JP2006105367A - Disc rotor and its gate position acknowledgement method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily acknowledge a position of a gate in casting a raw material of a disc rotor even after completion of machining processes. <P>SOLUTION: A bolt hole 54 of a hub bolt, a main gate position indicating portion 56 and an auxiliary gate position indicating portion 58 respectively having the different shapes, are formed on a flange portion 24 of the disc rotor 12. The main gate position indicating portion 56 is disposed on a position of the same phase as the gate in casting, and the auxiliary gate position indicating portion 58 is disposed on a phase position separating from the main gate position indicating member by a set angle. Both gate position indicating portions 56, 58 exist as recessed portions depressed from a machined face of an outer face of the flange portion 24. Both gate position indicating portions 56, 58 are formed on a pitch circle of the bolt hole 54 at an angular interval to allow a position of the gate to be confirmed on the basis of one of the gate position indicating portions which necessarily remains on a position out of the bolt hole 54. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a disc brake, and more particularly to investigation of the cause of abnormal wear of a disc rotor.

  The disk brake presses a friction pad against a disk rotor that rotates together with the wheel, and suppresses the rotation of the disk rotor and, consequently, the rotation of the wheel by a frictional force acting between the two. In general, a friction pad has a back plate fixed to the back surface of a friction material, and the back plate is held by a bracket so as to be movable in a direction parallel to the axis of the disk rotor. It is pressed against the friction surface of the disk rotor by an actuator such as an electric drive device as a drive source.

Of course, the friction pad is worn by repeated braking, but the disk rotor is inevitably worn. If the wear amount of the disk rotor exceeds a certain amount, it is necessary to replace it with a new one. Therefore, Patent Document 1 below proposes a means for easily recognizing that the disk rotor has reached the wear limit. For example, a notch or indentation of a certain depth is formed on the friction surface, or a groove is formed on the outer peripheral surface, and the notch or indentation becomes shallower or disappears as the friction surface wears, or the groove and the friction surface It is described that it is possible to recognize that the wear limit of the disk rotor is approaching or has reached the wear limit by visually confirming that the distance to the head has decreased or disappeared.
Further, in Patent Document 2, convex portions are provided at positions corresponding to each other between the disk rotor and the friction pad, and when the friction pad reaches the wear limit, both the convex portions come into contact with each other so that the friction pad is Techniques are described to indicate that the wear limit has been reached.
JP 2000-88018 A Japanese Utility Model Publication No. 63-45233

  Although it is desirable for the friction surface of the disk rotor to wear uniformly in the circumferential direction, the amount of wear may be uneven. And it is known that one of the causes of the abnormal wear is the uneven structure of the casting material. Disk rotors are often manufactured by machining cast materials, but the structure of cast materials may vary depending on the location, and the amount of wear in the circumferential direction becomes uneven due to the uneven structure. There is. It is known that there is a close relationship between the unevenness of the structure of the casting material and the casting method, particularly the dam position.

However, there is nothing in the conventional disk rotor manufactured by machining a casting material to indicate the position of the weir, so in order to investigate the relationship between abnormal wear and the casting method, There was no other way than destroying the rotor and examining its structure with a microscope, which required a lot of time.
The present invention has been made with the background described above as an object to make it possible to easily know the weir position in a disk rotor that has been machined.

The above-described problem is solved by providing the disk rotor with a dam position indicating section that indicates the dam position at the time of casting the material in a state that can be recognized even in the machining completion state.
In addition, (a) a disk rotor material manufacturing process in which molten metal is allowed to flow through a weir into a mold cavity to cast a disk rotor material and form a weir position indicating portion at a predetermined relative position with respect to the weir. And (b) a machining step in which the manufactured disk rotor material is machined to a state in which the dam indicator remains, while a trace of the dam disappears, and (c) a dam instruction that remains in the disk rotor after machining. Dam position recognition of the disk rotor including a dam position recognition step of recognizing the presence position of the trace of the dam before the machining based on a predetermined relative position between the dam indicator and the dam indicator and the dam It is also solved by the method.

In the disk rotor according to the present invention, since the dam position indicating portion is provided in a state that can be recognized even in the machining completion state, the dam position indicating portion and the predetermined relative position between the dam position indicating portion and the dam position It is possible to recognize the weir position based on the information. If the weir position can be recognized, it is possible to know the relationship between the disk rotor and the plan at the time of casting. For example, the work of investigating the relationship between the abnormal wear of the disc rotor after use for a certain period and the casting method becomes easy.
In the disc rotor weir position recognition method according to the present invention, the weir position can be recognized in the same manner.

Aspects of the Invention

  In the following, the invention that is claimed to be claimable in the present application (hereinafter referred to as “claimable invention”. The claimable invention is at least the “present invention” to the invention described in the claims. Some aspects of the present invention, including subordinate concept inventions of the present invention, superordinate concepts of the present invention, or inventions of different concepts) will be illustrated and described. As with the claims, each aspect is divided into sections, each section is numbered, and is described in a form that cites the numbers of other sections as necessary. This is for the purpose of facilitating the understanding of the claimable invention, and is not intended to limit the combinations of the constituent elements constituting the claimable invention to those described in the following sections. In other words, the claimable invention should be construed in consideration of the description accompanying each section, the description of the embodiments, etc., and as long as the interpretation is followed, another aspect is added to the form of each section. In addition, an aspect in which constituent elements are deleted from the aspect of each item can be an aspect of the claimable invention.

  In each of the following terms, (1) corresponds to claim 1, (2) corresponds to claim 2, (3) corresponds to claim 3, (4) corresponds to claim 4, Item (7) corresponds to item 5 respectively.

(1) A disk rotor characterized in that a weir position indicating section that indicates a weir position at the time of casting a material is provided in a state that can be recognized even in a processing completed state.
(2) The disk rotor according to item (1), wherein the weir position indicating section is formed on a straight line connecting the weir position and the center of the disk rotor.
According to the feature of this section, the weir position can be known most simply and clearly from the weir position indicating unit.
(3) The disk rotor according to (1) or (2), wherein the weir position indicating portion is formed near a pitch circle of a bolt hole of a hub bolt.
A plurality of hub bolts for attaching the disk rotor and the wheel to the hub are often arranged at equiangular intervals on one circumference, and in the vicinity of the pitch circle which is one circumference, the wheel and the disk rotor are separated from each other. In many cases, it cannot be adhered. Therefore, if the dam position indicating portion is formed in the vicinity of the pitch circle, the dam position indicating portion can be provided while avoiding the dam position indicating portion from adversely affecting the adhesion between the wheel and the disk rotor.
(4) The disk rotor according to (3), wherein the dam position indicating portion includes a main dam position indicating portion and an auxiliary dam position indicating portion formed at an angle different from an angle interval of the bolt hole forming position. .
If the angle interval between the main dam position indicator and the auxiliary dam position indicator is set to a size different from the angle interval of the bolt hole formation position, the main dam position indicator will be displayed no matter where the bolt hole is formed. At least one of the head and auxiliary dam position indicator remains on the disc rotor after machining, so the dam position can be easily recognized, compared to when bolt holes are formed while avoiding the dam position indicator Thus, the drilling operation of the bolt holes becomes easy. In many cases, four or five hub bolts are provided on the pitch circle. Therefore, both the main dam position indicating portion and the auxiliary dam position indicating portion are provided in the case where four or five hub bolts are provided. It is desirable to set the angular interval between the formation positions of the main dam position indicating portion and the auxiliary dam position indicating portion so as not to overlap the bolt holes.
(5) The disk rotor according to any one of (1) to (4), wherein the weir position indicating section is a recess formed at a predetermined relative position to the weir position.
If the weir position indicating portion is a recess, even if the weir position indicating portion is left in the disk rotor after machining, the weir position indicating portion can be prevented from interfering with other members. In particular, if the depth of the recess is made larger than the machining allowance of the recess forming surface, which is the surface on which the recess is formed, the weir position indicator may remain even if the recess forming surface is machined. it can.
(6) The disk rotor according to any one of items (1) to (4), wherein the weir position indicating portion is a convex portion formed at a predetermined relative position to the weir position.
As described above, in general, it is desirable that the weir position indicating portion is a recess, but if the weir position indicating portion is formed at a position where it does not interfere with other members, it should be a protrusion. Is also possible.
(7) A disk rotor material manufacturing process in which a molten metal is allowed to flow into a mold cavity through a weir to cast a disk rotor material, and a weir position indicating portion is formed at a predetermined relative position with respect to the weir;
Machining process for machining the manufactured disk rotor material to a state in which the trace of the weir disappears while the weir instruction portion remains,
Weir position recognition for recognizing the position of the trace of the weir before machining based on the weir indicator remaining on the disk rotor after machining and the predetermined relative position between the weir indicator and the weir A disc rotor weir position recognition method comprising the steps of:
Although the trace of the weir has disappeared after the completion of the machining process, since the weir position indicating part remains, the position of the weir can be easily known from the position of the weir position indicating part.
If the dam position in the disc rotor material manufacturing process is still in a recognizable stage, the dam position indicating portion can be formed on the disk rotor material by post-processing. However, if the dam position indicating portion is formed at the time of casting as in the next item, the step of forming the dam position indicating portion by post-processing can be omitted.
(8) The formation of the dam position indicating portion is performed by performing the casting using, as the mold, the one provided with the indicating portion forming portion in which the dam position indicating portion is reversed in concave and convex portions (7 The method for recognizing the weir position of the disk rotor according to the item.
(9) The machining process includes a drilling process in which a plurality of bolt holes of the hub bolt are formed at equiangular intervals, and the formation of the dam position indicating part by casting is in the vicinity of the pitch circle of the plurality of bolt holes. The disc rotor dam position recognition method according to (8), wherein the dam position recognition method is performed by a step of forming the main dam position indicating portion and the auxiliary dam position indicating portion at an angle different from the angle interval of the bolt hole forming positions.

  FIG. 1 shows a disc brake including a disc rotor according to an embodiment of the present invention. In the figure, reference numeral 10 denotes a hub. A disk rotor 12 and a wheel 14 are fixed to the hub 10 by hub bolts 16 and nuts 18. The disk rotor 12 includes a cylindrical portion 22, a flange portion 24 that extends radially inward from one axial end of the cylindrical portion 20, and a friction plate portion 26 that extends radially outward from the other end of the cylindrical portion 22. It is a hat-type rotor equipped. A plurality of ventilation holes 28 extending from the inner peripheral side to the outer peripheral side are formed inside the friction plate portion 26, and the disc rotor 12 is a ventilated disc. However, in the present invention, neither a hat type nor a ventilated type is essential.

  Friction surfaces 32 are formed on both sides of the friction plate portion 26, and two friction pads 34 are disposed so as to face the friction surfaces 32. These friction pads 34 are held so as to be movable in a direction parallel to the axis of the disk rotor 12 by a mounting bracket (not shown) and immovable in the circumferential direction. The friction pad 34 includes a friction material 36 slidably contacting the friction surface 32 and a back plate 38 fixed to the back surface thereof, and the back plate 38 is held by the mounting bracket. A caliper 42 is disposed so as to straddle the friction plate portion 26 and the two friction pads 34. The caliper 42 is also held by the mounting bracket so as to be movable in a direction parallel to the axis of the disk rotor 12 and not movable in the circumferential direction. The caliper 42 includes a cylinder portion 44 and a reaction portion 46. When the hydraulic pressure is supplied to the cylinder portion 44 and the piston 48 presses one friction pad 34 against the one friction surface 32, the reaction portion 46 is caused by the reaction force. Presses the other friction pad 34 against the other friction surface 32.

  The inner peripheral surface of the flange portion 24 of the disk rotor 12 is fitted to the outer peripheral surface of the hub 10, and the flange portion 24 is fixed to the flange portion 52 of the hub 10 by the hub bolt 16. There are a case where four bolt holes 54 are formed as shown in FIG. 2 and a case where five bolt holes 54 are formed as shown in FIG. The flange portion 24 is also formed with a main dam position indicating portion 56 and an auxiliary dam position indicating portion 58. Both of these weir position indicating parts 56 and 58 have a shape and size that can be distinguished from each other. In the present embodiment, the main weir position indicating unit 56 has a track shape in which two semicircular circumferences are connected by two parallel straight lines, and the auxiliary weir position indicating unit 58 has a circular shape. -ing The disk rotor 12 is a so-called all-processed rotor that has been machined except for the inner surface of the ventilation hole 28. However, even when the machining is completed, the main weir position indicator 56 and the auxiliary weir The position indicating portion 58 is a recessed portion that is recessed from the machining surface (in this embodiment, the outer surface of the flange portion 24 is a recess forming surface, and the surface after the recess forming surface is processed is a machining surface). The depths of the both weir position indicating parts 56 and 58 are selected so as to remain as follows.

  The disc rotor 12 is made of cast iron. As shown in FIG. 4, the molten metal flows into the cavity 72 formed by the sand mold 68 including the main molds 62 and 64, the core 66 and the like through the runner 74 and the weir 76. By casting. The main weir position indicating portion 56 is formed at the intersection of a straight line 78 connecting the center of the disk rotor 12 and the weir 76 and the pitch circle 79 of the bolt hole 54. The number of weirs 76 is not limited to one, but rather a plurality of weirs 76 are often formed at equiangular intervals. In that case, one of the plurality of weirs 76 and the main weir position indicating unit 56 The relative position is set as described above. The auxiliary dam position indicating portion 58 is formed on the pitch circle 79 at a position spaced 162 ° from the main dam position indicating portion 56. The main dam position indicating portion 56 is formed during casting by the convex portion 82 formed on the main mold 62, and the auxiliary dam position indicating portion 58 is formed in the same manner.

  As described above, the disk rotor material 84 cast as described above is all machined except for the inner surface of the ventilation hole 28, and the trace of the weir 76 disappears. And at least one of the auxiliary weir position indicating unit 58 remains. The machining includes drilling of the bolt holes 54, and the drilling is performed without considering the formation positions of the main dam position indicating unit 56 and the auxiliary dam position indicating unit 58. Therefore, for example, as shown in FIG. 5, one of the five bolt holes 54 may be formed at the position of the main dam position indicating portion 56. In this case, the main dam position indicating portion 65 is It will disappear. However, in that case, the bolt hole 54 is not always formed at the position of the auxiliary weir position indicating portion 58. As described above, since the angular interval between the formation positions of the main dam position indicating portion 65 and the auxiliary dam position indicating portion 58 is 162 °, five bolt holes 54 are formed as shown in FIG. In addition, if the main dam position indicating portion 56 overlaps with the bolt hole 54, the auxiliary dam position indicating portion 58 does not overlap with the bolt hole 54. For the same reason, when the auxiliary dam position indicating portion 58 overlaps with the bolt hole 54, the main dam position indicating portion 56 does not overlap with the bolt hole 54, and no matter what position the bolt hole 54 is formed. At least one of the dam position instruction part 56 and the auxiliary dam position instruction part 58 does not overlap with the bolt hole 54 and remains. Even when four bolt holes 54 are formed, at least one of the main dam position indicating portion 56 and the auxiliary dam position indicating portion 58 remains off the bolt hole 54 for the same reason.

  It may be necessary to know where the weir 76 was located after the machining of the disc rotor 12 has been completed. One example is a case where uneven wear occurs in the disk rotor 12. When the disk rotor 12 is mounted on a vehicle and used for a certain period, the friction surface 32 is worn. If this wear occurs uniformly in the circumferential direction, there is no problem, but if it is not uniform, the frictional force between the friction pad 34 and the disk rotor 12 will periodically fluctuate when the disk brake is applied, and this will be transmitted to the vehicle body. In some cases, low-frequency noise is generated, which may cause discomfort to the occupant. In order to investigate the cause, it may be necessary to know the position of the weir. If the main weir position indicating unit 56 remains, the position of the weir 76 that is in the same phase as the main weir position indicating unit 56 is also easily understood. On the other hand, when the main dam position indicating portion 56 has disappeared because the bolt hole 54 is formed at the position of the main dam position indicating portion 56, the main dam position indication is indicated from the position of the auxiliary dam position indicating portion 58. The position of the weir 76 can be determined based on the position of the main weir position indicating unit 56 that has been determined. And if the position of the weir 76 is known, the positions of the runner 74, the hot water pool, the vertical gate, the hot water, etc. can be specified. Thereby, it becomes easy to investigate the relationship between the plan and the uneven wear at the time of casting the disk rotor material 84.

  In addition, when there are a plurality of types of disk rotors having the same shape, the main dam position indicating unit 56 and the auxiliary dam position indicating unit 56 and the auxiliary dam position indicating unit 58 may be specified by changing the shapes of the main dam position indicating unit 56 and the auxiliary dam position indicating unit 58 for each type. The portion 58 can be used as a disc rotor type discrimination mark, and a dedicated identification mark can be omitted.

  As mentioned above, although one Example of this invention was described in detail, this is only an illustration and this invention is based on the knowledge of those skilled in the art including the aspect described in the above-mentioned [Aspect of invention]. The present invention can be implemented in variously modified forms.

1 is a front cross-sectional view showing a disc brake including a disrotor that is an embodiment of the present invention. It is a partial side view in one form of the above-mentioned disk rotor. It is a partial side view in another form of the said disk rotor. It is front sectional drawing for demonstrating casting of the raw material of the said disk rotor. It is a figure equivalent to FIG. 3 for demonstrating one of the effects of the said disk rotor.

Explanation of symbols

10: Hub 12: Disc rotor 14: Wheel 16: Hub bolt 22: Cylindrical part 24: Flange part 26: Friction plate part 28: Ventilation hole 32: Friction surface 34: Friction pad 36: Friction material 38: Back plate 42: Caliper 44 : Cylinder part 46: Reaction part 48: Piston 52: Flange part 54: Bolt hole 56: Main weir position instruction part 58: Auxiliary weir position instruction part 62, 64: Main mold 66: Core 68: Sand mold 72: Cavity 74: Runway 76: Weir 78: Straight line 79: Pitch circle

Claims (5)

  A disk rotor, characterized in that a weir position indicating section that indicates a weir position at the time of casting a material is provided in a state that can be recognized even in a processing completed state.   2. The disk rotor according to claim 1, wherein the weir position instruction section is formed on a straight line connecting the weir position and the center of the disk rotor.   The disk rotor according to claim 1, wherein the weir position indicating portion is formed near a pitch circle of a bolt hole of a hub bolt.   4. The disk rotor according to claim 3, wherein the dam position instruction section includes a main dam position instruction section and an auxiliary dam position instruction section formed at an angle different from an angular interval of the bolt hole formation position. Injecting the molten metal into the cavity of the mold through the weir, casting the disc rotor material, and forming the weir position indicating portion at a predetermined relative position with respect to the weir,
Machining process for machining the manufactured disk rotor material to a state in which the trace of the weir disappears while the weir instruction portion remains,
Weir position recognition for recognizing the position of the trace of the weir before machining based on the weir indicator remaining on the disk rotor after machining and the predetermined relative position between the weir indicator and the weir A disc rotor weir position recognition method comprising the steps of:

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