JP6594783B2 - Disc rotor and manufacturing method thereof - Google Patents

Description

  The present invention relates to a disk rotor and a manufacturing method thereof.

  A disk brake device is known as a vehicle braking device. This disc brake device includes a disc rotor and a disc pad. The disk rotor has a hat portion connected to the axle and an annular sliding portion provided on the outer peripheral side of the hat portion. When the vehicle is braked, the rotation of the wheel is braked by the friction generated between the two by sandwiching the sliding portion of the disk rotor rotating together with the axle with the disk pad.

  Conventionally, in this disk rotor, the hat portion and the sliding portion are integrally formed of cast iron. However, in such a configuration, since the sliding portion has frictional heat during vehicle braking, a thermal stress is generated due to a temperature difference from the hat portion. For this reason, the sliding portion is thermally deformed, which is a factor for generating vibration during vehicle braking.

  In view of this, there has been proposed a disk rotor that employs a two-piece structure in which a hat portion and a sliding portion are separate members and are connected to each other (see, for example, Patent Document 1). By adopting this two-piece structure, it is possible to adopt a configuration in which a space portion is formed in the connecting portion between the hat portion and the sliding portion and the thermal expansion of the sliding portion is absorbed. Can be suppressed.

JP 2010-106917 A

  However, the disk rotor described in Patent Document 1 has a configuration in which the hat portion and the sliding portion are connected by using a joining pin by caulking and using a bolt and a nut. In such a configuration, when manufacturing the disc rotor, after inserting a joining pin or bolt from one side into the connecting through hole provided in the hat portion and the sliding portion, the disc rotor is inverted. The work of fixing with caulking and nuts is necessary. Such a structure requiring reversal work has a problem of reducing the productivity of the disk rotor.

  Accordingly, an object of the present invention is to provide a disc rotor and a method for manufacturing the same that can increase productivity by eliminating the need for reversal work during manufacturing even if the configuration adopts a two-piece structure.

  In order to achieve the above object, a first invention includes a hat portion attached to a hub provided on an axle, and an annular sliding portion, and the sliding portion is arranged on the inner peripheral side of the hat portion. The disk rotor is joined to the outer peripheral flange plate portion and is connected to the outer peripheral flange plate portion so that the sliding portion protrudes to the outer peripheral flange plate portion side from the joint surface of the hat portion. A connecting projection made of a metal material having a hardness higher than that of the outer peripheral flange plate portion, and a hole portion provided in the outer peripheral flange plate portion for accommodating the connecting projection, A base portion provided on the sliding portion side, a distal end portion formed on the projecting side of the base portion and having an outer shape smaller than the base portion as viewed from the axle direction, and a groove portion provided at the proximal end of the distal end portion And the hole accommodates the base. 1 hole part, 2nd hole part which accommodates the said front-end | tip part, it protrudes inside the hole inner surface of the said 2nd hole part, enters into the said groove part, and contact | connects the groove inner surface of the said groove part, and the said connection protrusion is said And a retaining portion for restricting the withdrawal from the hole.

  According to a second aspect of the present invention, in the first aspect, the groove and the retaining portion are formed so as to form an annular shape when viewed from the axle direction in the entire outer circumferential direction of the connection protrusion.

  In a third aspect based on the first aspect, the base portion and the tip end portion are formed in a square shape when viewed from the axle direction, and the groove portion and the retaining portion are formed in a pair of opposite side portions. It is characterized by that.

  According to a fourth aspect of the present invention, in any one of the first to third aspects, the connection protrusion is a connection member provided separately from the sliding portion, and the retaining portion is the first retaining portion. As described above, the hat portion is restricted from being separated from the sliding portion, and the base portion is provided to be extended to a through-hole portion provided along the axle direction in the sliding portion, The extension portion is provided with a second retaining portion for restricting the sliding portion from being separated from the hat portion.

  According to a fifth invention, in the fourth invention, a space is formed around the coupling member accommodated in the through-hole portion, and the joint surface of the hat portion and the joint surface of the sliding portion are formed. A spring member is interposed between them.

  A sixth invention includes a hat portion attached to a hub provided on an axle, and an annular sliding portion, and the sliding portion is joined to an outer peripheral flange plate portion of the hat portion on an inner peripheral side thereof. A manufacturing method of a disc rotor in which the hat portion and the sliding portion are connected by a connecting member provided at the joint portion, wherein the connecting member is made of a metal material having a hardness higher than that of the outer peripheral flange plate portion. In addition, a through hole is formed on the inner peripheral side of the sliding portion along the axle direction, and a hole smaller than the through hole is formed on the outer peripheral flange plate portion along the axle direction. The connecting member includes a base that abuts on an opening peripheral edge of the hole when inserted into the through hole, a head larger than the base, a tip that enters the hole, and the tip. A groove provided at the base end of the The connecting member is inserted into the through-hole by aligning the through-hole and the hole, the base is brought into contact with the peripheral edge of the opening, and the head is brought into contact with the head of the sliding portion. The base member is pushed into the opening peripheral edge portion and plastically deformed by pushing the connecting member until the head comes into contact with the head contact surface. By filling, a retaining portion that contacts the groove inner surface of the groove and restricts the connecting member from coming out of the hole is formed.

  According to a seventh aspect of the present invention, there is provided a hat portion attached to a hub provided on an axle and an annular sliding portion, and the sliding portion is joined to an outer peripheral flange plate portion of the hat portion on an inner peripheral side thereof. A disk rotor manufacturing method in which both are connected at the joint portion, wherein the sliding portion is formed of a metal material having a hardness higher than that of the outer peripheral flange plate portion, and a hole is formed in the outer peripheral flange plate portion. A portion formed along the axle direction, and provided on the joint surface of the sliding portion at the base that contacts the opening peripheral edge of the hole, the tip that enters the hole, and the base of the tip A connecting projection formed integrally with the sliding portion is provided, and the base is brought into contact with the peripheral edge of the opening, and the connecting projection is pushed in from the base, whereby the base is Push the peripheral edge of the opening to plastically deform By filling the serial groove, the connection protrusions contact with the groove inner surface of the groove and forming a retaining portion for restricting the exit from the hole.

  According to the first aspect of the present invention, the hole provided in the outer peripheral flange plate portion and accommodating the connecting projection is provided with the retaining portion that enters the groove portion of the connecting projection and contacts the inner surface of the groove. The retaining portion restricts the connecting protrusion from coming out of the hole of the hat portion, and the hat portion and the sliding portion of the disk rotor can be connected.

  In this configuration, since the distal end portion of the connecting protrusion has a smaller outer shape than the base portion, a step portion is formed between the base portion and the distal end portion. Therefore, when the connection protrusion is formed of a material having a hardness higher than that of the outer peripheral flange plate portion, when the connection protrusion is inserted into the hole portion, the step portion presses the periphery of the hole portion to form the outer peripheral flange plate portion. Is plastically deformed and enters the groove to form a retaining portion. For this reason, as a connecting operation at the time of manufacturing the disk rotor, it is only necessary to insert and press the connecting protrusion into the hole, and the reversing operation required for the conventional connecting configuration such as caulking and bolt tightening becomes unnecessary. . Thereby, if the structure of this invention is employ | adopted, the productivity of a disk rotor can be improved.

  According to the second aspect, since the groove portion of the connecting projection and the retaining portion of the hole are formed in the entire outer circumferential direction of the connecting projection, the retaining action can be obtained over the entire outer circumferential direction. Thereby, a reliable retaining effect is obtained.

  According to the third invention, the groove portion and the retaining portion are formed on the pair of opposite side portions in a state where the base portion and the tip portion of the connecting projection are formed in a square shape. For this reason, even if the groove portion and the retaining portion are not formed in the entire outer circumferential direction, the retaining function acts evenly in the direction in which the respective joint surfaces of the hat portion and the sliding portion are separated from each other. be able to.

  According to the fourth aspect of the invention, since the connection protrusion is constituted by the connection member, a metal material having a hardness higher than that of the outer peripheral flange plate portion is used as the metal material forming the connection protrusion regardless of the metal material of the sliding portion. You can choose freely. For example, a metal material with higher hardness that makes it easy to form a retaining portion by plastic deformation can be employed.

  In this connecting member, the retaining portion in the first invention is the first retaining portion, and the sliding portion is restricted from being separated from the hat portion. A second retaining portion for restricting the sliding portion from being separated from the hat portion is provided at a portion where the base portion of the connecting member is extended to the through hole portion of the sliding portion. Due to the presence of the both retaining portions, the hat portion and the sliding portion can be reliably connected even when a connecting member that is a separate member from the hat portion and the sliding portion is used.

  According to the fifth aspect of the present invention, since the space is formed around the connecting member in the through hole portion of the sliding portion, the frictional heat is applied to the sliding portion due to the pressure contact of the disk pad during vehicle braking. Even if the sliding portion is thermally expanded, the expansion is absorbed by the space portion. Thereby, the heat deformation of a sliding part can be suppressed and the effect of having employ | adopted 2 piece structure can be heightened more.

  In addition, since a spring member is interposed between the joint surface of the hat portion and the joint surface of the sliding portion, the joint surface is worn due to friction with the spring member due to thermal expansion and contraction of the sliding portion. Even if this occurs, the backlash caused by this is absorbed by the biasing force of the spring member. Thereby, the generation of vibrations during vehicle braking can be further reduced.

  According to the sixth aspect of the present invention, the connecting member is used for connecting the hat portion and the sliding portion when the disk rotor is manufactured. Then, in a state where the through hole of the sliding portion and the hole portion of the hat portion are aligned, the connecting member is inserted into the through hole, and the base portion of the connecting member is brought into contact with the opening peripheral edge portion of the hole portion. By pushing the connecting member from there, the base pushes the peripheral edge of the opening to cause plastic deformation, and the groove is filled. Thereby, a retaining portion is formed in the groove of the connecting member. With this retaining portion, the connecting member itself is prevented from being detached from the hat portion. In addition, when the head of the connecting member comes into contact with the head contact surface of the sliding portion, the sliding portion is restricted from being separated from the hat portion, and is prevented from coming off. Thus, the disk rotor of the said 4th invention can be obtained suitably by connecting the hat part and sliding part of a disk rotor by a connection member.

  According to the seventh aspect, the connection protrusion formed integrally with the sliding portion is used when the disk rotor is manufactured. The distal end portion of the connecting protrusion is inserted into the hole portion of the hat portion, and the base portion is brought into contact with the opening peripheral edge portion of the hole portion. By pushing the connecting protrusion from there, the base pushes the peripheral edge of the opening to cause plastic deformation, and fills the groove. As a result, a retaining portion is formed in the groove of the connecting projection. This retaining portion restricts the connecting protrusion provided on the sliding portion from coming out of the hole portion of the hat portion, and the hat portion and the sliding portion of the disk rotor can be connected.

The perspective view of a disk rotor. AA sectional drawing of FIG. The expanded sectional view of the B section in FIG. The perspective view which shows a mode that a connection member is inserted in a connection hole part. Explanatory drawing which shows the state which inserted the connection member in the connection hole part. Sectional drawing which shows the 1st another example of a connection structure. Sectional drawing which shows the 2nd another example of a connection structure. The perspective view which shows the 3rd another example of a connection structure.

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

  A disc rotor 10 shown in FIG. 1 is a component used in a disc brake device that is a braking device of a vehicle. First, the overall configuration of the disk rotor 10 will be described with reference to the sectional view of FIG. 2. The disk rotor 10 has a two-piece structure including a hat portion 11 and a sliding portion 12, and slides on the hat portion 11. The part 12 is joined by a joint part 13.

  The hat portion 11 is a portion that is attached to a hub H provided at an end portion of the axle shaft S, and is formed of an aluminum alloy. Therefore, in this embodiment, an aluminum alloy becomes a hat material. As shown in FIG. 2, the hat portion 11 has a cylindrical shape having a lid portion. The lid portion is a mounting plate portion 21, and a mounting hole 22 is provided at the center of the mounting plate portion 21. A plurality of bolt insertion holes 23 are provided around the mounting hole 22. The disk rotor 10 is attached to the hub H using the attachment plate portion 21, the attachment hole 22, and the bolt insertion hole 23. The hat portion 11 is provided with an outer peripheral flange plate portion 24. The outer peripheral flange plate portion 24 is formed so as to extend laterally from the open end portion of the cylinder.

The sliding portion 12 is a portion that is sandwiched and pressed by a disk pad during vehicle braking. As shown in FIG.1 and FIG.2, the sliding part 12 is formed so that it may form plate shape and cyclic | annular form with cast iron. Both the front and back surfaces of the sliding portion 12 are a pair of sliding surfaces 31 and 32 that are press-contacted by a disk pad. On the inner peripheral side of the sliding portion 12, there is an overlapping plate portion 33 that is overlapped with the outer peripheral flange plate portion 24 of the hat portion 11. The outer peripheral flange plate portion 24 and the overlapping plate portion 33 are joined by bringing their joint surfaces 25 and 34 (see FIG. 3 described later) into contact with each other. This joined portion is a joined portion 13 of the disk rotor 10.
The hat portion 11 and the sliding portion 12 are integrally connected using the connecting member 40 in a state where the hat portion 11 and the sliding portion 12 are joined by the joint portion 13. The connecting member 40 has a circular cross section along the sliding surfaces 31 and 32. And in the junction part 13 which makes | forms the cyclic | annular form, the connection member 40 is provided with two or more by the circumferential direction. In this embodiment, ten connecting members 40 are provided at equal intervals. A configuration in which the outer peripheral flange plate portion 24 of the hat portion 11 and the overlapping plate portion 33 of the sliding portion 12 are connected using the connecting member 40 will be described with reference to FIG.

  As shown in FIG. 3, in the joint portion 13, the joint surface 25 of the hat portion 11 and the joint surface 34 of the sliding portion 12 are in contact with each other. The connecting member 40 is provided in the joint portion 13 in that state so as to straddle both the hat portion 11 and the sliding portion 12. The connecting member 40 is made of a stainless alloy that is a metal material having a hardness higher than that of the aluminum alloy forming the hat portion 11, and is formed in a substantially cylindrical shape as a whole. Therefore, the outer shape seen from the axle direction is circular. The connecting member 40 has a head portion 41, a large diameter portion 42 as a base portion, and a small diameter portion 43 as a distal end portion.

  The head portion 41 is provided on one side of the connecting member 40 in the axial direction, and is formed thinner than the plate thickness of the overlapping plate portion 33. Therefore, the head portion 41 is provided within the plate thickness dimension of the overlapping plate portion 33. In the following description, the head 41 side is the base end and the opposite side is the front end.

  The large diameter portion 42 is provided on the tip side of the head 41 and has a smaller diameter (diameter) than the head 41. Therefore, an annular first step surface 44 is formed between the large diameter portion 42 and the head portion 41 in the circumferential direction. The large-diameter portion 42 has a length in the axial direction from the distal end side of the head 41 provided on the sliding portion 12 to the hat portion 11 across the joining surfaces 25 and 34.

  The small-diameter portion 43 has a diameter smaller than that of the large-diameter portion 42, the distal-end surface 43 a being provided within the plate thickness dimension of the outer peripheral flange plate portion 24 on the distal end side of the large-diameter portion 42. Therefore, an annular second step surface 45 is formed between the small diameter portion 43 and the large diameter portion 42 in the circumferential direction. Further, a groove portion 46 is formed at the proximal end of the small diameter portion 43 over the entire circumferential direction. The groove section of the groove portion 46 has a rectangular shape, and the groove bottom surface 46 a is formed to have a smaller diameter than the small diameter portion 43. A groove inner surface 46 b formed in an annular shape around the groove bottom surface 46 a is parallel to the joint surfaces 25 and 34.

  The connecting member 40 having the above configuration is provided in the connecting hole portion 14 formed in the joint portion 13. The same number of connection holes 14 as the connection members 40 are formed at each location where the connection members 40 are provided. The connecting hole portion 14 has a circular cross section along the joint surfaces 25 and 34 and is formed along the axle direction. The connecting hole portion 14 has a bottomed hole portion 26 and a through hole portion 35. Among them, the bottomed hole portion 26 is provided in the outer peripheral flange plate portion 24 of the hat portion 11, and the through hole portion 35 that is a through hole is provided in the overlapping plate portion 33 of the sliding portion 12.

  The bottomed hole portion 26 corresponds to a hole portion and includes a first hole portion 51 and a second hole portion 52. The first hole portion 51 is provided on the opening side of the bottomed hole portion 26 and has substantially the same diameter (diameter) as the large diameter portion 42 of the connecting member 40. The first hole 51 is provided with a portion of the large-diameter portion 42 that is on the tip side of the joint surfaces 25 and 34. The second hole portion 52 is provided on the bottom side of the bottomed hole portion 26 and has substantially the same diameter as the small diameter portion 43 of the connecting member 40. The second hole portion 52 is provided with a small diameter portion 43, and the tip surface 43 a of the small diameter portion 43 is in contact with the hole bottom surface 53.

  An annular projecting portion 54 that forms an annular shape is provided along the opening edge of the opening end of the second hole portion 52. The annular projecting portion 54 projects inward from the inner surface of the hole of the second hole portion 52 and enters the groove of the groove portion 46 included in the connecting member 40. The annular projecting portion 54 corresponds to a retaining portion or a first retaining portion. The annular projecting portion 54 is formed by filling the inside of the groove portion 46 by plastic deformation of the aluminum alloy forming the hat portion 11 when the disk rotor 10 is manufactured. When the annular projecting portion 54 enters the groove portion 46, the annular projecting portion 54 and the groove inner surface 46 b on the tip side are in surface contact.

  The through hole portion 35 has a first through hole portion 61 and a second through hole portion 62. The first through-hole portion 61 is provided on the opposite side (anti-joining side) of the joining surface 25 and has substantially the same diameter (diameter) and axial length as the head portion 41 of the connecting member 40. The first through-hole portion 61 is provided with the head portion 41 being flush with the surface on the anti-joining side of the sliding portion 12.

  The second through hole portion 62 has substantially the same diameter as the large diameter portion 42 of the connecting member 40. The second through-hole portion 62 is provided with a portion of the large diameter portion 42 that is closer to the base end side than the joint surfaces 25 and 34. Since the second through-hole portion 62 has a smaller diameter than the first through-hole portion 61, an annular hole-side step surface 63 is formed between the two through-hole portions 61 and 62. The hole-side step surface 63 corresponds to a head contact surface, and the first step surface 44 of the connecting member 40 contacts.

  The connection member 40 is provided in the connection hole part 14 by the structure demonstrated above. In this configuration, as described above, of the groove inner surface 46b forming the groove portion 46 of the connecting member 40, the groove inner surface 46b on the distal end side and the annular projecting portion 54 that has entered the groove portion 46 are in surface contact. It is in a state of being. Thereby, the hat part 11 cannot be separated from the sliding part 12. On the other hand, the first step surface 44 of the connecting member 40 is in surface contact with the hole-side step surface 63 formed in the through-hole portion 35. Due to this surface contact, the sliding portion 12 cannot be separated from the hat portion 11. For this reason, the first step surface 44 corresponds to a second retaining portion.

  In the joint portion 13, separation is impossible by such a configuration at each location where the connecting member 40 is provided, and the hat portion 11 and the sliding portion 12 are integrally connected thereby. In this embodiment, the portion of the connecting member 40 that protrudes from the joint surface 34 of the sliding portion 12 and enters the outer peripheral flange plate portion 24, that is, the distal end side of the large-diameter portion 42 and the small-diameter portion 43 serve as connecting protrusions. Equivalent to. Further, in the large diameter portion 42, a portion existing in the through hole portion 35 corresponds to an extended portion provided to extend from the connecting projection portion to the through hole portion 35.

  Next, a method for manufacturing the disk rotor 10 connected using the connecting member 40 will be described with reference to the perspective view of FIG. 4 and the explanatory view of FIG. Here, since there is a characteristic in the method of connecting the hat part 11 and the sliding part 12 using the connection member 40, it demonstrates focusing on the characteristic part.

  As shown in FIG. 4, in the first step in connection, the overlapping plate portion 33 of the sliding portion 12 is joined to the outer peripheral flange plate portion 24 of the hat portion 11 to form the joint portion 13. At that time, the axis of the bottomed hole portion 26 formed in the outer peripheral flange plate portion 24 and the through hole portion 35 formed in the overlapping plate portion 33 are aligned, and one connecting hole portion 14 is formed by both. The connecting hole portion 14 has a bottom, and is open on the surface on the anti-joining side of the sliding portion 12.

  As shown in FIG. 4, in this first process step, the bottomed hole portion 26 provided on the outer peripheral flange plate portion 24 on the bottom side of the connection hole portion 14 is connected to the bottomed hole portion 26 using the connection member 40. The existing first hole 51 and second hole 52 are not formed yet. The bottomed hole portion 26 has substantially the same diameter as the small-diameter portion 43 of the connecting member 40 from the hole bottom surface 53 to the opening end of the joint surface 25. On the other hand, since the second through-hole portion 62 formed in the sliding portion 12 has substantially the same diameter as the large-diameter portion 42 of the connecting member 40, the diameter of the second through-hole portion 62 is the second hole portion 52. Bigger than that. As a result, an annular opening peripheral edge 55 is formed on the opening side of the bottomed hole 26 inside the connecting hole 14.

  In this state, the connecting member 40 manufactured separately from the hat portion 11 and the sliding portion 12 is inserted into the connecting hole portion 14 from the small diameter portion 43 side with its axis aligned with the axis of the connecting hole portion 14. Then, as shown in FIG. 5, the second step surface 45 of the connecting member 40 comes into contact with the opening peripheral edge portion 55 of the bottomed hole portion 26, and insertion of the connecting member 40 is once restricted there. In this state, a space region R <b> 1 is formed between the groove 46 and the inner surface of the bottomed hole 26. Further, the first step surface 44 of the connecting member 40 and the hole-side step surface 63 are separated from each other, and the tip surface 43 a of the small diameter portion 43 and the hole bottom surface 53 are also separated from each other.

  The separation distance L2 between the tip surface 43a of the small diameter portion 43 and the hole bottom surface 53 is the separation distance L1 between the first step surface 44 and the hole side step surface 63 or the axial length L3 ( It is set to be the same as or longer than those shown in FIG.

  Next, as shown in FIG. 5, in a state where the outer peripheral flange plate portion 24 is placed on the base D, the connecting member 40 is pressurized from the head portion 41 along the axial direction. The connecting member 40 is made of a stainless alloy that is harder than the aluminum alloy that forms the hat portion 11, and is harder than the hat portion 11. Therefore, when the connecting member 40 is pressed, the opening peripheral edge portion 55 of the bottomed hole portion 26 is pushed in by the second step surface 45. By this pushing, the aluminum alloy existing in the region R2 on the side of the pushing direction with respect to the opening peripheral portion 55 is plastically deformed, and flows into the groove portion 46 where the space region R1 was formed and filled. In this way, in the connecting member 40, the first step surface 44 abuts the hole-side step surface 63, the tip surface 43a of the small diameter portion 43 abuts the hole bottom surface 53, and the entire head 41 penetrates the first penetration. It is pushed in until it is received in the hole 61.

  As a result, as shown in FIG. 3 described above, the connecting member 40 is formed with the annular protruding portion 54 by the aluminum alloy that has entered the groove portion 46 by plastic deformation, and the annular protruding portion 54 is formed on the groove inner surface 46b. It will be in the state of surface contact with. Further, the first step surface 44 of the connecting member 40 comes into contact with the hole-side step surface 63 and is in surface contact. Due to these surface contacts, the hat portion 11 and the sliding portion 12 cannot be separated from each other. By providing the connecting member 40 in this way for each location where the connecting member 40 is provided, the disc rotor 10 in which the hat portion 11 and the sliding portion 12 are integrally connected is obtained.

  The disk rotor 10 and the manufacturing method thereof in the present embodiment are as described above, and according to this, the following effects can be obtained.

  (1) In the joint portion 13 between the hat portion 11 and the sliding portion 12, the hat portion 11 and the sliding portion 12 are connected by a connecting member 40 provided in the connecting hole portion. As the connecting structure, first, the annular projecting portion 54 provided in the bottomed hole portion 26 enters the groove portion 46 of the connecting member 40 and comes into contact with the groove inner surface 46b, so that the connecting member 40 becomes the bottomed hole. Exiting from the portion 26 is restricted. Further, the first step surface 44 of the connecting member 40 contacts the hole-side step surface 63 formed in the through-hole portion 35, thereby restricting the sliding portion 12 from being separated from the hat portion 11. By these restrictions, the hat portion 11 and the sliding portion 12 of the disk rotor 10 can be connected.

  (2) Said connection structure is obtained by inserting the connection member 40 in the connection hole part 14, and pushing in the connection member 40 from there further. First, the connecting hole portion 14 is formed by the through hole portion 35 of the sliding portion 12 and the bottomed hole portion 26 of the hat portion 11, the connecting member 40 is inserted into the connecting hole portion 14, and the second of the connecting member 40 is formed. The step surface 45 is brought into contact with the opening peripheral edge portion 55 of the bottomed hole portion 26. Then, when the connecting member 40 is pushed in until the first step surface 44 contacts the hole-side step surface 63, the second step surface 45 pushes the opening peripheral edge portion 55 to plastically deform it, and the groove portion 46 is filled therewith. . Thereby, the annular overhang | projection part 54 is formed in a groove | channel.

  In the case of this manufacturing method, the hat portion 11 and the sliding portion 12 are connected by simply pressing the connecting member 40 in one direction. Therefore, in the connecting operation, a reversing operation such as a conventional connecting structure such as caulking or bolt tightening is performed. Is no longer necessary. Thereby, the productivity of the disk rotor 10 can be increased. In addition, unlike the case where the hat portion 11 and the sliding portion 12 are connected by casting, the connecting operation is performed in a cold state, so that the occurrence of distortion in the connecting portion using the connecting member 40 can also be suppressed.

  (3) The groove inner surface 46b is parallel to the joint surfaces 25 and 34, and the annular projecting portion 54 is in surface contact with the groove inner surface 46b. For this reason, it becomes possible to work the retaining action perpendicular to the direction in which both the joint surfaces 25 and 34 are separated, and a reliable retaining effect can be obtained.

  (4) The groove portion 46 and the annular projecting portion 54 of the connecting member 40 are formed in an annular shape over the entire outer circumferential direction. For this reason, the retaining action is obtained over the entire outer circumferential direction of the connecting member 40. Thereby, a reliable retaining effect is obtained.

  (5) The connecting member 40 is configured as a separate member from the sliding portion 12. For this reason, a metal material having higher hardness than the metal material forming the hat portion 11 can be freely selected as the metal material forming the connecting member 40 regardless of the metal material of the sliding portion 12. Thereby, the optimal metal material can be selected in consideration of the manufacturing cost and the performance of the disk rotor 10.

  The present invention is not limited to the above-described embodiment, and for example, the following manufacturing method may be performed.

  (A) In the present embodiment, the connecting projection is configured by the connecting member 40 which is a member different from the sliding portion 12. However, as shown in FIG. 6 as a first alternative example, the connecting member 40 is connected to the sliding portion 12. A structure integrally formed with the joint surface 34 may be adopted. 6A shows a state before connection corresponding to FIG. 5, and FIG. 6B shows a state after connection corresponding to FIG. 3.

  As shown in each drawing, the protrusion 70 as a connecting protrusion is integrally formed on the joint surface 34 of the sliding portion 12 with the same material as the sliding portion 12. In this case, the sliding portion 12 is formed of a metal material having a hardness higher than that of the hat portion 11. The protruding portion 70 includes a large diameter portion 71 protruding from the joint surface 34 and a small diameter portion 72 provided on the protruding side of the large diameter portion 71 and having a smaller diameter than the large diameter portion 71. A step surface 73 is formed by the difference in diameter between the large diameter portion 71 and the small diameter portion 72, and a groove portion 74 is formed at the proximal end of the small diameter portion 72. These have the same configuration as the portion in which the connecting member 40 protrudes from the joint surface 34 of the sliding portion 12 in the above embodiment.

  Even in this configuration, as shown in FIG. 6A, the protruding portion 70 of the sliding portion 12 is inserted into the bottomed hole portion 26 of the outer peripheral flange plate portion 24, and the overlapping plate portion 33 of the sliding portion 12 is inserted therefrom. When pressed, the protrusion 70 is pushed into the bottomed hole 26. As a result, when the stepped surface 73 pushes the opening peripheral edge 55 of the bottomed hole portion 26, the aluminum alloy of the hat portion 11 enters the groove portion 74 by plastic deformation as shown in FIG. 54 is formed. The annular projecting portion 54 comes into surface contact with a pair of groove inner surfaces 74b forming the groove portion 74, so that the hat portion 11 and the sliding portion 12 cannot be separated from each other, and both are connected. Therefore, as in the above embodiment, the reversing operation is unnecessary, and the productivity of the disk rotor 10 can be increased.

  (B) In the above-described embodiment, the space formed between the tip surface 43a and the hole bottom surface 53 of the bottomed hole portion 26 in the state where the connection member 40 is inserted into the connection hole portion 14 is a closed space. However, as illustrated in FIG. 6, the flow hole 81 for extracting air may be formed. When the connecting member 40 is pushed in, the air in the closed space is discharged through the flow hole 81, so that the connecting member 40 can be pushed more smoothly.

  (C) In the above embodiment, the bottomed hole portion 26 has been described as an example of the hole portion in which the coupling protrusion is accommodated. However, the hole portion does not need to be bottomed, and the hole bottom surface 53 itself is omitted. Through holes may be formed.

  (D) In the above embodiment, in the state where the hat portion 11 and the sliding portion 12 are connected by the connecting member 40, as shown in FIG. 3, the distal end surface 43 a of the connecting member 40 and the bottomed hole portion 26. The hole bottom surface 53 is in contact. A space may be formed between the both surfaces.

  (E) In the above embodiment, the through-hole portion 35 provided in the sliding portion 12 has the same shape as the cross-sectional shape of the connecting member 40, but the through-hole portion 35 is illustrated as a second example. As shown in FIG. 7A, an oval shape may be formed. According to this configuration, the connecting member 40 provided in the connecting hole portion 14 is formed with the space portion 82 between the inner surface of the through-hole portion 35 on both sides in the major axis direction. Due to the presence of the space portion 82, frictional heat is generated in the sliding portion 12 due to the pressure contact of the disk pad, and even if the sliding portion 12 is thermally expanded, the expansion is absorbed by the space portion 82. Thereby, the heat deformation of the sliding part 12 can be suppressed and the effect of having employ | adopted 2 piece structure can be heightened more.

  Further, after forming the through-hole portion 35 in an oval shape in this way, as shown in FIG. 7B, between the joint surface 25 of the hat portion 11 and the joint surface 34 of the sliding portion 12, You may employ | adopt the structure which interposed the disc spring 83 centering on the connection member 40. FIG. When the sliding portion 12 slides in parallel with the joint surface 34 due to its thermal expansion and contraction, the joint surfaces 25 and 34 are worn due to rubbing between the joint surfaces 25 and 34, which causes the backlash. This becomes a factor for generating vibration during vehicle braking. Therefore, by interposing the disc spring 83, even if the joint surface 34 is worn due to rubbing with the disc spring 83, rattling caused by the disc spring 83 is absorbed by the biasing force of the spring. Thereby, the generation of vibrations during vehicle braking can be further reduced.

  In FIG. 7B, for easy understanding, the gap formed between the joint surface 25 of the hat portion 11 and the joint surface 34 of the sliding portion 12 is much wider than the actual size. It is shown in the figure. Further, as the interposed spring member, a spring different from the disc spring 83 may be adopted.

  (F) In the above embodiment, the cross sections of the connecting member 40 and the connecting hole portion 14 are circular, but the shape may be an elliptical shape or a square shape such as a quadrangular shape.

  (G) In the above embodiment, the groove portion 46 in the connecting member 40 is formed in an annular shape over the entire outer peripheral direction. However, when the connecting member 40 is formed in a square shape, a configuration formed in a part in the outer peripheral direction is used. It may be adopted. FIG. 8 shows a single connecting member 90 having a square shape as a third alternative example. The connecting member 90 is formed so that the cross section thereof forms a square shape. The connecting member 90 has a head portion 91, a base portion 92, and a distal end portion 93, and the groove portions 94 formed in the distal end portion 93 are formed in parallel opposite side portions forming a square shape. Even when this connecting member 90 is used, the hat portion 11 and the sliding portion 12 can be connected and the productivity of the disk rotor 10 can be improved, as in the effect obtained by the above embodiment.

  Further, when the connecting member 90 is used, unlike the above embodiment, the groove portion 46 and the annular projecting portion 54 are not formed in the entire outer circumferential direction of the connecting member 90. However, the groove part 94 is formed in a pair of opposite side part, and a pair of overhang | projection part which penetrates into the groove part 94 is formed in the hole inner surface of the bottomed hole part 26 in a connection state. Therefore, it can be made to act equally with respect to the direction which separates each joint surface 25 and 34, without the retaining action being biased to a part.

  Even in this configuration, if the through-hole portion 35 of the sliding portion 12 is formed so that the length along the direction in which the groove portion 94 is formed is longer than the dimension of the connecting member 90, the sliding portion 12 thermal expansions can be absorbed.

  (H) In the above-described embodiment, the head 41 of the connecting member 40 is formed so as to be flush with the surface on the anti-joining side of the sliding portion 12, but a configuration in which the head 41 protrudes from the surface is adopted. May be. Further, the first step surface 44 of the head 41 may be configured to abut against the opening edge of the through-hole portion 35 instead of accommodating the head portion 41 in the through-hole portion 35. This also makes it possible to prevent the sliding portion 12 from coming off.

  (I) In the above embodiment, the joint surface 25 of the outer peripheral flange plate portion 24 and the joint surface 34 of the overlapping plate portion 33 are configured to directly contact each other. A structure in which a corrosion inhibiting member is interposed may be adopted. When the metal materials constituting the hat portion 11 and the sliding portion 12 are different from each other, it is possible to reduce the possibility that the contact portion is corroded by contact of the dissimilar metals.

  (J) In the above embodiment, the hat portion 11 is made of an aluminum alloy, and the connecting member 40 is made of a stainless alloy. The metal material to be used is not particularly limited as long as the hardness of the metal material of the connecting member 40 is higher than the hardness of the metal material of the hat portion 11. For example, the hat portion 11 may be formed of a light alloy such as a magnesium alloy, and the connecting member 40 may be formed of a steel material.

  (K) In the above embodiment, the entire hat portion 11 is formed of the same metal material (aluminum alloy), but at least the outer peripheral flange plate portion 24 is formed of a material that is plastically deformed by the connecting member 40. It's enough.

  DESCRIPTION OF SYMBOLS 10 ... Disc rotor, 11 ... Hat part, 12 ... Sliding part, 13 ... Joining part, 24 ... Outer peripheral flange board part, 25 ... Joining surface, 26 ... Bottomed hole part (hole part), 34 ... Joining surface, 35 ... through-hole part (through-hole), 40 ... connecting member, 41 ... head, 42 ... large diameter part (base part), 43 ... small diameter part (tip part), 44 ... first step surface (second retaining part) , 46 ... groove part, 46 b ... groove inner surface, 51 ... first hole part, 52 ... second hole part, 54 ... annular projecting part (detachment preventing part), 55 ... opening peripheral part, 70 ... projection part (connecting projection) , 71 ... Large diameter part (base part), 72 ... Small diameter part (tip part), 74 ... Groove part, 74b ... Groove inner surface, 82 ... Space part, 83 ... Disc spring (spring member), 90 ... Connecting member, 94 ... Groove part , H ... hub, S ... axle.

Claims (2)

A hat portion that is attached to a hub provided on an axle, and an annular sliding portion, and the sliding portion is joined to the outer peripheral flange plate portion of the hat portion on the inner circumferential side thereof; A disk rotor in which both are connected,
A connecting protrusion made of a metal material having a higher hardness than the outer peripheral flange plate portion, provided on the sliding portion so as to protrude from the joint surface of the hat portion toward the outer peripheral flange plate portion;
A hole provided in the outer peripheral flange plate portion for accommodating the connection protrusion;
With
The connecting projection is
A base provided on the side of the sliding portion;
On the protruding side of the base portion, a front end portion whose outer shape seen from the axle direction is formed smaller than the base portion, and
A groove provided at the proximal end of the distal end,
Have
The hole is
A first hole accommodating the base;
A second hole for accommodating the tip,
A retaining portion that protrudes inward from the hole inner surface of the second hole portion, enters the groove portion, abuts against the groove inner surface of the groove portion, and restricts the connection protrusion from coming out of the hole portion;
I have a,
The base and the tip are formed in a square shape when viewed from the axle direction,
The disk rotor according to claim 1, wherein the groove portion and the retaining portion are formed on a pair of opposite side portions . A hat portion that is attached to a hub provided on an axle, and an annular sliding portion, and the sliding portion is joined to the outer peripheral flange plate portion of the hat portion on the inner circumferential side thereof; A method of manufacturing a disk rotor in which both are connected,
While forming the sliding portion by a metal material having a hardness higher than that of the outer peripheral flange plate portion,
A hole is formed in the outer peripheral flange plate portion along the axle direction,
The joint surface of the sliding portion has a base portion that contacts the peripheral edge of the opening of the hole portion, a distal end portion that enters the hole portion, and a groove portion provided at the proximal end of the distal end portion, and the sliding portion A connecting projection formed integrally with the moving part is provided,
When the base is brought into contact with the peripheral edge of the opening and the connecting projection is pushed in from there, the base pushes the peripheral edge of the opening and plastically deforms to fill the groove, thereby forming an inner surface of the groove. A method of manufacturing a disc rotor, comprising: a retaining portion that abuts and restricts the connecting projection from coming out of the hole.

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