JP2009030625A - Method of manufacturing brake disk - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a brake disk capable of securing the strength of a joined part while reducing the weight. <P>SOLUTION: The mounting projections 22 of a mounting disk body 2 are fitted into the mounting holes 12 of a brake body 1, respectively. The mounting disk body 2 is disposed on the inner peripheral side of the brake body 1. The shapes of the mounting projections 22 are deformed by the frictional heat due to the rotation of a rotating jig 4 by bringing the rotating jig 4 into contact with the ends of the mounting projections 22 while rotating the rotating jig 4, and the outer wall surfaces 23 of the mounting projections 22 are joined to the inner wall surfaces 15 of the mounting holes 12, respectively. Consequently, the brake body 1 is connected integrally to the mounting disk body 2. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a brake disk having a frictional sliding portion based on cast iron.

A method for joining iron-based cast members by friction welding is disclosed (Patent Document 1). According to this, the temperature gradient at the joint is set gently by reducing the friction pressure and increasing the friction time. Thereafter, the upset force is increased and the upset time is shortened, and the iron-based cast members are joined by friction welding.
JP-A-9-85469

  According to the above-described technique, since the iron-based cast members are joined to each other by friction welding, in the cast iron containing graphite, the friction-welded portion becomes a high temperature, and the strength of the joint is reduced due to the thermal effect. There is a fear, and it is not preferable as a brake which is an important safety part.

  The present invention has been made in view of the above circumstances, and it is an object of the present invention to provide a method for manufacturing a brake disk capable of ensuring the strength of the joint while reducing the weight.

  The method for manufacturing a brake disk according to the present invention includes (i) a frictional sliding portion that forms a ring shape having a central opening and frictionally slides with a mating member, and a circumferential direction around the central axis of the frictional sliding portion. A brake body based on a cast iron material having a plurality of mounting holes formed at intervals, and a base body made of aluminum alloy or magnesium alloy, and arranged in the central opening of the brake body And a plurality of mounting projections formed at intervals in the circumferential direction around the central axis of the disk portion so as to be inserted into the mounting holes of the brake body, respectively. And (ii) fitting the mounting protrusions of the mounting plate body into the mounting holes of the brake body, respectively, and preparing the mounting plate body to be attached to the wheel side, And (iii) friction heat generated by rotation of the rotating jig by rotating the rotating jig and abutting against the tip of the mounting protrusion. The shape of the mounting protrusion is deformed to join the outer wall surface of the mounting protrusion to the inner wall surface of each of the mounting holes, and the friction stir welding step for connecting the brake body and the mounting plate body together in order. It is characterized by carrying out.

  In the fitting and arranging step, the attachment projections of the attachment board body are fitted into the attachment holes of the brake body, and the attachment board body is arranged on the inner peripheral side of the brake body. In the friction stir welding step, the shape of the mounting protrusion is deformed by the frictional heat generated by the rotation of the rotating jig by rotating the rotating jig and bringing it into contact with the tip of the mounting protrusion. As a result, the outer wall surface of the mounting protrusion is brought into close contact with the inner wall surface of each mounting hole and joined. As a result, the brake main body and the mounting board body are integrally connected.

  At least one of the outer wall surface of the mounting protrusion and the inner wall surface of the mounting hole is preferably a cross section cut along the central axis of the mounting protrusion and has a gradient. In this case, in the fitting and placing step, when the mounting protrusions of the mounting plate body are respectively fitted to the mounting holes of the brake body, a gap is formed between the outer wall surface of the mounting protrusion and the inner wall surface of the mounting hole. Is preferably set so that the gap width increases toward the front end surface of the mounting projection. In this case, the deformability of the mounting projection is large on the tip surface side of the mounting projection pressed by the rotating jig. If the gap shape is set as described above, it is possible to cope with the deformation of the tip end portion of the mounting projection.

  In the friction stir welding step, at least a part of the attachment protrusions is exemplified as a form that is solidified after being melted. In this case, when the molten state is obtained, the deformability increases, so that the deformability of the attachment protrusion is likely to increase. In addition, since the cooling rate of the solidified portion after melting is high, the solidified structure is refined and the strength tends to increase. Alternatively, in the friction stir welding process, at least a part of the mounting protrusions is softened without melting, and a form spreading in the radially outward direction is exemplified.

  A form in which the anticorrosion film is coated on at least one of the brake main body and the attachment board body is exemplified so that the anticorrosion film is positioned between the brake body and the attachment board body. In this case, corrosion caused by the potential difference between the brake body and the mounting board is suppressed by the anticorrosion film.

  Since the mounting board body attached to the wheel side is formed using an aluminum alloy or a magnesium alloy as a base material, the weight can be reduced. Examples of the aluminum alloy constituting the mounting platen include aluminum-silicon, aluminum-silicon-magnesium, aluminum-manganese, and aluminum-silicon-magnesium. You may form with the magnesium alloy which comprises an attachment board body. Examples of magnesium alloys include magnesium-aluminum, magnesium-zinc, magnesium-aluminum-zinc, magnesium-zirconium-zinc, and magnesium-manganese.

  According to the present invention, the mounting protrusions of the mounting board body made of aluminum alloy or magnesium alloy are fitted into the mounting holes of the brake body made of cast iron. In this state, while rotating the rotating jig, it is brought into contact with the tip of the mounting protrusion, and the shape of the mounting protrusion is deformed by the frictional heat generated by the rotation of the rotating jig, so that the outer wall surface of the mounting protrusion is placed inside each mounting hole. The brake body and the mounting board body are integrally connected to the wall surface. As a result, it is possible to provide a method for manufacturing a brake disk capable of ensuring the strength of the joint while reducing the weight.

  Hereinafter, embodiments embodying the present invention will be described with reference to the drawings.

(Embodiment 1)
1 to 9 show Embodiment 1 of the present invention. In the preparation step, as shown in FIG. 1, a brake main body 1 having a disc shape that exhibits a braking action and a hat portion 2 (attachment plate body) to be attached on the axle side are prepared. The brake body 1 includes a ring-shaped friction sliding portion 11 having a central opening 10, and a plurality of mounting holes 12 formed at intervals in the circumferential direction around the central axis P <b> 1 of the friction sliding portion 11. It has. The frictional sliding part 11 includes surfaces 11x and 11y facing each other. The mounting hole 12 has a circular shape in cross section, and penetrates between the surfaces 11x and 11y of the friction sliding portion 11. The mounting hole 12 is formed on the inner peripheral side of the friction sliding portion 11. The friction sliding portion 11 is a ventilated type having excellent heat dissipation, and includes a flat friction sliding surface 13 that frictionally slides with a counterpart material, and a protrusion 18 that forms a through hole 17 through which cooling air passes. Is provided.

  The brake body 1 uses a cast iron-based material containing graphite as a base material in order to ensure slidability. Examples of cast iron materials include flake graphite cast iron, spheroidal graphite cast iron, worm-like graphite cast iron, and eutectic graphite cast iron. Examples of cast iron-based materials include ferrite, pearlite, ferrite / pearlite, austenite, and bainite.

  The hat portion 2 is formed using an aluminum alloy as a base material for weight reduction or the like. The aluminum alloy is an aluminum-silicon system, has a hypoeutectic composition, and contains silicon in a mass ratio of 4 to 10% and 5 to 8%. The hat portion 2 includes a disc portion 20 disposed in the central opening 10 of the brake body 1 and a plurality of mounting projections 22 formed at intervals in the circumferential direction around the central axis P2 of the disc portion 20. ing. The disk portion 20 has a hat shape, and includes a cylindrical portion 20a, an inner flange portion 20b extending radially inward from the cylindrical portion 20a, and an outer flange portion 20c extending radially outward from the cylindrical portion 20a. And. The attachment protrusion 22 protrudes toward the brake body 1 on a ring-shaped surface 11 s on the side facing the brake body 1. Accordingly, the mounting protrusion 22 is also formed using an aluminum-silicon based aluminum alloy as a base material. The attachment protrusion 22 can be inserted into each attachment hole 12 of the brake body 1.

  As shown in FIG. 2, the mounting hole 12 of the brake body 1 includes an inner peripheral wall surface 15 that is an inner wall surface thereof. The inner peripheral wall surface 15 has a first slope 16 having a slope in a cross section cut along the central axis Pa of the mounting hole 12 (cross section cut along the central axis Pe of the mounting protrusion 22). The first gradient 16 is inclined at an angle θ1 (see FIG. 2) with respect to the central axis Pa of the mounting hole 12. Therefore, the inner peripheral wall surface 15 of the mounting hole 12 has a conical surface shape. With respect to the mounting hole 12, if the inner diameter of the insertion opening 12a on the side where the mounting protrusion 22 is inserted is Da (see FIG. 2) and the inner diameter of the protruding opening 12b from which the mounting protrusion 22 protrudes is Db (see FIG. 2), Db is set larger than the inner diameter Db. In addition, the depth of the attachment hole 12 is shown as H1 (refer FIG. 2).

  As shown in FIG. 3, the mounting protrusion 22 includes an outer peripheral wall surface 23 that is an outer wall surface thereof. The outer peripheral wall surface 23 is a cross section cut along the central axis Pe of the mounting protrusion 22 and has a second gradient 24 having an inclination. The second gradient 24 has a gradient opposite to the first gradient 16 and is inclined at an angle θ2 (see FIG. 3) with respect to the central axis Pe of the mounting protrusion 22. Therefore, the outer peripheral wall surface 23 of the mounting protrusion 22 has a conical surface shape. Of the mounting projections 22, the outer diameter of the distal end surface 25 of the distal end portion 27 inserted into the mounting hole 12 is De, and the outer diameter of the mounting projection 22 on the proximal end 26 side is Df. Here, the outer diameter De is set smaller than the outer diameter Df. The amount of protrusion of the mounting protrusion 22 is indicated as H2. The protrusion amount H2 of the attachment protrusion 22 is set to be larger than the depth H1 of the attachment hole 12 (H2> H1).

  In the fitting and placing step, the fitting protrusions 22 of the hat portion 2 are fitted into the respective attachment holes 12 of the brake main body 1, and the hat portion 2 is arranged on the inner peripheral side of the brake main body 1. In the fitting and arranging step, as shown in FIG. 4, the mounting protrusions 22 of the hat portion 2 are respectively fitted into the mounting holes 12 of the brake body 1. In this case, as shown in FIG. 5, a ring-shaped gap 3 is formed between the outer peripheral wall surface 23 of the mounting protrusion 22 and the inner peripheral wall surface 15 of the mounting hole 12. The gap 3 is set to a gap width in which the gap width ta (see FIG. 5) increases toward the tip end face 25 of the mounting protrusion 22.

  As shown in FIG. 5, in the state in which the mounting protrusions 22 of the hat portion 2 are fitted in the mounting holes 12 of the brake body 1, the tip surface 25 of the mounting protrusion 22 protrudes from the peripheral edge 12 c of the mounting hole 12 by the dimension ΔH. ing. The dimension ΔH is necessary to secure a material meat portion that fills the space of the gap 3. Although it sets suitably according to the volume etc. of the clearance gap 3, 0.5-3 millimeters and 0.8-1.5 millimeters are illustrated. However, it is not limited to this. In the fitting and placing step, as shown in FIGS. 4 and 5, the mounting hole 12 has an insertion opening 12a having a relatively small inner diameter and a protruding opening 12b having a relatively large inner diameter. Here, the insertion opening 12a of the mounting hole 12 is located below the protruding opening 12b. The protruding opening 12b is positioned above the insertion opening 12a.

  In the friction stir welding process, a rotating jig 4 having high rigidity is used. The rotating jig 4 has a flat tip pressure surface 40 and an outer peripheral wall surface 41 having a cylindrical cross section. As can be understood from FIG. 5, the outer diameter of the rotating jig 4 is set to be smaller than the outer diameter of the distal end surface 25 of the mounting protrusion 22.

  Then, in a state where the brake body 1 and the hat portion 2 are fixed, the rotating jig 4 is rotated in one direction around the central axis Pk thereof. While rotating the rotating jig 4, the rotating jig 4 is pressurized along the direction of the arrow Y <b> 1 (direction along the central axes Pa and Pe), and the tip pressing surface 40 of the rotating jig 4 is moved to the tip surface of the mounting protrusion 22. A pressure is applied to 25 and brought into contact. Here, due to the rotation of the rotating jig 4, frictional heat is generated on the front end face 25 side of the mounting protrusion 22. The tip 27 of the mounting protrusion 22 is partially softened or melted by the frictional heat. The rotating jig 4 exerts a pressing force in the direction of the arrow Y1. For this reason, the mounting protrusion 22 is expanded and deformed in the radially outward direction (arrow X1 direction, see FIG. 5). As a result, the outer peripheral wall surface 23 of the attachment protrusion 22 of the hat portion 2 is brought into close contact with and joined to the inner peripheral wall surface 15 of the attachment hole 12 of the brake body 1. As a result, the brake body 1 and the hat portion 2 are integrally connected (see FIG. 6). Since the tip pressing surface 40 of the rotating jig 4 is strongly pressed in the direction of the arrow Y1, a kind of forging effect is expected, and the metal structure is densified. In this sense as well, it can contribute to increase the bonding strength.

  When the tip 27 of the mounting protrusion 22 is partially melted by the frictional heat generated based on the rotation of the rotating jig 4 in the friction stir welding process described above, the melted portion has fluidity. The jig 4 is cooled and re-solidified while spreading outward in the radial direction by the pressing of the jig 4. It is also expected that centrifugal force based on the rotation of the rotating jig 4 acts on the melted portion and spreads outward in the radial direction. In the friction stir welding process, since the tip pressing surface 40 of the rotating jig 4 is strongly pressed in the direction of the arrow Y1, a kind of forging effect is expected, the structure is densified, and the holes such as pinholes are formed. It can also contribute to reduction. Furthermore, since the cooling rate of the melted and re-solidified portion is high and the melted portion is rapidly cooled, the solidified structure is refined and the strength of the solidified structure is improved. In this sense, it can contribute to increase the strength of the joint. Thus, in the friction stir welding process, a part of the mounting protrusion 22 is solidified after being melted, so that the deformability of the mounting protrusion 22 is largely ensured.

  The material of the rotating jig 4 is preferably a material having high heat resistance. For example, heat resistant steel (SKD material) is exemplified. Although the rotation speed of the rotation jig | tool 4 is set suitably, 500-10000rpm, 1000-5000rpm, 2000-4000rpm, 2500-3500rpm are illustrated. However, it is not limited to these.

  According to the present embodiment, the outer peripheral wall surface 41 of the rotating jig 4 has a perfect circle shape in a cross section orthogonal to the central axis Pk of the rotating jig 4. In this case, it is easy to manufacture the rotating jig 4, and the manufacturing cost of the rotating jig 4 is reduced.

  However, depending on the case, the major axis / minor axis may be an elliptical shape of about 1.01 to 1.2. In this case, even when the gap width is large, the distal end portion 27 of the mounting projection 22 is biased in the radially outward direction so that the outer peripheral wall surface 23 of the mounting projection 22 is closely bonded to the inner peripheral wall surface 15 of the mounting hole 12. The effect can be expected.

  According to the present embodiment, in the friction stir welding process described above, some of the mounting protrusions 22 may be solidified after being melted. In this case, since the melted portion is more fluid than the solid portion, the deformability of the mounting protrusion 22 is increased, and the gap 3 can be filled well. Since the aluminum-silicon alloy constituting the mounting protrusion 22 has good castability, the gap 3 can be filled well. In addition, since the cooling rate of the solidified portion after melting is high, the solidified structure is refined, and the strength of the joint is also increased in this case.

  FIG. 6 shows a state immediately before the end of the friction stir welding process. As shown in FIG. 6, the tip pressing surface 40 of the rotating jig 4 is pushed into the tip portion 27 side of the mounting protrusion 22. FIG. 7 shows a state where the friction stir welding process is completed. When the friction stir welding process is completed, the front end surface 25 of the mounting protrusion 22 is substantially flush with the peripheral edge 12c of the mounting hole 12 (the surface 11x of the brake body 1). As shown in FIGS. 6 and 7, each mounting protrusion 22 of the hat portion 2 fills the space of the mounting hole 12 of the brake body 1 and is joined to the brake body 1. This ensures good slip-off resistance. Here, the first slope 16 of the inner peripheral wall surface 15 of the attachment hole 12 has an inclination that exhibits resistance against the attachment protrusion 22 of the hat portion 2 coming out of the attachment hole 12. Can function. For this reason, the retaining property of the brake body 1 and the hat portion 2 is further ensured. In addition, as shown in FIG. 7, a concave portion 22 h that is an indentation mark of the distal end pressing surface 40 of the rotating jig 4 is formed on the distal end surface 25 of the mounting protrusion 22 after the friction stir welding process is performed. .

  According to the present embodiment, as shown in FIG. 7, at least one of the brake body 1 and the hat part 2 is provided with an anticorrosion film so that the anticorrosion film 5 is located between the brake body 1 and the hat part 2. 5 is coated. Specifically, the anticorrosion film 5 is coated on the surface of the hat portion 2 made of an aluminum alloy as a base material on the side in contact with the brake body 1. The anticorrosion film 5 has high electrical insulation, and examples thereof include a paint film, an alumite treatment film, and a resin film. However, the anticorrosion film 5 may be provided as necessary, and may be abolished in some cases.

  FIG. 8 shows a plan view of the completed brake disc. M1 and M2 indicate orthogonal lines that define the central axes P1 and P2. As shown in FIG. 8, the hat portion 2 is coaxially disposed on the inner peripheral side of the brake body 1. Therefore, the central axis P1 of the brake body 1 and the central axis P2 of the hat portion 2 are arranged coaxially. The plurality of mounting protrusions 22 are formed at equal intervals along a virtual arc M4 around the central axis P1. In the hat portion 2, main holes 29 are formed at equal intervals along a virtual arc M5 around the central axis P2. The brake disc is attached to the wheel side by a fixture (not shown) inserted through the main hole 29.

  In the above-described friction stir welding process, two rotation jigs 4 are prepared out of the plurality of mounting protrusions 22, and two of them that are symmetrical with respect to the central axes P1 and P2 are friction stir welded. . That is, as shown in FIG. 8, the attachment protrusions 22a and 22b are positioned symmetrically with respect to the central axes P1 and P2. The attachment protrusions 22c and 22d are positioned symmetrically with respect to the central axes P1 and P2. The attachment protrusions 22e and 22f are positioned symmetrically with respect to the central axes P1 and P2. The mounting protrusions 22g and 22h are positioned symmetrically with respect to the central axes P1 and P2. The attachment protrusions 22i and 22k are positioned symmetrically with respect to the central axes P1 and P2. According to the present embodiment, the mounting protrusions 22a and 22b that are symmetrically arranged are simultaneously friction stir welded. The mounting protrusions 22c and 22d, which are arranged symmetrically, are simultaneously friction stir welded. The mounting protrusions 22e and 22f, which are arranged symmetrically, are simultaneously friction stir welded. The mounting protrusions 22g and 22h, which are arranged symmetrically, are simultaneously friction stir welded. The mounting protrusions 22i and 22k, which are arranged symmetrically, are simultaneously friction stir welded. As described above, the two mounting protrusions 22 that are symmetrically arranged are simultaneously friction stir welded, which is advantageous in maintaining the uniformity of joining.

  Moreover, according to this embodiment, it is not limited to the above-mentioned joining form, You may decide to carry out friction stir welding of the some attachment protrusion 22 in order one each. Alternatively, the three attachment protrusions 22 may be simultaneously friction stir welded. Alternatively, the five mounting protrusions 22 may be simultaneously friction stir welded. In some cases, all the mounting protrusions 22 may be friction stir welded simultaneously.

(Embodiment 2)
10 and 11 show the second embodiment. This embodiment has basically the same configuration and the same operation and effect as the first embodiment. As shown in FIG. 10, the mounting hole 12 </ b> B includes a first hole 121 formed in the brake body 1 and a ring-shaped second hole 122 having an inner diameter larger than the inner diameter of the first hole 121. . The first hole 121 and the second hole 122 are coaxial. As shown in FIG. 10, when the attachment protrusion 22 is fitted in the attachment hole 12 </ b> B, the second hole 122 is located on the distal end portion 27 side of the attachment protrusion 22.

  FIG. 11 shows a state immediately before the end of the friction stir welding process. As shown in FIG. 11, the tip pressing surface 40 of the rotating jig 4 is pressed into the tip surface 25 of the tip portion 27 of the mounting protrusion 22. As shown in FIG. 11, the distal end portion 27 of the mounting projection 22 is deformed in the radially outward direction to form an engaging portion 22m. The engaging portion 22 m is embedded in the second hole 122 and engaged with the second hole 122. As a result, the ability to prevent the brake body 1 and the hat portion 2 from coming off is further secured.

(Embodiment 3)
FIG. 12 shows a third embodiment. This embodiment has basically the same configuration and the same operation and effect as the first embodiment. As shown in FIG. 12, when the inner diameter of the protruding opening 12b of the mounting hole 12 (the maximum inner diameter of the mounting hole 12) is set to 100 in relative display, the rotational jig 4 has an outer diameter of 80 or more. The outer diameter of the tool 4 is increased. In this case, when the rotating jig 4 pressurizes the distal end portion 27 of the mounting protrusion 22 and pushes it in the direction of the arrow Y1 (pressing direction), the material pushing amount is secured and the material spreads in the radially outward direction. For this reason, there is an advantage that the outer peripheral wall surface 23 of the mounting projection 22 can be easily bonded to the inner peripheral wall surface 15 of the mounting hole 12.

(Embodiment 4)
FIG. 13 shows a fourth embodiment. This embodiment has basically the same configuration and the same operation and effect as the first embodiment. According to the present embodiment, the dimension ΔH shown in FIG. Therefore, when the friction stir welding step is performed, as shown in FIG. 13, the protruding portion 22 w protruding toward the rotating jig 4 from the protruding opening 12 b of the mounting hole 12 (opening having the maximum inner diameter of the mounting hole 12) is formed. It is formed in a bowl shape. The outer diameter of the protruding portion 22 w is larger than the inner diameter of the protruding opening 12 b of the mounting hole 12. For this reason, the protruding portion 22w prevents the mounting protrusion 22 of the hat portion 2 from coming off from the mounting hole 12 of the brake body 1. Therefore, the retaining effect is improved.

(Embodiment 5)
FIG. 14 shows a fifth embodiment. This embodiment has basically the same configuration and the same operation and effect as the first embodiment. As shown in FIG. 14, the distal end portion 400 (lower end portion) of the rotating jig 4B has a conical shaft shape, and has a flat distal end pressure surface 40B and an outer peripheral wall surface 41B having a conical surface shape. The outer peripheral wall surface 41 </ b> B has a conical shape with a diameter decreasing toward the attachment protrusion 22. As shown in FIG. 14, when the distal end portion 400 of the rotating jig 4B is pushed into the distal end surface 25 of the mounting protrusion 22, an urging force is applied in a direction perpendicular to the outer peripheral wall surface 41B of the rotating jig 4B (arrow E1 direction). generate. For this reason, the front-end | tip part which the attachment protrusion 22 fuse | melted or softened is urged | biased by arrow E1 direction by the outer peripheral wall surface 41B of the rotation jig 4B. For this reason, the outer peripheral wall surface 23 of the attachment protrusion 22 is easily joined tightly to the inner peripheral wall surface 15 of the attachment hole 12 and can contribute to densification of the joint portion.

(Embodiment 6)
Since this embodiment basically has the same configuration and the same function and effect as those of the first embodiment, FIGS. 1 to 9 are applied mutatis mutandis. The hat portion 2 is formed using an aluminum-silicon based aluminum alloy as a base material. The amount of silicon is 11 to 15%, and the aluminum alloy has a hypereutectic composition.

(Embodiment 7)
Since this embodiment basically has the same configuration and the same function and effect as those of the first embodiment, FIGS. 1 to 9 are applied mutatis mutandis. The hat portion 2 is formed using a magnesium alloy as a base material. Examples of magnesium alloys include magnesium-aluminum, magnesium-zinc, magnesium-aluminum-zinc, magnesium-zirconium-zinc, and magnesium-manganese.

(Embodiment 8)
FIG. 15 shows an eighth embodiment. This embodiment has basically the same configuration and the same operation and effect as the first embodiment. As shown in FIG. 15, a caliper 60 is provided that applies a friction material to the friction sliding surface 13 of the friction sliding portion 11 of the brake disk to apply braking.

(Other)
According to the above-described embodiment, the rotating jig 4B is formed of heat resistant steel, but may be formed of titanium alloy, ceramics, or the like. According to the above-described embodiment, the outer diameter of the rotating jig 4 is set to be smaller than the outer diameter of the distal end surface 25 of the mounting projection 22, but not limited to this, as long as the dimension ΔH is secured, The outer diameter of the rotating jig 4 may be set larger than the outer diameter of the distal end surface 25 of the mounting protrusion 22. The present invention is not limited to the embodiment described above and shown in the drawings, and can be implemented with appropriate modifications within a range not departing from the gist. Configurations and functions specific to one embodiment can be applied to other embodiments. Therefore, the features of a plurality of embodiments can be merged.

  The present invention can be applied to disc brake devices for vehicles, industrial equipment, and the like.

It is sectional drawing which shows a brake main body and a hat part. It is sectional drawing which shows the attachment hole vicinity of a brake main body. It is sectional drawing which shows the attachment protrusion vicinity of a hat part. It is sectional drawing which shows the state just before fitting the attachment protrusion of a hat part in the attachment hole of a brake main body. It is sectional drawing which shows the state which has fitted the attachment protrusion of the hat part in the attachment hole of the brake main body. It is sectional drawing which shows the state which deform | transforms the attachment protrusion of a hat part with a rotation jig, and has closely attached the attachment protrusion to the inner peripheral wall surface of the attachment hole of a brake main body. It is sectional drawing which shows the state which deform | transformed the attachment protrusion of the hat part and closely attached the attachment protrusion to the inner peripheral wall surface of the attachment hole of the brake body. It is a front view of a brake disc. It is sectional drawing of a brake disc. FIG. 10 is a cross-sectional view illustrating a state in which the attachment protrusion of the hat portion is fitted in the attachment hole of the brake body according to the second embodiment. FIG. 10 is a cross-sectional view illustrating a state in which the attachment protrusion of the hat portion is deformed by a rotating jig and the attachment protrusion is closely bonded to the inner peripheral wall surface of the attachment hole of the brake body according to the second embodiment. FIG. 10 is a cross-sectional view illustrating a state in which the attachment protrusion of the hat portion is deformed by a rotating jig and the attachment protrusion is closely bonded to the inner peripheral wall surface of the attachment hole of the brake body according to the third embodiment. FIG. 10 is a cross-sectional view illustrating a state in which the attachment protrusion of the hat portion is deformed by a rotating jig and the attachment protrusion is closely bonded to the inner peripheral wall surface of the attachment hole of the brake body according to the fourth embodiment. FIG. 10 is a cross-sectional view illustrating a state in which the attachment protrusion of the hat portion is deformed by a rotating jig and the attachment protrusion is closely bonded to the inner peripheral wall surface of the attachment hole of the brake body according to the fifth embodiment. FIG. 10 is a perspective view showing a disc brake device according to Embodiment 8 and showing a state in which a caliper is mounted.

Explanation of symbols

  1 is a brake body, 10 is a central opening, 11 is a friction sliding portion, 12 is a mounting hole, 13 is a friction sliding surface, 15 is an inner peripheral wall surface (inner wall surface), 16 is a first gradient, 2 is a hat portion ( (Mounting plate body), 20 is a disk portion, 22 is a mounting protrusion, 23 is an outer peripheral wall surface (outer wall surface), 24 is a second gradient, 25 is a tip surface, 27 is a tip portion, 4 is a rotating jig, and 40 is a tip added. The pressure surface, 41 is an outer peripheral wall surface, and 5 is an anticorrosion film.

Claims (4)

(I) A friction sliding portion having a ring shape having a central opening and friction sliding with a mating member, and a plurality of attachments formed at intervals in a circumferential direction around the central axis of the friction sliding portion A brake body based on a cast iron material provided with holes,
An aluminum alloy or a magnesium alloy is used as a base material, and a disk portion disposed in the central opening of the brake body and a central axis of the disk portion so as to be inserted into the mounting holes of the brake body, respectively. A plurality of mounting protrusions formed at intervals in the circumferential direction, and preparing a mounting plate body to be mounted on the wheel side;
(Ii) a fitting and arranging step of fitting the mounting projections of the mounting plate body into the mounting holes of the brake body and arranging the mounting plate body on the inner peripheral side of the brake body;
(Iii) While rotating the rotating jig, the outer surface of the mounting protrusion is deformed by bringing the tip of the mounting protrusion into contact with the tip of the mounting protrusion and deforming the shape of the mounting protrusion by frictional heat generated by the rotation of the rotating jig. A method of manufacturing a brake disc, comprising: sequentially joining a friction stir welding step of joining the brake main body and the mounting plate body together by joining to an inner wall surface of the mounting hole. In claim 1, at least one of the outer wall surface of the mounting protrusion and the inner wall surface of the mounting hole has a gradient in a cross section cut along the central axis of the mounting protrusion,
In the fitting and arranging step, when the mounting protrusions of the mounting plate body are respectively fitted to the mounting holes of the brake body, a gap is formed between the outer wall surface of the mounting protrusion and the inner wall surface of the mounting hole. And the gap is set so that the gap width increases toward the tip end surface of the mounting projection.   3. The method of manufacturing a brake disk according to claim 1, wherein in the friction stir welding step, at least a part of the mounting protrusion is solidified after being melted.   4. The anticorrosion film according to claim 1, wherein at least one of the brake main body and the mounting plate body is positioned between the brake main body and the mounting plate body. 5. A method for manufacturing a brake disc, characterized in that:

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