JP4024090B2 - Brake disk manufacturing method and intermediate product for brake disk - Google Patents

Brake disk manufacturing method and intermediate product for brake disk Download PDF

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JP4024090B2
JP4024090B2 JP2002180752A JP2002180752A JP4024090B2 JP 4024090 B2 JP4024090 B2 JP 4024090B2 JP 2002180752 A JP2002180752 A JP 2002180752A JP 2002180752 A JP2002180752 A JP 2002180752A JP 4024090 B2 JP4024090 B2 JP 4024090B2
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casting
intermediate product
machining allowance
mold
brake disk
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JP2004025190A (en
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寛 早坂
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Aisin Takaoka Co Ltd
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Aisin Takaoka Co Ltd
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Description

【0001】
【発明の属する技術分野】
本発明は、ブレーキディスクの製造方法と、その製造過程で生じるブレーキディスク用中間製品的鋳造品とに関するものである。
【0002】
【従来の技術】
形状が複雑で且つ高い表面加工精度が求められる鋳物製品として、例えば、ディスクブレーキ用のベンチレーテッドディスクがあげられる。この種のブレーキディスクでは、ディスクの内部に多数の通風孔を確保する必要から、鋳造時には鋳型内に、通風孔をかたどった中子を配置すると共に、鋳型内壁と中子との間にできた成形空間(キャビティ)内に金属溶湯を流し込むことで、中間製品としてのブレーキディスク鋳造品を鋳造している。ブレーキディスクの摩擦面(制動時にシューと接触摺動する面)には優れた平滑性が求められるため、鋳造品の鋳肌をそのままディスクの摩擦面として用いることはあり得ない。それ故、ブレーキディスク鋳造品の表面を所定の取代分だけ削り取ることにより、平滑な摩擦面を削り出して最終製品に仕上げている。つまり、中間製品の鋳造は、その後の切削加工で削り取ることになる取代を見込んだ鋳造となっている(例えば、特開平3−151138号公報参照)。
【0003】
【発明が解決しようとする課題】
しかしながら、従来の製造方法で得られる鋳物製品には、キライ不良の発生率が高いという問題があった。キライ(「吹かれ」ともいう)とは、鋳型内の成形空間に金属溶湯を流し込んだときに中子等から発生したガスが気泡となって金属溶湯中に紛れ込み、その気泡を巻き込んだまま金属が冷却固化することで鋳造品内部に形成される細かな穴や空間をいう(図7参照)。鋳造直後の鋳造品の外観を観察しただけではキライの有無はなかなか分からないが、平滑面の削り出しのために鋳造品の表面を切削したときにキライの存在が発覚することが多い。平滑化したい面にとってキライは致命的な凹状欠陥であるから、ブレーキディスク鋳造品にキライが見つかった場合、それはもはや最終製品(良品)とはなり得ず、不良品として廃棄するほかない。製造現場での経験則によれば、鋳鉄製ブレーキディスクにおけるキライ不良の発生率は1.4%以上にものぼる。キライ不良はブレーキディスク量産時の不良原因のうちでも最大のものとなっている。
【0004】
本発明はかかる事情に鑑みてなされたものである。本発明の目的は、キライ不良の発生率を従来よりも大幅に低減することが可能なブレーキディスクの製造方法を提供することにある。また、その製造方法による製造過程で生じるブレーキディスク用中間製品的鋳造品を提供することにある。
【0005】
【課題を解決するための手段】
請求項1の発明は、成形空間を区画するための内壁部の少なくとも一部に凹凸形状が付与されると共に通気性を有する鋳型と、中子とを用いて、前記凹凸形状を反映した凹凸を有する取代を含んだブレーキディスク用中間製品的鋳造品を鋳造する鋳造工程と、前記ブレーキディスク用中間製品的鋳造品から前記凹凸を有する取代を削り取る切削工程とを順次実行することを特徴とするブレーキディスクの製造方法である。
【0006】
この方法によれば、ブレーキディスク用中間製品的鋳造品の鋳造工程で用いられる鋳型は、鋳造時の成形空間を区画するための内壁部の少なくとも一部に凹凸形状が付与された鋳型であり、凹凸形状の付与によって当該内壁部の表面積は、凹凸が無い場合(即ち平らな内壁面)に比べて非常に大きくなっている。従って、成形空間内に金属溶湯を流し込むことで、凹凸形状が付与された当該内壁部に金属溶湯が接したときも、その接触面積は従来になく大きいので、金属溶湯から鋳型の内壁部へのガス移動性が飛躍的に向上する。このため、成形空間内に金属溶湯を流し込んだ際にガスが発生し、そのガスが気泡となって金属溶湯中に紛れ込んだとしても、そのガスの多くは金属溶湯が固化する前に凹凸形状が付与された内壁部を介して溶湯中から鋳型の方へ移動し、あるいは取代の領域内に移動する。故に、ブレーキディスク用中間製品的鋳造品にあっては、取代以外の部位(即ち最終製品となるべき部分)には、キライがあまり残らない。鋳造工程後の切削工程で、ブレーキディスク用中間製品的鋳造品から前記凹凸を有する取代を削り取ることで、目的とする鋳物製品(ブレーキディスク)を得ることができる。鋳造工程の工夫により、ブレーキディスク用中間製品的鋳造品の取代以外の部位にはキライがあまり残らないので、取代を削り取って得た製品がキライ不良となる確率は、従来よりも大幅に低減する。
【0008】
鋳型が所定の通気性を有することで、成形空間内に金属溶湯を流し込んだ際に金属溶湯中に紛れ込んだガスが、溶湯中から鋳型あるいは取代の領域内に向けて移動し易くなり、ブレーキディスク用中間製品的鋳造品の奥深くにキライが残存する事態を効果的に防止できる。従って、キライ不良の発生率を従来よりも大幅に低減することが可能となる。
【0010】
発明が解決しようとする課題の欄で説明したように、中子がキライの原因となるガスの発生源となることが多いことから、鋳造工程で中子を併用する場合には特に本発明の有用性が高い。なお、「前記中子が砂を有機材料で固めて形成したものである」とき、金属溶湯の熱で有機材料が燃焼し、その燃焼ガスがキライの原因となることから、そのような場合には尚更、本発明の有用性が高まる。
【0011】
請求項2の発明は、後加工により削り取られるべき取代を含んだブレーキディスク用中間製品的鋳造品であって、前記取代の少なくとも一部には、鋳造時に鋳型との接触面積を確保する目的で付与された凹凸が残されていることを特徴とするブレーキディスク用中間製品的鋳造品である。
【0012】
このブレーキディスク用中間製品的鋳造品は、請求項1の製造方法における鋳造工程を経て得られる中間製品である。このブレーキディスク用中間製品的鋳造品に対して適切な後加工(例えば切削加工)を施し、凹凸付きの取代を削り取れば、キライ不良のない鋳物製品(ブレーキディスク)をほぼ確実に得ることができる。
【0013】
なお、上記ブレーキディスク用中間製品的鋳造品の取代に残された凹凸としては、例えば、「取代の表面に同心円状に複数設けられた円弧状の溝」(請求項3)、「取代の表面に渦巻き状に設けられた螺旋溝」(請求項4)、又は「取代の表面にディンプル状に複数設けられた凹部」を例示することができる。
【0014】
【発明の実施の形態】
以下、本発明をディスクブレーキ用のベンチレーテッドディスクの製造に具体化した一実施形態について図面を参照しつつ説明する。最終製品としてのベンチレーテッドディスクは、図4(半径方向断面)に示すように、第1及び第2の摩擦面11,12を有する略円盤状のディスク本体部10、取付フランジ部20、並びに、ディスク本体部10と取付フランジ部20とを連結する円筒状のハット部30を備えている。ディスク本体部10には、複数の通風孔13(一つのみ図示)が半径方向に沿って放射状に貫通形成されている。取付フランジ部20は、その中心位置のインロー孔21と、複数のボルト挿通孔(図示略)とを備えている。図4のディスク製品は、鋳型及び中子を用いた鋳造工程と、その後の切削工程とを経て製造される。
【0015】
図1に示すように、鋳造用の鋳型としては上鋳型40と下鋳型50とが組み合わせて使用される。各鋳型は、砂とベントナイトとの混練物を圧縮して付き固めるながらそれぞれの形状に成形したものである。使用する砂の性質や配合割合を調節することで、各鋳型の通気性(通気度)をコントロールしている。また、図1から分かるように、上鋳型40の内壁部にはディスク製品の第1摩擦面11と対応する位置において、凹凸形状(即ち、断面波々形状)が付与されている。具体的には、上鋳型40の内壁部の当該位置には、鋳型の中心軸線を同心円状に取り囲む複数の溝41が形成されている。上鋳型40を下から見上げたとき、各溝41は周方向に延び円形状をなしている。
【0016】
図2に示すように、鋳造に際しては上下鋳型40,50の他に中子60が使用される。この中子60は、各通風孔13の内部形状や取付フランジ部20及びハット部30の内側形状をかたどったものであり、砂をレジンで固めて成形したものである。尚、レジンとは有機材料の一種であり、接着材として使用している。図2に示すように、上下両鋳型40,50間に中子60を配置した状態で両鋳型40,50を接合することにより、鋳型内には、成形空間(キャビティ)が区画される。この成形空間の形状及び大きさは、後述の切削加工により削り取られるべき取代を含んだ中間製品的鋳造品の形状及び大きさに対応する。
【0017】
鋳型の成形空間内に金属(例えば鋳鉄)の溶湯を流し込み、冷却固化後、上下鋳型40,50から型外しすることで、取代を含んだ中間製品的鋳造品(図3及び図6参照)が得られる。図3に示すように、その鋳造品には、第1摩擦面11に対応する取代部分の表面において、上鋳型内壁部の同心円状の溝41の形状を反映した同心円状の凹凸形状(図3の半径方向断面では波々形状)が付与されている。
【0018】
成形空間内に金属溶湯を流し込むことにより、その熱で中子60を構成するレジンが燃焼し、及び/又は、中子60に含まれる湿気が水蒸気と化す。流し込まれた金属溶湯が凹凸形状を付与した上鋳型40の内壁部に接したときも、その接触面積は、凹凸形状がない場合(即ち図7に示す平らな内壁面の場合)に比べて大きい。このため、上記燃焼ガスや水蒸気が気泡となって金属溶湯中に紛れ込んだとしても、それらのガスの多くは、金属溶湯が固化する前に凹凸形状が付与された内壁部を介して上鋳型40の方へ移動し、あるいは取代の領域内に移動する(図6参照)。従って、冷却固化後の中間製品的鋳造品において、取代以外の部位には、キライがあまり残らない。
【0019】
鋳造工程後、図3の中間製品的鋳造品に対しては、旋盤を用いて切削加工が施される。この切削加工を通じて、前記断面波々の凹凸形状が付与された取代が削り取られ、図4に示すような最終製品としてのベンチレーテッドディスクが完成する。前述のように、上鋳型40の内壁部の形状を断面波々形状とすることにより、中間製品的鋳造品の取代以外の部位にはキライがあまり残らないので、取代を削り取って得た製品がキライ不良となる確率は低い。
【0020】
(製造実験1及び2並びに比較実験)
図5に示すように、中間製品的鋳造品の取代に付与される凹凸形状において、断面略台形状の凸部の高さをa、その凸部の上辺の幅(即ち溝41の幅)をb、隣り合う凸部間の間隔をcとする。そして、製造実験1及び製造実験2として、a,b及びcの各値が表1に記載の値(単位はmm)となるような鋳造品を上記実施形態の手順でそれぞれ1000個ずつ製造する実験を行った。また、比較実験として、取代に凹凸がない従来の鋳造品(即ちa=0mm)を従来の製造手順で1000個製造する実験を行った。
【0021】
【表1】

Figure 0004024090
【0022】
表1は各実験の結果を示す。表1中、表面積とは、ディスクの第1摩擦面11に対応する取代部分の表面の表面積を比較した値であり、比較実験の鋳造品の表面積を100とした場合における相対値を示す。キライ不良率とは、切削加工により第1摩擦面11にキライが露出して不良品と判定された個体数の割合を示す。例えば比較実験における1.4%とは、1000個中14個にキライ不良があったことを示す。主軸の電流値とは、鋳造品に切削を施す際の旋盤の主軸にかかる電気的負荷の大きさ(平均値)を示し、その値は切削抵抗の大きさを間接的に示している。
【0023】
表1から分かるように、本発明に従う製造実験1及び2では、キライ不良率を比較実験(従来の方法)の場合よりも大幅に低減することができた。また、主軸の電流値も製造実験1及び2の方が比較実験の場合よりも小さくなっており、本発明によれば、切削加工時における切削抵抗の低減ひいてはエネルギー消費の低減を図ることができる。
【0024】
なお、比較実験並びに製造実験1及び2では、取代をいずれも2.5mmとしたが、製造実験1及び2に関しては凹凸付与の関係で、2.5mm厚の取代の全領域が金属で満たされるわけではない。製造実験2の中間製品的鋳造品について仮に取代部分の凹凸を均一にならして平坦化したならば、その場合の取代の厚みは約1.9mmに換算される。つまり、切削工程で削り取られる金属の量は、製造実験2の鋳造品では比較実験の鋳造品の1.9/2.5=76%に過ぎない。削り取られた金属は回収して再溶解(再利用)することになるが、再溶解に回す量が少ないほど、エネルギー効率及び生産効率が良いことは言うまでもない。この点で、製造実験1及び2は比較実験よりもエネルギー効率及び生産効率がよいと言える。
【0025】
(変更例)本発明の実施形態を以下のように変更してもよい。
・上記実施形態では、鋳型40の内壁部に付与する凹凸形状を、鋳型40の中心軸線を同心円状に取り囲む複数の円弧状溝41で構成した。これに代えて、鋳型の中心軸線を渦巻き状に取り巻く1条の螺旋溝を採用してもよい。あるいは、これらの溝に代えて、鋳型40の内壁部に、例えばディンプル状の凹部を複数形成し、その内壁面をデコボコした凹凸形状としてもよい。
【0026】
・上記実施形態では、ブレーキディスクのディスク本体部10の第1摩擦面11に対応する位置において、上鋳型40の内壁部に凹凸形状を付与した。これに代えて又はこれと共に、ディスク本体部10の第2摩擦面12に対応する位置において、下鋳型50の内壁部に凹凸形状を付与してもよい。また、ブレーキディスクの取付フランジ部20の上端面に対応する位置において、上鋳型40の内壁部に凹凸形状を付与してもよい。
【0027】
【発明の効果】
以上詳述したように本発明のブレーキディスクの製造方法によれば、キライ不良の発生率を従来よりも大幅に低減することが可能となる。また、本発明のブレーキディスク用中間製品的鋳造品によれば、これに適切な後加工(例えば切削加工)を施して凹凸付きの取代を削り取れば、キライ不良のないブレーキディスクをほぼ確実に得ることができる。
【図面の簡単な説明】
【図1】ブレーキディスク鋳造用の鋳型の半径方向断面図。
【図2】中子を配置した状態での鋳型の半径方向断面図。
【図3】中間製品的鋳造品の半径方向断面図。
【図4】最終製品としてのブレーキディスクの半径方向断面図。
【図5】中間製品的鋳造品における凹凸形状の寸法の説明図。
【図6】本発明におけるキライの発生状況を概念的に示す図。
【図7】従来例におけるキライの発生状況を概念的に示す図。
【符号の説明】
10…ディスク本体部、11…第1摩擦面、12…第2摩擦面、13…通風孔、40…上鋳型、41…溝(鋳型内壁部における凹凸形状を構成する)、50…下鋳型、60…中子。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a brake disk, and the intermediate product specific castings for brake discs caused by the manufacturing process.
[0002]
[Prior art]
As a cast product having a complicated shape and requiring high surface processing accuracy, for example, a ventilated disc for a disc brake can be mentioned. In this type of brake disc, it was necessary to secure a large number of ventilation holes inside the disc. Therefore, a core that shaped the ventilation holes was placed in the mold during casting, and it was formed between the inner wall of the mold and the core. By casting molten metal into the molding space (cavity), a brake disc casting as an intermediate product is cast. Since the friction surface of the brake disk (surface that slides in contact with the shoe during braking) is required to have excellent smoothness, the casting surface of the cast product cannot be used as the friction surface of the disk as it is. Therefore, by scraping the surface of the brake disc casting product by a predetermined machining allowance, the smooth friction surface is shaved to finish the final product. In other words, the casting of the intermediate product is a casting that allows for a machining allowance that will be scraped off in the subsequent cutting process (see, for example, JP-A-3-151138).
[0003]
[Problems to be solved by the invention]
However, the casting product obtained by the conventional manufacturing method has a problem that the occurrence rate of the defective defect is high. Kirai (also called “blow”) means that when the molten metal is poured into the molding space in the mold, the gas generated from the core and the like is bubbled into the molten metal, and the bubbles remain entrained. It refers to fine holes and spaces formed in the casting as the metal cools and solidifies (see FIG. 7). Just observing the appearance of the cast product immediately after casting makes it difficult to determine the presence or absence of clean, but often the presence of clear is detected when the surface of the cast product is cut to cut out a smooth surface. Since Kirai is a fatal concave defect for the surface to be smoothed, if it is found in a brake disc casting product, it can no longer be a final product (good product) and must be discarded as a defective product. According to empirical rules at the manufacturing site, the incidence of defects in cast iron brake discs is 1.4% or more. The failure is the biggest cause of brake disc mass production.
[0004]
The present invention has been made in view of such circumstances. An object of the present invention is to provide a method of manufacturing a brake disk that can significantly reduce the occurrence rate of defective defects as compared with the prior art. It is another object of the present invention to provide an intermediate product casting for a brake disc produced in the manufacturing process by the manufacturing method.
[0005]
[Means for Solving the Problems]
The invention according to claim 1, a mold having at least a portion irregularities is given to Rutotomoni breathable inner wall portion for partitioning the molding space, by using the core, the unevenness reflecting the uneven shape brake, wherein a casting step of casting an intermediate product specific castings for brake discs containing allowance, that sequentially executes a cutting step of scraping off allowance with the uneven from intermediate product specific castings for the brake disk having A method for manufacturing a disk .
[0006]
According to this method, the mold used in the casting process of the intermediate product for the brake disc is a mold in which a concavo-convex shape is imparted to at least a part of the inner wall part for defining the molding space at the time of casting, By providing the uneven shape, the surface area of the inner wall portion is much larger than when there is no unevenness (that is, a flat inner wall surface). Therefore, by pouring the molten metal into the molding space, even when the molten metal comes into contact with the inner wall portion provided with the irregular shape, the contact area is larger than before, so that the molten metal is transferred from the molten metal to the inner wall portion of the mold. Gas mobility is greatly improved. For this reason, even when a molten metal is poured into the molding space, gas is generated, and even if the gas is bubbled into the molten metal, most of the gas has an uneven shape before the molten metal solidifies. It moves from the inside of the molten metal to the casting mold through the inner wall portion provided, or moves into the machining allowance region. Therefore, in an intermediate product casting for a brake disc , there is not much clearness in the portion other than the machining allowance (that is, the portion to be the final product). In the cutting process after the casting process, the desired casting product (brake disk) can be obtained by scraping the machining allowance having the unevenness from the intermediate product for brake disk . As a result of the ingenuity of the casting process, there is not much clearance remaining in parts other than the removal allowance for intermediate products for brake discs, so the probability that a product obtained by removing the allowance will be significantly less than before is greatly reduced. .
[0008]
Because the mold has a predetermined air permeability, when the molten metal is poured into the molding space, the gas mixed in the molten metal easily moves from the molten metal to the mold or the area of the allowance, and the brake disk It is possible to effectively prevent a situation in which a ghost remains deep in the intermediate product casting. Therefore, it is possible to significantly reduce the occurrence rate of sharp defects as compared with the prior art.
[0010]
As explained in the section of the problem to be solved by the invention, since the core is often a source of gas causing the cracks, especially when the core is used together in the casting process, Highly useful. It should be noted that when “the core is formed by solidifying sand with an organic material”, the organic material is combusted by the heat of the molten metal, and the combustion gas causes cleanup. Still further, the usefulness of the present invention is enhanced.
[0011]
The invention of claim 2 is an intermediate product casting product for a brake disk including a machining allowance to be cut off by post-processing, and at least a part of the machining allowance is for the purpose of ensuring a contact area with a mold during casting. It is an intermediate product casting for a brake disc , characterized in that the provided irregularities remain.
[0012]
This brake disc intermediate product casting product is an intermediate product obtained through a casting process in the manufacturing method of claim 1 . Appropriate post-processing (for example, cutting) is performed on the intermediate product for brake discs, and the machining allowance with unevenness is removed, so that a cast product (brake disc) free from defects is almost certainly obtained. it can.
[0013]
In addition, as the unevenness remaining in the machining allowance of the intermediate product for the brake disk, for example, “a plurality of concentric circular grooves formed on the surface of the machining allowance” (Claim 3), “surface of machining allowance” The spiral groove provided in a spiral shape ” (Claim 4) or“ a plurality of concave portions provided in a dimple shape on the surface of the machining allowance ”can be exemplified.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment in which the present invention is embodied in the manufacture of a ventilated disc for a disc brake will be described with reference to the drawings. As shown in FIG. 4 (radial cross section), the ventilated disk as the final product has a substantially disc-shaped disk main body 10 having first and second friction surfaces 11 and 12, a mounting flange 20 and A cylindrical hat portion 30 for connecting the disc main body portion 10 and the mounting flange portion 20 is provided. A plurality of ventilation holes 13 (only one is shown) are formed in the disk main body 10 so as to penetrate radially along the radial direction. The mounting flange portion 20 includes an inlay hole 21 at the center thereof and a plurality of bolt insertion holes (not shown). The disc product of FIG. 4 is manufactured through a casting process using a mold and a core and a subsequent cutting process.
[0015]
As shown in FIG. 1, an upper mold 40 and a lower mold 50 are used in combination as a casting mold. Each mold is formed into each shape while compressing and solidifying a kneaded product of sand and bentonite. The air permeability (air permeability) of each mold is controlled by adjusting the properties and blending ratio of the sand used. As can be seen from FIG. 1, the inner wall portion of the upper mold 40 is provided with an uneven shape (that is, a wave shape in cross section) at a position corresponding to the first friction surface 11 of the disk product. Specifically, a plurality of grooves 41 that concentrically surround the central axis of the mold are formed at the position of the inner wall portion of the upper mold 40. When the upper mold 40 is looked up from below, each groove 41 extends in the circumferential direction and has a circular shape.
[0016]
As shown in FIG. 2, a core 60 is used in addition to the upper and lower molds 40 and 50 during casting. The core 60 is shaped like the internal shape of each ventilation hole 13 and the inner shape of the mounting flange portion 20 and the hat portion 30 and is formed by sanding with resin. The resin is a kind of organic material and is used as an adhesive. As shown in FIG. 2, a molding space (cavity) is defined in the mold by joining the molds 40 and 50 with the core 60 disposed between the upper and lower molds 40 and 50. The shape and size of the molding space correspond to the shape and size of an intermediate product casting including a machining allowance to be cut by a cutting process described later.
[0017]
A molten metal (for example, cast iron) is poured into the molding space of the mold, and after cooling and solidification, the mold is removed from the upper and lower molds 40 and 50, so that an intermediate product casting product including a machining allowance (see FIGS. 3 and 6) can be obtained. can get. As shown in FIG. 3, the cast product has a concentric uneven shape (FIG. 3) reflecting the shape of the concentric groove 41 of the inner wall of the upper mold on the surface of the machining allowance corresponding to the first friction surface 11. In the radial cross section, a wave shape is given.
[0018]
By pouring the molten metal into the molding space, the resin composing the core 60 is combusted by the heat, and / or the moisture contained in the core 60 is changed to water vapor. Even when the poured molten metal comes into contact with the inner wall portion of the upper mold 40 having a concavo-convex shape, the contact area is larger than when there is no concavo-convex shape (that is, the flat inner wall surface shown in FIG. 7). . For this reason, even if the combustion gas or water vapor is bubbled into the molten metal, most of the gas is injected into the upper mold 40 through the inner wall portion to which the concavo-convex shape is given before the molten metal is solidified. Or move into the allowance area (see FIG. 6). Therefore, in the intermediate product cast product after cooling and solidification, there is not much clearness in parts other than the machining allowance.
[0019]
After the casting process, the intermediate product casting in FIG. 3 is cut using a lathe. Through this cutting process, the machining allowance to which the corrugated shape of the cross-sectional wave is given is cut off, and a ventilated disk as a final product as shown in FIG. 4 is completed. As described above, since the shape of the inner wall portion of the upper mold 40 has a corrugated cross-section, there is not much clearance remaining in the portion other than the machining allowance of the intermediate product casting, so that the product obtained by cutting the machining allowance is obtained. There is a low probability of being irrelevant.
[0020]
(Production Experiments 1 and 2 and Comparative Experiment)
As shown in FIG. 5, in the concavo-convex shape given to the machining allowance of the intermediate product casting, the height of the convex portion having a substantially trapezoidal cross section is a, and the width of the upper side of the convex portion (that is, the width of the groove 41). b, the interval between adjacent convex portions is c. Then, as the manufacturing experiment 1 and the manufacturing experiment 2, 1000 pieces of cast products in which the values of a, b, and c are the values shown in Table 1 (unit: mm) are manufactured by the procedure of the above embodiment. The experiment was conducted. In addition, as a comparative experiment, an experiment was performed in which 1000 conventional castings (ie, a = 0 mm) having no machining allowances were manufactured by a conventional manufacturing procedure.
[0021]
[Table 1]
Figure 0004024090
[0022]
Table 1 shows the results of each experiment. In Table 1, the surface area is a value obtained by comparing the surface area of the surface of the machining allowance corresponding to the first friction surface 11 of the disk, and indicates a relative value when the surface area of the cast product of the comparative experiment is 100. The failure defect rate indicates a ratio of the number of individuals that are determined to be defective due to exposure of the first friction surface 11 by cutting. For example, 1.4% in the comparative experiment indicates that 14 out of 1000 defects were defective. The current value of the main spindle indicates the magnitude (average value) of the electrical load applied to the main spindle of the lathe when cutting the cast product, and the value indirectly indicates the magnitude of the cutting resistance.
[0023]
As can be seen from Table 1, in the manufacturing experiments 1 and 2 according to the present invention, the failure defect rate could be significantly reduced as compared with the comparative experiment (conventional method). Also, the current value of the spindle is smaller in the manufacturing experiments 1 and 2 than in the comparative experiment, and according to the present invention, it is possible to reduce the cutting resistance during the cutting process and thus to reduce the energy consumption. .
[0024]
In the comparative experiment and the manufacturing experiments 1 and 2, the machining allowance is set to 2.5 mm. However, with respect to the manufacturing experiments 1 and 2, the entire area of the machining allowance having a thickness of 2.5 mm is filled with metal due to the provision of unevenness. Do not mean. If the unevenness of the machining allowance portion is leveled and flattened for the intermediate product casting product of the manufacturing experiment 2, the machining allowance thickness in that case is converted to about 1.9 mm. That is, the amount of metal scraped off in the cutting process is only 1.9 / 2.5 = 76% of the cast product of the comparative experiment in the cast product of the manufacturing experiment 2. The scraped metal is recovered and re-dissolved (reused), but it goes without saying that the smaller the amount transferred to re-dissolution, the better the energy efficiency and production efficiency. In this respect, it can be said that the manufacturing experiments 1 and 2 have better energy efficiency and production efficiency than the comparative experiments.
[0025]
(Modification) The embodiment of the present invention may be modified as follows.
In the above-described embodiment, the uneven shape to be imparted to the inner wall portion of the mold 40 is configured by the plurality of arc-shaped grooves 41 that concentrically surround the center axis of the mold 40. Instead, a single spiral groove that spirally surrounds the central axis of the mold may be employed. Alternatively, instead of these grooves, for example, a plurality of dimple-shaped recesses may be formed on the inner wall portion of the mold 40, and the inner wall surface may be uneven.
[0026]
In the above embodiment, the concave and convex shape is imparted to the inner wall portion of the upper mold 40 at a position corresponding to the first friction surface 11 of the disc main body portion 10 of the brake disc. Instead of or together with this, an uneven shape may be imparted to the inner wall portion of the lower mold 50 at a position corresponding to the second friction surface 12 of the disc main body portion 10. Further, an uneven shape may be imparted to the inner wall portion of the upper mold 40 at a position corresponding to the upper end surface of the mounting flange portion 20 of the brake disk.
[0027]
【The invention's effect】
As described above in detail, according to the brake disk manufacturing method of the present invention, it is possible to significantly reduce the occurrence rate of failure defects as compared with the prior art. Further, according to the intermediate product casting product for a brake disc of the present invention, if an appropriate post-processing (for example, cutting) is performed to remove the unevenness, the brake disc having no defect is almost certainly obtained. Obtainable.
[Brief description of the drawings]
FIG. 1 is a radial sectional view of a mold for casting a brake disc.
FIG. 2 is a radial cross-sectional view of a mold in a state where a core is arranged.
FIG. 3 is a radial sectional view of an intermediate product casting.
FIG. 4 is a radial sectional view of a brake disc as a final product.
FIG. 5 is an explanatory diagram of the size of the uneven shape in an intermediate product casting.
FIG. 6 is a diagram conceptually showing a state of occurrence of fire in the present invention.
FIG. 7 is a diagram conceptually showing a situation of occurrence of fire in a conventional example.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Disc main-body part, 11 ... 1st friction surface, 12 ... 2nd friction surface, 13 ... Ventilation hole, 40 ... Upper casting_mold | template, 41 ... Groove (it comprises the uneven | corrugated shape in a mold inner wall part), 50 ... Lower casting | molding, 60 ... Nakako.

Claims (4)

成形空間を区画するための内壁部の少なくとも一部に凹凸形状が付与されると共に通気性を有する鋳型と、中子とを用いて、前記凹凸形状を反映した凹凸を有する取代を含んだブレーキディスク用中間製品的鋳造品を鋳造する鋳造工程と、
前記ブレーキディスク用中間製品的鋳造品から前記凹凸を有する取代を削り取る切削工程とを順次実行することを特徴とするブレーキディスクの製造方法。
A mold with at least a portion irregularities is given to Rutotomoni breathable inner wall portion for partitioning the molding space, by using the core, the brake disk containing allowance having unevenness reflecting the uneven shape a casting step of casting the use intermediate product specific castings,
A method of manufacturing a brake disk , comprising sequentially performing a cutting step of scraping the machining allowance having the irregularities from the intermediate product for a brake disk .
後加工により削り取られるべき取代を含んだブレーキディスク用中間製品的鋳造品であって、前記取代の少なくとも一部には、鋳造時に鋳型との接触面積を確保する目的で付与された凹凸が残されていることを特徴とするブレーキディスク用中間製品的鋳造品。 An intermediate product casting product for a brake disk including a machining allowance to be scraped off by post-processing, and at least part of the machining allowance is left with unevenness provided for the purpose of securing a contact area with the mold during casting. An intermediate product casting for brake discs , characterized by 前記凹凸は、前記取代の表面に同心円状に複数設けられた円弧状の溝により形成されていることを特徴とする請求項2に記載のブレーキディスク用中間製品的鋳造品。3. The intermediate product casting for a brake disc according to claim 2, wherein the unevenness is formed by a plurality of arc-shaped grooves concentrically provided on the surface of the machining allowance. 4. 前記凹凸は、前記取代の表面に渦巻き状に設けられた螺旋溝により形成されていることを特徴とする請求項2に記載のブレーキディスク用中間製品的鋳造品。The intermediate product for a brake disc according to claim 2, wherein the unevenness is formed by a spiral groove provided in a spiral shape on the surface of the machining allowance.
JP2002180752A 2002-06-21 2002-06-21 Brake disk manufacturing method and intermediate product for brake disk Expired - Fee Related JP4024090B2 (en)

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