JP6812513B2 - Disc rotor and its manufacturing method - Google Patents

Description

The present invention relates to a disc rotor and a method for manufacturing the same.

A disc brake device is known as a vehicle braking device. This disc brake device includes a disc rotor and a disc pad. The disc 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 sliding portion of the disc rotor that rotates with the axle is sandwiched between the disc pads, and the friction generated between the two brakes the rotation of the wheels.

In this disc rotor, the hat portion and the sliding portion were conventionally integrally formed of cast iron. However, in such a configuration, since the sliding portion has frictional heat when braking the vehicle, thermal stress is generated due to the temperature difference from the hat portion. Therefore, the sliding portion is thermally deformed, which is a factor of generating vibration when braking the vehicle.

Therefore, a disc rotor having adopted a two-piece structure in which the hat portion and the sliding portion are separated from each other and both are connected has been proposed (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 at the connecting portion between the hat portion and the sliding portion to absorb the thermal expansion of the sliding portion, and the thermal deformation of the sliding portion is prevented. It can be suppressed.

JP-A-2010-106917

However, in the disc rotor described in Patent Document 1, the hat portion and the sliding portion are connected by using a joining pin by caulking and fixing, or by using a bolt and a nut. In such a configuration, when manufacturing a disc rotor, a joining pin or a bolt is inserted from one side into a through hole for connection provided in the hat portion and the sliding portion, and then the disc rotor is inverted. It is necessary to fix it with caulking or nuts. A structure that requires such reversing work has a problem of lowering the productivity of the disc rotor.

Therefore, an object of the present invention is to provide a disc rotor and a method for manufacturing the same, which can improve productivity without the need for reversing work at the time of manufacturing even in a configuration adopting a two-piece structure.

In order to achieve the above object, the first invention includes a hat portion attached to a hub provided on an axle and a sliding portion forming an annular shape, and the sliding portion is on the inner peripheral side of the hat portion. It is a disc rotor that is joined to the outer peripheral flange plate portion of the above and both are connected at the joint portion, so that the sliding portion protrudes toward the outer peripheral flange plate portion from the joint surface of the hat portion. The connecting protrusion is provided with a connecting protrusion 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 protrusion. A base portion provided on the side of the sliding portion, a tip portion formed on the protruding side from the base portion and having an outer shape smaller than the base portion when viewed from the axle direction, and a groove portion provided at the base end of the tip portion. , The hole portion has a first hole portion accommodating the base portion, a second hole portion accommodating the tip portion, and the groove portion projecting inward from the inner surface of the hole of the second hole portion. It is characterized by having a retaining portion that enters and comes into contact with the inner surface of the groove of the groove portion to prevent the connecting protrusion from coming out of the hole portion.

The second invention is characterized in that, in the first invention, the groove portion and the retaining portion are formed so as to form an annular shape when viewed from the axle direction over the entire outer peripheral direction of the connecting protrusion.

In the third invention, in the first invention, the base portion and the tip 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.

In the fourth aspect of the invention, in any one of the first to third aspects, the connecting protrusion is a connecting member provided separately from the sliding portion, and the retaining portion is used as the first retaining portion. As a result, the hat portion is restricted from being separated from the sliding portion, and the base portion is provided so as to extend to a through hole portion provided in the sliding portion along the axle direction. The extension portion is provided with a second retaining portion that regulates the sliding portion from being separated from the hat portion.

In the fifth aspect of the invention, in the fourth aspect, a space portion is formed around the connecting member housed in the through hole portion, and the joint surface of the hat portion and the joint surface of the sliding portion are formed. It is characterized in that 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 the inner peripheral side thereof. A method for manufacturing 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. Along with the formation, a through hole is formed along the axle direction on the inner peripheral side of the sliding portion, and a hole portion smaller than the through hole is formed along the axle direction on the outer peripheral flange plate portion. The connecting member is provided with a base portion that comes into contact with the opening peripheral edge portion of the hole portion when inserted into the through hole, a head portion larger than the base portion, a tip portion that enters the hole portion, and the tip portion. The connecting member is inserted into the through hole by aligning the through hole and the hole portion, and the base portion is brought into contact with the opening peripheral edge portion. The head is separated from the head contact surface of the sliding portion, and the connecting member is pushed from there until the head comes into contact with the head contact surface, whereby the base portion is said to be in contact with the head contact surface. By pushing the peripheral edge of the opening and plastically deforming it to fill the groove, a retaining portion is formed which abuts on the inner surface of the groove of the groove and restricts the connecting member from coming out of the hole. To do.

In the seventh invention, a hat portion attached to a hub provided on the axle and a sliding portion forming an annular shape are provided, and the sliding portion is joined to the outer peripheral flange plate portion of the hat portion on the inner peripheral side thereof. This is a method for manufacturing a disc rotor in which both are connected at the joint portion. The sliding portion is formed of a metal material having a hardness higher than that of the outer peripheral flange plate portion, and the outer peripheral flange plate portion has a hole. The portion is formed along the axle direction, and the joint surface of the sliding portion is provided with a base portion that abuts on the opening peripheral edge portion of the hole portion, a tip portion that enters the hole portion, and a base end portion of the tip portion. A connecting projection having a grooved portion and integrally formed with the sliding portion is provided, and the base portion is brought into contact with the opening peripheral edge portion and the connecting projection is pushed in from the base portion. By pushing the peripheral edge of the opening into plastic deformation and filling the groove, a retaining portion is formed that abuts on the inner surface of the groove of the groove and prevents the connecting protrusion from coming out of the hole. And.

According to the first invention, the hole provided in the outer peripheral flange plate portion for accommodating the connecting protrusion is provided with a retaining portion that enters the groove portion of the connecting protrusion and comes into contact with the inner surface of the groove. The retaining portion prevents the connecting protrusion from coming out of the hole portion of the hat portion, and makes it possible to connect the hat portion and the sliding portion of the disc rotor.

In this configuration, since the tip 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 tip portion. Therefore, if the connecting protrusion is formed of a material having a hardness higher than that of the outer peripheral flange plate portion, when the connecting 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 the connecting work at the time of manufacturing the disc rotor, it is sufficient to insert the connecting protrusion into the hole and press it, and the reversing work required for the conventional connecting configuration such as caulking and bolt tightening becomes unnecessary. .. Thereby, if the configuration of the present invention is adopted, the productivity of the disc rotor can be increased.

According to the second invention, since the groove portion and the retaining portion of the hole portion of the connecting protrusion are formed in the entire outer peripheral direction of the connecting protrusion, the retaining action can be obtained over the entire outer peripheral direction. As a result, a reliable retaining effect can be obtained.

According to the third invention, the groove portion and the retaining portion are formed on a pair of opposite side portions in a state where the base portion and the tip portion of the connecting protrusion are formed in a quadrangular shape. Therefore, even if the groove portion and the retaining portion are not formed in the entire outer peripheral direction, the retaining action is evenly applied to the direction in which the joint surfaces of the hat portion and the sliding portion are separated from each other without being biased to a part. be able to.

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

Then, in this connecting member, the retaining portion according to the first invention is used as the first retaining portion, and the sliding portion is restricted from being separated from the hat portion. A second retaining portion that regulates 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 both retaining portions, the hat portion and the sliding portion can be reliably connected even if a connecting member that is a member different from the hat portion and the sliding portion is used.

According to the fifth invention, since a space portion is formed around the connecting member in the through hole portion of the sliding portion, frictional heat is generated in the sliding portion due to pressure contact of the disc pad during vehicle braking. Even if the sliding portion is thermally expanded, the expansion is absorbed by the space portion. As a result, thermal deformation of the sliding portion can be suppressed, and the effect of adopting the two-piece structure can be further enhanced.

In addition, since the 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 by rubbing against the spring member due to thermal expansion and contraction of the sliding portion. However, the rattling caused by the occurrence is absorbed by the urging force of the spring member. As a result, the generation of vibration during vehicle braking can be further reduced.

According to the sixth invention, a connecting member is used to connect the hat portion and the sliding portion at the time of manufacturing the disc rotor. Then, with the through hole of the sliding portion and the hole portion of the hat portion 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 opening peripheral edge into plastic deformation, which fills the groove. As a result, a retaining portion is formed in the groove of the connecting member. By this retaining portion, the connecting member itself is in a state of being secured 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 at that portion, and is prevented from coming off. In this way, the hat portion and the sliding portion of the disc rotor are connected by a connecting member, and the disc rotor of the fourth invention can be preferably obtained.

According to the seventh invention, a connecting protrusion integrally formed with the sliding portion is used when manufacturing the disc rotor. The tip of the connecting protrusion is inserted into the hole of the hat, and the base is brought into contact with the peripheral edge of the opening of the hole. By pushing the connecting protrusion from there, the base pushes the peripheral edge of the opening to plastically deform it, and fills the groove. As a result, a retaining portion is formed in the groove of the connecting protrusion. The retaining portion prevents the connecting protrusion provided on the sliding portion from coming off from the hole portion of the hat portion, and the hat portion and the sliding portion of the disc rotor can be connected.

Perspective view of the disc rotor. A cross-sectional view taken along the line AA of FIG. FIG. 2 is an enlarged cross-sectional view of a portion B in FIG. The perspective view which shows the state of inserting a connecting member into a connecting hole part. Explanatory drawing which shows the state which the connecting member was inserted into the connecting hole part. FIG. 5 is a cross-sectional view showing a first alternative example of the connected structure. FIG. 2 is a cross-sectional view showing a second alternative example of the connected structure. The perspective view which shows the 3rd alternative example of the connection structure.

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

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

The hat portion 11 is a portion attached to a hub H provided at an end portion of the axle S, and is formed of an aluminum alloy. Therefore, in this embodiment, the aluminum alloy is the 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 in the central portion of the mounting plate portion 21. A plurality of bolt insertion holes 23 are provided around the mounting holes 22. The disc rotor 10 is attached to the hub H by using the attachment plate portion 21, the attachment hole 22, and the bolt insertion hole 23. Further, 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 side end portion of the cylinder.

The sliding portion 12 is a portion that is sandwiched and pressure-welded by the disc pad when the vehicle is braked. As shown in FIGS. 1 and 2, the sliding portion 12 is formed of cast iron so as to form a plate and an annular shape. Both the front and back surfaces of the sliding portion 12 are a pair of sliding surfaces 31 and 32 that are pressure-welded by the disc pad. On the inner peripheral side of the sliding portion 12, there is a laminated 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 laminated 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 the joint portion 13 of the disc rotor 10.
The hat portion 11 and the sliding portion 12 are integrally connected by using a connecting member 40 in a state of being joined by the joining portion 13. The connecting member 40 has a circular cross section along the sliding surfaces 31 and 32. A plurality or a large number of connecting members 40 are provided at the annular joint portion 13 in the circumferential direction thereof. In this embodiment, 10 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 laminated plate portion 33 of the sliding portion 12 are connected by using the connecting member 40 will be described with reference to FIG. 3 in which the portion B of FIG. 2 is enlarged.

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 at 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, which is a metal material having a higher hardness than the aluminum alloy forming the hat portion 11, and is formed in a substantially columnar shape as a whole. Therefore, the outer shape seen from the axle direction has a circular shape. The connecting member 40 has a head 41, a large diameter portion 42 as a base portion, and a small diameter portion 43 as a tip portion.

The head 41 is provided on one side of the connecting member 40 in the axial direction, and is formed thinner than the thickness of the laminated plate portion 33. Therefore, the head 41 is provided within the plate thickness dimension of the laminated plate portion 33. Hereinafter, the description will proceed with the side of the head 41 as the base end and the opposite side as the tip.

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

The small diameter portion 43 is provided on the tip end side of the large diameter portion 42, and its tip surface 43a is provided within the plate thickness dimension of the outer peripheral flange plate portion 24, and has a diameter smaller than that 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 base end of the small diameter portion 43 over the entire circumferential direction. The groove cross section of the groove portion 46 has a quadrangular shape, and the groove bottom surface 46a is formed to have a smaller diameter than the small diameter portion 43. The groove inner surface 46b formed in an annular shape around the groove bottom surface 46a is parallel to the joint surfaces 25 and 34.

The connecting member 40 having the above structure is provided in the connecting hole portion 14 formed in the joint portion 13. The same number of connecting hole portions 14 as the connecting member 40 are formed at each location where the connecting member 40 is 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, which is a through hole, is provided in the overlapping plate portion 33 of the sliding portion 12.

The bottomed hole portion 26 corresponds to the hole portion and has 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 portion 51 is provided with a portion of the large diameter portion 42 that is closer to the tip side than 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. A small diameter portion 43 is provided in the second hole portion 52, and the tip surface 43a of the small diameter portion 43 is in contact with the hole bottom surface 53.

At the opening end of the second hole 52, an annular overhang 54 forming an annular shape is provided along the opening edge. The annular overhanging 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 of the connecting member 40. The annular overhanging portion 54 corresponds to a retaining portion or a first retaining portion. The annular overhanging portion 54 is formed by plastically deforming the aluminum alloy forming the hat portion 11 at the time of manufacturing the disc rotor 10 so that the aluminum alloy is filled inside the groove portion 46. Since the annular overhanging portion 54 enters the groove portion 46, the annular overhanging portion 54 and the groove inner surface 46b on the distal end side are in surface contact with each other.

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

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 diameter of the second through-hole portion 62 is smaller than that of the first through-hole portion 61, an annular hole-side step surface 63 is formed between the second through-hole portion 62 and the two through-hole portions 61 and 62. The hole-side step surface 63 corresponds to the head contact surface, and the first step surface 44 of the connecting member 40 is in contact with the head contact surface.

The connecting member 40 is provided in the connecting hole portion 14 according to the configuration described above. In this configuration, as already described, 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 overhanging portion 54 that has entered the inside of the groove portion 46 are in surface contact. It is in a state of being. As a result, the hat portion 11 is inseparable from the sliding portion 12. On the other hand, the first stepped surface 44 of the connecting member 40 is in surface contact with the hole-side stepped surface 63 formed in the through hole portion 35. Due to this surface contact, the sliding portion 12 is inseparable from the hat portion 11. Therefore, the first stepped surface 44 corresponds to the second retaining portion.

In the joint portion 13, the hat portion 11 and the sliding portion 12 are integrally connected to each other at each location where the connecting member 40 is provided so that the joint portion 13 cannot be separated due to such a configuration. In this embodiment, of the connecting member 40, a 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 tip side of the large diameter portion 42 and the small diameter portion 43 are connected protrusions. Equivalent to. Further, in the large diameter portion 42, the portion existing in the through hole portion 35 corresponds to an extension portion provided by extending from the connecting protrusion portion to the through hole portion 35.

Subsequently, a method of manufacturing the disc rotor 10 connected by 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 the method of connecting the hat portion 11 and the sliding portion 12 by using the connecting member 40 is characteristic, the description will be focused on the characteristic portion.

As shown in FIG. 4, in the first step at the time of connection, the laminated 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 axes 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 opened on the anti-joining side surface of the sliding portion 12.

Then, as shown in FIG. 4, in this first step, the bottomed hole portion 26 provided on the outer peripheral flange plate portion 24 and located on the bottom side of the connecting hole portion 14 is connected to the bottomed hole portion 26 by using the connecting member 40. The existing first hole 51 and the second hole 52 have not yet been formed. 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 on 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. Greater than that of. As a result, inside the connecting hole portion 14, an annular opening peripheral edge portion 55 is formed on the opening side of the bottomed hole portion 26.

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 side of the small diameter portion 43 so that the axis thereof is aligned with the axis of the connecting hole portion 14. Then, as shown in FIG. 5, the second stepped surface 45 of the connecting member 40 comes into contact with the opening peripheral edge portion 55 of the bottomed hole portion 26, and the insertion of the connecting member 40 is once restricted there. In this state, the groove portion 46 is formed with a space region R1 between the groove portion 46 and the inner surface of the bottomed hole portion 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 43a 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 and the axial length L3 of the groove portion 46 ( It is set to be the same as or longer than those (see FIG. 3).

Next, as shown in FIG. 5, with the outer peripheral flange plate portion 24 placed on the pedestal D, the connecting member 40 is pressurized along the axial direction from its head 41. The connecting member 40 is made of a stainless alloy having a higher hardness than the aluminum alloy forming 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 by the second stepped surface 45. By this pushing, the aluminum alloy existing in the region R2 on the side of the opening peripheral edge portion 55 in the pushing direction is plastically deformed and flows into the groove portion 46 in which the space region R1 is formed to be filled. In this way, in the connecting member 40, the first step surface 44 abuts on the hole side step surface 63, the tip surface 43a of the small diameter portion 43 abuts on the hole bottom surface 53, and the entire head 41 penetrates first. It is pushed in until it is accommodated in the hole 61.

As a result, as shown in FIG. 3 described above, the connecting member 40 is formed with an annular overhang portion 54 by the aluminum alloy that has entered the inside of the groove portion 46 due to plastic deformation, and the annular overhang portion 54 is formed on the groove inner surface 46b. Is in 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 a state of surface contact. Due to these surface contacts, the hat portion 11 and the sliding portion 12 become inseparable from each other. By providing the connecting member 40 in this way at each location where the connecting member 40 is provided, a disc rotor 10 in which the hat portion 11 and the sliding portion 12 are integrally connected can be obtained.

The disc 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) At 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 14. As the connection configuration, first, the annular overhanging 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, whereby the connecting member 40 has a bottomed hole. Exiting Part 26 is restricted. Further, the first stepped surface 44 of the connecting member 40 comes into contact with the hole-side stepped surface 63 formed in the through hole portion 35, whereby the sliding portion 12 is restricted from being separated from the hat portion 11. According to these regulations, the hat portion 11 and the sliding portion 12 of the disc rotor 10 can be connected to each other.

(2) The above connecting configuration is obtained by inserting the connecting member 40 into the connecting hole portion 14 and further pushing the connecting member 40 from there. First, a 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, and the connecting member 40 is inserted into the connecting hole portion 14 to form a second connecting member 40. The stepped surface 45 is brought into contact with the opening peripheral edge portion 55 of the bottomed hole portion 26. From there, when the connecting member 40 is pushed in until the first stepped surface 44 comes into contact with the hole-side stepped surface 63, the second stepped surface 45 pushes in the opening peripheral edge portion 55 to plastically deform it, and the groove portion 46 is filled. .. As a result, the annular overhanging portion 54 is formed in the groove.

In the case of this manufacturing method, the hat portion 11 and the sliding portion 12 are connected only by pressing the connecting member 40 in one direction. Therefore, in the connecting operation, a reversing operation such as caulking or bolt tightening as in a conventional connecting configuration is performed. Is no longer needed. As a result, the productivity of the disc rotor 10 can be increased. Further, unlike connecting the hat portion 11 and the sliding portion 12 by casting, since the connecting operation is performed cold, it is possible to suppress the occurrence of distortion in the connecting portion using the connecting member 40.

(3) The groove inner surface 46b is parallel to the joint surfaces 25 and 34, and the annular overhanging portion 54 is in surface contact with the groove inner surface 46b. Therefore, it is possible to exert the retaining action perpendicularly to the direction in which the joint surfaces 25 and 34 are separated from each other, and a reliable retaining effect can be obtained.

(4) The groove portion 46 and the annular overhanging portion 54 of the connecting member 40 are formed in an annular shape over the entire outer peripheral direction. Therefore, a retaining action can be obtained over the entire outer peripheral direction of the connecting member 40. As a result, a reliable retaining effect can be obtained.

(5) The connecting member 40 is configured as a member separate from the sliding portion 12. Therefore, as the metal material forming the connecting member 40, a metal material having a hardness higher than that of the metal material forming the hat portion 11 can be freely selected regardless of the metal material of the sliding portion 12. As a result, the optimum metal material can be selected while considering the manufacturing cost, the performance of the disc rotor 10, and the like.

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

(A) In the present embodiment, the connecting protrusion is composed of a connecting member 40 which is a member different from the sliding portion 12, but as a first alternative example, as shown in FIG. 6, the connecting member 40 is formed by the sliding portion 12. You may adopt the structure integrally formed with the joint surface 34 of. In FIG. 6, FIG. 6A shows a state before connection corresponding to FIG. 5, and FIG. 6B shows a state after connection corresponding to FIG.

As shown in each figure, the protrusion 70 as the 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 made of a metal material having a hardness higher than that of the hat portion 11. The protruding portion 70 has 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 diameter smaller than that of the large diameter portion 71. A stepped surface 73 is formed due to 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 base end of the small diameter portion 72. These have the same configuration as the portion where the connecting member 40 in the above embodiment protrudes from the joint surface 34 of the sliding portion 12.

Also in this configuration, as shown in FIG. 6A, the protrusion 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 from there. When pressed, the protrusion 70 is pushed into the bottomed hole 26. As a result, when the stepped surface 73 pushes in the opening peripheral edge portion 55 of the bottomed hole portion 26, as shown in FIG. 6B, the aluminum alloy of the hat portion 11 enters the groove portion 74 due to plastic deformation, and the annular overhanging portion 54 is formed. When the annular overhanging portion 54 comes into surface contact with the pair of groove inner surfaces 74b forming the groove portion 74, 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, since the reversing work is unnecessary, the productivity of the disc rotor 10 can be increased.

(B) In the above embodiment, in the state where the connecting member 40 is inserted into the connecting hole portion 14, the space formed between the tip surface 43a thereof and the bottom surface 53 of the bottomed hole portion 26 is defined as a closed space. However, as illustrated in FIG. 6, a flow hole 81 for bleeding 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 in 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 connecting protrusion is accommodated, but the hole portion does not have to be bottomed, and the hole bottom surface 53 itself is omitted. You may form a through hole portion.

(D) In the above embodiment, when the hat portion 11 and the sliding portion 12 are connected by the connecting member 40, as shown in FIG. 3, the tip surface 43a of the connecting member 40 and the bottomed hole portion 26 It is in a state of being in contact with the bottom surface 53 of the hole. A space may be formed between both sides thereof.

(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 shown as a second alternative example. As shown in 7 (a), it may be formed so as to form an oval shape. According to this configuration, in the connecting member 40 provided in the connecting hole portion 14, space portions 82 are formed on both sides in the major axis direction between the connecting member 40 and the inner surface of the through hole portion 35. 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 disc pad, and even if the sliding portion 12 thermally expands, the expansion is absorbed by the space portion 82. As a result, thermal deformation of the sliding portion 12 can be suppressed, and the effect of adopting the two-piece structure can be further enhanced.

Further, after the through hole portion 35 is formed 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. A configuration may be adopted in which the disc spring 83 is interposed around the connecting member 40. 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 rubbed against each other, causing wear on the joint surfaces 25 and 34, which causes rattling. This becomes a factor that causes vibration when braking the vehicle. Therefore, by interposing the disc spring 83 in between, even if the joint surface 34 is worn due to rubbing against the disc spring 83, the rattling caused by the wear is absorbed by the urging force of the spring. As a result, the generation of vibration during vehicle braking can be further reduced.

In FIG. 7B, in order to make the explanation easier to understand, 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 illustrated. Further, as the intervening spring member, a spring different from the disc spring 83 may be adopted.

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

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

Further, when this connecting member 90 is used, unlike the above-described embodiment, the groove portion 46 and the annular overhanging portion 54 are not formed in the entire outer peripheral direction of the connecting member 90. However, the groove portions 94 are formed on the pair of opposite side portions, and in the connected state, a pair of overhanging portions that enter the groove portions 94 are formed on the inner surface of the bottomed hole portion 26. Therefore, the retaining action can be applied evenly in the direction in which the joint surfaces 25 and 34 are separated from each other without being partially biased.

Also 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 Twelve thermal expansions can be absorbed.

(H) In the above embodiment, the head 41 of the connecting member 40 is formed so as to be flush with the surface of the sliding portion 12 on the anti-joining side, but the head 41 protrudes from the surface. You may. Further, instead of accommodating the head 41 in the through hole portion 35, the first stepped surface 44 of the head 41 may be configured to abut on the opening edge portion of 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 laminated plate portion 33 are directly in contact with each other, but between the joint surfaces 25 and 34. A configuration in which a corrosion suppressing 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, the possibility that the contact portions are corroded due to the contact between the dissimilar metals can be reduced.

(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. 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, the metal material used is not particularly limited. 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.

10 ... Disc rotor, 11 ... Hat part, 12 ... Sliding part, 13 ... Joint part, 24 ... Outer flange plate part, 25 ... Joint surface, 26 ... Bottomed hole part (hole part), 34 ... Joint surface, 35 ... Through hole portion (through hole), 40 ... connecting member, 41 ... head, 42 ... large diameter portion (base portion), 43 ... small diameter portion (tip portion), 44 ... first stepped surface (second retaining portion) , 46 ... groove portion, 46b ... groove inner surface, 51 ... first hole portion, 52 ... second hole portion, 54 ... annular overhanging portion (retaining portion), 55 ... opening peripheral edge portion, 70 ... protrusion (connecting protrusion) , 71 ... Large diameter part (base), 72 ... Small diameter part (tip), 74 ... Groove, 74b ... Groove inner surface, 82 ... Space, 83 ... Belleville spring (spring member), 90 ... Connecting member, 94 ... Groove , H ... hub, S ... axle.

Claims (5)

A hat portion having a tubular shape having a lid portion and a hub provided on the axle attached to the inside of the lid portion,
An outer peripheral flange plate portion extending laterally from the open side end portion of the hat portion and
An annular sliding part and
With
A disc rotor in which the sliding portion is joined to the outer peripheral flange plate portion on the inner peripheral side thereof, and both are connected at the joint portion.
A connecting projection provided on the sliding portion so as to project from the joint surface of the hat portion toward the outer peripheral flange plate portion and made of a metal material having a hardness higher than that of the outer peripheral flange plate portion.
A hole provided on the joint surface of the outer peripheral flange plate portion and accommodating the connecting protrusion,
With
The connecting protrusion
A base provided on the side of the sliding portion and
A tip portion that is formed on the protruding side of the base portion and whose outer shape as viewed from the axle direction is smaller than that of the base portion.
A groove provided at the base end of the tip portion and
Have,
The hole is
A first hole for accommodating the base and
A second hole for accommodating the tip and
A retaining portion that projects inward from the inner surface of the hole of the second hole portion, enters the groove portion, abuts on the inner surface of the groove of the groove portion, and regulates the connecting protrusion from coming out of the hole portion.
Have,
A connecting member provided separately from the sliding portion has the connecting protrusion.
The base portion is provided so as to extend to a through hole formed along the axle direction on the inner peripheral side of the sliding portion, and a head larger than the base portion extends in the circumferential direction of the base portion. It is provided without a peripheral groove in between ,
The through hole is provided at a step between a first through hole in which the head is accommodated, a second through hole in which an extension portion of the base is accommodated, and the first through hole and the second through hole. A disc rotor, characterized in that a stepped surface with which the head is in contact is formed. The disc rotor according to claim 1, wherein the groove portion and the retaining portion are formed so as to form an annular shape when viewed from the axle direction over the entire outer peripheral direction of the connecting protrusion. The sliding portion has a pair of sliding surfaces, and one of the sliding surfaces is joined to the outer peripheral flange plate portion of the hat portion.
Before SL head, according to claim 1 or 2, characterized in that provided in the first through-hole in a condition that the other sliding surface flush with one of the pair of sliding surfaces Disc rotor. A space is formed around the connecting member housed in the through hole .
The disc rotor according to any one of claims 1 to 3 , wherein a spring member is interposed between the joint surface of the hat portion and the joint surface of the sliding portion. A hat portion having a tubular shape having a lid portion and a hub provided on the axle attached to the inside of the lid portion,
An outer peripheral flange plate portion extending laterally from the open side end portion of the hat portion and
An annular sliding part and
A method for manufacturing a disc rotor, wherein the sliding portion is joined to the outer peripheral flange plate portion on the inner peripheral side thereof, and the hat portion and the sliding portion are connected by a connecting member provided at the joint portion. And
The connecting member is formed of a metal material having a hardness higher than that of the outer peripheral flange plate portion.
A through hole is formed along the axle direction on the inner peripheral side of the sliding portion.
On the joint surface of the outer peripheral flange plate portion with the sliding portion, a hole portion smaller than the through hole is formed along the axle direction.
The connecting member includes a base portion that comes into contact with the opening peripheral edge portion of the hole portion when inserted into the through hole, a head portion larger than the base portion, a tip portion that enters the hole portion, and a base portion of the tip portion. It has a groove portion provided at the end, and the head portion is provided between the head portion and the base portion without a circumferential groove extending in the circumferential direction of the base portion .
In the through hole, there is a step between the first through hole into which the head of the connecting member is inserted, the second through hole into which the base is inserted, and the first through hole and the second through hole. The provided stepped surface is formed,
The connecting member was inserted into the through hole by combining the through hole and the hole portion, the base portion was brought into contact with the opening peripheral edge portion, and the head was separated from the stepped surface of the through hole. State and
By pushing the connecting member from there until the head abuts on the stepped surface, the base portion pushes the opening peripheral edge portion into plastic deformation to fill the groove portion and abuts on the groove inner surface of the groove portion. A method for manufacturing a disc rotor, which comprises forming a retaining portion for restricting the connecting member from coming out of the hole.

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