ‧ step five
(S6)‧‧‧步驟六 (S6) ‧‧‧Step six
第一圖：本發明較佳實施例之製造方法步驟流程圖 First Figure: Flow chart of the manufacturing method of the preferred embodiment of the present invention
第二圖：以本發明較佳實施例製作之剎車活塞進行制振性試驗的顯微鏡照片圖 Second Figure: Micrograph of a vibration-damping test of a brake piston made in accordance with a preferred embodiment of the present invention
第三圖：以本發明較佳實施例製作之剎車活塞分別於煞車總泵、碟式煞車分泵以及鼓式煞車分泵進行粗糙度測試結果圖 The third figure: the results of the roughness test of the brake pistons produced by the preferred embodiment of the present invention in the brake master cylinder, the disc brake sub-pump and the drum brake sub-pump respectively
本發明之目的及其結構功能上的優點，將依據以下圖面所示之結構，配合具體實施例予以說明，俾使審查委員能對本發明有更深入且具體之瞭解。 The object of the present invention and its structural and functional advantages will be explained in conjunction with the specific embodiments according to the structure shown in the following drawings, so that the reviewing committee can have a more in-depth and specific understanding of the present invention.
首先，請參照第一圖所示，為本發明之耐磨耗鋁合金剎車活塞其製造方法之較佳實施例的步驟流程圖，係主要包括有如下步驟：步驟一(S1)：以100%的組成成份總重量百分比計算，準備包括有10~20wt%的矽、1~5wt%的鐵、1~5wt%的錳、1~5wt%的銅，以及剩餘重量百分比的鋁之鋁合金材質；步驟二(S2)：將鋁合金材質加熱使其成為熔融狀態；步驟三(S3)：將熔融狀態之鋁合金材質均勻地充分攪拌；步驟四(S4)：將充分攪拌後之熔融狀態鋁合金材質鑄入鑄模中，並使熔融狀態鋁合金材質凝固過程中受到壓縮應力，以成型剎車活塞；於本實施例中，係藉由模具於鑄模中進行活塞作動以壓縮熔融狀態鋁合金材質至接近剎車活塞成品之形狀； 步驟五(S5)：將成型之剎車活塞依序經由T4與T6熱處理；於本實施例中，T4熱處理係於攝氏約510度持續3個小時後，再予以水冷處理，而T6熱處理係於攝氏約200度持續2個小時後，再予以空冷處理；以及步驟六(S6)：將熱處理後之剎車活塞置入機具內做二次機械加工處理，以符合實際使用之需要；於本實施例中，二次機械加工處理係為車削加工。 First, referring to the first figure, the flow chart of the preferred embodiment of the method for manufacturing the wear-resistant aluminum alloy brake piston of the present invention mainly includes the following steps: Step 1 (S1): at 100% Calculating the total weight percentage of the composition, including 10-20% by weight of bismuth, 1~5 wt% of iron, 1~5 wt% of manganese, 1~5 wt% of copper, and aluminum alloy material of remaining weight percentage; Step 2 (S2): heating the aluminum alloy material to be in a molten state; Step 3 (S3): uniformly stirring the aluminum alloy material in a molten state uniformly; Step 4 (S4): melting the aluminum alloy after being sufficiently stirred The material is cast into the mold, and the aluminum alloy material in the molten state is subjected to compressive stress during the solidification process to form the brake piston. In the embodiment, the piston is actuated by the mold in the mold to compress the molten aluminum alloy material to be close to The shape of the finished brake piston; Step 5 (S5): The formed brake piston is heat-treated sequentially through T4 and T6; in this embodiment, the T4 heat treatment is performed at about 510 degrees Celsius for 3 hours, and then water-cooled, and the T6 heat treatment is in Celsius. After about 200 hours for 2 hours, the air cooling treatment is performed; and step 6 (S6): the heat-treated brake piston is placed in the machine for secondary machining to meet the needs of actual use; in this embodiment The secondary machining process is turning.
此外，上述之鋁合金材質可進一步添加有1wt%以下的鎂以增加其材質強度，亦或是添加1wt%以下的鎳以增加材質之抗腐蝕性，亦或是同時添加1wt%以下的鎂以及1wt%以下的鎳。 In addition, the aluminum alloy material may further add 1 wt% or less of magnesium to increase the material strength thereof, or add 1 wt% or less of nickel to increase the corrosion resistance of the material, or add 1 wt% or less of magnesium at the same time. 1 wt% or less of nickel.
再者，利用本發明之耐磨耗鋁合金剎車活塞其製造方法所製作成型之剎車活塞，因將鋁合金材質加熱使其成為熔融狀態，並均勻地充分攪拌，使得鋁合金材質所析出之矽結晶粒不僅分佈均勻，且平均粒徑係小於80μm，較佳係介於30μm~80μm之間；且同時藉助第二相介在物(inclusion)的分散強化效應，使得成型之剎車活塞具有較優異強度以及耐磨耗性，使其可改善於頻繁地往覆位移作動後易產生裂縫，甚而發生裂斷之情形，以減少剎車分泵中因剎車活塞的磨損而形成剎車油洩漏之情形發生；請參閱第二圖所示，為以利用本發明之耐磨耗鋁合金剎車活塞其製造方法所製作成型之剎車活塞進行制振性試驗的顯微鏡照片圖，由圖中可清楚看出，因鋁合金材質所析出之矽結晶粒分佈均勻，制振性試驗所產生之裂縫並非一直線穿裂，而係必須閃過矽結晶粒，也因此剎車活塞不易發生裂斷之情形。 Furthermore, the brake piston formed by the manufacturing method of the wear-resistant aluminum alloy brake piston of the present invention is heated by the aluminum alloy material to be in a molten state, and uniformly stirred uniformly, so that the aluminum alloy material is precipitated. The crystal grains are not only uniformly distributed, but the average particle diameter is less than 80 μm, preferably between 30 μm and 80 μm; and at the same time, by means of the dispersion strengthening effect of the second phase in the inclusion, the molded brake piston has superior strength. And wear resistance, so that it can be improved after frequent displacement and displacement, and even cracks occur, so as to reduce the brake fluid leakage caused by the brake piston wear in the brake cylinder; Referring to the second figure, a micrograph of a vibration-damping test for a brake piston formed by the manufacturing method of the wear-resistant aluminum alloy brake piston of the present invention can be clearly seen from the figure. The crystal particles are evenly distributed, and the cracks generated by the vibration test are not straight through, but the system must flash through the crystal grains. Breaking the piston case less likely to occur.
又，本發明之耐磨耗鋁合金剎車活塞經過步驟五(S5)之T4 與T6熱處理後，經實驗證實其洛氏硬度(HRB)係大於70；而最大抗拉强度(UTS)係大於300MPa；伸長率(EL)則大於5%；且於攝氏60度之高溫下，測試作動18萬次後並無剎車油洩漏之情形發生，大幅超越14萬次的合格車輛認證規範標準；請參閱第三圖所示，為以利用本發明之耐磨耗鋁合金剎車活塞分別於煞車總泵(Master cylinder)、碟式煞車分泵(Caliper)以及鼓式煞車分泵(Brake Cylinder)所進行之粗糙度測試結果，可清楚看出本發明之活塞作動前後的表面粗糙度並無顯著差異。 Moreover, the wear-resistant aluminum alloy brake piston of the present invention passes the T4 of step 5 (S5). After heat treatment with T6, it is confirmed by experiments that the Rockwell hardness (HRB) is greater than 70; the maximum tensile strength (UTS) is greater than 300 MPa; the elongation (EL) is greater than 5%; and at a high temperature of 60 degrees Celsius, After the test was activated 180,000 times, there was no brake oil leakage, which greatly exceeded the 140,000 times of qualified vehicle certification standards; please refer to the third figure, in order to utilize the wear-resistant aluminum alloy brake piston of the present invention. The roughness test results of the Master cylinder, the Caliper and the Brake Cylinder show that the surface roughness of the piston of the present invention before and after the actuation of the piston is not Significant difference.
由上述之實施說明可知，本發明與現有技術相較之下，本發明具有以下優點： It can be seen from the above description that the present invention has the following advantages compared with the prior art:
1.本發明將熔融狀態之鋁合金材質均勻地充分攪拌並鑄入鑄模成型，與傳統利用鋁擠型方式成型所析出約為300μm之初晶矽結晶粒徑相較下，本發明之鋁合金材質所析出之矽結晶粒不僅分佈較為均勻，且平均粒徑更遠小於傳統之300μm，約介於30μm~80μm之間，且同時藉助第二相介在物的分散強化效應，即可改善剎車活塞於頻繁地往覆位移作動後易產生裂縫，甚而發生裂斷之情形，使其具有較優異強度以及耐磨耗性，以減少剎車分泵中因剎車活塞的磨損而形成剎車油洩漏之情形發生。 1. In the present invention, the aluminum alloy material in a molten state is uniformly stirred and cast into a mold, and the aluminum alloy of the present invention is compared with a crystal grain size of a primary crystal of about 300 μm which is conventionally formed by an aluminum extrusion molding method. The crystal particles deposited by the material are not only uniformly distributed, but the average particle size is much smaller than the conventional 300 μm, which is between 30 μm and 80 μm, and the brake piston can be improved by the dispersion strengthening effect of the second phase. It is easy to produce cracks after frequent displacement and even cracking, so that it has better strength and wear resistance, so as to reduce the brake oil leakage caused by the brake piston wear in the brake cylinder. .
2.本發明將成型之剎車活塞依序經由T4與T6熱處理，經實驗能使最大抗拉强度達到300MPa以上，而洛氏硬度可至70以上，伸長率則大於5%，且於攝氏60度之高溫經測試作動18萬次後並無剎車油洩漏之情形發生，大幅超越14萬次的合格車輛認證規範標準。 2. The brake pedal of the invention is heat-treated by T4 and T6 in sequence, and the maximum tensile strength can reach 300 MPa or more through experiments, and the Rockwell hardness can be above 70, the elongation is more than 5%, and the temperature is 60 degrees Celsius. After the test of the high temperature of 180,000 times, there was no brake oil leakage, which greatly exceeded the 140,000 times of qualified vehicle certification standards.
綜上所述，本發明之耐磨耗鋁合金剎車活塞及其製造方法，的確能藉由上述所揭露之實施例，達到所預期之使用功效，且本發明亦未曾公開於 申請前，誠已完全符合專利法之規定與要求。爰依法提出發明專利之申請，懇請惠予審查，並賜准專利，則實感德便。 In summary, the wear-resistant aluminum alloy brake piston of the present invention and the method of manufacturing the same can achieve the intended use efficiency by the above-disclosed embodiments, and the present invention has not been disclosed in Before applying, Cheng has fully complied with the requirements and requirements of the Patent Law.爰Issuing an application for a patent for invention in accordance with the law, and asking for a review, and granting a patent, is truly sensible.
惟，上述所揭之圖示及說明，僅為本發明之較佳實施例，非為限定本發明之保護範圍；大凡熟悉該項技藝之人士，其所依本發明之特徵範疇，所作之其它等效變化或修飾，皆應視為不脫離本發明之設計範疇。 The illustrations and descriptions of the present invention are merely preferred embodiments of the present invention, and are not intended to limit the scope of the present invention; those skilled in the art, which are characterized by the scope of the present invention, Equivalent variations or modifications are considered to be within the scope of the design of the invention.
(S1)‧‧‧步驟一 (S1)‧‧‧Step one
(S2)‧‧‧步驟二 (S2)‧‧‧Step 2
(S3)‧‧‧步驟三 (S3) ‧ ‧ Step 3
(S4)‧‧‧步驟四 (S4)‧‧‧Step four
(S5)‧‧‧步驟五 (S5) ‧ ‧ step five
(S6)‧‧‧步驟六 (S6) ‧‧‧Step six
Claims (10)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW101106698A TWI488765B (en) | 2012-03-01 | 2012-03-01 | Wear-resistance brake piston of aluminum alloys and method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW101106698A TWI488765B (en) | 2012-03-01 | 2012-03-01 | Wear-resistance brake piston of aluminum alloys and method thereof |
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| Publication Number | Publication Date |
|---|---|
| TW201336718A TW201336718A (en) | 2013-09-16 |
| TWI488765B true TWI488765B (en) | 2015-06-21 |
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| TW101106698A TWI488765B (en) | 2012-03-01 | 2012-03-01 | Wear-resistance brake piston of aluminum alloys and method thereof |
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| CN110735070B (en) * | 2019-10-24 | 2021-07-30 | 珠海格力节能环保制冷技术研究中心有限公司 | Aluminum alloy material, wear-resistant part, preparation method and scroll compressor |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TW570986B (en) * | 2001-12-24 | 2004-01-11 | Metal Ind Res & Dev Ct | Method to obtain the brake disc and the compressor scroll by using aluminum based alloy materials |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TW570986B (en) * | 2001-12-24 | 2004-01-11 | Metal Ind Res & Dev Ct | Method to obtain the brake disc and the compressor scroll by using aluminum based alloy materials |
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| TW201336718A (en) | 2013-09-16 |
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