US20070102247A1 - Brake disk producing method and brake disk - Google Patents

Brake disk producing method and brake disk Download PDF

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Publication number
US20070102247A1
US20070102247A1 US10/581,313 US58131304A US2007102247A1 US 20070102247 A1 US20070102247 A1 US 20070102247A1 US 58131304 A US58131304 A US 58131304A US 2007102247 A1 US2007102247 A1 US 2007102247A1
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US
United States
Prior art keywords
corner portion
rotor plate
outer peripheral
brake disk
chamfered
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/581,313
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English (en)
Inventor
Tadashi Takenaka
Koji Tamura
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Sunstar Engineering Inc
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Individual
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Publication date
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Assigned to SUNSTAR ENGINEERING INC. reassignment SUNSTAR ENGINEERING INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAKENAKA, TADASHI, TAMURA, KOJI
Publication of US20070102247A1 publication Critical patent/US20070102247A1/en
Priority to US12/923,587 priority Critical patent/US8250898B2/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/026—Braking members; Mounting thereof characterised by a particular outline shape of the braking member, e.g. footprint of friction lining
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/1304—Structure
    • F16D2065/1316—Structure radially segmented
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D2065/13—Parts or details of discs or drums
    • F16D2065/134—Connection
    • F16D2065/1392—Connection elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D2069/004—Profiled friction surfaces, e.g. grooves, dimples
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0008—Ferro
    • F16D2200/0017—Ferro corrosion-resistant
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0026—Non-ferro
    • F16D2200/003—Light metals, e.g. aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0023—Shaping by pressure

Definitions

  • the present invention relates to a method of producing a brake disk whose outer peripheral shape is formed to have recesses and ridges repeated in the radial direction and to the improvement of the brake disk, in a brake disk of a disk brake device used in a motorcycle and the like.
  • a disk brake device is used widely as a brake device for a motorcycle, a car, a pickup truck, or the like (see Japanese Patent Application Laid-Open No. 2003-74604, for example).
  • a brake disk As the main component of such disk brake device, there is a brake disk.
  • the brake disk rotates integrally with a wheel, transmits, to the wheel, braking force caused by the pressure of the brake pad pressing against the both surfaces of the brake disk, and has a function of radiating frictional heat generated between the brake disk and the brake pad at the time of braking.
  • there is a circle brake disk as is usually generally used (see Japanese Patent Application Laid-Open No. 2003-74604, for example) and a brake disk having a surface with recesses and ridges repeated in the radial direction (see Japanese Design Registration No. 1179058, and International Patent Publication WO 04/042247, for example).
  • the brake disk whose outer peripheral shape is formed to have recesses and ridges repeated in the radial direction, is preferred in terms of its improved heat radiation capability, light-weight body, improved design and the like
  • the brake disk with such outer peripheral shape has problems that the brake pad wears out significantly and the processing cost for molding the brake disk rises.
  • the processing for the formation needs to be carried out for a long period of time using an expensive processing machine or special processing machine such as an NC machining tool or the like since the outer peripheral shape is formed to have recesses and ridges repeated in the radial direction.
  • the brake disk whose outer peripheral shape is formed to have recesses and ridges repeated in the radial direction, comprises the characteristics of the improved heat radiation capability, the light weight body, the improved design and the like, but has, on the other hand, a problem that such brake disk lacks practicability due to the poor durability of the braking performance and high production costs.
  • the present invention is contrived in order to solve the problem described above, and an object thereof is to provide a method of producing a highly practical brake disk capable of maintaining the desired performance and at the same time suppressing increase in production costs even in a case of forming a chamfered surface at a corner portion of an outer peripheral edge of a brake disk whose outer peripheral shape is formed to have recesses and ridges repeated in the radial direction, and to provide such brake disk.
  • the method of producing a brake disk according to the present invention is a method of producing a brake disk that rotates integrally with a wheel, comprising an outer periphery pressing step for forming an outer peripheral shape of a rotor plate of the brake disk into an outer peripheral shape having recesses and ridges repeated in the radial direction by means of press molding, and a chamfering step for forming a chamfered surface on the rotor plate having the repeated shape formed in the outer periphery pressing step, by pressing, against a corner portion on an outer peripheral edge of the rotor plate having the repeated shape, a die provided with an inclined surface contacting with the corner portion in accordance with the repeated shape, and by plastically deforming the corner portion.
  • the method of producing a brake disk is preferably provided with an outer periphery cut-processing step for machining, after the chamfering step, a part on a leading end side of a ridged portion configuring the repeated shape, in accordance with a circular arc of a circle which is concentric with the center of rotation of the rotor plate, and cut-processing, on the corner portion, a chamfered surface continuing to the chamfered surface obtained by using the die.
  • the method of producing a brake disk is preferably provided with a heat processing step for performing heat processing in order to cure a braking front face and a braking back face of the rotor plate.
  • the chamfered surface be formed using the die, only on a corner portion with no sag, of the corner portions of the outer peripheral edge of the rotor plate, the sag being formed by the press molding in the outer periphery pressing step.
  • the chamfering step is preferably to form a chamfered surface throughout the entire periphery of the rotor plate having the repeated shape formed in the outer periphery pressing step, by pressing, against a corner portion on an outer peripheral edge of the rotor plate having the repeated shape, a die provided with an inclined surface contacting with the corner portion throughout the entire periphery of the rotor plate, in accordance with the repeated shape, and by plastically deforming the corner portion.
  • a chamfered length of the chamfered surface correspond to the size of the sag of the corner portion on the outer peripheral edge of the rotor plate, the sag being formed in the outer periphery pressing step.
  • a chamfered length from the corner portion on the outer peripheral edge of the rotor plate toward a direction of a surface contacting with the brake pad, and a chamfered length from the corner portion toward a direction of an outer peripheral end surface may be greater than or equal to 0.1 mm and less than or equal to 2.0 mm, preferably greater than or equal to 0.1 mm and less than or equal to 1.0 mm, or more preferably greater than or equal to 0.2 mm and less than or equal to 0.7 mm.
  • the brake disk according to the present invention is a brake disk that rotates integrally with a wheel, wherein a recessed and ridged portion which is recessed and protruded in a radial direction is formed repeatedly on an outer peripheral edge of a rotor plate of the brake disk along a circumferential direction, and a chamfered surface is provided on a corner portion of the recessed and ridged portion by means of press molding.
  • a cut-processed outer peripheral surface is formed in a leading end portion of a ridged portion of the recessed and ridged portion by cut-processing a part on the leading end side of the ridged portion in accordance with a circular arc of a circle concentric with the center of rotation of the rotor plate, and a chamfered surface which is formed on a corner portion of the cut-processed outer peripheral surface by means of cut-processing is provided so as to continue to the chamfered surface obtained by means of the press molding.
  • the recessed and ridged portion be formed by means of press molding, that a chamfered surface be formed, by pressing, on the side of the recessed and ridged portion where a corner portion has no sag, and that the side of the recessed and ridged portion where the corner portion has sag be made to serve as an attaching surface to a wheel.
  • a chamfered length of the chamfered surface correspond to the size of the sag of the corner portion on the outer peripheral edge of the rotor plate, the sag being formed by means of the press molding.
  • a chamfered length from the corner portion on the outer peripheral edge of the rotor plate toward a direction of a surface contacting with the brake pad may be greater than or equal to 0.1 mm and less than or equal to 2.0 mm, preferably greater than or equal to 0.1 mm and less than or equal to 1.0 mm, or more preferably greater than or equal to 0.2 mm and less than or equal to 0.7 mm.
  • the method of producing a brake disk according to the present invention is a method of producing a brake disk rotating integrally with a wheel, comprising an outer periphery pressing step for forming an outer peripheral shape of a rotor plate of the brake disk into a shape having recesses and ridges repeated in the radial direction by means of press molding, and a chamfering step for forming a chamfered surface on the rotor plate having the repeated shape molded in the outer periphery pressing step, by pressing, against a corner portion on an outer peripheral edge of the rotor plate having the repeated shape, a die provided with an inclined surface contacting with the corner portion in accordance with the repeated shape, and by plastically deforming the corner portion.
  • the outer periphery pressing step the repeated shape of recesses and ridges in the radial direction can be processed using a pressing device and the processing time can be reduced, thus it is possible to realize a brake disk capable of improving heat radiation capability, reducing the weight thereof, reducing moment of inertia, and suppressing increase in production costs.
  • a chamfered surface can be molded on the rotor plate having the repeated shape by using a pressing device and the processing time can be reduced, thus it is possible to realize a brake disk capable of improving safety in handling and controlling production costs.
  • the amount of wear of a brake pad pressed by the brake disk is suppressed by forming the chamfered surface, so that durability of braking performance can be improved.
  • a brake disk capable of improving design can be realized by means of an external appearance of the repeated shape of recesses and ridges and of the chamfered surface.
  • the method of producing a brake disk is provided with an outer periphery cut-processing step for machining a part of a leading end of a ridged portion configuring the repeated shape, in accordance with a circular arc of a circle which is concentric with the center of rotation of the rotor plate, and cut-processing, on the corner portion, a chamfered surface continuing to the chamfered surface obtained by using the die.
  • a part on a leading end side of the ridged portion can be processed using a lathe or the like and the processing time can be reduced, thus production costs can be controlled and accuracy of the shape of a portion of the rotor plate where an outer diameter is largest and deflection accuracy at the time of rotation can be enhanced. Further, by machining and processing at high accuracy, the effect of suppressing the amount of wear of the brake pad and design can be improved.
  • the method of producing a brake disk is provided with a heat processing step for performing heat processing in order to cure a braking front face and a braking back face of the rotor plate. Therefore, long-term reliability of the disk brake device can be improved by improving wear resistance of the rotor plate.
  • the chamfered surface is formed using the die, only on a corner portion with no sag, of the corner portions of the outer peripheral edge of the rotor plate, the sag being formed by the press molding in the outer periphery pressing step. Therefore, it is possible to improve productivity while securing safety in handling the rotor plate and to suppress increase in production costs.
  • the chamfering step is to form a chamfered surface throughout the entire periphery of the rotor plate having the repeated shape formed in the outer periphery pressing step, by pressing, against a corner portion on an outer peripheral edge of the rotor plate having the repeated shape, a die provided with an inclined surface contacting with the corner portion throughout the entire periphery of the rotor plate, in accordance with the repeated shape, and by plastically deforming the corner portion. Therefore, increase in production costs can be further suppressed.
  • a chamfered length of the chamfered surface corresponds to the size of the sag of the corner portion on the outer peripheral edge of the rotor plate, the sag being formed by means of the press molding, thus an integrated impression can be obtained to enhance design. Moreover, the amount of wear of the brake pads on both sides which are pressed by the brake disk produced in the production method can be reduced, and the amount of wear of the both brake pads can be made substantially even.
  • the a chamfered length from the corner portion on the outer peripheral edge of the rotor plate toward a direction of a surface contacting with the brake pad, and a chamfered length from the corner portion toward a direction of an outer peripheral end surface are greater than or equal to 0.1 mm and less than or equal to 2.0 mm, preferably greater than or equal to 0.1 mm and less than or equal to 1.0 mm, or more preferably greater than or equal to 0.2 mm and less than or equal to 0.7 mm.
  • the brake disk according to the present invention is a brake disk rotating integrally with a wheel, wherein a recessed and ridged portion which is uneven in a radial direction is formed repeatedly on an outer peripheral edge of a rotor plate of the brake disk along a circumferential direction, and a chamfered surface is provided on a corner portion of the recessed and ridged portion by means of press molding. Accordingly, it is possible to improve heat radiation capability, reduce the weight and moment of inertia, improve safety in handling, and suppress increase in production costs. Further, the amount of wear of the brake pad pressed by the brake disk can be reduced by forming the chamfered surface. In addition, an impression of the repeated shape of recesses and ridges and of the chamfered surface can improve the design.
  • a cut-processed outer peripheral surface is formed in a leading end portion of a ridged portion of the recessed and ridged portion by cut-processing a part on the leading end side of the ridged portion in accordance with a circular arc of a circle concentric with the center of rotation of the rotor plate, and a chamfered surface which is cut-processed on a corner portion of the cut-processed outer peripheral surface by means of cut-processing is provided so as to continue to the chamfered surface obtained by means of the press molding. Accordingly, it is possible to improve heat radiation capability, reduce the weight thereof, reduce moment of inertia, improve safety in handling, and suppress increase in production costs.
  • an impression of the repeated shape of recesses and ridges and of the chamfered surface can improve the design. Further, accuracy of the shape of the portion of the rotor plate where an outer diameter is largest and deflection accuracy at the time of rotation can be enhanced.
  • the recessed and ridged portion is formed by means of press molding, a chamfered surface is formed, by pressing, on each side of the recessed and ridged portion where a corner portion has no sag, and the side of the recessed and ridged portion where a corner portion has sag is made to serve as an attaching surface to the wheel. Accordingly, increase in production costs can be further suppressed.
  • a chamfered length of the chamfered surface corresponds to the size of the sag of the corner portion on the outer peripheral edge of the rotor plate, the sag being formed by means of the press molding, thus an integrated impression can be obtained to enhance design. Moreover, the amount of wear of the brake pads on both sides which are pressed by the brake disk can be reduced, and the amount of wear of the both brake pads can be made substantially even.
  • a chamfered length from the corner portion on the outer peripheral edge of the rotor plate toward a direction of a surface contacting with the brake pad, and a chamfered length from the corner portion toward a direction of an outer peripheral end surface are greater than or equal to 0.1 mm and less than or equal to 2.0 mm, preferably greater than or equal to 0.1 mm and less than or equal to 1.0 mm, or more preferably greater than or equal to 0.2 mm and less than or equal to 0.7 mm.
  • FIG. 1 is a perspective view showing a configuration example of a brake disk according to an embodiment of the present invention, wherein a floating brake disk is shown;
  • FIG. 2 is an explanatory diagram of an outer peripheral shape of an outer rotor plate
  • FIG. 3 is a perspective view showing an enlarged outer peripheral portion of the outer rotor plate
  • FIG. 4 is an explanatory diagram showing an example of a production process for the outer rotor plate according to the embodiment of the present invention
  • FIG. 5 is a cross-sectional view showing a method of molding a chamfered surface on a corner portion of an outer peripheral edge of the outer rotor plate, wherein FIG. 5 ( a ) shows a state of the chamfered surface before molded, FIG. 5 ( b ) shows a state of the chamfered surface after molded, and FIG. 5 ( c ) shows all components surrounding the chamfered surface;
  • FIG. 6 is a partial cross-sectional perspective view of a die which is used for molding the chamfered surface on the corner portion on the outer peripheral edge of the outer rotor plate;
  • FIG. 7 is a cross-sectional view showing an example of cut-processing a part on a leading end side of a ridged portion on the outer peripheral shape of the outer rotor plate by machining, the cut-processing being performed after performing heat processing;
  • FIG. 8 is a figure showing changes of the amount of wear of a brake pad in accordance with a chamfered length of the chamfered surface which is formed on the corner portion on the outer peripheral edge of the outer rotor plate.
  • FIG. 1 is a perspective view showing a configuration example of a brake disk according to an embodiment of the present invention, wherein a floating brake disk is shown.
  • the brake disk 1 comprises an outer rotor plate 2 , an inner rotor plate 3 provided with attached holes 3 a , 3 a , . . . for a wheel which is not shown, and a floating pin 4 , 4 , . . . connecting the outer rotor plate 2 and the inner rotor plate 3 . Only the inner rotor plate 3 is fixed to the wheel by means of the attached holes 3 a , 3 a , . . . by using bolts, and the outer rotor plate 2 is not fixed to the wheel.
  • this brake disk 1 is characterized in that operation of pressing the outer rotor plate 2 by means of a brake pad is stabled, and has other characteristics.
  • the outer rotor plate 2 and the floating pin 4 , 4 , . . . are made of metal such as stainless steel, and the inner rotor plate 3 is made of metal such as aluminum alloy.
  • metal such as stainless steel
  • aluminum alloy having relatively large coefficient of thermal expansion can be used for the primary objective of reducing the weight of the brake disk.
  • the size of the outer rotor plate 2 is, for example, approximately 300 mm at external diameter thereof and approximately 6 mm at thickness thereof.
  • a braking front face 2 a and a braking back face 2 b of the outer rotor plate 2 which are surfaces contacting with the brake pad, are subjected to heat processing such as induction of hardening for curing the braking surfaces in order to improve wear resistance.
  • FIG. 2 is an explanatory diagram of an outer peripheral shape of the outer rotor plate 2 .
  • FIG. 3 is a perspective view showing an enlarged outer peripheral portion of the outer rotor plate.
  • the outer peripheral shape 5 of the outer rotor plate 2 is a repeated shape of recesses and ridges (a recess portion 5 a and a ridged portion 5 b ) in the radial direction, and, as shown in FIG. 2 , partially overlaps with a circular arc of a circle A which is concentric with the center of rotation of the wheel, i.e. the centers of rotation of the outer rotor plate 2 and the inner rotor plate 3 .
  • Such shape of the outer rotor plate 2 can improve heat radiation capability by increasing the surface area, reduce the weight and moment of inertia, and improve the design.
  • the pitch of the recesses and ridges (the number of recesses and ridges) in the repeated shape of recesses and ridges in the radial direction on the outer periphery of the outer rotor plate 2 , the depth of the recess portion 5 a , and the like can be set accordingly from the perspective of the improvement of heat radiation capability by increasing the surface area, reduction of the weight and moment of inertia, and improvement of the design.
  • an inner peripheral shape of the outer rotor plate may be taken as the repeated shape of recesses and ridges in the radial direction.
  • At least the corner portion on the outer peripheral side of the braking front face 2 a is formed with a chamfered surface 6 .
  • the outer rotor plate 2 is formed with a number of punched holes 2 c , 2 c , . . . in an axial direction of rotation of the wheel, so that improvement of heat radiation capability by increasing the surface area, improvement of the braking performance by reducing the weight and moment of inertia, improvement of performance of eliminating scrap and dirt causing wear of the brake disk, and improvement of the design can be achieved.
  • FIG. 4 is an explanatory diagram showing an example of a production process for the outer rotor plate according to the embodiment of the present invention.
  • a plate like material made of stainless steel or the like for example, is punched out by means of pressing to form a disk CP which is the base of the outer rotor plate 2 (step (a)).
  • the inside of the disk CP is punched out by pressing to form the shape on an inner diameter side of the outer rotor plate 2 (step (b)).
  • the punched holes 2 c , 2 c , . . . of the outer rotor plate 2 are formed on the disk CP by means of press molding (step (c)).
  • the outer peripheral shape 5 of the outer rotor plate 2 i.e. the repeated shape of recesses and ridges (the recess portion 5 a and the ridged portion 5 b ) in the radial direction is formed into, for example, a roughly corrugated or trapezoidal repeated shape by means of press molding (outer periphery pressing step (d)).
  • FIG. 5 is a cross-sectional view showing a method of molding the chamfered surface 6 on the corner portion of the outer peripheral edge 2 d of the outer rotor plate 2 , wherein FIG. 5 ( a ) shows a state of the chamfered surface 6 before molded, FIG. 5 ( b ) shows a state of the chamfered surface 6 after molded, and FIG. 5 ( c ) shows all components surrounding the chamfered surface. Also, FIG. 6 is a partial cross-sectional perspective view of a die which is used for molding the chamfered surface 6 on the corner portion on the outer peripheral edge of the outer rotor plate 2 .
  • a die 7 for molding the chamfered surface 6 on a corner portion 2 d of the outer peripheral edge of the outer rotor plate 2 is provided with an inclined surface 7 a which contacts with the corner portion 2 d throughout the entire periphery of the outer rotor plate 2 in accordance with the repeated shape of recesses and ridges in the radial direction of the rotor plate, the repeated shape being molded in the outer periphery pressing step (d) shown in FIG. 4 .
  • the inclined surface 7 a of the die 7 is pressed against the corner portion 2 d throughout the entire periphery of the outer rotor plate 2 having the repeated shape, in accordance with the repeated shape, and the corner portion 2 d is plastically deformed, whereby the chamfered surface 6 can be formed at once on the corner portion 2 d of the outer peripheral edge throughout the entire periphery of the outer rotor plate 2 having the repeated shape (chamfering step (e) shown in FIG. 4 ).
  • the angle of chamfer can be changed by changing the angle of inclination of the inclined surface 7 a of the die 7 , so that the chamfered surface 6 having a general angle of chamfer of 45°, an angle of chamfer of 30°, an angle of chamfer of 60° or the like can be formed easily.
  • the angle of inclination of the inclined surface 7 a may be set to 45°, and it is possible to easily form the chamfered surface 6 of approximately 0.1 mm through 2 mm or in which a chamfered length L 1 from the corner portion 2 d on the outer peripheral edge of the outer rotor plate 2 toward the direction of the braking front face 2 a (direction of the surface contacting with the brake pad) and a chamfered length L 2 from the corner portion 2 d toward a direction of an outer periphery end surface E is approximately equivalent to a sag 2 e of the corner portion on the outer peripheral edge of the outer rotor plate 2 .
  • the chamfered surface 6 may be formed at once on the complicated outer peripheral shape of the outer rotor plate 2 by means of the chamfering step (e) shown in FIG. 4 , or may be formed in a plurality of separate steps, whereby the processing time and processing costs can be reduced significantly.
  • the inclined surface 7 a of the die 7 does not have to be a inclined surface extending throughout the entire periphery of the corner portion 2 d on the outer peripheral edge of the outer rotor plate 2 , thus it may be an inclined surface contacting only with a part of the entire periphery.
  • the inclined surface 7 a of the die 7 extends throughout the entire periphery of the corner portion 2 d of the outer peripheral edge of the outer plate 2 , the chamfered surface 6 can be formed as described above, thus the effects of reducing processing time and processing costs is significant.
  • the die 7 does not have to be one unit, thus separate dies may be used.
  • the chamfered surface 6 may be formed on both the braking front face 2 a and the braking back face 2 b of the outer rotor plate 2 .
  • the portion with sag does not disturb safety in handling the outer rotor plate 2 , thus chamfering of the portion with sag may be omitted.
  • the chamfered surface 6 is certainly formed on the corner portion of the braking front face 2 a of the outer rotor plate 2 , as described above.
  • the chamfered surface 6 is formed only on the corner portion of the braking front face 2 a of the outer rotor plate 2 by means of the chamfering step (e) shown in FIG. 4 , so that the processing time and processing costs can be reduced. Moreover, the formation of the chamfered surface 6 does not degrade safety in handling and the design.
  • the surfaces contacting with the brake pads on both the braking front face 2 a and braking back face 2 b of the outer rotor plate 2 are subjected to heat processing such as induction of hardening for curing the braking surfaces in order to improve wear resistance. Steps of the heat processing are not shown in FIG. 4 .
  • FIG. 7 is a cross-sectional view showing an example of cut-processing a part on a leading end side of the ridged portion 5 b on the outer peripheral shape of the outer rotor plate 2 by performing machining such as lathe turning, cutting, grinding or the like, the cut-processing being performed after the heat processing.
  • the part of the ridged portion 5 b on the outer peripheral shape of the outer rotor plate 2 after the heat processing is subjected to cut-processing by machining in accordance with the circular arc of the circle A (see FIG. 2 ) which is concentric with the center of rotation of the outer rotor plate 2 , whereby a cut-processed outer peripheral surface 8 is formed.
  • a corner portion generated by the machining is also subjected to cut-processing by machining, whereby a chamfered surface 6 a , 6 a is formed as shown in FIG. 7 (outer periphery cut-processing step (f) shown in FIG. 4 ).
  • the outer periphery cut-processing step (f) of FIG. 4 is a simple machining processing performed in accordance with the circular arc of the circle A (see FIG. 2 ) which is concentric with the center of rotation of the outer rotor plate 2 , thus the processing time and processing costs can be controlled. The effect of controlling the processing time and processing costs is significant if lathe turning is performed.
  • FIG. 8 is a figure showing changes of the amount of wear of the brake pad in accordance with the chamfered length of the chamfered surface which is formed on the corner portion on the outer peripheral edge of the outer rotor plate, and the present measurement is pursuant to the endurance strength test of Society of Automotive Engineers standard (Section 7.2 in JASO C 419-89) (set reduced speed is 1.2 G).
  • the positions for measuring the amount of wear of the both brake pads contacting with the braking front face 2 a and braking back face 2 b respectively of the outer rotor plate 2 of the disk 1 are where the recess portion 5 a of the outer rotor plate 2 is held between the both brake pads, which are locations of inner, center, and outer sides in respective radial directions of the inlet side, the outlet side, the center of the inlet side and outlet side of the brake pad with respect to the direction of rotation of the outer rotor plate 2 .
  • the inlet side, center and outlet side of the outer rotor plate 2 in radial directions are taken as three measuring positions, and the total of eighteen brake pads on the both sides are measured.
  • the amount of wear of the brake pad shown in FIG. 8 indicates a result of measurement on the braking front and back surfaces on the inlet side, center, and outlet side.
  • the chamfering length L 1 in the direction of the surface contacting with the brake pad and the chamfering length L 2 from the corner portion toward the direction of the outer periphery end surface E are changed to 0.3 mm (C0.3), 0.5 mm (C0.5), 0.7 mm (C0.7), 1.0 mm (C1.0), and 1.5 mm (C1.5), and a result obtained by measuring the amount of wear when the chamfered surface is not formed on the recess portion 5 a (C0) is shown.
  • the widths of the braking front and back faces of the outer rotor plate 2 which contact with the brake pads become narrower than the width of the brake pad, thus nonuniform wear of the brake pad occurs, which is not desirable.
  • the chamfered length L 1 from the corner portion on the outer peripheral edge of the outer rotor plate toward the direction of the surface contacting with the brake pad and the chamfered length L 2 from the corner portion toward the direction of the outer periphery end surface be set to greater than or equal to 0.1 mm and less than or equal to 2.0 mm.
  • the chamfered lengths L 1 and L 2 may be set so as to correspond to the size of the sag which is substantially equivalent to the size of the sag in the corner portion on the outer peripheral edge of the outer rotor plate 2 , which is formed in the outer periphery pressing step.
  • the integrated impression thereof can enhance the design.
  • the amount of wear of the both brake pads pressed by the brake disk produced in the production method can be reduced, and the amount of wear of the both brake pads can be made substantially even.
  • the chamfered length L 1 from the corner portion on the outer peripheral edge of the outer rotor plate toward the direction of the surface contacting with the brake pad and the chamfered length L 2 from the corner portion toward the direction of the outer periphery end surface be set to greater than or equal to 0.1 mm and less than or equal to 1.0 mm, or more preferably greater than or equal to 0.2 mm and less than or equal to 0.7 mm, from the perspective of, mainly, reducing the amount of wear of the brake pad effectively.
  • the external shape of the outer rotor plate may be formed into a desired final shape by performing press working by means of the outer peripheral pressing step (d), without performing machining in the outer periphery cut-processing step (f).
  • the present invention is not limited to the application to the floating brake disk, but also can be applied to a rigid brake disk in which an outer rotor plate and an inner rotor plate are not separated or independent but are obtained as an integrated rotor plate.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
US10/581,313 2003-12-02 2004-11-26 Brake disk producing method and brake disk Abandoned US20070102247A1 (en)

Priority Applications (1)

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US12/923,587 US8250898B2 (en) 2003-12-02 2010-09-29 Brake disk producing method and brake disk

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JP2003403674 2003-12-02
JP2003-403674 2003-12-02
PCT/JP2004/017571 WO2005054703A1 (fr) 2003-12-02 2004-11-26 Procede de production d'un disque de frein et disque de frein ainsi produit

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US20070102247A1 true US20070102247A1 (en) 2007-05-10

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US10/581,313 Abandoned US20070102247A1 (en) 2003-12-02 2004-11-26 Brake disk producing method and brake disk
US12/923,587 Expired - Fee Related US8250898B2 (en) 2003-12-02 2010-09-29 Brake disk producing method and brake disk

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US (2) US20070102247A1 (fr)
EP (1) EP1803960B1 (fr)
JP (2) JP4155301B2 (fr)
AT (1) ATE434733T1 (fr)
DE (1) DE602004021732D1 (fr)
ES (1) ES2325267T3 (fr)
WO (1) WO2005054703A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100051398A1 (en) * 2008-08-29 2010-03-04 Stanislav Spacek Floating brake disc
US20100243390A1 (en) * 2009-03-31 2010-09-30 Honda Motor Co., Ltd. Brake disks for a vehicle, method of manufacturing same, and vehicle incorporating same
US20110079474A1 (en) * 2008-07-08 2011-04-07 Nobuhiro Fujita Floating type brake disc
US20120097491A1 (en) * 2009-04-30 2012-04-26 Naoki Yamanaka Floating brake disk assembling method
EP3244086A1 (fr) * 2016-04-13 2017-11-15 Sram, Llc. Rotor de frein
USD830256S1 (en) * 2017-04-13 2018-10-09 Lyndall P Kittrell, Jr. Brake disk for a motorcycle
USD830257S1 (en) * 2017-04-13 2018-10-09 Lyndall P Kittrell, Jr. Brake disk for a motorcycle
USD873739S1 (en) * 2018-01-16 2020-01-28 GRIMECA S.r.l. Disc brake
CN113613990A (zh) * 2019-03-22 2021-11-05 新时代技研株式会社 制动盘

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JP2007064297A (ja) * 2005-08-30 2007-03-15 Yamaha Motor Co Ltd ディスクブレーキ装置及び該ディスクブレーキ装置を備えた自動二輪車
JP2008298094A (ja) * 2007-05-29 2008-12-11 Sunstar Engineering Inc ブレーキディスクの製造方法及びブレーキディスク
JP2011256949A (ja) * 2010-06-09 2011-12-22 Yutaka Giken Co Ltd ブレーキディスクの製造方法及びブレーキディスク
CN102615181B (zh) * 2012-02-27 2014-04-09 昆山三景科技股份有限公司 适用于冲制汽车刹车片的连续冲压模具及冲压方法
JP2012141065A (ja) * 2012-04-25 2012-07-26 Yutaka Giken Co Ltd ブレーキディスクの製造方法
US10352382B2 (en) * 2016-07-27 2019-07-16 Shimano Inc. Bicycle disc brake rotor
JP6712340B1 (ja) 2019-03-06 2020-06-17 サンスター技研株式会社 ブレーキディスクを製造する方法及びブレーキディスク
JP7117261B2 (ja) * 2019-03-22 2022-08-12 サンスター技研株式会社 回転伝達ディスク

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US20020003071A1 (en) * 2000-07-04 2002-01-10 Akira Torii Wheel bearing assembly
US20040084261A1 (en) * 2002-11-01 2004-05-06 Performance Friction Corporation Brake rotor with a surface having a plurality of indentations formed therein
US20040200674A1 (en) * 2003-03-28 2004-10-14 Campbell Darren J. Quick-mount disc brake rotor

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110079474A1 (en) * 2008-07-08 2011-04-07 Nobuhiro Fujita Floating type brake disc
US8353391B2 (en) * 2008-07-08 2013-01-15 Yutaka Giken Co., Ltd. Floating type brake disc
US8474580B2 (en) * 2008-08-29 2013-07-02 Stanislav Spacek Floating brake disc
US20100051398A1 (en) * 2008-08-29 2010-03-04 Stanislav Spacek Floating brake disc
EP2236850A1 (fr) * 2009-03-31 2010-10-06 Honda Motor Co., Ltd. Procédé de fabrication pour disque de frein et disque de frein
CN101850499A (zh) * 2009-03-31 2010-10-06 本田技研工业株式会社 制动盘的制造方法以及制动盘
US20100243390A1 (en) * 2009-03-31 2010-09-30 Honda Motor Co., Ltd. Brake disks for a vehicle, method of manufacturing same, and vehicle incorporating same
US8430215B2 (en) 2009-03-31 2013-04-30 Honda Motor Co., Ltd. Brake disks for a vehicle, method of manufacturing same, and vehicle incorporating same
US20120097491A1 (en) * 2009-04-30 2012-04-26 Naoki Yamanaka Floating brake disk assembling method
US9057413B2 (en) * 2009-04-30 2015-06-16 Sunstar Engineering Inc. Floating brake disk assembling method
US10626935B2 (en) 2016-04-13 2020-04-21 Sram, Llc Brake rotor
TWI657206B (zh) * 2016-04-13 2019-04-21 速聯有限責任公司 剎車轉子及其製造方法
EP3244086A1 (fr) * 2016-04-13 2017-11-15 Sram, Llc. Rotor de frein
TWI737963B (zh) * 2016-04-13 2021-09-01 美商速聯有限責任公司 剎車轉子及其製造方法（一）
USD830256S1 (en) * 2017-04-13 2018-10-09 Lyndall P Kittrell, Jr. Brake disk for a motorcycle
USD830257S1 (en) * 2017-04-13 2018-10-09 Lyndall P Kittrell, Jr. Brake disk for a motorcycle
USD873739S1 (en) * 2018-01-16 2020-01-28 GRIMECA S.r.l. Disc brake
CN113613990A (zh) * 2019-03-22 2021-11-05 新时代技研株式会社 制动盘
US11859682B2 (en) 2019-03-22 2024-01-02 Sunstar Engineering Inc. Brake disc

Also Published As

Publication number Publication date
ATE434733T1 (de) 2009-07-15
WO2005054703A1 (fr) 2005-06-16
EP1803960A4 (fr) 2007-10-31
ES2325267T3 (es) 2009-08-31
JP2008232441A (ja) 2008-10-02
US20110016943A1 (en) 2011-01-27
JP4973586B2 (ja) 2012-07-11
EP1803960A1 (fr) 2007-07-04
EP1803960B1 (fr) 2009-06-24
JPWO2005054703A1 (ja) 2007-06-28
JP4155301B2 (ja) 2008-09-24
US8250898B2 (en) 2012-08-28
DE602004021732D1 (fr) 2009-08-06

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