Study On Collaborative Design Of Structure And Forming Process Of Forged Steel Brake Discs

Brake disc is an important component of the braking system, its service reliability depends on the material, structure, forming quality and service conditions of the brake disc. Based on numerical simulation technology for the selected materials and conditions of service, the influence of structure design of brake disc to heat stress and process factors on the forming process were discussed. A forged steel brake disc collaborative design of structure and forming process were proposed.The main research contents and conclusions are as follows:(1) Based on thermal stress analysis technology using ANSYS and forging simulation technology using QForm, the principle of structure design of forged steel brake discs was explained in-depth. Main factors of structure design of brake discs was clarified, including thickness of the friction surface, shape and distribution of radiating rib, number of bolt holes, assembly types between disc and hub. The effects of structure design on thermal stress during service and forging process were discussed.(2) According to the the actual service condition of EMUs, a new structure design of the forged brake disc using ZDPH steel was proposed. The design of the new structure can prevent warping deformation of brake discs friction surface and the good ventilation and heat dissipation performance.(3) According to the structural characteristics of the brake disc, the forging design and the die design of the brake disc were completed referring to the forging process manual and related standards.(4) Based on the QForm forging analysis technology, die forging simulation of the steel brake disc has been conducted.type of forging equipment, materials size and forging process parameter have been determined. The result shows that the optimized beginning temperature of 1230℃～1250℃ and the die preheating temperature is 200 ℃. The minimum capacity of the forging equipment is 8000t (type J53-8000), with blank size of 0520×0316×70mm. Withthe forging equipment of J53-10000, brake disc forgings shows good quality with blank size of (?)580mm<D<(?)600mm and (?)306mm<d<0312mm and 45mm<h<50mm.The research results obtained in this paper have independent intellectual property rights, and it plays an important role in research and development of the EMU brake discs.