Study On Structure And Forming Process Of Aluminum Matrix Composites Axial Brake Disc For Urban Rail

SiCp/A356 matrix composite brake discs have become the the friction parts of the basic brake system of the next generation urban rail due to their advantages such as high specific strength,light weight and low noise.Aluminum matrix composite materials are significantly different from traditional steel materials,and their structural design is also unique.In addition,it is easy to generate gas during the forming process,the Aluminum matrix composite materials have poor mobility and they are difficult to feed.In order to obtain high-quality brake disc castings,higher requirements for the forming process are proposed.Therefore,combined the braking conditions of the brake disc,based on the finite element simulation analysis technology,the structural design and forming process of the axis-mounted brake disc are studied.By analyzing the function and influence of the structural elements such as the heat dissipation ribs,connecting parts,the basic principles of the brake disc design are determined,and the brake disc body and its assembly are completed by the Solidworks software according to the size of the brake disc interface.Structural design of the attachment.The thermal and stress analysis of SiCp/A356 axis-mounted brake discs was carried out for specified service lines,braking conditions and vehicle information by using the ANSYS software,The analysis results show that the temperature and stress simulation analysis of the improved design structure of the SiCp/A356 axis-mounted disc was carried out.The simulation results showed that the working temperature is in the range of 30-122.33? in the condition of two times consecutive emergency braking,while the working temperature is 30-300.25? in the range of in the condition of full round trip braking.The upper limit temperature of the working range is beyond the allowable temperature of the composite material;The maximum von mises stress is 111.21 MPa while the maximum 1st principle stress is 130.11 MPa,which are lower than the material tensile strength at the corresponding moment.The simulation analysis of the axis-mounted brake disc forming process was carried out by ProCAST.Based on the simulation results,and combined with the analysis method of the casting feeding channel and the idea of structural process collaborative design.Through process adjustment and simulation analysis,a high quality brake disc casting process without shrinkage is obtained.The research results of the thesis have good engineering application value and reference value of subsequent research.It has a certain impetus to the application of aluminum matrix composite brake disc in the basic brake system of urban rail train.