Manufacturing method of railroad transport means brake shoe with firm inserts, and moulding tool used for method realisation

FIELD: engineering industry.

SUBSTANCE: invention refers to engineering industry, and namely to manufacturing methods of friction items with firm inserts, which are meant for various transport types. Method is realised by hot moulding of shoe from polymer compound in a moulding tool under pressure at simultaneous alignment thereof with metal frame and firm inserts. Hot moulding is carried out in moulding tool with grooves located in a punch that forms the shoe working surface in firm insert location areas. Process projections are formed from polymer friction material on shoe working surface in those zones; then, shoe working surface is machined and process projections are removed, thus providing arrangement of working surfaces of firm inserts and polymer friction material in one plane. Moulding tool used for shoe manufacturing consists of a matrix and upper and lower punches. Punch forming the shoe working surface is equipped with grooves meant for each of the inserts arranged in location areas of firm insert working surfaces. Each groove is bigger than the appropriate insert.

EFFECT: providing the possibility of manufacturing railroad transport means brake shoe and locating working surfaces of firm inserts and working surface of friction material of shoe friction element in one and the same plane, providing efficient operation from the very beginning of brake shoe operation, and minimising the number of expensive friction material waste appearing during machining of shoe working surface.

2 cl, 3 dwg, 4 ex

 

The claimed group of inventions relates to a method of manufacturing friction products with solid inserts for different types of transport, in particular brake pads for railway transport. These friction products made from polymeric friction material (composition) and contain a metal frame.

The main steps of the manufacture of friction products are:

- preparation of a polymeric composition;

- briquetting polymeric composition;

- forming and heat treatment of friction products;

- machining friction products (Nphenyl, MBA, Ulanovsky. Production of asbestos technical products. L., Chemistry, 1983, p.40-61, 91-152).

The closest analogue claimed is a method of manufacturing a brake pad of a rail vehicle with a solid insert, described in the patent of the Russian Federation No. 2309072, F16D 65/04. 2007

The method includes the following steps:

- manufacturing (cast) cast iron insert;

- manufacturing (stamping) metal frame;

the Assembly of the insert with frame and its welding to the frame;

- laying in the mold frame with welded insert and hinge fluff polymeric composition;

- molding pads in the mold under pressure and subsequent vulcanization.

If this is m solid insert in the working part of the pad may have a vertical section along the length of the insert, keystone, rectangular or another shape, and the width of the insert may have a form similar to the form of the composite friction element, but with a smaller size because of leaving gaps in the molding to avoid damage to the mold.

The essential features well-known way to "manufacture insertion", "making a metal frame, Assembly of the insert with frame", "production polymer composition" and "laying in the mold frame with the insertion and fixing of fluff and polymer compositions" are shared with the essential features of the proposed method.

The method according closest analogue allows the manufacture of friction products (rail pads) with a solid insert having a stable coefficient of friction, reliable in operation and have a positive impact on the surface of the rolling wheel. However, the pads are made in a known manner, have a cleansing and regenerating effect on the rolling surface of the wheel after some period of operation which is subject to wear of the friction layer covering the solid box, and then braking hard insert. Existing method can produce a Shoe with a solid insert, located in the same plane with the working surface of the composite element, Anacapri this requires a full treatment of the working surface of the friction element pads, that is an inefficient use of costly friction composition.

Known molds consist of two main parts: the matrix and punch. (Vhmulticam. Manufacturing of dies, molds and fixtures, Meters, High school, 1974, s-322). In the manufacture of products with complex profile of the mold supply special inserts and slots, in which before pressing stack armature (ibid, s-331).

The closest analogue of the inventive mold for the manufacture of friction products is a mold for thermoforming, which main elements are the matrix, the upper and lower punch (Nphenyl, MBA, Ulanovsky. Production of asbestos technical products, L., Chemistry, 1983, pp.96-97). Now apply the mold open and closed. The main elements of the mold machined to a high degree of purity. Perhaps the chrome plating of the main elements of molds. This increases the wear resistance of the mold and provides a good surface manufactured products.

The essential features well-known mold "the matrix", "the upper and lower punches" are shared with the essential features of the claimed molds.

However, the known molds are not used for the manufacture of products with a solid insert, loc is defined directly on its surface, because of possible damage to the hard insert surface expensive molds.

The task, which directed the claimed group of inventions is the ability to manufacture brake pads for railway vehicles with the location of the working surfaces of solid inserts in the same plane with the working surface of the friction material of the friction element pads that will allow you since the start of operations of the pad to ensure its effective operation, and to minimize the amount of waste costly friction material formed by machining the working surface of the pad.

The set problem is solved by a method of manufacturing friction products with solid inserts that involves several steps. Pre-mixing of components made of polymer friction composition. Made of a metal frame and placed on it firm paste. Then the mold is loaded metal frame with solid inserts required a portion of the polymer composition and spend hot forming under pressure. During thermoforming of the polymeric composition is formed of a polymeric friction material, which in this case is formed of a friction element pads, and on the working surface Kolodkin the area of the working surfaces of solid inserts are formed of technological projections. Geometrical dimensions of technological projections larger than the corresponding dimensions of solid inserts. Then spend machining pads. When machining is removed by grinding, milling or otherwise process the protrusions and thus provides a location in the same plane working surfaces of solid inserts and friction material of the friction element pads. Before the hot forming may briquetting polymeric composition while combining it with a metal frame and solid inserts. After thermoforming to improve and stabilize the friction properties properties pads can hold its heat treatment.

For the implementation of the proposed method using a special mold. Mold for the manufacture of friction products with solid inserts contains a matrix, the upper and lower punches. When the punch forming the working surface of the pad with grooves placed in the areas of the working surfaces of solid inserts. The grooves can be made in both the upper and lower punches. The dimensions of each recess of the mold is larger than the corresponding insertion length and width.

The essential features of the claimed method "molding in the mold with grooves, u is contained in the punch, forming the working surface of the pad, forming with the formation on the working surface of the pad in the areas of the working surfaces of solid inserts technological projections of polymeric friction material", "mechanical treatment of the working surface of the pad with the removal of technological tabs" and "providing locations in the same plane working surfaces of solid inserts and friction polymer material are distinctive from the essential features of the closest analogue.

The essential features of the claimed molds "punch forming the working surface of the Shoe with cut-outs for each of the inserts and the size of each of the inserts larger than the corresponding inserts are distinctive from the essential features of the closest analogue.

Figure 1 shows the brake pad of a rail vehicle with one rigid insert located in the Central part of the pad, where:

1 - polymer friction element

2 - metal frame,

3 - solid paste,

4 - technological ledge.

Section a-a shown on the block, which has not been machined, and the incision is on the block after machining.

Figure 2 presents mold for the manufacture of brake pads f is a road vehicle with solid inserts, where:

1 - high punch,

2 - matrix

3 is a bottom punch,

4 - the notch in the lower punch in the area of solid insert.

3 shows the mold for the manufacture of brake pads railway vehicle with solid inserts, where:

1 - high punch,

2 - matrix

3 is a bottom punch

4 - the notch in the top of the punch in the area of solid inserts.

The inventive method is illustrated by the following examples.

Example 1.

Made polymer composition by mixing the components in the mixer closed. The polymer composition contains as a binder a synthetic rubber, phenolic resin, or combinations thereof, a fibrous reinforcing filler and powder fillers, giving the required performance properties of the block. In the mold with the upper punch, made with the notch in the Central part, put a metal frame with a fortified it hard to insert and polymer composition. Metal frame is a steel wire frame, combined with celnikom of a perforated sheet. Solid inserts made of special cast iron. Hot forming is carried out in the mold under pressure. At the end of the molding strip is subjected to heat treatment in furnaces and machining what Itanium to remove formed on the working surface in the Central part of the pad technological ledge, bringing the working surface of the solid insert is in the same plane with the working surface of the friction material of the friction element pads.

Example 2.

Manufacturing pads are similar to example 1 but forming lead into the mold with the lower punch, made with the notch in the Central part.

Example 3.

Manufacturing pads are similar to example 1, but the solid insert is made of metal-ceramic friction material.

Example 4.

Manufacturing pads are similar to example 1, but the upper punch of the mold is made with two notches for the two inserts.

The inventive method and mold for its implementation enables the manufacture of brake pads for railway vehicles with solid inserts that ensure effective operation since the start of operations. When the present method significantly reduces waste of expensive materials required to manufacture pads, and eliminates the possibility of damaging the surface of the molds.

1. The method of manufacturing brake pads railway vehicle with solid inserts by forming pads in the mold under pressure from polymeric friction material while combining it with a metal Kark the som and solid inserts, wherein the hot forming lead into the mold with the slots arranged in the punch forming the working surface of the pad, in the areas of the solid inserts, with education on the working surface of the pad in these areas of technological projections of polymeric friction material with subsequent machining the working surface of the pad with the removal process of the tabs and securing locations are in the same plane working surfaces of solid inserts and friction polymer material.

2. Mold for the manufacture of brake pads for railway vehicles with solid inserts containing matrix, the upper and lower punches, characterized in that the punch forming the working surface of the Shoe with cut-outs for each of the inserts placed in the areas of the working surfaces of solid inserts, and the size of each of the grooves is larger than the corresponding insert.



 

Same patents:

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9 cl, 6 dwg

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EFFECT: reliable and efficient braking in high-speed conditions, longer life and lower noise.

8 cl, 8 dwg

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SUBSTANCE: braking block incorporates a steel plate, a black iron arc-like body made up of the main and section parts with a passage made therein and friction elements. The said friction elements are placed in the block main part body on the friction surface side and into the section body part, i.e. in the block passage. The block arc-like body main part represents a carcass with chambers that can be divided into cells to house the friction elements. The chambers, or cells and friction inserts corresponding to them represent truncated pyramids or cones with their smaller bases turned towards the block friction surface and their walls inclined at the angle of α=10° to 15° to form a fixed joint of the dovetail type. The steel plate covering the main section rear side represents a plate shaped spring with ledges arranged under the shoe point of bearing and rests on the stop bulges. A corrugated heat-resistant fluoroplastic lining is arranged between the aforesaid spring and the block body. The section part passage lateral wall is furnished with a truncated-pyramid cavities with their smaller bases facing the block passage friction surfaces, the said cavities housing the appropriate friction elements to form the aforesaid dovetail joint.

EFFECT: reliable and efficient braking in high-speed conditions, longer life and lower noise.

8 cl, 8 dwg

FIELD: railway transport; brake shoes.

SUBSTANCE: proposed brake shoe contains metal skeleton, polymeric composite friction member, one or several abrasive friction inserts and support layer placed between polymeric composite friction member and metal skeleton. Support layer is placed also between polymeric composite friction member and abrasive friction insert (inserts), or between polymeric composite friction member and part of surface of abrasive friction insert (inserts). Invention is aimed at improving operating characteristics of shoe owing to increased strength of connection of insert (inserts) and polymeric composite friction member by additional locking and reduced possibility of burning out of polymeric composite friction member in zone of insert (inserts) owing to provision of heat insulation of member relative to insert.

EFFECT: increased service life of shoe.

3 dwg

FIELD: railway transport; brake shoes.

SUBSTANCE: proposed brake shoe contains metal skeleton and fitted-on composite friction member consisting of two longitudinal layers of different thermal conductivity. Lower conductivity layer is made of composite friction material of greater adhesion to metal and strength as compared with layer arranged at working surface of shoe. Thickness of lower heat thermal conductivity layer is less than minimum thickness of shoe approved for operation, but is greater than thickness from rear surface of shoe to projecting parts of metal skeleton. According to second design version, brake shoe contains metal skeleton and fitted-on composite friction member consisting of two longitudinal layers and cast iron insert arranged in central part of shoe. Lower thermal conductivity layer is made of composition friction material featuring higher adhesion to metal and strength, as compared with layer arranged from working surface of shoe. Thickness of lower thermal conductivity layer is less than minimum thickness of shoe approved for operation, but is greater than thickness from rear surface of shoe to projecting parts of metal skeleton.

EFFECT: increased strength, improved reliability and increased service life of shoe.

3 cl, 2 dwg

FIELD: transport engineering.

SUBSTANCE: invention relates to brake shoes, mainly, to drum-type brake shoe units with high friction coefficient. Proposed brake shoe unit has cylindrical curved platform of brake shoe forming part of cylinder, inner support surface and outer support surface and matrix made of brake friction material. Said matrix is arranged on outer support surface of brake shoe platform forming braking surface. Great number of bosses project from outer support surface of brake shoe platform through matrix to friction surface. Said bosses engage with friction surface to create friction with opposite rotating member of vehicle wheel.

EFFECT: improved efficiency at emergency braking.

10 cl, 10 dwg

FIELD: railway transport; brake systems.

SUBSTANCE: proposed brake shoe contains composite friction member, metal skeleton made of steel strip and hard insert welded to skeleton and arranged in central part of shoe, wire framing, central boss and two side bosses. Wire framing consists essentially of two closed frames press-fitted into composite friction material from rear side of shoe over perimeter of shoe, whose inner parts are relatively overlapped and bent outwards relative to rear part of shoe, thus forming eye to pass cotter pin. Central boss is provided with hole for cotter, pin. Two side bosses are made of composite friction material. Metal skeleton made of steel strip has width less than width of wire framing, being bent to radius of rear surface of shoe and press-fitted into rear surface of shoe between side bosses and under central boss. Composite friction member consists of two longitudinal layers of material. Strength of layer arranged from rear side of shoe is greater than that of layer arranged from working side of shoe.

EFFECT: increased strength of shoe.

2 dwg

FIELD: transport.

SUBSTANCE: braking block comprises metal carcass, composite material friction element and two solid inserts arranged symmetrically relative to the block horizontal axis and overlapping its friction part over the width. The said metal carcass represents a wire carcass representing two closed frames press-fitted into the block rear part friction material and perforated tin press-fitted into the block rear part composite friction material. Inner parts of the said frames are partially interoverlapped and bent outwards from the block rear part to form an ear designed to pass the cotter. Rear nonoperating part of every cotter has consoles arranged on each side of the aforesaid inserts all along their length. One of the said consoles is bent towards the block rear surface and arranged in the central boss, the other one being located between the central and auxiliary bosses. Each of the inserts is fitted into one of the wire carcass frames and jammed therein. The inserts, along with the carcass, are pressed in the composite friction material so that the insert console rear surfaces are located in one plate with the perforated tin of the block rear side.

EFFECT: higher durability and safety, longer service life, sable braking capacity and wheel surface recovery in braking.

3 cl, 3 dwg

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