JPH08193631A - Manufacture of disc rotor - Google Patents

Abstract

PURPOSE: To improve heat conductivity in addition to improving wear resistance and brake effect by forming a metal film by the explosive flame spraying of metal powder in a disc rotor manufacturing method of forming the metal film on the face, opposed to a friction pad, of a disc rotor body formed of a light alloy, by the explosive flame spraying of metal powder. CONSTITUTION: Plural places out of the face, opposed to a friction pad, of a disc rotor body 10a are covered with jigs 15, and the jigs 15 are removed after the end of explosive flame spraying. Plural light alloy face exposed parts 10c avoided being covered with metal films 10b are thereby formed at the opposed face of the disc rotor body 10a.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a disk rotor, which is formed by forming a metal coating by explosive spraying of metal powder on the surface of a disk rotor body made of a light alloy, which faces the friction pad.

[0002]

2. Description of the Related Art Such a manufacturing method is disclosed in, for example, Japanese Patent Laid-Open No. 62-62.
It is already known from JP-60855.

[0003]

However, in the above-mentioned prior art, the entire surface of the disk rotor body facing the friction pad is coated with a metal film formed by the explosive spraying of the metal powder. Although it was possible to improve the braking effectiveness, a decrease in heat transfer performance was inevitable.

The present invention has been made in view of such circumstances, and a disk rotor having improved heat resistance and wear resistance and braking effect by forming a metal film by explosive spraying of metal powder. It is an object of the present invention to provide a method for manufacturing a disk rotor, which is capable of manufacturing a disk.

[0005]

In order to achieve the above object, the present invention comprises a metal coating formed by explosive spraying of metal powder on the surface of a disc rotor body made of a light alloy facing a friction pad. In the disk rotor manufacturing method, during explosive spraying of metal powder, a plurality of parts of the surface facing the friction pad of the disk rotor body are covered with jigs, and after the explosive spraying is completed, the jigs are removed to form a metal film. It is characterized in that a plurality of light alloy surface exposed portions which are prevented from being covered are formed on the facing surface of the disk rotor body.

[0006]

By forming a metal film by explosive spraying of metal powder on the surface of the disk rotor body facing the friction pad, it is possible to improve the wear resistance and the braking effect, and further, the opposing surface is By forming a plurality of exposed portions of the light alloy surface that are not covered with the metal coating, it is possible to improve heat transferability. Further, since the exposed portion of the light alloy surface becomes a recess with respect to the metal coating, the hardened surface of the friction pad can be removed by the metal coating on the peripheral edge of the recess during braking.

[0007]

Embodiments of the present invention will be described below with reference to the drawings.

1 to 8 show a first embodiment of the present invention. FIG. 1 is a side view of a disc brake, and FIG.
Is a front view of the disk rotor, FIG. 3 is a front view of the jig, and FIG.
5 is a front view of a jig mounted on a disc rotor, FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4, FIG. 6 is a diagram showing the results of experiments on the effect of temperature on the friction coefficient, and FIG. Figure showing the results of experiments on the effect of hydraulic pressure on the coefficient,
FIG. 8 is a diagram showing the result of an experiment on the effect of speed on the coefficient of friction.

First, in FIG. 1, the disc brake is
Disc rotor 10 that rotates with wheels (not shown)
And the blocks 11 ₁ , 1 on both sides of the disk rotor 10.
1 and ₂ are coupled to each other and a disc rotor 1
The caliper body 11 straddling 0 and a pair of friction pads 12 ₁ and 12 ₂ supported by the caliper body 11 to enable frictional contact with both surfaces of the disc rotor 10 are provided, and both blocks 11 ₁ and 11 of the caliper body 11 are provided. the _2, the friction pads 12 _1, 12 back plate 13 ₁ of _2, 13 can press the piston 14 _{1 2} to the disk rotor 10 side, 14 ₂ is slidably fitted, respectively.

In FIG. 2, a disc rotor 10 is a friction pad 1 for both sides of a disc rotor body 10a made of a heat-resistant aluminum material (extruded rapidly solidified alloy) containing 5 to 10 weight percent of SiC or a light alloy such as titanium.
The opposing faces of the 2 _1, 12 ₂ are those obtained by forming a metal film 10b by detonation spraying of a metal powder such as S20C powder or S45C powder, the thickness of the metal coating 10b is preferably from 0.15 to 0 It is set to .60 mm.

Referring also to FIGS. 3, 4 and 5,
A jig 15 is prepared for explosive spraying of the metal powder onto the disk rotor body 10a. The jig 15 is configured such that the outer periphery of the disc rotor body 10 is brought into contact with the inner periphery of the disc rotor body 10a so that the friction pads 12 ₁ , 12 of the disc rotor body 10a.
Cylindrical outer peripheral regulating portion 1 that defines the outer peripheral side of the surface facing ₂
5a, a ring-shaped inner peripheral restricting portion 15b that defines the inner peripheral side of the facing surface by covering the inner peripheral side of the disk rotor body 10a, an outer peripheral restricting portion 15a, and an inner peripheral restricting portion 15
and a plurality of connecting portions 15c for connecting between b. Thus, each of the connecting portions 15c connects a plurality of portions of the inner peripheral regulating portion 15b that are equally spaced in the circumferential direction and a plurality of portions of the outer peripheral regulating portion 15a that are equally spaced in the circumferential direction. , Each connecting part 1
The portions 5c ... Connected to the inner peripheral restricting portion 15b and the outer peripheral restricting portion 15a are displaced from each other along the circumferential direction. That is, each connecting portion 15c is formed so as to incline toward one side in the circumferential direction of the jig 15 as it goes outward in the radial direction of the jig 15.

With such a jig 15 mounted on the disc rotor body 10a, the explosive spraying of the metal powder is performed toward the disc rotor body 10a, so that the friction pads 12 ₁ , 12 ₂ of the disc rotor body 10a. It is possible to form the metal coating 10b on the surface facing the friction pad 12 ₁ , 1 of the disc rotor body 10a.
Since a plurality of places on the surface facing 2 ₂ are covered with the respective connecting portions 15c of the jig 15, the metal coating 10b is not formed, and the jig 15 is mounted on the disk rotor body after the explosive spraying is completed. When removed from 10a, a plurality of light alloy surface exposed portions 10c, which are not covered with the metal coating 10b, can be formed on the facing surface of the disk rotor body 10a.

By the way, the explosive spraying of metal powder such as S20C powder and S45C powder is desirable to be 0.15 to
A disc rotor 10 formed by forming a metal coating 10b having a thickness of 0.60 mm on a disc alloy main body 10a made of a light alloy.
On the other hand, the friction pad 1 is made of resin mold material such as non-asbestos or semi-metallic, sintered metal, carbon fiber reinforced carbon composite material or carbon fiber reinforced ceramic composite material.
It is desirable to form 2 ₁ and 12 ₂ so that excellent braking effect and wear resistance can be exhibited.

Here, when non-asbestos and carbon fiber reinforced carbon composite materials are used as materials for the friction pad,
FIG. 6, FIG. 7 and FIG. 8 show the results when a test according to JIS D4411 was performed for the braking effect.
become that way. That is, FIG. 6 shows the influence of temperature on the coefficient of friction. The average coefficient of friction when using non-asbestos was 0.5, and the average coefficient of friction when using carbon fiber reinforced carbon composite was 0.45. Met. FIG. 7 shows the effect of hydraulic pressure, that is, the pressing force of the friction pad on the friction coefficient. The average friction coefficient when non-asbestos is used is 0.5, and when the carbon fiber reinforced carbon composite material is used. The average coefficient of friction was 0.52. Further, FIG. 8 shows the influence of the speed of a vehicle equipped with a disc brake on the friction coefficient. The average friction coefficient when non-asbestos is used is 0.5, and when the carbon fiber reinforced carbon composite material is used. The average coefficient of friction was 0.52. Such results are obtained even when a sintered metal or a carbon fiber reinforced ceramic composite material is used as the material of the friction pad, and the friction coefficient obtained when the cast iron disk rotor is 0. It can be seen that a large braking effect can be obtained as compared with 3 to 0.4.

The amount of wear measured after completion of the above-mentioned test is as follows when a non-asbestos friction pad is used.
The wear amount of the disk rotor 10 is 0.002 to 0.003
mm, the wear amount of the friction pad is 0.460 mm, and when the friction pad made of the carbon fiber reinforced carbon composite material is used, the wear amount of the disc rotor 10 is 0.001 mm,
The wear amount of the friction pad is 0.168 mm, which shows that excellent wear resistance is obtained.

The operation of this embodiment will be described below. At the time of explosive spraying of the metal powder onto the disk rotor body 10a, the friction pad 12 of the disk rotor body 10a is used.
_A plurality of portions of the surface facing ₁ and 12 ₂ are covered with the connecting portions 15c of the jig 15, and the jig 15 is removed after the explosion spraying is completed. As a result, a plurality of light alloy surface exposed portions 10c, which are not covered with the metal coating 10b, can be formed on the disk rotor body 10a. Therefore, it is possible to improve the wear resistance and the braking effect by the metal film 10b, and at the same time, the plurality of light alloy surface exposed portions 10c are provided.
The heat dissipation from the disk rotor 10 can be improved by the heat dissipation from the disk rotor 10, and thus the braking effect can be further improved.

Moreover, the light alloy surface exposed portions 10c ... Are recessed with respect to the metal coatings 10b, and the metal coatings 10b on the periphery of these recesses are friction pads 12 ₁ , 1 during braking.
It is also possible to obtain the effect of eliminating the 2 ₂ hardened surface.

9 to 11 show a second embodiment of the present invention. FIG. 9 is a front view of a disk rotor, and FIG.
0 is a front view with the jig mounted on the disc rotor,
11 is a sectional view taken along line 11-11 of FIG.

The disc rotor 10 'comprises both friction pads 12 ₁ , 1 of a disc rotor body 10a' made of a light alloy.
S20C powder or S45 on the surface facing 2 ₂ (see FIG. 1)
Explosive spraying of metal powder such as C powder is desirable to be 0.1
It is formed by forming a metal coating 10b 'having a thickness of 5 to 0.60 mm.

Jigs 16, 17 and a plurality of jigs 18 are prepared for the explosive spraying of the metal powder onto the disk rotor body 10a '. Thus, the jig 16 is formed in a cylindrical shape so as to define the outer peripheral side of the friction pad facing surface of the disc rotor body 10a 'by bringing the outer periphery of the disc rotor body 10' into contact with the inner periphery. 17
Is formed in a ring shape so as to define the inner peripheral side of the facing surface by covering the inner peripheral side of the disk rotor body 10a '. Further, the jigs 18 are a plurality of places equally spaced in the circumferential direction of the jig 16, and a plurality of places equally spaced in the circumferential direction of the jig 17 at positions displaced from the jig 16 in the circumferential direction. And 3 are arranged between each and. Each jig 18
Is a pin having a circular cross section, having a large diameter portion 18a having one end in contact with the friction pad facing surface of the disk rotor body 10a 'and a small diameter portion 18b coaxially connected to one end of the large diameter portion 18a. The disc rotor body 10a 'is provided with fitting recesses 19 ... In which the small diameter portions 18b of the jigs 18 are fitted.

Also in this second embodiment, when the disk rotor body 10a 'is explosively sprayed with metal powder, a plurality of parts of the surface facing the friction pad of the disk rotor body 10a' are covered with jigs 18 ... By removing the jigs 18 after the thermal spraying, a plurality of light alloy surface exposed portions 10c ', which are not covered with the metal coating 10b', can be formed on the disk rotor body 10a '. The same effect as can be obtained.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and various design changes can be made without departing from the present invention described in the claims. It is possible.

[0023]

As described above, according to the present invention, at the time of explosive spraying of metal powder, a plurality of parts of the surface of the disk rotor body facing the friction pad are covered with jigs, and after the explosive spraying is finished, the cure is completed. Since multiple light alloy surface exposed parts that avoid being covered with a metal film by removing the tool are formed on the facing surface of the disk rotor body, it is possible to improve wear resistance and braking effect by the metal film. In addition, the heat dissipation of the disc rotor can be improved by the exposed parts of the light alloy surface, and the braking effect can be further improved. Further, the exposed part of the light alloy surface becomes a recess with respect to the metal film. This allows the hardened surface of the friction pad to be removed by the metal coating on the peripheral edge of the recess during braking.

[Brief description of drawings]

FIG. 1 is a side view of a disc brake according to a first embodiment.

FIG. 2 is a front view of a disc rotor.

FIG. 3 is a front view of a jig.

FIG. 4 is a front view showing a state in which a jig is attached to a disc rotor.

FIG. 5 is a sectional view taken along line 5-5 in FIG. 4;

FIG. 6 is a diagram showing a result of an experiment on the influence of temperature on the coefficient of friction.

FIG. 7 is a diagram showing the results of experiments on the effect of hydraulic pressure on the coefficient of friction.

FIG. 8 is a diagram showing a result of an experiment on the influence of speed on the coefficient of friction.

FIG. 9 is a front view of the disk rotor of the second embodiment.

FIG. 10 is a front view showing a state in which a jig is attached to a disc rotor.

FIG. 11 is a sectional view taken along line 11-11 of FIG. 10;

[Explanation of symbols]

10 '... disk rotor 10a, 10A' ... disc rotor body 10b, 10b '... metal film 10c, 10 c' ... light alloy surfaces exposed portion 12 _1, 12 ₂ ... friction pads 15, 18 ... Jig

Claims (1)

[Claims] 1. A disk rotor body (1) made of a light alloy.
0a, 10a ') on the surface facing the friction pads (12 ₁ , 12 ₂ ), the metal coating (10
b, 10b '), a method of manufacturing a disk rotor, the friction pads (12 ₁ , 12) of the disk rotor body (10a, 10a') at the time of explosive spraying of metal powder.
₂ ) is covered with jigs (15, 18) at a plurality of positions, and the jigs (15, 18) are covered after the explosive spraying is finished.
The exposed parts (10) of the light alloy surface avoiding being covered with the metal coating (10b, 10b ') by removing the
c, 10c ') is the disk rotor body (10a, 10a
′) Formed on the facing surface of the disk rotor.