Process and device for producing a brake drum or brake disc

A die casting machine for producing a composite two-component friction member for a brake including a light metal alloy carrier and a friction lining comprised of a light metal alloy and an internal reinforcing filler, the machine being comprised of:

• a bottom die;
• a filler pipe in communication with the bottom die;
• a filler plunger movably positioned in the filler pipe;
• a sealing structure for the filler plunger;
• an induction coil positioned to heat metal contained in the filler pipe;
• a top die,
• the top and bottom dies being movable relative to each other to form a cavity that defines the shape of the friction member;
• a plurality of movable core pullers positioned in passages located in at least one of the dies, the core pullers being operative after molten casting material for forming a first component of the friction member has been introduced into the bottom die and cooled to the point of dimensional stability, to clear a space into which molten casting material for forming a second component of the friction member may be introduced, and in which:
• the bottom die comprises a heated base and a cooled area which delimit the circumference of the casting;
• the base of the bottom die and the top die are heated to approximately 300° C.;
• and
• the area which delimits the circumference of the casting is cooled to 100° C.

A die casting machine for producing a composite two-component friction member for a brake including a light metal alloy carrier and a friction lining comprised of a light metal alloy and an internal reinforcing filler, the machine being comprised of:

• a bottom die;
• a filler pipe in communication with the bottom die;
• a filler plunger movably positioned in the filler pipe;
• a sealing structure for the filler plunger;
• an induction coil positioned to heat metal contained in the filler pipe;
• a top die,
• the top and bottom dies being movable relative to each other to form a cavity that defines the shape of the friction member;
• a plurality of movable core pullers positioned in passages located in at least one of the dies, the core pullers being operative after molten casting material for forming a first component of the friction member has been introduced into the bottom die and cooled to the point of dimensional stability, to clear a space into which molten casting material for forming a second component of the friction member may be introduced;
• and
• a magnetic screen between the induction coil and the bottom die.

A die casting machine for producing a composite two-component friction member for a brake including a light metal alloy carrier and a friction lining comprised of a light metal alloy and an internal reinforcing filler, the machine being comprised of:

• a bottom die;
• a filler pipe in communication with the bottom die;
• a filler plunger movably positioned in the filler pipe;
• a sealing structure for the filler plunger;
• an induction coil positioned to heat metal contained in the filler pipe;
• a top die,
• the top and bottom dies being movable relative to each other to form a cavity that defines the shape of the friction member;
• a plurality of movable core pullers positioned in passages located in at least one of the dies, the core pullers being operative after molten casting material for forming a first component of the friction member has been introduced into the bottom die and cooled to the point of dimensional stability, to clear a space into which molten casting material for forming a second component of the friction member may be introduced;
• and
• a squeezing plunger disposed in the top die and positioned coaxially with respect to the filler pipe;
• and
• in which the squeezing plunger includes a portion operative as a punching tool for sprues formed on the first and second components of the friction member.

A die casting machine for producing a composite two-component friction member for a brake including a light metal alloy carrier and a friction lining comprised of a light metal alloy and an internal reinforcing filler, the machine being comprised of:

• a bottom die;
• a filler pipe in communication with the bottom die;
• a filler plunger movably positioned in the filler pipe;
• a sealing structure for the filler plunger;
• an induction coil positioned to heat metal contained in the filler pipe;
• a top die,
• the top and bottom dies being movable relative to each other to form a cavity that defines the shape of the friction member;
• a plurality of movable core pullers positioned in passages located in at least one of the dies, the core pullers being operative after molten casting material for forming a first component of the friction member has been introduced into the bottom die and cooled to the point of dimensional stability, to clear a space into which molten casting material for forming a second component of the friction member may be introduced;
• and
• a squeezing plunger disposed in the top die and positioned coaxially with respect to the filler pipe;
• and in which the squeezing plunger is comprised of an inner part and a concentric annular part, the annular part being operative as a punching tool for sprues formed on the first and second components of the friction members.

A die casting machine for producing a composite two-component friction member for a brake including a light metal alloy carrier and a friction lining comprised of a light metal alloy and an internal reinforcing filler, the machine being comprised of:

• a bottom die;
• a filler pipe in communication with the bottom die;
• a filler plunger movably positioned in the filler pipe;
• a sealing structure for the filler plunger;
• an induction coil positioned to heat metal contained in the filler pipe;
• a top die,
• the top and bottom dies being movable relative to each other to form a cavity that defines the shape of the friction member;
• a plurality of movable core pullers positioned in passages located in at least one of the dies, the core pullers being operative after molten casting material for forming a first component of the friction member has been introduced into the bottom die and cooled to the point of dimensional stability, to clear a space into which molten casting material for forming a second component of the friction member may be introduced;
• a squeezing plunger;
• and
• an actuator for the squeezing plunger, and in which:
• the bottom die includes a base portion and a side portion which delimits the circumference of the casting;
• and
• the top die, the base and side portions of the bottom die, the core puller and the actuator of the squeezing plunger include seals for maintaining a vacuum within the die cavity.