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CN111207168A - Split wheel-mounted brake disc for urban fast rail train and high-speed motor train unit train - Google Patents

Split wheel-mounted brake disc for urban fast rail train and high-speed motor train unit train Download PDF

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Publication number
CN111207168A
CN111207168A CN201910033175.5A CN201910033175A CN111207168A CN 111207168 A CN111207168 A CN 111207168A CN 201910033175 A CN201910033175 A CN 201910033175A CN 111207168 A CN111207168 A CN 111207168A
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China
Prior art keywords
brake disc
wheel
mounted brake
heat dissipation
casting
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Pending
Application number
CN201910033175.5A
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Chinese (zh)
Inventor
陈国贤
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Jiangsu Dingtai Engineering Material Co ltd
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Jiangsu Dingtai Engineering Material Co ltd
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Publication of CN111207168A publication Critical patent/CN111207168A/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/12Discs; Drums for disc brakes
    • F16D65/128Discs; Drums for disc brakes characterised by means for cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/22Moulds for peculiarly-shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/18Making specific metal objects by operations not covered by a single other subclass or a group in this subclass brake shoes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/78Features relating to cooling
    • F16D65/84Features relating to cooling for disc brakes

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

Abstract

The invention relates to a split wheel-mounted brake disc for urban fast rail trains and high-speed motor train units, wherein an integral annular rib plate is added on the top surface of a radiating rib in the manufacturing process of the brake disc, the top surfaces of the radiating ribs are connected one by one, and the annular rib plate and the wheel-mounted brake disc are cast and formed at one time to form a stable annular frame structure with double rings arranged on the upper surface and the lower surface, so that the cooling uniformity of the wheel-mounted brake disc is improved, and the wheel-mounted brake disc is prevented from being warped and deformed in the cooling process; designing the machining allowance top of the friction surface into a conical surface, increasing the deformation resistance to keep the friction surface stably contracted, removing the annular rib plate on the top surface of the heat dissipation rib after cooling is finished, and machining the machining allowance top of the friction surface into a plane to obtain the integral wheel-mounted brake disc; after the integral wheel-mounted brake disc is integrally inspected, the integral wheel-mounted brake disc is divided into two parts along the preset cutting line, so that the completely symmetrical split wheel-mounted brake disc is obtained, the dynamic balance detection performance is met, and meanwhile, the operation is easy and the replacement is convenient in the subsequent installation process.

Description

Split wheel-mounted brake disc for urban fast rail train and high-speed motor train unit train
Technical Field
The invention relates to a split wheel-mounted brake disc and a manufacturing method thereof, in particular to a split wheel-mounted brake disc for urban fast rail trains and high-speed motor train sets.
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.
Chinese patent CN200820124337.3, wheel dress brake disc device have disclosed a wheel dress brake disc that heat exchange performance is good, including locating the brake disc ring of wheel pair both sides, one side of brake disc ring is the friction surface, and the opposite side is equipped with a plurality of heat dissipation muscle 3 for the cooling surface, a plurality of heat dissipation muscle 3 are the strip that the width equals and are radial scattering form evenly distributed, form radial air current passageway between heat dissipation muscle 3. The heat dissipation surface of the brake disc ring is further provided with a casting boss 4, a bolt boss 5 and a centering positioning table 6, and the heat dissipation ribs 3, the casting boss 4, the bolt boss 5 and the centering positioning table 6 are respectively distributed on the heat dissipation surface of the whole brake disc ring in a scattering and symmetrical mode. The wheel-mounted brake disc is installed in the installation process, the brake disc installed on the outer side of the vehicle wheel pair is an integral brake disc, and the brake disc installed on the inner side of the vehicle wheel pair and needing to penetrate through an axle is often required to be installed and maintained due to the fact that the vehicle wheel pair is inconvenient to detach.
The invention discloses an integral wheel-mounted brake disc which can prevent the integral wheel-mounted brake disc from warping and deforming in the cooling process, and is not suitable for quick installation and inconvenient disassembly of the inner side of a vehicle wheel pair, wherein the integral wheel-mounted brake disc is disclosed by the invention patent with the Chinese patent application number of 201510447645.4 and the name of the wheel-mounted brake disc and the wheel-mounted brake disc manufactured by applying the method.
Disclosure of Invention
In order to overcome the problems in the prior art, the invention provides the split wheel-mounted brake disc which is easy to mount and avoids buckling deformation.
The technical scheme of the invention is as follows: a split type wheel-mounted brake disc comprises a prefabricated annular integral wheel-mounted brake disc, wherein one side of the integral wheel-mounted brake disc is a friction surface, the other side of the integral wheel-mounted brake disc is a radiating surface, the radiating surface is provided with a plurality of radiating ribs, the radiating ribs are in a strip shape with equal width and are uniformly distributed in a scattering shape along the radial direction, and radial airflow channels are formed among the radiating ribs; the inner side of the integral wheel-mounted brake disc is also provided with a casting boss, a bolt boss and a centering positioning table, and the heat dissipation ribs, the casting boss, the bolt boss and the centering positioning table are respectively distributed on the heat dissipation surface of the whole brake disc ring in a scattering symmetry manner; the scattering symmetry angle of the radiating ribs is 7.5 degrees, the scattering symmetry angle of the bolt boss is 30 degrees, the scattering symmetry angle of the centering positioning table is 60 degrees, and the scattering symmetry angle of the casting boss is 180 degrees; one heat dissipation rib is superposed with one bolt boss, one heat dissipation rib is superposed with one centering positioning table, and four heat dissipation ribs are superposed with one casting boss; the cast boss is a preset cutting line along the radial center line of the integral wheel-mounted brake disc, and the integral wheel-mounted brake disc is divided into two parts along the preset cutting line, so that the completely symmetrical split wheel-mounted brake disc is obtained.
According to the manufacturing method of the split wheel-mounted brake disc, in the casting process, the whole annular rib plates (the thickness of the annular rib plates is 10mm, or 5mm, or 6mm, or 7mm, or 8mm, or 9 mm) are added on the top surfaces of the heat dissipation ribs of the wheel-mounted brake disc, the top surfaces of the heat dissipation ribs are connected one by one, the annular rib plates and the wheel-mounted brake disc are cast and formed at one time, a stable annular frame structure with double rings on the upper surface and the lower surface is formed, the cooling uniformity of the wheel-mounted brake disc is improved, the wheel-mounted brake disc is prevented from warping and deforming in the cooling process, the machining allowance of the friction surfaces of the wheel-mounted brake disc is designed into a conical surface, the deformation resistance of a casting is increased, the casting keeps stable shrinkage, after cooling is completed, the annular rib plates are removed, and the machining allowance of the friction surfaces; and after the integral wheel-mounted brake disc is integrally inspected, dividing the integral wheel-mounted brake disc into two parts along a preset cutting line to obtain the completely symmetrical split wheel-mounted brake disc.
A manufacturing method of a split wheel-mounted brake disc comprises the following specific steps:
A. simulation analysis is carried out on the design structure process and the casting process of the wheel-mounted brake disc through computer simulation software, the reasonability of the shape of the design structure is determined, the size of an annular rib plate on the top surface of a radiating rib is determined, meanwhile, the machining allowance top of the friction surface of the wheel-mounted brake disc is designed into a conical surface, the section of the conical surface is changed from a rectangle into a triangle, the deformation resistance of a wheel-mounted brake disc casting is increased, the wheel-mounted brake disc casting is kept stably contracted, and deformation is prevented;
B. the casting process of the wheel-mounted brake disc is manufactured, bottom pouring is carried out in a mode of introducing molten metal from bottom to bottom, and the molten metal enters a cavity from the bottom of the ceramic 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 9 mm;
D. manufacturing a mold core, closing the mold, smelting and casting, cooling and solidifying, and molding and shakeout;
E. roughly processing and thermally treating the wheel-mounted brake disc, and removing the processing allowance top of the annular rib plate and the friction surface;
F. carrying out quenching and tempering and finish machining on the wheel-mounted brake disc to obtain an integral wheel-mounted brake disc;
G. and (3) inspecting the obtained integral wheel-mounted brake disc, and dividing the obtained qualified product into two parts along a preset cutting line to obtain the split wheel-mounted brake disc.
Before simulation analysis is carried out, the technical requirements which need to be met by the product are analyzed, and the design structure process and the casting process of the wheel-mounted 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 design structure process and a casting process which can meet the technical requirements of the wheel-mounted brake disc through continuous parameter debugging.
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 symmetrically arranged radiating ribs 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.
Further, in the step G, the inspection comprises ultrasonic inspection, surface magnetic particle inspection and dynamic balance inspection, so that the product quality is ensured.
Furthermore, the material that this brake disc of casting chose to use is cast iron, and wear resistance is better, and life is longer.
The invention has the technical effects that: (1) compared with the prior art, in the manufacturing process, the integral annular rib plate is added on the top surface of the radiating rib of the radiating surface of the wheel-mounted brake disc, and the annular rib plate and the wheel-mounted 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) designing the machining allowance top of the friction surface of the wheel-mounted brake disc into a conical surface from a plane, increasing the deformation resistance of the casting and keeping the casting stably contracted; (3) after cooling forming, removing the annular rib plate through machining, and processing the machining allowance of the friction surface of the wheel-mounted brake disc into a plane to obtain the integral wheel-mounted brake disc, wherein the integral wheel-mounted brake disc has no influence on the structural shape of a casting, and only a small amount of processing time needs to be added in the processing process, so that the dynamic balance detection passing rate of a product is greatly improved; (4) and carrying out ultrasonic flaw detection, surface magnetic particle flaw detection and dynamic balance detection on the obtained integral wheel-mounted brake disc, dividing the obtained qualified product into two parts along a preset cutting line to obtain a split wheel-mounted brake disc, and easily operating and facilitating replacement in the subsequent installation process.
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 one-piece wheel-mounted brake disc;
FIG. 2 is a process flow chart of a method for manufacturing a split wheel-mounted brake disc according to the present invention;
FIG. 3 is a schematic diagram of a blank structure of an integral wheel-mounted brake disc;
FIG. 4 is a schematic sectional view taken along line A-A of FIG. 3;
fig. 5 is a structural schematic diagram of the split wheel-mounted brake disc of the invention.
In the figure: the friction surface 1, the machining allowance top 11, the integral wheel-mounted brake disc 2, the heat dissipation ribs 3, the annular rib plate 31, the casting boss 4, the bolt boss 5, the centering positioning table 6, the annular rib plate 7 and the preset cutting line 8.
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 2, and the casting method comprises the following steps in sequence:
A. the casting process and the casting mold of the wheel-mounted 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 wheel-mounted brake disc is designed to be a conical surface, the machining allowance is 10mm, the section of the machining allowance top 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 (3) making a casting process of the wheel-mounted brake disc, and performing bottom pouring in 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 wheel-mounted brake disc, and removing machining allowance tops of the annular rib plate and the friction surface.
F. Carrying out quenching and tempering and finish machining on the wheel-mounted brake disc to obtain an integral wheel-mounted brake disc;
G. and carrying out ultrasonic flaw detection, surface magnetic particle flaw detection and dynamic balance detection on the obtained integral wheel-mounted brake disc, and dividing the obtained qualified product into two parts along a preset cutting line by adopting linear cutting to obtain the completely symmetrical split wheel-mounted 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 31 on the top surface of the heat dissipation rib 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 11 of the friction surface 1 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 assembling is completed, after the smelting and casting processes are carried out, the annular rib plate 31 is firstly solidified in the cooling and solidifying process and is used for fixing a plurality of symmetrically arranged heat dissipation ribs 3, the situation that the friction surface is warped and deformed to form a wavy surface due to deformation in the cooling process of the heat dissipation ribs 3 is avoided, the parallelism of the two annular surfaces is completely within the range of technological requirements, the brake disc is machined after the mold is beaten and the sand is fallen.
One side of the obtained integral wheel-mounted brake disc 2 is a friction surface 1, the other side of the obtained integral wheel-mounted brake disc is a heat dissipation surface, a plurality of heat dissipation ribs 3 are symmetrically arranged on the heat dissipation surface, the heat dissipation ribs 3 are in a strip shape with equal width and are uniformly distributed in a scattering shape along the radial direction, radial air flow channels are formed among the heat dissipation ribs 3, the heat dissipation surface of the integral wheel-mounted brake disc 2 is further provided with a casting boss 4, a bolt boss 5 and a centering positioning table 6, and the heat dissipation ribs 3, the casting boss 4, the bolt boss 5 and the centering positioning table 6 are respectively and symmetrically distributed on the heat dissipation surface of the whole. Wherein the scattering symmetry angle of the heat dissipation ribs 3 is 7.5 degrees, namely, one heat dissipation rib 3 is arranged every 7.5 degrees; the scattering symmetry angle of the bolt bosses 5 is 30 degrees, namely, one bolt boss 5 exists every 30 degrees; the scattering symmetry angle of the centering and positioning table 6 is 60 degrees, namely, one centering and positioning table 6 is arranged at intervals of 60 degrees; the cast bosses 4 have a scattering symmetry angle of 180 degrees, i.e. there is one cast boss 4 every 180 degrees. The preset cutting line 8 is the center line of the cast boss along the radial direction of the brake disc ring. The integral wheel-mounted brake disc is subjected to nondestructive testing, the testing requirements of radiographic inspection I level, ultrasonic inspection II level and magnetic powder inspection I level are met, the integral wheel-mounted brake disc which is qualified in detection is paired to carry out wheel pair dynamic balance inspection, the obtained qualified product is divided into two parts along a preset cutting line 8, so that the completely symmetrical split wheel-mounted brake disc is obtained, and pairing identification, pairing packaging and pairing material supply are carried out, and the balance performance is ensured. The invention mainly considers and adapts to the special requirements of the assembly and replacement of the existing subway and passenger train, and in the design and manufacturing process of the wheel-mounted brake disc, the shape and the structure are selected to meet the performance requirements and the aerodynamic requirements of the vehicle under the conditions of normal braking and emergency braking to the maximum extent and meet the special requirements of dynamics detection and use and replacement.
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.

Claims (3)

1. A split type wheel-mounted brake disc is characterized by comprising a prefabricated annular integral wheel-mounted brake disc, wherein one surface of the integral wheel-mounted brake disc is a friction surface (1), the other surface of the integral wheel-mounted brake disc is a heat dissipation surface, the heat dissipation surface is provided with a plurality of heat dissipation ribs (3), and the plurality of heat dissipation ribs (3) are in the shape of bars with equal width and are uniformly distributed in a scattering shape along the radial direction; the heat dissipation surface of the integral wheel-mounted brake disc is also provided with a casting boss (4), a bolt boss (5) and a centering positioning table (6), and the heat dissipation ribs (3), the casting boss (4), the bolt boss (5) and the centering positioning table (6) are respectively and symmetrically distributed on the heat dissipation surface of the whole brake disc ring; the scattering symmetry angle of the radiating ribs (3) is 7.5 degrees, the scattering symmetry angle of the bolt boss (5) is 30 degrees, the scattering symmetry angle of the centering positioning table (6) is 60 degrees, and the scattering symmetry angle of the casting boss (4) is 180 degrees; the wheel-mounted brake disc comprises a heat dissipation rib (3), a bolt boss (5), a centering positioning table, four casting bosses (4), a casting boss (6), a heat dissipation rib, a casting boss (3), a preset cutting line (8), and a split wheel-mounted brake disc, wherein the heat dissipation rib coincides with the bolt boss (5), the heat dissipation rib coincides with the centering positioning table (6), the casting boss (4) divides the integral wheel-mounted brake disc into two parts along the preset cutting line (8), and the split wheel-mounted brake disc is completely symmetrical.
2. The split type wheel-mounted brake disc according to claim 1, wherein in the casting process, an annular rib plate (31) is added on the top surface of the heat dissipation rib of the wheel-mounted brake disc, and the annular rib plate (31) and the wheel-mounted brake disc are cast and formed at one time; after casting and forming, removing the annular rib plate (31) to obtain an integral wheel-mounted brake disc; after the integral wheel-mounted brake disc is integrally inspected, the integral wheel-mounted brake disc is divided into two parts along a preset cutting line (8), and a completely symmetrical split wheel-mounted brake disc is obtained.
3. The split type wheel-mounted brake disc of claim 2, further comprising designing the machining allowance tips (11) of the friction surfaces (1) of the wheel-mounted brake disc as a tapered surface during casting; after casting, the machining allowance top (11) of the friction surface (1) of the wheel-mounted brake disc is machined into a plane.
CN201910033175.5A 2015-11-30 2016-05-27 Split wheel-mounted brake disc for urban fast rail train and high-speed motor train unit train Pending CN111207168A (en)

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Application Number Priority Date Filing Date Title
CN2015108624648 2015-11-30
CN201510862464 2015-11-30
CN201610368755.6A CN106812835B (en) 2015-11-30 2016-05-27 A kind of manufacturing method that split type wheel is brake disk mounted

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CN201910033191.4A Pending CN111140609A (en) 2015-11-30 2016-05-27 Split type wheel-mounted brake disc easy to mount and capable of avoiding warping deformation
CN201910033175.5A Pending CN111207168A (en) 2015-11-30 2016-05-27 Split wheel-mounted brake disc for urban fast rail train and high-speed motor train unit train
CN201610368755.6A Active CN106812835B (en) 2015-11-30 2016-05-27 A kind of manufacturing method that split type wheel is brake disk mounted

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CN201610368755.6A Active CN106812835B (en) 2015-11-30 2016-05-27 A kind of manufacturing method that split type wheel is brake disk mounted

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