Abstract:
A method is used to treat a surface of a brake disc to increase the adhesive power of a coating to the surface. The method includes roughening the surface by introducing at least one depression in the surface. The width of the depression is widened with increasing depth of the depression. A positive connection is formed between the brake disc and the coating via an undercut.

Description:
This application is a 35 U.S.C. §371 National Stage Application of PCT/EP2011/069619, filed on Nov. 8, 2011, which claims the benefit of priority to Serial No. DE 10 2010 064 350.5, filed on Dec. 29, 2010 in Germany, the disclosures of which are incorporated herein by reference in their entirety. 
     The present disclosure relates to a brake disk and to a method for treating a surface, in particular that of a brake disk, wherein, to increase the adhesive power of a coating on the surface, said surface is roughened by introducing into the surface at least one depression, the width of which increases with increasing depth of the depression, and a positive connection between the brake disk and the coating is produced by means of this undercut. 
     The disclosure furthermore relates to a cutting tool for producing at least one depression in a surface, in particular in the surface of a brake disk, wherein the cutting tool produces at least one depression in the surface in such a way that the width of said depression increases with increasing depth. For this purpose, the cutting tool has at least two cutting edges, wherein the two cutting edges are at a slope angle to the perpendicular of the workpiece surface and the two cutting edges simultaneously form a common plane in the orthogonal direction. 
     BACKGROUND 
     The practice, in the case of thermal coating processes, such as flame spraying or plasma spraying, of subjecting the surfaces to activation before coating is known from the prior art. Normally, this activation consists in roughening the surface by machining the surface with pressurized abrasive particles, in particular sharp-edged particles, such as white corundum. This step is also referred to as a jet machining process. 
     Jet machining processes of this kind have the disadvantage that the characteristics of the surfaces produced cannot be accurately reproduced and that the associated adhesive power of the coatings may be subject to large fluctuations, which is inappropriate for large-scale manufacture. 
     SUMMARY 
     The focus of the present disclosure is to produce accurately reproducible surface activation in order to apply surface coatings to the activated surfaces with as small as possible fluctuations in the process parameters. 
     According to the disclosure, this is achieved by the features described below. Advantageous developments and embodiments will become apparent from the description below. 
     Here, the disclosure comprises a workpiece, in particular a brake disk, which has the surface activation according to the disclosure, and furthermore comprises a method for surface activation and a tool, in particular a cutting tool, for carrying out the surface activation on workpiece surfaces. 
     To increase the adhesive power of a coating on the surface, the workpiece, in particular the brake disk, having the surface according to the disclosure has structuring, wherein the structuring of the surface has at least one depression, the width of which increases with increasing depth. This makes it possible to produce a positive connection between a coating to be applied subsequently and the workpiece, wherein the positive connection exhibits accurate reproducibility. 
     It is advantageous if the at least one depression has a cross-sectional profile in a dovetail shape, thereby giving rise to positive engagement. 
     It is furthermore advantageous that the at least one depression is in the form of one or more concentric circles or in the form of a spiral depression, similar to the groove in a gramophone record. This makes it possible to carry out the surface activation by means of machining of the material, in particular a turning process, wherein the surface activation can be carried out very quickly and economically. 
     It is advantageous if the thickness of the coating to be applied is greater than the depth of the at least one depression, with the result that the depression is completely filled with coating material and a completely flat surface is formed after the coating process. 
     It is furthermore advantageous that the coating is composed of a material with a high abrasion resistance and the surface, in particular the surface of the brake disk, is very wear resistant. It is particularly advantageous if the surface activation is carried out by means of at least one depression, which produces a positive connection between the coating and the brake disk, on the regions of the brake disk at which the coated brake disk subsequently comes into contact with the brake pads. 
     Within the scope of the disclosure, a method for treating a surface, in particular the surface of a brake disk, for increasing the adhesion of a coating on the surface is provided, wherein at least one depression, the width of which increases with increasing depth, is formed on the surface. The positive engagement between the workpiece surface and the coating is thereby made possible according to the disclosure. 
     It is advantageous if the at least one depression is produced by machining of the material, in particular by means of turning. 
     It is advantageous if the at least one depression is produced in a plurality of steps. After the turning tool has been plunged into the surface of the material, a first undercut is produced on the first side flank of the depression in a first step by moving the turning tool in a counterclockwise first direction relative to the workpiece, thereby producing the first undercut. In a second step, a second undercut is produced on the opposite side flank of the depression by moving the cutting tool in a clockwise second direction, which is opposite to the first direction. By means of this step, a further undercut is produced. After the cutting tool has been moved into a central position and moved away from the workpiece, two undercuts remain, jointly producing a depression, the width of which increases with increasing depth and which has a profile in a dovetail shape. By means of the two undercuts formed in opposite directions, positive engagement with the coating subsequently applied is produced, anchoring the coating permanently to the workpiece. 
     It is advantageous if a plurality of depressions is produced simultaneously with a single tool by using a cutting tool with a plurality of cutting edges of the same kind arranged adjacent to one another in the form of a comb. It is thereby possible to achieve a multiple benefit since a multiplicity of adjacent depressions of the same kind is produced in a single working step, thereby making it possible to carry out surface activation more quickly and hence more economically. 
     It is furthermore advantageous if a cutting tool having what is referred to as standard cutting inserts can be used since it is thereby possible to achieve economical production and maintenance of the tool and it is thereby likewise possible to carry out rapid surface activation. For this purpose, a tool having a plurality of cutting edges, in particular two cutting edges, is provided, where the matched feed rate of the tool relative to the workpiece is matched to the speed of rotation of the workpiece in such a way that a first undercut is produced on the first side flank of the depression with a first cutting edge of the tool and, at the same time, a second undercut is produced on the opposite side flank of the depression with a second cutting edge of the tool. Here, the two undercuts are arranged in such a way, by virtue of the matched feed rate, that they jointly form a common depression, wherein the width of the cross-sectional profile of the depression increases with increasing depth and, once again, a cross-sectional profile in a dovetail shape is formed. Here, the first undercut and the second undercut are produced simultaneously and are produced in a spiral shape across the surface of the workpiece by virtue of the feed rate, like the sound groove in a gramophone record. 
     According to the disclosure, a cutting tool for producing at least one depression in a surface, in particular in the surface of a brake disk, is furthermore provided, wherein the cutting tool is configured in such a way that it introduces at least one depression into the surface, wherein the width of the at least one depression increases with increasing depth. This can advantageously be produced by means of a cutting tool which has at least two cutting edges, wherein the first cutting edge has a slope angle to the perpendicular of the workpiece surface and produces a first part of the at least one depression, and the second cutting edge has a slope angle to the perpendicular of the workpiece surface in the opposite direction to the slope angle of the first cutting edge and produces a second part of the at least one depression, and the two cutting edges form a common plane. 
     It is advantageous if the at least two cutting edges of the cutting tool slope at an angle to the center line of the tool, with the result that said edges converge. However, there is also the possibility here that the point of intersection of the two extension lines of the cutting edges lie within the workpiece or, alternatively, on the side of the tool facing away from the workpiece, depending on which embodiment of the cutting tool is being considered, wherein both form embodiments of the disclosure. Here, the center line of the tool is to be taken as being arranged parallel to the perpendicular of the workpiece surface. 
     It is advantageous if the at least two cutting edges are arranged in a dovetail shape, with the result that the common points of intersection of the two lateral cutting edges lies on the side of the cutting tool facing away from the workpiece. As a result, the cutting edges are arranged facing away from one another, thereby giving a substantially tooth-shaped profile similar to the profile of the depression, but merely of narrower configuration than the latter. 
     It is furthermore advantageous that the cutting tool has a multiplicity of cutting edges of the same type arranged in a dovetail shape, thereby making it possible to produce a plurality of depressions of the same type in a single pass and providing a multiple benefit. 
     It is particularly advantageous here if the multiplicity of cutting edges of the same type arranged in a dovetail shape is arranged at uniform intervals in a line, giving rise to a comb-like tool shape. In this case, the cutting tool can be of integral configuration. 
     According to the disclosure, it is furthermore advantageous that the tool for producing the depression takes place in such a way that, after the vertical plunging of the cutting tool into the workpiece, a first movement parallel to the workpiece surface is carried out, thereby producing a first undercut, which forms a first side flank of the depression. By means of a subsequent movement of the cutting tool in the opposite direction relative to the workpiece, which likewise takes place parallel to the workpiece surface, a second undercut is produced, the profile of which is formed as a mirror image of the first undercut and which forms a second side flank of the depression. By means of the two undercuts formed as mirror images of one another, which form the two side flanks of the depression, a depression with a cross section in a dovetail shape is produced, whereby a surface activation is carried out by means of this tool, connecting a subsequently applied coating positively and permanently to the surface. 
     It is furthermore advantageous that the cutting tool produces in the workpiece at least one depression in the form of a concentric circle or of a plurality of concentric circles by a process in which a plurality of depressions with (a) dovetail-shaped cross section/s is/are structured into the surface of the workpiece by means of a turning process. 
     It is furthermore advantageous that the at least two cutting edges are arranged at an acute angle to one another, i.e. so as to converge. This means that the point of intersection of the two straight extension lines and two cutting edges is in front of the tool, i.e. within the workpiece. 
     It is particularly advantageous that the at least two cutting edges consist of two cutting inserts secured on a common tool holder. It is particularly economical here if two standard indexable cutting inserts can be used, thereby making it possible to provide a particularly economical tool since special manufacture is not necessary. This is achieved by a tool consisting of a cutting insert holder on which two standard indexable cutting inserts are secured, wherein the two cutting inserts have at least one acute angle. The two cutting inserts are secured on the cutting tool in such a way that the respective axes of symmetry passing through the corners with the acute angles converge, with the result that the two mirror-symmetrical longitudinal axes intersect outside the tool. In this case, the point of intersection lies within the workpiece during cutting operation of the tool. In this case, the first half of the at least one depression is turned by means of the first cutting insert, wherein said first half advantageously consists of an undercut which tapers with increasing cutting depth. It is advantageous if the second cutting insert simultaneously cuts a further undercut into the workpiece in a horizontally offset position, wherein the tool moves at a feed rate relative to the rotating workpiece, with the result that, after a whole number of workpiece revolutions, the tip of the second cutting inserts is almost precisely at the position at which the tip of the first cutting insert cut the first half of the at least one depression before the whole number of workpiece revolutions. Here, the tip of the second cutting insert likewise cuts an undercut into the workpiece, wherein said second undercut likewise tapers with increasing cutting depth but, owing to the converging orientation of the two cutting insert axes, is arranged as a mirror image of the first undercut. Since both undercuts run almost precisely toward one another but are slightly offset relative to one another, the combination of these two undercuts gives at least one depression, the width of which increases with increasing depth owing to the two undercuts tapering with increasing depth, with the result that a cross-sectional profile of the depression in a dovetail shape is obtained. It is particularly advantageous here that the first of the at least two cutting edges produces the first half of the at least one depression in the surface and, at the same time, the second of the at least two cutting edges produces the second half of the at least one depression in the surface, wherein the second half of the at least one depression complements the first half of the at least one depression in such a way that the at least one depression in a dovetail shape is formed. It is possible here to provide the entire surface with a single spiral depression to cover the surface, said depression being similar in design to a sound groove of a gramophone record and being capable of being produced in a single pass. 
     It is advantageous if the cutting tool produces one or more spiral depression/s in the workpiece by a process in which the feed rate is matched to the speed of rotation of the workpiece and one or more spiral depressions are produced in a single pass, like the spiral sound groove of a gramophone record. 
     It is furthermore advantageous that the cutting tool is configured in such a way that the depression produced thereby is a microstructure, in particular that the microstructure has a depth in a range of from 10 μm to 1000 μm. 
     By virtue of the dovetail-like geometry with an undercut portion, the microstructure advantageously leads to improved adhesion of the layer to be applied. To reduce the process time, it is advantageous here to produce all the structures at the same time with a correspondingly wide tool. In this case, each individual structure can be introduced serially with a single tool, in particular in order to create more flexibility, e.g. in the configuration of the structure spacings or structure depths. A person skilled in the art can find a large number of possible combinations, of cross-sectional profiles, combinations and division of the production process into individual processes within the scope of the disclosure. In comparison with surface activation by means of conventional sandblasting, this method is suitable for large-scale manufacture by virtue of its process capability. In addition to reduced reject costs in comparison with sandblasting, this method offers further cost advantages since no relevant wear phenomena, as in jet machining, occur on the tool and the machine. When this method is employed for castings, there is a further advantage since a turning process is generally used in any case to remove the casting skin or for precise shaping of brake disks, and this turning process can additionally carry out said operation. The entire process chain is thus simplified and leads to further cost advantages. The application of microstructure turning for flat surfaces of brake disks has been carried out by way of example but, in principle, this method is suitable for all turning processes. It is likewise possible, as an alternative for non-rotating surfaces, to produce comparable structures by means of milling, broaching, shaping or planing instead of a turning process. 
     A tool which consists of a holder and two standard indexable cutting inserts with as small as possible a cutting edge radius is particularly advantageous for the production of specific undercuts. This makes it possible to produce dovetail-like microstructures which are not produced as concentric structures but have a spiral microstructure profile. By virtue of the dovetail-like geometry with an undercut portion, these microstructures lead to improved adhesion of the coating to be applied, wherein a major advantage lies in the very low tool costs since standard indexable cutting inserts can be used. Only the initial setting of the microcutting edges relative to one another may be regarded as an increased cost. 
     As an alternative to a dovetail-like cross-sectional profile, it is also possible to introduce simple structures which, although they have an increasing width of the cross-sectional profile with increasing depth, can otherwise differ in details from a precise dovetail profile. The advantage of this variant is simplified construction or the omission of setting for the two indexable cutting inserts, although it is disadvantageous here that a smaller number of undercuts is obtained. 
     Further features, possible applications and advantages of the disclosure will become apparent from the following description of illustrative embodiments of the disclosure, which are shown in the figures of the drawing. Here, all the features described or shown, individually or in any combination, form the subject matter of the disclosure, irrespective of the collation thereof in the description or the dependency references thereof and irrespective of the wording or depiction thereof in the description and in the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Illustrative embodiments of the disclosure are explained below with reference to drawings, in which: 
         FIG. 1  shows an illustrative workpiece, e.g. a brake disk, 
         FIG. 2  shows an illustrative embodiment of a first tool according to the disclosure, 
         FIG. 3  shows the use of the first tool according to the disclosure, 
         FIG. 4  shows the activated surface after the machining according to the disclosure, 
         FIG. 5  shows an illustrative embodiment of a further tool according to the disclosure, and 
         FIG. 6  shows the use of the further tool according to the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a workpiece  1 , which can be embodied as a brake disk for example. A workpiece  1  of this kind has an axis  2  of rotation, around which the workpiece  1  rotates during a turning process. A surface  3  is furthermore provided, which surface is structured by means of the tool and method according to the disclosure and into which a microstructure is introduced to increase the adhesive power of a coating to be applied subsequently, which is applied by means of a flame spraying method or of a plasma spraying method for example. 
       FIG. 2  shows an illustrative embodiment of a possible tool  4  for producing the microstructure according to the disclosure. Here, the tool  4  has, on one side, at least two cutting edges  6 ,  7 , which converge in such a way that the extension lines of the two cutting edges  6 ,  7  intersect on the side facing away from the workpiece  1 . This gives a cutting edge profile  5  which is reminiscent of a tooth shape and is referred to below as a cutting tooth  5 . Here, the at least two cutting edges  6 ,  7  form the left-hand and right-hand side flank of the cutting tooth  5  respectively, giving a dovetail shape of the microstructure produced in the workpiece. To increase the efficiency of a tool of this kind, provision is furthermore made to arrange a plurality of cutting teeth  5  along a line of the tool  4 , wherein the cutting teeth are advantageously arranged at regular tooth intervals  8 . 
       FIG. 3  shows, by way of example, the use of the tool  4  shown in  FIG. 2  to machine the workpiece  1  shown in  FIG. 1 . The workpiece, e.g. a brake disk, is shown here as a cutaway, whereof the surface  3  to be machined is in an upright position relative to the viewing direction in  FIG. 3 . The tool  4  is furthermore likewise shown as a cutaway, wherein the cutting teeth  5  arranged at the tooth interval  8  are positioned relative to the workpiece  1  and cut into the surface  3  to be structured. It can be seen here that each cutting tooth  5  has a left-hand and a right-hand side edge, which are known as at least two cutting edges  6 ,  7  from  FIG. 2 . During the microstructuring of the surface  3  of the workpiece  1  by means of a turning method, the workpiece  1  rotates relative to the tool  4  in such a way that the portion of the workpiece  1  shown in  FIG. 3  moves downward, and the workpiece  1  overall performs a rotation about a horizontal axis  2  of rotation, as shown in  FIG. 1 . During this process, the cutting teeth  5  cut into the surface  3  and produce regular depressions  9  in the surface  3  at intervals  8  when the tool  4  is moved toward the workpiece  1  in the plunge-cutting direction  20 . Once the tool  4  has been fed into the workpiece  1  to such an extent that the cutting edges  6 ,  7  produce depressions with a desired depth  10 , the tool  4  is moved parallel to the surface  3  in a first direction  21  of movement. During this first movement  21 , the first cutting edge  6  widens the depression  9  in such a way that a first undercut  9   a  is formed on the left-hand edges of the depressions  9 . Movement then takes place in a second direction  22  of movement, in which the tool  4  is likewise moved parallel to the surface  3  but now in the opposite direction to the workpiece  1 . During this process, the second side flank  7  of the cutting teeth  5  now cuts a second undercut  9   b  into the right-hand edges of the depressions  9 , with the result that the depressions  9  have respective mirror-image undercuts on the two sides  9   a  and  9   b . The tool  4  is then moved somewhat in direction  21  again, with the result that the cutting teeth  5  assume a central position in the depressions  9  and can be moved out of the depressions  9 , counter to the plunge-cutting direction  20 , without touching the workpiece. The microstructures  9  which are produced during this procedure are shown once again on a larger scale in  FIG. 4 . 
     In  FIG. 4 , the workpiece  1 , e.g. a brake disk, is again illustrated, being shown in a cutaway view, having a surface  3  that is to be structured by means of a turning method and, in  FIG. 4 , as in  FIG. 3 , facing forward. Depressions  9 , spaced apart at a tooth interval  8 , have been introduced into this surface  3 . Here, the depth  10  of the depressions is the depth of the plunge cut of the tool, which can be in a range of from 10 μm to 1000 μm. The depressions  9  each furthermore consist of two undercuts  9   a ,  9   b , with the first undercut  9   a  in each case being shown at the left-hand edge of the depression  9  and the second undercut  9   b  being shown at the right-hand edge of the depression  9  in each case. These two undercuts  9   a ,  9   b  result in cross-sectional profiles of a dovetail-like shape which allow positive connection to a coating to be applied subsequently. 
       FIG. 5  shows another illustrative embodiment of a tool  30  according to the disclosure, in which a cutting insert holder  30  accommodates two standard indexable cutting inserts  31 ,  32 . Both cutting inserts  31 ,  32  are secured on the cutting tool  30  by means of fastening screws  35 . Here, the two cutting inserts  31 ,  32  are arranged adjacent to one another in such a way that one corner and at least one cutting edge in each case projects at the top above the edge of the cutting tool. Here, the cutting inserts  31 ,  32  are chosen in such a way that the tip, which projects at the top above the edge of the tool, has as acute an angle as possible with as small as possible a radius in order to be able to produce as small as possible a microstructure in the form of the depressions  9 ,  42 ,  43  with as shallow a depth  10  as possible. Both cutting inserts  31 ,  32 , which are advantageously diamond shaped, are secured on the cutting insert holder  30  in such a way that the axes  33 ,  34  of symmetry of the inserts  31 ,  32  are not parallel in the longitudinal direction but converge and intersect outside the cutting insert holder  30 . The cutting insert holder is likewise advantageously manufactured so as to be symmetrical, with the result that the point of intersection of the two longitudinal axes  33 ,  34  of the cutting inserts lies on the center line  36  of the cutting insert holder. Here, the slope of the two center lines  33 ,  34  of the cutting inserts relative to one another must be sufficiently steep to ensure that the two inner cutting edges  37   b  and  38   b  of the two cutting inserts  31  and  32  likewise converge and that the imaginary extension lines thereof intersect above the tool. If these two inner cutting edges  37   b  and  38   b  run parallel to one another or even diverge outward, with the result that the extension lines intersect within the cutting insert holder  30  or below the latter, it is not possible to produce undercuts  9   a ,  9   b ,  42 ,  43  in the surface  3  of the workpiece  1  in the manner shown in  FIG. 6 . Here, the outer edges  37   a  and  38   a  of the cutting tool advantageously likewise have cutting edges since the advantageous standard indexable cutting inserts described usually have cutting edges  37   a ,  37   b ,  38   a ,  38   b  running around on both sides, which also allow the tool  30  to be plunged into the surface  3  of the workpiece  1  in a simple manner. 
       FIG. 6  shows the use of the tool  30  described in  FIG. 5  to produce dovetail-like depressions  42 ,  43  in a surface  3  of a workpiece  1 . Here, the cutting insert holder  30  is not shown for reasons of clarity, but the cutting inserts  31  and  32  which project above said holder are shown in part. Since the cutting inserts  31 ,  32  move relative to the workpiece  1  with a feed motion  41 , which is indicated by a rightward-pointing arrow in  FIG. 6 , a leading cutting edge  32  and a trailing cutting edge  31  result from this orientation. Here, the leading cutting edge  32  is positioned in such a way with the center line  34  thereof that it points away from the feed direction, and the inner, leading cutting edge  38  likewise slopes to such an extent that it slopes counter to the feed direction  42 . When this leading cutting edge  32  is in contact with the workpiece  1 , it produces a depression  42  that forms the first part of the subsequent microstructure  9 . Owing to the slope described of the inner cutting edge  38   b , a first undercut  42  is obtained, forming an undercut on the left-hand side (i.e. counter to the feed direction) in the depression but tapering with increasing depth  10  of the depression. The feed rate  42 , which is matched to the speed of rotation of the workpiece  1 , results in an encircling spiral partial depression  42 . The precise matching of the feed rate  41 , of the speed of rotation and of the spacing of the two cutting edge tips makes it possible for the trailing cutting edge  31  to cut in almost exactly in the depression of the leading cutting edge  32   b  while being offset slightly in the feed direction, with the result that the first half  42  of the microstructure  9 , said first half being produced by the leading cutting edge  32 , is complemented by the second half  43  which then follows. In this case, the trailing cutting insert  31  slopes in the opposite direction to the leading cutting insert  32   b  in such a way that the center line  33  slopes in the feed direction in the longitudinal direction of the cutting insert  31 . Here too, it is necessary that the slope should be so pronounced that the inner, trailing cutting edge  37   b  should likewise slope in the direction of the leading cutting edge  32   b  (i.e. in the feed direction  41 ). This second, trailing cutting edge  37   b  produces a plunge cut  43  which, owing to the slope described of the trailing cutting insert  31 , likewise produces an undercut  43 , which is mirror-symmetrical with respect to the first depression  42 . Since both depressions  42  and  43  are produced almost one on top of the other in the workpiece  1  and are only slightly offset horizontally relative to one another, the two undercuts  42  and  43  complement one another to form a dovetail-like microstructure  9 , the width of which increases with increasing depth  10 . In this case, the second half  43  of the microstructure  9  is produced simultaneously with the first half  42  of the microstructure  42  but, owing to the spacing between the two cutting edges, the speed of rotation and the feed rate, which is likewise matched thereto, the second half  43  of the microstructure  9  is completed only after a whole number of revolutions of the workpiece  1  in the same location at which the leading cutting edge  32  has generated the first half  42  of the microstructure  9 . This results in a microstructure  9  extending on the surface  3 , said microstructure extending in a spiral similar to a sound groove of a gramophone record and being repeated at regular intervals  39  due to the spiral shape. Both undercuts  42  and  43  are thus produced simultaneously but at different positions, and therefore the two undercuts  42  and  43  are produced one after the other in a single position and yet, by virtue of the encircling spiral structure, are produced simultaneously and in parallel in a single pass. The two inner cutting edges  37   b  and  38   b  thus form the two side flanks of the microstructure  9 , and therefore the opening angle  40  of the microstructure is the same angle as the slope angle of the two inner cutting edges  37   b  and  38   b  relative to one another. The two outer cutting edges  37   a  and  38   a  cut surfaces out of the workpiece surface which merge into one another and connect the two halves  42  and  43  of the microstructure  9 , wherein the angle of the two outer cutting edges  37   a  and  38   a  relative to one another is of secondary importance.