JP2000317615A - Forming parts of metallic matrix composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide formed parts of a metallic matrix composite material which can reduce the cost. SOLUTION: In a disk 10 for brake, a disk part 18 is constituted with the metallic matrix composite material, and a hub part 11 is constituted with a material impregnating a metallic material into the metallic matrix composite material. Therefore, the use of the comparatively expensive metallic matrix composite material can be reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a molded part of a metal matrix composite.

[0002]

2. Description of the Related Art FIG. 7 is a cross-sectional view of a typical conventional disk brake device for an automobile.
0 shows a state in which the hub 101 is mounted, the brake disk 103 of the disk brake device 102 is mounted on the hub 101, and the brake disk 103 is inserted into the caliper 106. The hydraulic pressure is transmitted from a supply channel 108 to a cylinder (not shown) of the caliper 106, and the wheels 109 are braked by pressing the brake pads 107, 107 against the disk portion 105 of the brake disk 103.

The disk part 1 of the brake disk 103
Since the brake pads 107, 107 are pressed against the disc 05, the brake disc 103 needs to be formed of a high-strength material. On the other hand, in order to reduce the weight of the body of the automobile, it is preferable to manufacture the brake disc 103 with a light material. A metal matrix composite material (MMC (metal matrix composite)) is known as a high-strength and light material. For example, by using a metal matrix as an Al (aluminum) alloy, the weight can be reduced.
High strength can be achieved by including SiC (silicon carbide) particles in the alloy matrix. Next, a method for manufacturing the brake disc 103 using an Al alloy matrix composite material will be described with reference to the following drawings.

FIG. 8 is a sectional view of a conventional injection molding apparatus for a metal matrix composite material, in which a movable mold 110 and a fixed mold 111 form a cavity 112.
To an injection cylinder 115 via a gate 113,
A piston 116 is attached to the injection cylinder 115 so as to be able to move up and down.
A state in which the on-off valve 119 is attached to the outlet side of the supply path 117 by connecting the C supply means 118 is shown.

[0005] Opening the on-off valve 119, MMC supply means 1
From 18, the Al alloy matrix composite material is supplied into the injection cylinder 115 as shown by the arrow a, and the piston 116 is raised as shown by the outline arrow b to fill the cavity 112 with the Al alloy matrix composite material through the gate 113. Next, the movable mold 110 is lifted up as indicated by white arrows c and c to open the mold and take out the injection molded product. Less than,
An injection molded product will be described.

FIG. 9 is an explanatory view of an injection-molded product taken out of a mold, and shows a state in which a non-product part 122 is separated from an injection-molded product 120. The injection molded product 120 is a member of the Al alloy matrix composite material molded in the cavity 112, and is processed to obtain the brake disk 103 shown in FIG. That is, the brake disk 103 is a member made of an Al alloy matrix composite material.
The non-product part 122 is a member of the Al alloy matrix composite material formed by the gate 113.

[0007]

The brake disk 103 shown in FIG. 7 was made of an Al alloy matrix composite material. Since the Al alloy matrix composite material is a relatively expensive material, configuring the entire brake disk 103 with the Al alloy matrix composite material will increase the cost of the product part.

Accordingly, it is an object of the present invention to provide a technique for reducing the cost of a molded part.

[0009]

According to a first aspect of the present invention, there is provided a molded part in which a part requiring high strength is formed of a metal matrix composite material, and other parts are formed of metal. It is characterized by comprising a matrix composite material impregnated with a metal material.

[0010] Since the portions (other portions) that do not require high strength are formed by impregnating the metal material into the metal matrix composite material, the amount of the relatively expensive metal matrix composite material can be reduced. . For this reason,
The cost of molded parts can be reduced.

According to a second aspect of the present invention, the molded component is a brake disk, and the portion requiring high strength is a portion facing the brake pad.

Since the portion of the brake disc that does not face the brake pad is made of a metal matrix composite material impregnated with a metal material, the amount of the relatively expensive metal matrix composite material used can be reduced. it can. As a result, the cost of the disk brake can be reduced.

[0013]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a perspective view of a molded part of the metal matrix composite material according to the present invention, showing a brake disk 10 as the molded part. The brake disk 10 includes a hub portion 11 as a “other portion” formed in a cylindrical shape, and a disk portion 18 as a “portion requiring high strength” integrally formed with the hub portion 11.

The hub portion 11 has a lid 13 on the outer end of the peripheral wall 12.
Are integrally formed, and an opening 14 is opened in the center of the lid 13, and bolt holes 15... (A plurality is shown; the same applies hereinafter) and stud holes 16 are opened around the opening 14. Insert a bolt (not shown) from the bolt hole 15.
The brake disk 10 is attached to the drive shaft (not shown) with these bolts. The stud holes 16 are holes into which studs (not shown) are press-fitted in order to attach wheels to the brake disk 10. The disc portion 18 is a disc-shaped portion that faces the brake pad of the caliper (not shown) and presses the brake pad from both sides. For this reason, the disk part 18 has high strength,
Excellent wear resistance is required.

FIG. 2 is a sectional view taken along line 2-2 of FIG. Since the hub portion 11 is a portion to be attached to the drive shaft side, it is not required that the hub portion 11 be as strong as the disk portion 18 or be excellent in wear resistance. Therefore, the hub 1
No. 1 was constituted by impregnating an Al alloy as a metal material into an Al alloy matrix as a metal matrix composite material. The region E1 in which the Al alloy matrix composite material is impregnated with the Al alloy is indicated by oblique lines. Since the disc portion 18 presses the brake pads from both sides, the disc portion 18 is required to have high strength and excellent wear resistance. For this reason, the disk portion was formed only of the Al alloy matrix composite material. The region E2 of the Al alloy matrix composite material is shown by a mesh.

As described above, the portion (ie, the hub portion 11) of the brake disk 10 that does not face the brake pad (not shown) is made of an Al alloy matrix composite material impregnated with an Al alloy. This can reduce the amount of the relatively expensive Al alloy matrix composite material used. As a result, costs can be reduced.

Hereinafter, an injection molding apparatus for injection molding a molded part of a metal matrix composite material for molding a brake disk will be described. FIG. 3 is a cross-sectional view of an injection molding apparatus for a metal matrix composite material according to the present invention. The injection molding apparatus 20 for a metal matrix composite material includes a movable mold 21 that can move up and down, and a fixed member that forms a cavity 22 together with the movable mold 21. A mold 23, an injection cylinder 26 attached to the fixed mold 23, a piston 30 attached to the injection cylinder 26 so as to be able to move up and down, an Al alloy supply means 34 for supplying an Al alloy to the injection cylinder 26, and an Al alloy supply means 34
And an Al alloy supply path 35 connecting A to the injection cylinder 26;
an on-off valve 36 for Al alloy mounted on the outlet side 35a of the l-alloy supply path 35, an MMC supply means 37 for supplying the Al alloy matrix composite material to the injection cylinder 26, and an MMC supply path connecting the MMC supply means 37 to the injection cylinder 26 3
8 and M attached to the outlet side 38a of the MMC supply path 38.
And an MC on-off valve 39.

The fixed mold 23 is a member in which a gate 24 connecting the cavity 22 and the injection cylinder 26 is formed.
The piston 30 is a member that is movably disposed in the injection cylinder 26 and pushes the Al alloy matrix composite material or the Al alloy in the injection cylinder 26 through the gate 24 into the cavity 22.
It is a member attached to. By moving the rod 32 of the cylinder unit 31 forward and backward, the piston 30 is moved as indicated by a white arrow.

The Al alloy supply means 34 feeds the semi-solidified Al alloy from the Al alloy supply hole 27 of the injection cylinder 26 to the injection cylinder 2 with the Al alloy on-off valve 36 opened.
6. The MMC supply means 37
With the MC on-off valve 39 opened, the molten Al alloy matrix composite material is supplied into the injection cylinder 26 from the MMC supply hole 28 of the injection cylinder 26.

Next, the manufacturing process of the molded part of the metal matrix composite material according to the present invention will be described. The “closed” state of the Al alloy on-off valve 36 and the MMC on-off valve 39 is shown in black. 4 (a) and 4 (b) are views for explaining a first production step of a molded part of the metal matrix composite material according to the present invention. In (a), the on-off valve 39 for MMC is closed and the on-off valve 36 for Al alloy is opened, and the Al alloy 40 in a semi-solid state is injected into the injection cylinder 26 from the Al alloy supply hole 27 by the Al alloy supply means 34. Supply as shown by the arrow,
A semi-solid Al alloy 40 is filled on the piston 30. Here, the filling amount of the Al alloy 40 is made slightly larger than the capacity of the gate 24.

In (b), the on / off valve for Al alloy 36 is closed and the on / off valve 39 for MMC is opened, and the MMC supply means 37 supplies the molten Al alloy matrix composite material 42.
Is supplied from the MMC supply hole into the injection cylinder 26 as shown by the arrow. Here, the filling amount of the metal matrix composite material 42 is made slightly smaller than the capacity of the cavity 22.
By setting the Al alloy 40 in a semi-solid state and the Al alloy matrix composite material 42 in a molten state, the Al alloy matrix composite material 42 can be filled on the Al alloy 40 in a separated state.

FIGS. 5 (a) and 5 (b) are views for explaining a second manufacturing process of a molded part of the metal matrix composite material according to the present invention. In (a), after closing the MMC on-off valve 39, the rod 32 of the cylinder unit 31 is advanced to move the piston 30 as shown by a white arrow. The semi-solid Al alloy 40 rises and supplies the molten Al alloy matrix composite 42 to the cavity 22 through the gate 24.

In (b), the piston 30 is fixed
3 until it reaches the lower surface. By filling the gate 24 with the semi-solidified Al alloy 40, the molten Al
The disk 22 a of the cavity 22 is filled with the alloy matrix composite material 42. The region filled with the Al alloy matrix composite material 42 is indicated by a mesh, and this region corresponds to the region E2 in FIG. Incidentally, a part of the Al alloy 40 enters the cavity 22 from the gate 24, and
Impregnate the alloy matrix composite 42. A region 43 in which the Al alloy matrix composite material 42 is impregnated with the Al alloy 40 is indicated by oblique lines, and this region corresponds to E1 in FIG.
Next, the movable mold 21 is moved as indicated by a white arrow to open the mold.

FIG. 6 is an explanatory view of a third manufacturing process of a molded part of the metal matrix composite material according to the present invention. The injection molded article 45 is taken out from the opened mold. Reference numeral 47 denotes a non-product part 47 separated from the injection molded product 45. By processing the injection-molded article 45, the brake disk 10 shown in FIG. 2 is obtained. Here, since the non-product 47 is made of only the Al alloy, it can be reused.

The metal matrix composite material is made of Al
Al alloy matrix composite material containing SiC particles in the alloy matrix, but other metal materials are used as the matrix, and the metal matrix contains a fibrous, particulate or plate-like reinforcing material (SiC or alumina). It can be applied to matrix composites. Also,
Although the molded part has been described as the brake disk 10,
It can be applied to other molded parts.

Further, in the embodiment, the filling amount of the metal matrix composite material 42 into the injection cylinder 26 is slightly smaller than the capacity of the cavity 22. However, the filling amount of the metal matrix composite material 42 may be appropriately changed. . Further, the amount of the Al alloy 40 charged into the injection cylinder 26 can be arbitrarily changed.

[0027]

According to the present invention, the following effects are exhibited by the above configuration. According to the first aspect of the present invention, a portion of the molded component requiring high strength is formed of a metal matrix composite material, and the other portion is formed of a metal matrix composite material impregnated with a metal material. Therefore, the amount of the relatively expensive metal matrix composite material used can be reduced. As a result, the cost of the molded part can be reduced while maintaining the necessary parts at high strength.

According to a second aspect of the present invention, a portion of the brake disc that does not face the brake pad is made of a metal matrix composite material impregnated with a metal material. As a result, the amount of the relatively expensive metal matrix composite material used can be reduced, so that the cost of the brake disk can be reduced while maintaining the portion facing the brake pad with high strength.

[Brief description of the drawings]

FIG. 1 is a perspective view of a molded member of a metal matrix composite material according to the present invention.

FIG. 2 is a sectional view taken along line 2-2 of FIG.

FIG. 3 is a cross-sectional view of a metal matrix composite injection molding apparatus according to the present invention.

FIG. 4 is an explanatory view of a first manufacturing process of a molded part of the metal matrix composite material according to the present invention.

FIG. 5 is an explanatory view of a second manufacturing process of a molded part of the metal matrix composite material according to the present invention.

FIG. 6 is an explanatory view of a third manufacturing step of a molded part of the metal matrix composite material according to the present invention.

FIG. 7 is a cross-sectional view of a conventional typical automobile disk brake.

FIG. 8 is a cross-sectional view of a conventional metal matrix composite injection molding apparatus.

FIG. 9 is an explanatory view of an injection molded product taken out of a mold.

[Explanation of symbols]

10: Molded part of metal matrix composite material (disc for brake), 11: Other parts (hub part), 18 ...
Part requiring high strength (disk part), 40: metal material (Al alloy), 42: metal matrix composite material (A
1 alloy matrix composite).

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B22D 18/02 B22D 18/02 R 19/14 19/14 A C22C 1/10 C22C 1/10 G 47 / 12 47/12 47/18 47/18 F16D 65/12 F16D 65/12 E // B22F 5/00 B22F 5/00 S (72) Inventor Yutaka Sugaya 1-10-1, Shinsayama, Sayama, Saitama Engineering Co., Ltd. (72) Inventor Takashi Kato 1-10-1, Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd. (72) Inventor Ryuji Echigo 1-10-1, Shinsayama, Sayama City, Saitama Prefecture Honda Engineering Co., Ltd. In-house F term (reference) 3J058 BA61 CB12 EA02 EA08 EA35 EA36 4K018 AA15 AB02 EA60 FA35 HA02 JA32 KA02 4K020 AA22 AC01 BB26

Claims (2)

[Claims] 1. A part requiring high strength in a molded part is formed of a metal matrix composite material, and the other part is formed by impregnating the metal matrix composite material with a metal material. Molded parts of metal matrix composites. 2. The molded part of a metal matrix composite material according to claim 1, wherein the molded part is a brake disc, and the part requiring high strength is a part facing a brake pad.