WO2012058883A1 - 高强度轻量化双金属制动鼓的制造方法及其双金属制动鼓 - Google Patents

高强度轻量化双金属制动鼓的制造方法及其双金属制动鼓 Download PDF

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WO2012058883A1
WO2012058883A1 PCT/CN2011/071163 CN2011071163W WO2012058883A1 WO 2012058883 A1 WO2012058883 A1 WO 2012058883A1 CN 2011071163 W CN2011071163 W CN 2011071163W WO 2012058883 A1 WO2012058883 A1 WO 2012058883A1
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Prior art keywords
brake drum
liner
finished product
previous step
semi
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PCT/CN2011/071163
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English (en)
French (fr)
Inventor
张建荣
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嘉兴四通车轮股份有限公司
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Publication of WO2012058883A1 publication Critical patent/WO2012058883A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force
    • B22D13/04—Centrifugal casting; Casting by using centrifugal force of shallow solid or hollow bodies, e.g. wheels or rings, in moulds rotating around their axis of symmetry
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/26—Making other particular articles wheels or the like
    • B21D53/34—Making other particular articles wheels or the like brake drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/10—Drums for externally- or internally-engaging brakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/132—Structure layered
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0008—Ferro
    • F16D2200/0013—Cast iron
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0008—Ferro
    • F16D2200/0021—Steel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting

Definitions

  • the invention relates to a method for manufacturing a high-strength lightweight bi-metal brake drum and a bi-metal brake drum.
  • the application is submitted to the Chinese Patent Office on November 2, 2010, and the application number is 201010535561.3, and the invention name is "high-strength lightweight bi-metal system".
  • the priority of the method of manufacturing a drum and its bimetallic brake drum is disclosed in the entire contents of the application.
  • the present invention relates to a method of manufacturing an automobile accessory, a method of manufacturing a high-strength lightweight bimetallic brake drum, and a metal brake drum. Background technique
  • the brake is mainly composed of a brake drum and a brake shoe.
  • the frictional resistance is used to convert the kinetic energy of the vehicle into heat energy, thereby decelerating the vehicle or Parking to ensure safe driving.
  • the temperature of the inner wall of the brake drum rises sharply, and the temperature difference between the inner and outer parts increases.
  • the high temperature mechanical properties also drop dramatically.
  • the larger the wall thickness of the brake drum the greater the temperature difference between the inside and the outside.
  • the temperature difference stress plus the high temperature mechanical properties of the material deteriorates, often causing the inner wall of the brake drum to develop from longitudinal microcracking to cracking, so that the final brake drum is cracked.
  • the present invention is directed to a method of manufacturing a high strength lightweight bimetallic brake drum in which a steel outer casing of a bimetallic brake drum and a cast iron inner liner can be firmly joined.
  • the manufacturing method of the high-strength lightweight bimetallic brake drum comprises the following steps: (a) Cutting: The steel plate is cut into discs according to design requirements;
  • heat treatment heat treatment of the product obtained in the previous step to eliminate internal stress and make the cast iron liner reach the hardness required for the brake drum;
  • the bimetallic brake drum produced in this way comprises a steel outer casing and a cast iron inner liner formed by a centrifugal casting method.
  • the cylindrical outer ring of the outer casing has a plurality of outwardly projecting convex rings, and the inner wall of the convex ring is evenly distributed with a plurality of inner IHJ portions in the circumferential direction.
  • the inner lining of the cast iron is in close contact with the inner surface of the cylindrical outer ring of the outer casing.
  • the method of the present invention forms the inner lining of the cast iron by the centrifugal casting method, and the cylindrical outer ring of the outer casing has a plurality of convex rings protruding outward, the inner wall of the convex ring is evenly distributed in the circumferential direction.
  • the resulting cast iron inner lining of the bimetallic brake drum is extremely strong in combination with the steel outer casing, and the braking torque can be directly transmitted between the cast iron lining and the steel outer casing without the need for screws or rivets.
  • the fasteners are assembled with the outer ring and the inner lining of the brake drum to prevent the sliding of the outer ring relative to the inner lining and the stress concentration of the inner lining at the screw or rivet joint, thereby reducing the cost and prolonging the service life of the brake drum;
  • the original design of the combination of the drum, the inner liner and the outer ring thin wall structure can reduce the crack caused by the excessive thickness of the brake drum wall and the excessive temperature difference, and improve the braking condition.
  • FIG. 1 is a schematic view of a process flow of the present invention
  • Figure 2 is a structural view of a bimetallic brake drum
  • Figure 3 is a cross-sectional view of A-A
  • the method of manufacturing such a high-strength lightweight bimetallic brake drum includes the following steps:
  • Casting Cast iron lining is cast in the semi-finished product obtained in the above step by centrifugal casting to fuse the inner liner and outer shell into a whole;
  • heat treatment heat treatment of the product obtained in the previous step to eliminate internal stress and make the cast iron liner reach the hardness required for the brake drum;
  • the structure of the bimetallic brake drum manufactured by the method for manufacturing such a high-strength lightweight bimetallic brake drum is as shown in Fig. 2, and includes a steel outer casing 1 and a cast iron inner liner 2 formed by a centrifugal casting method.
  • the cylindrical outer ring 11 of the outer casing has a plurality of outwardly projecting convex rings 12.
  • the inner wall of the convex ring is evenly distributed with a plurality of inner concave portions 14 in the circumferential direction, for example, 10 to 20 inner concave portions. .
  • the inner liner 2 of the cast iron is in close contact with the inner surface of the cylindrical outer ring 11 of the outer casing.
  • 13 is the mounting plane of the brake drum.
  • This bimetallic brake drum has the following features:
  • the outer casing of the brake drum is made of high-strength steel plate by spin-spinning, and then the inner lining is cast by centrifugal casting in a high-strength steel casing, and the inner lining and the outer casing are fused into a whole double Metal material can increase the strength of the brake drum by more than 10%.
  • the high-strength steel housing also acts as a safety shield to prevent cracking of the brake drum.
  • Light weight of brake drum The traditional surface of the brake drum with a working surface diameter of 410mm, the weight of the blank casting is 85kg, and the net weight of the finished product is 72.4 kg. The part of the casting made by this method weighs 40 kg and the net weight of the finished product is 56 kg. Each piece reduces the cast iron consumption by 45 kg, and each finished product loses 16.4 kg. 3.
  • Spin-formed equal-strength structure The outer shell of the bi-metal brake drum can be designed with equal strength according to the force analysis, and the brake drum casing with unequal cross-section designed according to the same strength can be made by the spin forming process.
  • the outer surface of the brake drum has a number of convex rings. Compared with the traditional integral cast brake drum, the surface area is increased, which is beneficial to the heat dissipation of the brake drum and can increase the service life of the brake drum.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Braking Arrangements (AREA)

Description

高强度轻量化双金属制动鼓的制造方法及其双金属制动鼓 本申请要求于 2010 年 11 月 02 日提交中国专利局、 申请号为 201010535561.3、 发明名称为"高强度轻量化双金属制动鼓的制造方法及其 双金属制动鼓 "的中国专利申请的优先权，其全部内容通过引用结合在本申 请中。 技术领域
本发明涉及一种汽车配件的制造方法， 一种高强度轻量化双金属制动 鼓的制造方法及其金属制动鼓。 背景技术
在载重汽车上目前广泛应用的是传统的整体铸造的鼓式制动器， 该制 动器主要由制动鼓和制动蹄组成， 利用摩擦阻力使汽车运动的动能转化为 热能， 从而使行驶的汽车减速或停车， 以保证行车安全。 当汽车重载、 高 速行驶时， 尤其在下长坡或陡坡时， 由于制动力大， 且连续多次制动， 使 得制动鼓内壁温度急剧升高， 同时其内外温差加大， 制动鼓材料的高温力 学性能也急剧下降。 制动鼓壁厚越大， 内外温差越大。 温差应力加上材料 的高温力学性能恶化， 常导致制动鼓内壁由纵向微裂发展为龟裂， 以致最 后制动鼓开裂。
为解决上述问题， 通常是在保持机械性能的前提下， 减少制动鼓壁厚 和内外温差， 国内有一种"组合式制动鼓"， 它是将一个内衬套入一个整体 式制动鼓外圈， 用螺钉或铆钉等紧固件钻孔后装配而成， 对减少因制动鼓 壁过厚、 温差过大引起的开裂能起到一定的作用。 但由于它是通过制动鼓 的外圈向鼓盘传递力矩， 外圈与内衬结合面传递的扭矩较大， 易引起外圈 相对内衬的滑动和内衬在螺钉或铆钉联接处的应力集中的开裂， 影响制动 效果和减少制动鼓使用寿命。 发明内容
本发明旨在提出一种高强度轻量化双金属制动鼓的制造方法， 所制得 的双金属制动鼓的钢制的外壳与铸铁的内衬能牢固地相结合。
这种高强度轻量化双金属制动鼓的制造方法包括以下步骤： ( a ) 下料： 将钢板按设计要求切割成圓盘状；
( b ) 冲孔： 在上步所得的圓盘状工件上冲压出中心孔和螺栓孔：
( c )旋压： 将上步所得半制品的外沿旋压成具有若干凸环的圓筒形的 外圈；
( d )滚旋： 在安装有旋压头和滚压头的旋压机上将上步所得的半制品 的凸环的内壁滚压出均匀分布的内 IHJ部；
( e ) 浇铸： 用离心浇铸的方法在上步所得半制品内浇铸出铸铁内衬；
( f )热处理： 将上步所得制品进行热处理， 以消除内应力并使铸铁内 衬达到制动鼓要求的硬度；
( g )精加工： 对制动鼓的安装平面、 中心孔、 外壳的口沿和内衬的内 表面进行切削加工。
用这种方法制成的双金属制动鼓包括钢制的外壳和用离心浇铸方法形 成的铸铁的内衬。 外壳的圓筒形外圈上有数圈向外凸出的凸环， 上述凸环 的内壁在圓周方向均匀分布着多个内 IHJ部。 铸铁的内衬与外壳的圓筒形外 圈的内表面相紧贴。
由于本发明的方法釆用离心浇铸的方法形成铸铁的内衬， 又由于外壳 的圓筒形的外圈上有数圈向外凸出的凸环， 凸环的内壁在圓周方向均匀分 布着多个内 部， 因而所制得的双金属制动鼓的铸铁的内衬与钢制的外壳 相结合得极为牢固， 铸铁内衬与钢制外壳之间可直接传动制动力矩， 不需 要用螺钉或铆钉等紧固件装配制动鼓外圈和内衬， 能防止外圈相对内衬的 滑动和内衬在螺钉或铆钉联接处的应力集中， 降低成本， 延长制动鼓使用 寿命； 同时由于不改变原设计的鼓盘、 内衬和外圈的薄壁结构组合， 所以 能减少因制动鼓壁过厚、 温差过大引起的开裂， 改善制动条件。 附图说明
图 1为本发明的工艺流程示意图；
图 2双金属制动鼓的结构图；
图 3为 A-A剖面图；
图 4为本发明所提供的制造方法的流程图。 具体实施方式
如图 1和图 4所示， 这种高强度轻量化双金属制动鼓的制造方法包括 以下步骤：
( a ) 下料： 将钢板按设计要求切割成圓盘状；
( b ) 冲孔： 在上步所得的圓盘状工件中部冲压出中心孔和螺栓孔；
( c )旋压： 用旋压机将上步所得半制品的外沿旋压成具有若干凸环的 圓筒形的外圈；
( d )滚旋： 在安装有旋压头和滚压头的旋压机上将上步所得的半制品 的凸环的内壁滚压出均匀分布的内 IHJ部；
( e ) 浇铸： 用离心浇铸的方法在上步所得半制品内浇铸出铸铁内衬， 使内衬和外壳熔合成整体；
( f )热处理： 将上步所得制品进行热处理， 以消除内应力并使铸铁内 衬达到制动鼓要求的硬度；
( g )精加工： 对制动鼓的安装平面、 中心孔、 外壳的口沿和内衬的内 表面进行切削加工， 最终制成合格的双金属制动鼓产品。
用这种高强度轻量化双金属制动鼓的制造方法制成的双金属制动鼓的 结构如图 2所示， 包括钢制的外壳 1和用离心浇铸方法形成的铸铁的内衬 2。 外壳的圓筒形外圈 11上有数圈向外凸出的凸环 12, 如图 3所示， 上述 凸环的内壁在圓周方向均匀分布着多个内凹部 14,例如 10 ~ 20个内凹部。 铸铁的内衬 2与外壳的圓筒形外圈 11的内表面相紧贴。 图中 13为制动鼓 的安装平面。
这种双金属制动鼓有如下特点：
1、 提高制动鼓强度： 制动鼓中的外壳用高强度钢板经旋压加工而成， 然后在高强度钢外壳内用离心浇铸的方法浇铸出内衬， 内衬和外壳熔合成 整体双金属材料， 可提高制动鼓强度 10%以上。 高强度钢外壳还相当于安 全防护罩可有效防止制动鼓开裂。
2、制动鼓轻量化： 工作表面直径为 410mm传统的整体铸造式制动鼓， 坯料铸件重 85kg,成品净重 72.4 kg,用本方法制造的产品铸件部分坯料重 40 kg, 成品净重 56 kg 。 每件降低铸铁消耗 45 kg, 每件成品减重 16.4 kg。 3、旋压成形的等强度结构： 双金属制动鼓的外壳可按受力分析进行等 强度设计， 再用旋压成形的工艺制作出按等强度设计的不等截面的制动鼓 外壳。
4、 制动鼓外表面具有若干凸环， 与传统的整体铸造式制动鼓相比， 表 面积增加了， 有利于制动鼓散热， 可增加制动鼓的使用寿命。

Claims

权 利 要 求
1、 一种高强度轻量化双金属制动鼓的制造方法， 包括以下步骤：
(a) 下料： 将钢板按设计要求切割成圓盘状；
(b) 冲孔： 在上步所得的圓盘状工件上冲压出中心孔和螺栓孔： 其特征是此方法还包括以下步骤：
( c )旋压： 将上步所得半制品的外沿旋压成具有若干凸环的圓筒形的 外圈；
(d)滚旋： 在安装有旋压头和滚压头的旋压机上将上步所得的半制品 的凸环的内壁滚压出均匀分布的内 IHJ部；
(e) 浇铸： 用离心浇铸的方法在上步所得半制品内浇铸出铸铁内衬；
(f)热处理： 将上步所得制品进行热处理， 以消除内应力并使铸铁内 衬达到制动鼓要求的硬度；
(g)精加工： 对制动鼓的安装平面、 中心孔、 外壳的口沿和内衬的内 表面进行切削加工。
2、一种用权利要求 1所述的方法制作的双金属制动鼓， 包括钢制的外 壳（ 1 )和用离心浇铸方法形成的铸铁的内衬（2), 其特征是所述的外壳的 圓筒形外圈（ 11 )上有数圈向外凸出的凸环（ 12), 上述凸环的内壁在圓周 方向均匀分布着多个内 IHJ部 （14), 所述的内衬（2)与外壳的圓筒形外圈 (11 ) 的内表面相紧贴。
PCT/CN2011/071163 2010-11-02 2011-02-22 高强度轻量化双金属制动鼓的制造方法及其双金属制动鼓 WO2012058883A1 (zh)

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CN 201010535561 CN102000950A (zh) 2010-11-02 2010-11-02 高强度轻量化双金属制动鼓的制造方法及其双金属制动鼓
CN201010535561.3 2010-11-02

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