JP2014104490A - Manufacturing method of brake disc - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of a brake disc capable of reducing cost, without impairing an aesthetic appearance, in the manufacturing method of the brake disc having an outer peripheral shape of a recess-projection repeating shape of repeating a radial directional recess-projection in the circumferential direction.SOLUTION: The manufacturing method comprises a punching process of punching the brake disc of a recess-projection repeating shape of the outer peripheral shape from a plate material by a press and a chamfering process of forming a chamfering surface by cutting a corner part of the brake disc by a blade tool 6 guided to a copying member 7 moving along the outer peripheral edge of the brake disc for removing a burr generated in the corner part between the outer peripheral edge and a side surface of the brake disc by the punching process, and the chamfering process is executed in a state of correcting strain in the plate thickness direction of a disc body by a correction member 9 for pressing the side surface of the brake disc.

Description

  The present invention relates to a method for manufacturing a brake disk used in a disk brake device such as a motorcycle, and more particularly, to a method for manufacturing a brake disk having an outer circumferential shape having a concave and convex shape in which radial unevenness is repeated in the circumferential direction.

  Conventionally, a method described in Patent Document 1 is known as a method for manufacturing this type of brake disk. This is a punching process in which a brake disk with an uneven outer peripheral shape is pressed from a plate material with a press, and a corner part between the outer peripheral edge and the side surface of the brake disk is pressed with a chamfering mold to plastically deform to form a chamfered surface. Chamfering process.

  Here, since the brake disc is an external part, an improvement in aesthetics is desired. In the above-mentioned conventional example, the chamfering mold is pressed so as to crush the burr generated at the corner between the outer peripheral edge and the side surface of the brake disk in the punching process, so that the crushing burr remains on the chamfered surface. . Further, if the punched and molded disk main body has variations in plate thickness or distortion in the plate thickness direction, the chamfering mold does not hit evenly, and a uniform chamfered surface cannot be obtained over the entire circumference.

  Furthermore, if the brake disc is of a multi-model, low-volume production, a chamfering mold is required for each model, resulting in an increase in cost.

JP 2008-232441 A

  In view of the above points, an object of the present invention is to provide a method for manufacturing a brake disk that can reduce the cost without impairing the aesthetic appearance.

  In order to solve the above problems, the present invention is a method of manufacturing a brake disk having an outer circumferential shape of a concave / convex repeating shape in which radial irregularities are repeated in the circumferential direction, the outer peripheral shape of the brake disk having the concave / convex repeating shape. A punching tool guided by a copying member that moves along the outer peripheral edge of the brake disk in order to remove a burr generated at the corner between the outer peripheral edge and the side surface of the brake disk in the punching process. A chamfering step of cutting the corner portion of the brake disc to form a chamfered surface, and the chamfering step is performed in a state where the distortion in the thickness direction of the disc body is corrected by a correction member that presses the side surface of the brake disc. It is characterized by that.

  According to the present invention, since the chamfered surface is formed by cutting the corner portion between the outer peripheral edge and the side surface of the brake disc with the cutting tool, no burr remains. In addition, since the correction is performed in a state in which the distortion in the plate thickness direction of the disc main body is corrected by the correction member, the cutting tool comes into contact with the corners of the outer peripheral side and the side surface of the brake disc uniformly, and the chamfered surface is uniform over the entire circumference. Can improve aesthetics. Further, since the cutting tool is guided by the copying member that moves along the outer peripheral edge, it is not necessary to replace the cutting tool regardless of the brake disc model, and the cost can be reduced in the multi-model small-volume production.

  Further, in the present invention, the straightening member has a circular outer peripheral shape, and the outer diameter of the straightening member is obtained by cutting the corner portion between the smallest outer diameter portion and the side surface of the outer peripheral edge of the brake disc with the cutting tool. It is desirable to set the outer diameter of the correction member as large as possible within a range in which the blade does not interfere with the blade. According to this, it is possible to effectively correct the distortion in the plate thickness direction of the disc body by pressing the brake disc over as wide a range as possible while avoiding interference between the correction member and the cutting tool. .

  Further, in the present invention, the correction member has an outer peripheral shape similar to the outer peripheral shape of the brake disc, and the outer diameter of the irregularities of the correction member is determined by the corners between the respective portions of the outer peripheral edge of the brake disc and the side surfaces. When cutting with the cutting tool, it is set so that the cutting tool does not interfere with the correction member. Preferably, the outer diameter of each part of the correction member is made as large as possible within a range in which the cutting tool does not interfere. According to this, while avoiding the interference between the correction member and the cutting tool, the brake disc is pressed over the widest possible range by the correction member in accordance with the outer peripheral shape of the brake disc, The distortion in the thickness direction can be effectively corrected.

The side view of the floating type brake disc to which the embodiment of the present invention is applied. The figure which shows the chamfering process of embodiment of this invention. The figure which shows the state corrected with the correction member of FIG.

  Hereinafter, an embodiment in which the present invention is applied to a floating brake disc will be described. The floating brake disc is composed of a rotor 1 and a hub (not shown) that is disposed inside the rotor 1 and is fixed to an axle (not shown) of a vehicle such as a motorcycle. On the inner periphery of the rotor 1, four projecting pieces 2 projecting radially inward are formed at predetermined intervals in the circumferential direction. Then, the rotor 1 and the hub are connected through the fixing hole 21 formed in the protruding piece 2.

  The rotor 1 has a concavo-convex outer peripheral shape in which a radial concave portion 3 and a convex portion 4 are repeated in the circumferential direction. In addition, the number of the recessed parts 3 and the convex parts 4 may be more or less than what is shown by FIG. A plurality of circular holes 5 are formed in a portion where a brake pad (not shown) of the rotor 1 is in sliding contact. The outer punch hole 5 has a larger hole diameter than the inner punch hole 5 and is formed in the same circumferential direction as the convex portion 4.

  Next, a method for manufacturing the rotor 1 of the floating brake disc will be described. First, a punching process is performed in which the rotor 1 whose outer peripheral shape is the concavo-convex shape is punched from one side in the plate thickness direction of the plate with a press. In this punching process, burrs are generated at the corner between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction. Thereafter, the inner punch hole 5 and the outer punch hole 5 are pierced in order on the rotor 1, and the inner circumference of the rotor 1 is further processed.

  Next, as shown in FIG. 2, a chamfering process is performed using the blade 6 and the copying member 7. The cutting tool 6 is disposed so that the tip formed in a taper shape is in contact with the corner between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction, and is rotated by a driving means (not shown). The copying member 7 is arranged so that the tip thereof is in contact with the outer peripheral edge of the rotor 1. Although not shown, the blade 6 and the copying member 7 are coupled so as to move together in the radial direction of the rotor 1, and transmit the movement of the copying member 7 to the blade 6. The rotor 1 is mounted on a mounting table 8 slightly smaller than the rotor 1, and is rotated by a drive shaft 81 connected to the mounting table 8.

  Then, in order to remove burrs generated in the punching process, the copying member 7 is moved along the outer peripheral edge of the rotor 1 in the radial direction of the rotor 1 (left and right in FIG. 2), and the cutting tool 6 guided by the copying member 7 is used. Thus, a corner portion between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction is cut to form a chamfered surface.

  Here, the punched rotor 1 has variations in thickness and distortion in the thickness direction. Therefore, the chamfering process of the present embodiment is performed in a state where the distortion in the plate thickness direction of the rotor 1 is corrected by the correction member 9 that presses one side surface of the rotor 1 in the plate thickness direction. The correction member 9 is applied with a pressing force from a pressing member 91 disposed on the upper surface thereof.

  As shown in FIG. 3, the correction member 9 has an outer peripheral shape that is similar to the outer peripheral shape of the rotor 1. Further, the outer diameter of the unevenness of the correction member 9 can be within a range in which the blade 6 does not interfere with the correction member 9 when the blade 6 cuts the corner between each part of the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction. Set as large as possible. For example, the outer diameter of each part of the correction member 9 is set so that the outer peripheral edge of the correction member 9 is positioned radially inward from the cutting tool 6 by a predetermined distance (for example, 1 mm) necessary for preventing interference. According to this, while avoiding the interference between the correction member 9 and the cutting tool 6, the rotor 1 is pressed over the widest possible range by the correction member 9 according to the outer peripheral shape of the rotor 1, Variations in the thickness of the rotor 1 and distortion in the thickness direction can be effectively corrected.

  Moreover, the correction member 9 may have a circular outer peripheral shape. In this case, the outer diameter of the correction member 9 is a range in which the cutting tool 6 does not interfere with the correction member 9 when the cutting tool 6 cuts the corner between the minimum outer diameter portion of the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction. Is set as large as possible. For example, the outer diameter of the correction member 9 is set so that the outer peripheral edge of the correction member 9 is positioned radially inward from the blade 6 by a predetermined distance (for example, 1 mm) necessary for preventing interference. According to this, while avoiding interference between the correction member 9 and the cutting tool 6, the rotor 1 is pressed over the widest possible range by the correction member 9, and the distortion in the plate thickness direction of the rotor 1 is effectively prevented. Can be corrected.

  In addition, a certain correction effect is acquired by making the outer periphery shape of the correction member 9 into the shape which presses at least the part which the brake pad of the rotor 1 slidably contacts.

  After performing the chamfering process, the rotor 1 is quenched. For this reason, the chamfered surface is formed in a state where the hardness of the corner portion between the outer peripheral edge and the side surface of the rotor 1 is low. As a result, the life of the cutting tool 6 is extended, and the cost can be reduced.

  Then, after quenching, processing such as drilling of the fixed holes 21 by machining, surface treatment, grinding of each side surface of the rotor 1 is performed.

  As described above, according to the present embodiment, the cutting edge 6 cuts the corner between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction to form a chamfered surface, so that no burr remains. In addition, since the correction member 9 corrects the distortion in the plate thickness direction of the rotor 1, the cutting tool comes into contact with the corner between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction. A uniform chamfered surface can be obtained, and the aesthetic appearance is improved.

  Here, if the correcting member 9 is not used, the cutting tool 6 may not be able to cut the corner portion between the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction with a constant width. On the other hand, according to the present embodiment, since the distortion in the plate thickness direction of the rotor 1 is corrected by the correction member 9, burrs generated at the corners of the outer peripheral edge of the rotor 1 and one side surface in the plate thickness direction have a constant width. The desired chamfered surface can be formed by removing the aesthetic appearance.

  Further, according to the present embodiment, since the cutting tool 6 is guided by the copying member 7 that moves along the outer peripheral edge, it is not necessary to replace the cutting tool 6 regardless of the brake disk model, and the multi-model small-volume production is possible. Cost reduction.

  As mentioned above, although embodiment of this invention was described with reference to drawings, this invention is not limited to this. For example, in the above-described embodiment, the case where the rotor 1 of the floating brake disc is manufactured has been described as an example. However, a single plate structure in which a portion where the brake pad slides and a portion where the axle is inserted is integrally formed. The invention can also be applied to the manufacture of brake discs.

  DESCRIPTION OF SYMBOLS 1 ... Rotor, 3 ... Concave part, 4 ... Convex part, 6 ... Cutting tool, 7 ... Copying means, 9 ... Correction means.

Claims (3)

A method for manufacturing a brake disc having a concave and convex outer circumferential shape in which radial irregularities are repeated in the circumferential direction,
A punching process in which the outer peripheral shape is punched out of the plate material by pressing the brake disk having the concave and convex shape repeatedly,
In order to remove burrs generated at the corners of the outer periphery and side surfaces of the brake disc in the punching process, the corners of the brake disc are cut by a cutting tool guided by a copying member that moves along the outer periphery of the brake disc. And a chamfering process for forming a chamfered surface,
The chamfering step is performed in a state in which distortion in the plate thickness direction of the disc main body is corrected by a correction member that presses a side surface of the brake disc.   The straightening member has a circular outer peripheral shape, and the outer diameter of the straightening member is such that the cutting tool does not interfere with the straightening member when the corner between the smallest outer diameter portion and the side surface of the outer peripheral edge of the brake disc is cut with the cutting tool. The method for manufacturing a brake disk according to claim 1, wherein the brake disk is set.   The correction member has an outer peripheral shape that is similar to the outer peripheral shape of the brake disc, and the outer diameter of the unevenness of the correction member is determined by cutting the corners of each part of the outer peripheral edge and the side surface of the brake disc with the cutting tool. 2. The method of manufacturing a brake disk according to claim 1, wherein the cutting tool is set so as not to interfere with the correction member.

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