JP2002059243A - Casting device for disk brake - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make the temperature of molten metal difficult to lower by the increase of molten metal amount by arranging an over-flowing part 44 and to prevent the generation of cold shut and flow mark by fully joining confluent part when molten metals divided into the right and the left sides are joined. SOLUTION: A casting device for disk brake is constituted so that the molten metal can come in the cover-flowing part 44 together with a cavity 51 when casting is performed by adding the over-flowing part 44 bulged from the upper part 52 of the cavity 51 for brake ring part 31 in a metallic mold 14.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an improved technique for a disc brake casting apparatus.

[0002]

2. Description of the Related Art FIG. 10 is an explanatory view of a conventional casting apparatus. In a conventional casting apparatus 100, a press fitting mechanism 101 is made to face a mold 102, and a cavity 104 is formed through a gate 103.
The molten metal 105 is poured. The melt 105 is in the cavity 10
If solidified in 4, the disc brake 108 can be obtained.

[0003]

FIG. 11 is a view showing an example of a disc brake including a casting defect. This disc brake 108 has a casting boundary 106, which is a casting defect, and a hot water wrinkle on the side facing the gate. 107 is defective. That is, it is considered that the molten metal collides with the upper part of the cavity 104 after pouring upward from the lower gate 103 in FIG.

[0004]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems of the generation of hot water borders and hot lines, and the main factor is that the molten metal is cooled in a cavity far from the entrance. It was found that hot water and hot water wrinkles occurred. Therefore, in order to make it difficult to cool the molten metal, the amount of hot metal stored in the cavity far from the inlet was increased, the temperature of the molten metal flowing far away was kept almost constant, and a sound disc brake casting was successfully obtained.

More specifically, the first aspect of the present invention is a donut disk-shaped brake ring, a small-diameter substantially disk-shaped center, and an inner edge of the brake ring with the center separated from the brake ring by a predetermined distance. The metal matrix composite is melted in a casting mold in which a disc brake consisting of a connecting part connecting the outer periphery of the center part and a cavity for the brake ring part and a cavity for the center part are arranged vertically. Is poured upward from the bottom to produce a disc brake casting device, wherein a cavity for a brake ring portion is added with an overflow portion bulged from the top of the cavity, and a cavity is formed during casting. With
The molten metal can enter the overflow section.

In this casting apparatus, since the molten metal of the metal matrix composite is poured upward from below, in the case of a disc brake cavity, when the molten metal enters from the lower part of the mold, it once separates into right and left and merges at the upper part. Since the bulging overflow portion is provided at the upper portion of the cavity for the brake ring portion, the volume of the cavity is increased by the overflow portion, and the amount of molten metal at the upper portion is increased. As a result, the temperature at the tip of the molten metal is difficult to cool down, and when merging at the upper part, the occurrence of hot boundaries and hot lines on the casting of the disc brake can be suppressed.

According to a second aspect of the present invention, the overflow portion is provided so as to face one surface of the brake ring portion.
An overflow portion was provided so as to face one side. If it is one side, the contact area with the molten metal is large, and the shape of the overflow portion can be freely set. As a result, it is possible to increase the amount of hot water stored while reducing the resistance of inflow to the overflow section. Therefore, the temperature at the tip of the molten metal is more difficult to cool.

According to a third aspect of the present invention, the overflow portion extends radially from the center of the brake ring portion and is formed in a rib shape. Since the overflow portion extends radially from the center and the overflow portion is formed in a rib shape, the inflow port of the overflow portion can be formed from the center side to the outer edge. As a result, it is possible to increase the amount of hot water stored while reducing the resistance of inflow to the overflow section. Also,
Since the overflow portion can be cut at the same time as the cutting of the brake ring portion, it is not necessary to remove the overflow portion.

[0009]

Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings should be viewed in the direction of reference numerals. FIG. 1 is a view showing a main part of a disc brake casting apparatus according to the present invention. The disc brake casting apparatus 10 includes a press-fitting mechanism 12 mounted on a gantry 11, a mold clamping mechanism 13, and a mold 14 which is a casting mold attached to the mold clamping mechanism 13. . Reference numeral 15 denotes a hot water supply mechanism.

The press-fitting mechanism 12 is provided with an elevating means 22 provided on a conveying means 21 and an injection means 23 attached to the elevating means 22. Inject. Conveying means 2
1 moves the elevating means 22 and the injection means 23 toward the hot water supply mechanism 15 (in the direction of the arrow) as indicated by an imaginary line, and conveys the molten metal 24 supplied from the hot water supply mechanism 15 (in the direction of the arrow). The elevating means 22 moves up as indicated by an imaginary line (in the direction of the arrow).
Then, the injection means 23 is connected to the mold 14, and the injection means 23 injects the molten metal 24 and then descends.

The mold clamping mechanism 13 includes a mold mounting board 25 (fixed board 25a, movable board 25b), a tie bar 26 supporting the mold mounting board 25, a mold clamping cylinder 27 for opening and closing the mold 14, and a toggle link mechanism. 28. In this example, the opening and closing direction of the mold 14 is horizontal (horizontal). The movable platen 25b moves in the mold opening direction (the direction of the arrow) as indicated by the imaginary line, opens the mold 14, and removes the cast disc brake by a take-out device (not shown).

FIG. 2 is a perspective view of a disc brake according to the present invention. Here, the disc brake means a "disc (brake disc)" which is a component of the disc brake.

The disc brake 30 includes a donut-shaped brake ring portion 31 and a small-diameter substantially disc-shaped central portion 32.
A fixed distance L from the brake ring portion 31 to the central portion 32
And a connecting portion 35 that connects the inner edge 33 of the brake ring portion 31 and the outer edge 34 of the central portion 32 in a separated state.
Reference numeral 36 denotes one surface of the brake ring portion 31.

FIG. 3 is a sectional view of a main part of a mold according to the present invention. The mold 14 comprises a fixed mold 41 and a movable mold 42, and a mold surface 43 is formed on the fixed mold 41. An overflow portion 44 is formed above the surface 43, and a gate 45 continuous with the mold surface 43 is formed below the mold surface 43, and pin holes 46 and 4 are formed.
6 (not shown), a mold surface 47 is formed on the movable mold 42, a continuous gate 48 is formed on the mold surface 47, and positioning pins 49, 49 (not shown).
And the cavity 5 is formed by the mold surface 43 and the mold surface 47.
1 is formed. That is, this is a casting mold in which the overflow portion 44 is bulged in the upper portion 52 of the cavity 51 so that the cavity 51 is oriented vertically. 5
Reference numeral 3 denotes a parting line (partition line).

FIG. 4 is a perspective view of a mold according to the present invention.
A mold 14 in which a mold surface 43, an overflow portion 44, and pin holes 46, 46 are formed in a fixed mold 41 on the right side of the figure and a mold surface 47 and positioning pins 49, 49 are provided on a movable mold 42 on the left side of the figure is shown. Reference numeral 55 denotes a dividing surface of the fixed die 41, and reference numeral 56 denotes a dividing surface of the movable die 42.

The mold surface 43 is connected to the brake ring 31 (FIG. 2).
Mold surface 61 for molding the connecting portion 35 and a mold surface 63 for molding the central portion 32 (see FIG. 2).
Is formed. The mold surface 47 includes a mold surface 64 for forming the brake ring portion 31 and a mold surface 6 for forming the connecting portion 35.
5 and a mold surface 66 for molding the central portion 32. That is, a cavity 51 (see FIG. 3) for the brake ring portion 31 is formed by the mold surfaces 61 and 64, and a cavity 51 for the central portion 32 (see FIG. 2) is formed by the mold surface 6.
3, 66 are formed. The overflow part 44 is provided on the mold surface 6.
1 is provided with concave portions 71, 72, 73, 74, 75 at the center 76 of the mold.
It extends radially from and is formed in a groove shape.

FIG. 5 is a perspective view of a disc brake casting according to the present invention.
This shows that the convex portion 79 radially extends from the center 81 of the brake ring portion 31 and is formed in a rib shape on one surface 36 of the brake ring portion 31 due to the overflow portion.

The operation of the disk brake casting apparatus described above will now be described. 6 (a) to 6 (c) are operation diagrams of the disc brake casting apparatus according to the present invention, schematically showing the flow of the molten metal 24 in the cavity 51, a plan view is shown on the left side of the drawing, and a right side of the drawing. I also added a side view to
It shows a total of six figures.

In FIG. 3A, the mold 14 is
Then, the molten metal 24 of the metal matrix composite is injected upward from below and injected. The molten metal 24 flows right and left inside the cavity 51 as indicated by arrows. At the same time, when traveling inside the cavity 51 on the right side of the figure, a cooling action occurs at the tips 83, 83 of the molten metal 24.

In FIG. 2B, the molten metal 24 flows through the cavity 51 as shown by the arrow and enters the overflow section 44. Recess 7 of overflow section 44
1 and 72, the cross-sectional area of the flow path (cavity 51) is increased and the amount of the molten metal 24 is increased.
The temperature of No. 3 is unlikely to decrease. The flow path (cavity 5)
The cross-sectional area of 1) is increased, the resistance acting on the molten metal 24 is reduced, and the stagnation of the molten metal 24 can be prevented.

In (c), the tips 83, 8 of the molten metal 24
3 further enters the overflow section 44. That is, by the concave portions 73 and 74 of the overflow portion 44,
The amount of hot water stored can be increased, the temperature can be maintained, and stagnation can be prevented.

Further, the molten metal 24 enters the concave portion 75 of the overflow portion 44 and the leading ends 83, 8 of the molten metal 24.
When the three join, the tips 83, 83 can be pressed together, and the joining portion 84 can be completely fused. Therefore, it is possible to prevent the occurrence of hot water borders and hot water lines.

By providing the overflow portion 44 so as to face the one surface 36 of the brake ring portion 31, the cross-sectional area of the inflow port 85 of the overflow portion 44 can be increased. As a result, the amount of hot water stored can be increased while reducing the resistance of inflow into the overflow section 44, and the molten metal 2
4 becomes difficult to cool.

Further, since the overflow portion 44 extends radially from the center 81 of the brake ring portion 31 and is formed in a rib shape, the inflow port 85 of the overflow portion 44 opens from the center 81 side to the edge 86 side. As a result, the amount of hot water stored increases from the center 81 side to the edge 86 side, and the center 8
The molten metal 24 from the 1st side to the rim 86 side becomes difficult to cool,
The tips 83 of the molten metal 24 can be completely fused. Therefore, it is possible to prevent the occurrence of hot water borders and hot water wrinkles.

Since the overflow portion 44 extends radially from the center 81 of the brake ring portion 31 and is formed in a rib shape, the convex portion 79 (see FIG. 2) of the overflow portion is formed simultaneously with the cutting of the brake ring portion 31 (see also FIG. 2). (See also Fig. 5)
Can be cut, and the convex portion 79 of the overflow portion can be easily removed.

In addition, since the overflow portion 44 extends radially from the center 81 of the brake ring portion 31 and is formed in the shape of a rib, even if the joining position of the tips 83 of the molten metal 24 changes, it can cope with the change. Can be. That is, the confluence 84 of the molten metal 24 is not always formed by the recess 75, and the same effect can be exerted between the recesses 71 to 75 even if the position of the confluence 84 changes.

FIGS. 7 (a) and 7 (b) are comparison diagrams of a cast disk brake. (A) shows a disc brake 108 cast by a conventional disc brake casting apparatus, and shows a hot water boundary 106 and a hot water wrinkle 107 generated in the disc brake 108. (B) shows the disc brake 30 cast by the disc brake casting apparatus of the present invention. As shown in the figure, in the casting apparatus of the present invention, the hot water boundary 106 and the hot water wrinkles 107 do not occur.

Next, another embodiment of the disc brake casting apparatus according to the present invention will be described. FIGS. 8 (a) and 8 (b) are diagrams of another embodiment. The same components as those of the embodiment shown in FIGS. 3 and 4 are denoted by the same reference numerals and description thereof is omitted.
(A) is a sectional view of a main part of a mold 14B. Mold 14B
In the (fixed mold 41B and movable mold 42B), the overflow portion 44B is communicated with the outer edge 88 of the cavity 51 and provided above the cavity 51.

(B) is a plan view of the movable mold 42B,
It is a b arrow view of (a). The overflow section 44B is
A trough-shaped recess 91 is formed in the divided surface 56 of the movable mold 42B,
Similarly, a gutter-shaped concave portion 92 is formed in the fixed die 41B (see FIG. 8A).

As shown, the overflow portion 44B communicates with the outer edge 88 of the cavity 51, and
Since it is provided at a position higher than 1, the air pushed by the molten metal flows into the overflow section 44B, and the molten metal compresses the air in the overflow section 44B. As a result, the amount of stored hot water is increased to prevent the temperature from lowering, and air is not accumulated in the cavity 51. Therefore, the tips of the molten metal are surely in contact with each other, and the tips of the molten metal can be fused. Therefore, it is possible to prevent the occurrence of hot water borders and hot water lines.

FIGS. 9 (a) and 9 (b) are diagrams showing still another embodiment. The same components as those in the embodiment shown in FIGS. 3 and 4 are denoted by the same reference numerals and description thereof is omitted. (A) is a sectional view of a main part of a mold 14C. Mold 14C (fixed mold 41
C, the movable mold 42C) is provided with heating means, for example, heaters 94 and 95 near the upper portion of the cavity 51. The heater holes 96 and 97 are opened at predetermined distances S and S from the cavity 51, and the heater holes 96 and 97 are opened. The cartridge heaters 98, 98 are fitted into the heater holes 96, 97.

FIG. 2B is a sectional view taken along line bb of FIG.
The heater 94 includes three cartridge heaters 98, 98, 9
8 are provided at a predetermined pitch P apart. The heater 95 is the same as the heater 94, and the description is omitted.

As shown in the figure, since the cartridge heater 98 is provided near the upper portion of the cavity 51, it is possible to prevent the temperature at the tip of the molten metal from dropping. Therefore, it is possible to prevent the occurrence of hot water borders and hot water lines. Except for the cavity 51, the space for filling the molten metal is only the gates 45 and 48, so that the volume is small, the material can be saved, and the cutting efficiency can be increased.

The overflow portion 44 shown in FIG. 4 according to the embodiment of the present invention can be further provided on the mold surface for molding the central portion 32. Also, the overflow section 4
It is also possible to form a large concave portion by connecting the four concave portions 71 to 75. It is also possible to combine the overflow section 44 and the overflow section 44B. The disc brake casting apparatus is the disc brake casting apparatus 1 shown in FIG.
It is not limited to zero. For example, a mechanism other than the toggle link mechanism 28 can be used, a piping system can be adopted for the hot water supply mechanism 15, and an electric motor can be used instead of the mold clamping cylinder 27.

[0035]

According to the present invention, the following effects are exhibited by the above configuration. According to the first aspect, an overflow portion bulged from the upper portion of the cavity is added to a casting mold in which a cavity for forming a donut-shaped brake ring portion is placed vertically. At the time of casting, the molten metal enters the overflow section together with the cavity, so that the overflow area increases the amount of molten metal and makes it difficult to cool the temperature of the tip of the molten metal. As a result, when the tips of the molten metal separated into right and left merge, the merging portion can be completely fused, and the occurrence of hot water border and hot water wrinkles can be prevented.

In the second aspect, since the overflow portion is provided so as to face one surface of the brake ring portion, the cross-sectional area of the inflow port of the overflow portion is increased, resistance to entry is reduced, and the molten metal easily enters the cavity. Become. As a result, the tips of the molten metal can be joined without substantially lowering the temperature of the molten metal, and the tips can be completely fused. Therefore, it is possible to prevent the occurrence of hot water borders and hot water lines.

In the third aspect, since the overflow portion extends radially from the center of the brake ring portion and is formed in a rib shape, the inflow port of the overflow portion opens between the center side and the outer edge, and the molten metal storage amount is increased. Increase. as a result,
It becomes difficult for the molten metal to cool from the center side to the outer edge, and the confluence is completely fused. Therefore, it is possible to prevent the occurrence of hot water borders and hot water lines. In addition, since the overflow portion extends radially from the center of the brake ring portion and is formed in a rib shape, the removal of the overflow portion can be performed simultaneously with the cutting of the brake ring portion. It does not take.

[Brief description of the drawings]

FIG. 1 is a diagram showing a main part of a disc brake casting apparatus according to the present invention.

FIG. 2 is a perspective view of a disc brake according to the present invention.

FIG. 3 is a sectional view of a main part of a mold according to the present invention.

FIG. 4 is a perspective view of a mold according to the present invention.

FIG. 5 is a perspective view of a disc brake casting according to the present invention.

FIG. 6 is an operation view of a disc brake casting apparatus according to the present invention.

FIG. 7 is a comparison diagram of a cast disk brake.

FIG. 8 is a diagram of another embodiment.

FIG. 9 is a view showing still another embodiment.

FIG. 10 is an explanatory view of a conventional casting apparatus.

FIG. 11 is a diagram showing an example of a disc brake including a casting defect.

[Explanation of symbols]

10: Disc brake casting device, 14, 14B, 1
4C: Casting mold (die), 24: Molten metal matrix composite, 30: Disc brake, 31: Brake ring part, 32: Central part, 33: Inner edge of brake ring part, 34: Outer edge of central part, 35: connecting portion, 36: one surface of the brake ring portion, 44: overflow portion, 51: cavity, 52: upper portion of the cavity, 81: center of the brake ring portion, L: fixed distance.

Continuing from the front page (72) Inventor Sugaya advantageous 1-10-1 Shinsayama, Sayama-shi, Saitama Honda Engineering Co., Ltd. (72) Inventor Takashi Kato 1-10-1 Shin-Sayama, Sayama-shi, Saitama Honda Engineering Co., Ltd. In-house (72) Inventor Ryuji Echigo 1-10-1 Shinsayama, Sayama-shi, Saitama Honda Engineering Co., Ltd. F-term (reference) 4E093 NA03 NA04 TA04

Claims (3)

[Claims] 1. A donut-shaped brake ring portion, a small-diameter substantially disk-shaped central portion, and an inner edge of the brake ring portion and an outer edge of the central portion with the central portion separated from the brake ring portion by a predetermined distance. The melt of the metal matrix composite is poured upward from the bottom into a casting mold in which the cavity for the brake ring and the cavity for the center are vertically oriented. By doing so, it is a disc brake casting device to be manufactured, wherein the cavity for the brake ring portion is added with an overflow portion bulged from the upper portion thereof, and at the time of casting, the cavity and the overflow portion are added to the cavity. A disc brake casting apparatus, which is configured to allow molten metal to enter. 2. The disc brake casting apparatus according to claim 1, wherein said overflow portion is provided so as to face one surface of a brake ring portion. 3. The disc brake casting apparatus according to claim 2, wherein the overflow portion extends radially from the center of the brake ring portion and is formed in a rib shape.