JP2009299887A - Disk rotor and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve a problem with a conventional ventilated type disk rotor that the number of air passages which can be formed is limited. <P>SOLUTION: In this disk rotor 10, a plurality of air passages 14 are formed radially from the inner side to the outer peripheral edge direction between two cast plate-shaped members 12a, 12b. Each of the air passages 14 is partitioned by the adjacent air passage 14 and a metallic plate 16, and both ends 16a, 16b of the metallic plate 16 are cast into the corresponding plate-shaped members 12a, 12b. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a disk rotor and a method for manufacturing the same, and more particularly to a disk rotor in which a plurality of air passages are radially formed between two plate-like members from the inside to the peripheral direction and a method for manufacturing the same.

As shown in FIG. 7, the disk rotor used for automobile braking is mounted on the wheel hub 200. As such a disk rotor, a ventilated type disk rotor 100 (hereinafter, simply referred to as a disk rotor 100) with excellent cooling performance is adopted in accordance with demands for higher speed performance and improved reliability of automobiles. ing. In the disk rotor 100, a plurality of air passages 104, 104,... Are radially formed between the two plate-like members 102a, 102b from the inside to the peripheral direction.
Conventionally, all of the disk rotor 100 has been formed by casting. However, in order to improve the fuel consumption of an automobile, the disk rotor 100 is also required to be reduced in size and weight.
In order to meet the demands for reducing the size and weight of the disk rotor 100, the following Patent Document 1 discloses that the disk rotor 100 is manufactured by casting a steel plate forming the air passages 104, 104,. A manufacturing method has been proposed.

In the manufacturing method of such a disk rotor 100, first, as shown in FIG. 8A, a cast-in steel plate is formed. This cast-in steel plate is formed by laminating a disk-shaped steel plate 150a having a plurality of convex portions formed radially and a flat disk-shaped steel plate 150b, and the air passage convex portions 152, 152,. Is formed. Furthermore, a metal melt passage hole 154 is formed between the air passage convex portions 152 and 152.
The cast-in steel plate shown in FIG. 8A is sandwiched between the casting molds 156 as shown in FIG. 8B, and most of the air passage projections 152, 152 of the cast-in steel plate are formed in the cavity 158. Inserted inside. However, the inner peripheral surface side end portion and the outer peripheral surface side end portion of the air passage convex portions 152, 152 protrude from the cavity 158.
Next, after a molten metal is poured into the cavity 158 of the casting mold 156 shown in FIG. 8B and cooled, the disk rotor 100 is taken out of the casting mold 156, and as shown in FIG. 8C. The air passages 104, 104,... Surrounded by the steel plates 150a, 150b by cutting the end portions of the air passage convex portions 152, 152 protruding from the inner and outer peripheral surfaces of the plate-like members 102a, 102b. Can be formed.
Japanese Patent Publication No. 64-6500

The disk rotor 100 obtained by the manufacturing method shown in FIG. 8 can form the air passages 104, 104,... With the steel plates 150a, 150b, so that the strength of the disk rotor 100 is maintained even if the plate-like members 102a, 102b are thinned. It is possible to meet the demand for smaller and lighter weight.
Incidentally, in the disk rotor 100, it is preferable to form as many air passages 104, 104,.
However, in the disk rotor 100 manufactured by the manufacturing method shown in FIG. 8, since the air passages 104, 104,... Are formed by the steel plates 150a, 150b, the number of air passages 104, 104,. .
In addition, the manufacturing method shown in FIG. 8 is extremely difficult to bend each of the air passages 104, 104,... In the rotational direction of the disk rotor 100 in order to enhance the effect of exhausting air from each of the air passages 104, 104,. That is.
Therefore, the present invention solves the problem of the conventional ventilated type disk rotor in which the number of air passages that can be formed is limited, and is a ventilated type that can easily form significantly more air passages than in the past. An object of the present invention is to provide a disc rotor and a method of manufacturing the same.

As a result of studying the above problems, the present inventor has found that a plurality of air passages can be easily formed by separating each air passage from an adjacent air passage by a metal plate. did.
That is, the present invention is a disk rotor in which a plurality of air passages are radially formed between two cast plate-like members from the inside toward the outer peripheral edge, and each of the air passages is adjacent to each other. The disk rotor is separated from the passage by a metal plate, and both end portions of the metal plate on the plate-like member side are cast into the corresponding plate-like member.
Further, in the present invention, when a disk rotor in which a plurality of air passages are radially formed from the inside to the outer peripheral edge between two plate-like members is manufactured by casting, the air passages are adjacent to each other. After forming the core which the metal plate which separates from an air channel | path protrudes and hold | grips the both ends cast in the said plate-shaped member, the said core is equipped in the shaping | molding die for casting, and both ends of the said metal plate A disk rotor is manufactured by projecting each portion into a cavity for a plate-like member formed in the casting mold, and then pouring a molten metal into the cavity of the casting mold Is in the way.

In the present invention, by using a metal plate that curves in a predetermined direction as the metal plate, an air passage that curves in a predetermined direction can be formed, and air can be discharged efficiently with the rotation of the disk rotor.
Further, by forming a core that holds 80 or more metal plates, 80 or more air passages can be formed between the two plate-like members, and the cooling efficiency can be improved.
Furthermore, by forming through holes in both end portions of the metal plate protruding into the cavity for the plate member, each end portion of the metal plate cast into the two plate members is firmly fixed. it can.

In the disk rotor according to the present invention, the plurality of air passages formed between two cast plate-like members are adjacent to each other by a metal plate having end portions cast into the corresponding plate-like members. Therefore, the weight of the disk rotor can be easily reduced.
Moreover, a remarkably large number of air passages can be easily formed between the two plate-like members, and the cooling efficiency of the disk rotor can be remarkably improved.
Further, when a metal plate curved in a predetermined direction is used as the metal plate, an air passage curved in a predetermined direction can be formed, and air discharge efficiency can be improved.

An example of a ventilated type disk rotor according to the present invention is shown in FIG. FIG. 1A is a partial cross-sectional front view of a ventilated type disk rotor 10 that rotates in the direction of arrow A. FIG.
A ventilated type disk rotor 10 (hereinafter sometimes simply referred to as a disk rotor 10) shown in FIG. 1 (a) is provided between two cast donut-shaped plate-like members 12a and 12b. A large number of air passages 14, 14,... Are formed from the inner peripheral side toward the outer peripheral edge.
Each of the air passages 14, 14... Is separated from the adjacent air passage 14 by a metal plate 16. The metal plate 16 is a steel plate and is curved in the rotational direction of the disk rotor 10. Therefore, the air passages 14, 14... Formed between the two plate-like members 12 a and 12 b are also curved in the rotational direction of the disk rotor 10.
In this way, each of the air passages 14, 14,... Is curved in the rotational direction of the disk rotor 10, so that the donut-shaped plate member 12a is accompanied by the rotation of the disk rotor 10 in the arrow A direction. , 12b can be efficiently discharged from the inner peripheral side toward the outer peripheral side.

In the disk rotor 10 shown in FIG. 1, as shown in FIG. 1B, which is a partial cross-sectional view of the disk rotor 10 shown in FIG. 1A, both end portions 16 a on the plate-like members 12 a and 12 b side of the metal plate 16. , 16b are cast into the corresponding plate-like members 12a, 12b. For this reason, each of the metal plates 16, 16,... Is firmly fixed to each of the plate-like members 12a, 12b, and the disk rotor 10 can be sufficiently reinforced. For this reason, in order to further reduce the weight of the disk rotor 10, the plate-like members 12a and 12b can be formed thinner.
1, the mounting holes 18, 18,... For mounting the disk rotor 10 on the wheel hub 200 shown in FIG. 7 are extended from the inner peripheral edge of the plate member 12a toward the center. It is formed in the extension part 19.

The disc rotor 10 shown in FIG. 1 is manufactured by casting. The core 20 shown in FIG. 2 is used for such casting.
The core 20 is mainly formed by a donut-shaped core body 22 formed of sand and resin, as shown in FIG. Each of the plurality of metal plates 16, 16... Is held by the core body 22 along the outer peripheral edge thereof. Each of the metal plates 16, 16... Has an upper end portion 16 a protruding from the upper surface of the core body 22, and a lower end portion 16 b protruding into a concave groove 22 a formed on the lower surface side of the core body 22. ing.
As each of the metal plates 16, 16..., A metal plate 16 curved in a predetermined direction is used as shown in FIG. 2B which is a partial front view of the core 20.
The core 20 shown in FIG. 2 can be obtained by filling a mixture in which sand and resin are mixed into a core forming mold in which the metal plates 16, 16.

The core 20 shown in FIG. 2 is housed in a casting mold 30 as shown in FIG. The casting mold 30 is formed of sand and, if necessary, resin, and cavities 32 a and 32 b that form the plate-like members 12 a and 12 b of the disk rotor 10 are formed. Each end 16a, 16b of the metal plate 16 held by the core 20 protrudes from each of the cavities 32a, 32b.
Next, a molten metal is poured into each of the cavities 32a and 32b in the casting mold 30 and then cooled, and then the casting mold 30 and the core 20 are broken, and the cast disc shown in FIG. The rotor 10 is taken out.
The cavity 32 b formed in the casting mold 30 corresponds to the concave groove 22 a formed in the core 20.

Since the disk rotor 10 shown in FIG. 1 separates the air passages 14, 14,... By the metal plates 16, 16,..., 80 or more (preferably 100 or more) metal plates 16, 16,. In use, 80 or more (preferably 100 or more) air passages 14, 14,... Can be easily formed.
In this way, the disk rotor 10 in which 100 or more air passages 14, 14,... Are formed between the plate-like members 12a and 12b is shown in FIG. 8 where it is difficult to form 100 or more air passages. Compared with the conventional disk rotor 100, the cooling efficiency can be remarkably improved.
Further, as shown in FIG. 4, both end portions 16a and 16b of the metal plate 16 project from the upper surface of the core body 22 and project into the groove 22a formed on the lower surface side of the core body 22. The through holes 34 are preferably formed. When cast into the plate-like members 12a and 12b, the biting between the both end portions 16a and 16b of the metal plate 16 and the plate-like members 12a and 12b can be further improved, and the metal plate 16 is made to have the plate-like members 12a and 12b. It can be firmly fixed to.

In the disk rotor 10 shown in FIGS. 1 to 4 described above, the air passages 14, 14,... Curved in a predetermined direction are formed using the metal plates 16, 16,. However, as shown in FIG. 5, a straight air passage 14 may be formed using a straight metal plate 16. In the disk rotor 10 shown in FIG. 5, there is no limitation on the rotation direction.
Further, as shown in FIG. 6 (a), by projecting the metal pins 17, 17,... From the metal plate 16 toward the air passage 14, the heat radiation area of the metal plate 16 can be expanded, and the plate-like members 12a, 12a, The heat dissipation from 12b can be improved. Instead of the metal pins 17, 17..., Small pieces made of metal may be projected from the metal plate 16 as fins.
Further, as shown in FIG. 6 (b), the metal plate 16 may be provided with through holes 21, 21,. By forming the through holes 21, 21,... In the metal plate 16, even when the vehicle stops traveling, the heated air remains in the metal plates 16, 16 even if the discharge of air from the air passage 14 is stopped. It is possible to eliminate the risk that the brake oil or the like will be boiled due to the stagnation of the heated air during stoppage after passing through the through-holes 21 formed in each of the disc rotors 10 and being discharged from the disc rotor 10.
The metal pins 17, 17, and the through holes 21, 21, and the like may coexist on the same metal plate 16.
6 shows the straight metal plate 16, the metal plate 16 may also have the metal pins 17, 17... And the through holes 21, 21. -You may form one or both.

In the manufacturing method of the disk rotor 10 described so far, casting is performed using the casting mold 30 formed of sand and resin using the core 20, but casting may be performed using a die casting mold. Alternatively, casting may be performed using a disappearing mold.
This disappearing mold is formed by forming a mold having the same shape as the plate-like members 12a and 12b of the disk rotor 10 shown in FIG. 1 or 5 with a disappearing material that disappears in contact with the molten metal, for example, foamed polystyrene. The metal plates 16, 16,... Are inserted into predetermined positions of the molds for the plate-like members 12a, 12b made of polystyrene, and positioned to form a disappearing mold.
Next, after the disappearance mold is embedded in the casting sand, the molten metal is poured into the pouring gate so that the molten metal is filled into the cavity where the lost material portion disappears by contact with the molten metal, and the plate-like member 12a. , 12b, the disk rotor 10 shown in FIG. 1 or FIG. 5 in which the metal plates 16, 16,.

It is the fragmentary sectional front view and fragmentary sectional view explaining an example of the disc rotor concerning the present invention. It is sectional drawing and the partial front view explaining the core which manufactures the disk rotor shown in FIG. It is a fragmentary sectional view explaining the state which equipped the core shown in FIG. 2 in the shaping | molding die for casting. It is a fragmentary sectional view of the core explaining the other example of the metal plate 16 which can be used by this invention. It is a partial section and a partial front view explaining other examples of a disc rotor concerning the present invention. It is explanatory drawing explaining the other example of the metal plate 16 which can be used by this invention. It is a perspective view explaining a disk rotor. It is process drawing explaining the manufacturing process of the conventional disk rotor.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Disc rotor 12a, 12b Plate-like member 14 Air passage 16 Metal plate 16a, 16b Both ends 20 Core 22 Core body 22a Groove 30 Casting mold 32a, 32b Cavity 34 Through-hole

Claims (8)

A disk rotor in which a plurality of air passages are radially formed from the inside to the outer peripheral edge direction between two cast plate-like members,
Each of the air passages is separated from an adjacent air passage by a metal plate, and both end portions of the metal plate on the plate-like member side are cast into the corresponding plate-like member. Features a disc rotor.   2. Each of the air passages is an air passage that curves in a predetermined direction, and a metal plate that separates each of the air passages from an adjacent air passage is a metal plate that curves in a predetermined direction. Disc rotor.   3. The disk rotor according to claim 1, wherein 80 or more air passages are formed between the two plate-like members.   The disc rotor according to any one of claims 1 to 3, wherein a through hole is formed in each of both end portions of a metal plate cast into the plate-like member. When manufacturing a disk rotor in which a plurality of air passages are formed radially from the inside to the outer peripheral edge between two plate-like members by casting,
After forming the core that separates each of the air passages from the adjacent air passages, the cores projecting and gripping both ends cast into the plate member,
The core is housed in a casting mold, and both end portions of the metal plate protrude into a cavity for a plate-shaped member formed in the casting mold,
Subsequently, a molten metal is poured into the cavity of the casting mold, and the manufacturing method of the disk rotor is characterized by the following.   6. The method of manufacturing a disk rotor according to claim 5, wherein a metal plate curved in a predetermined direction is used as the metal plate so that an air passage curved in the processing direction can be formed.   The disk rotor manufacturing method according to claim 5 or 6, wherein a core for holding 80 or more metal plates is formed so that 80 or more air passages can be formed between two plate-like members.   The manufacturing method of the disk rotor as described in any one of Claims 5-7 which forms a through-hole in each of the both ends of the metal plate which protrudes in the cavity for plate-shaped members.

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