WO2016136832A1 - 金属板成形品及びそれを用いたノイズ低減ブレーキディスク並びに金属板成形品の製造方法 - Google Patents
金属板成形品及びそれを用いたノイズ低減ブレーキディスク並びに金属板成形品の製造方法 Download PDFInfo
- Publication number
- WO2016136832A1 WO2016136832A1 PCT/JP2016/055505 JP2016055505W WO2016136832A1 WO 2016136832 A1 WO2016136832 A1 WO 2016136832A1 JP 2016055505 W JP2016055505 W JP 2016055505W WO 2016136832 A1 WO2016136832 A1 WO 2016136832A1
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- WIPO (PCT)
- Prior art keywords
- metal plate
- inner member
- outer member
- plate molded
- friction damping
- Prior art date
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Classifications
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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
- F16D65/0006—Noise or vibration control
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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
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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
- F16D65/123—Discs; Drums for disc brakes comprising an annular disc secured to a hub member; Discs characterised by means for mounting
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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
- F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
Definitions
- the present invention relates to a metal plate molded product, a noise reduction brake disk using the metal plate molded product, and a method of manufacturing the metal plate molded product.
- a brake disc for a motorcycle As a brake disc for a motorcycle, a brake disc having a wheel mounting portion and a sliding portion with a brake pad, which is formed by press-molding a single metal plate, or a slide on which the brake pad is pressed.
- a so-called floating brake disc having an annular sliding disc having a portion, a hub disc mounted on the inside of the sliding disc, and a plurality of connecting means for connecting both discs has been widely put into practical use (for example, patents). References 1 and 2).
- brake discs for motorcycles are mass-produced through various performance tests after their design, but as a result of braking tests on actual vehicles, they are designed based on the occurrence of brake noise (brake judder) such as brake noise. You may be forced to change. Brake noise is a very important issue that needs to be improved because it reduces the product quality.
- the mechanism of brake noise generation has not yet been fully elucidated, but if noise is confirmed in the designed brake disc, the configuration of the brake pad material and shape, etc., or the pattern hole of the brake disc can be changed. This can be done by changing the shape, size, formation position, or changing the thickness of the brake disc.
- a progressive press is widely adopted as a method for pressing a metal plate.
- the product in order to improve the outer diameter shape and outer dimensions of the product, the product is once punched from the material metal plate. It has also been proposed that the product is immediately fitted back (pushbacked) against the punched hole formed in the material metal plate by punching the product, and then the product is extracted from the material metal plate (for example, (See Patent Document 3).
- An object of the present invention is to provide a metal plate molded product having an excellent vibration damping function, a noise reduction brake disk using the same, and a method for manufacturing the metal plate molded product.
- the present inventor says that the punched extraction member is fitted back into the sliding disk (pushbacked) in the process of manufacturing the sliding disk by punching out the central portion of the circular metal sheet when manufacturing the brake disk. Focusing on the fact that the impact sound when a defective product with a malfunction is accidentally dropped on the floor is different from that when the metal sheet is dropped on the floor, and by examining the cause, the present invention is completed. It came to.
- a metal plate molded product according to the present invention is a metal plate molded product including an inner member made of a metal plate and an outer member made of a metal plate fitted on the metal plate, and the inner member and the outer member are fitted to each other. A friction damping surface that is pressed against each other is formed.
- this metal plate molded product a friction damping surface that presses against the fitting surface of the inner member and the outer member is formed. Therefore, when the metal plate molded product vibrates, the inner member and the outer member As the metal structures rub against each other, vibrations acting on the metal plate molded product are attenuated. For this reason, if this metal plate molded product constitutes a product that generates vibration or noise, for example, a power transmission member such as a brake disc, clutch disc, sprocket, gear, or pulley, it effectively suppresses the generation of vibration and noise. Or can be prevented.
- a power transmission member such as a brake disc, clutch disc, sprocket, gear, or pulley
- the inner member and the outer member include an inner member formed by punching a metal plate by press molding, and an outer member formed by a punched frame after the inner member is punched, and the inner member is fitted to the outer member. It is a preferred embodiment to form a friction damping surface that presses against the fitting surface of the inner member and the outer member by returning.
- the inner member after punching the metal plate with a punch, when the punch returns to the initial position, the inner member can be fitted back to the outer member, so that the productivity of the metal plate molded product can be improved,
- the inner member can be easily fitted back to the appropriate position without being displaced in the circumferential direction or the radial direction with respect to the outer member, and the variation in fitting pressure between the inner member and the outer member between products can be reduced. Less.
- a noise reduction brake disk is a brake disk made of the above-mentioned metal plate molded product, and a sliding surface on which a brake pad can be pressure-contacted with a hub portion having a plurality of mounting holes through which mounting bolts to a wheel are inserted.
- the friction damping surface is provided so as to surround the mounting holes individually or collectively, and an inner member and an outer member are formed inside and outside the friction damping surface. It is.
- the friction damping surface is formed so as to surround the mounting holes individually or collectively, so that the brake disk vibration generated during the braking is generated by the pressure contact between the brake pad and the sliding part. Is transmitted to the mounting hole of the hub portion from the sliding portion, and is attenuated by the friction of the metal structure of the inner member and the outer member on the friction damping surface, thereby effectively suppressing or preventing the generation of brake noise. Will be.
- the friction damping surface is formed in an annular shape along the outer peripheral portion of the hub portion so as to surround all of the mounting holes.
- the friction damping surface may be formed so as to individually surround the mounting holes.
- an annular shape is formed along the outer periphery of the hub portion so as to surround all of the mounting holes. It is preferable to form.
- the friction damping surface When the friction damping surface is formed in an annular shape along the outer peripheral portion of the hub portion, a plurality of fitting convex portions are provided on the inner peripheral edge of the outer member so as to protrude toward the central portion with a circumferential interval. It is also a preferred embodiment to provide a plurality of fitting recesses into which the fitting projections are fitted on the outer peripheral edge of the inner member.
- the length of the friction damping surface can be increased to improve the fitting strength between the inner member and the outer member on the friction damping surface, and the concave and convex fitting between the fitting convex portion and the fitting concave portion can increase the outer side. This is preferable because the relative rotation between the member and the inner member can be received.
- the friction damping surface is formed in an annular shape so as to surround all of the mounting holes, the inner member and the outer member are connected without a step, and inside the sliding surface with the brake pad,
- a connecting hole is formed between one or both of the inner member and the outer member, and a connecting means for connecting the inner member and the outer member is provided in the connecting hole.
- the inner member and the outer member can be connected not only by the friction damping surface but also by the connecting means, the connection strength between the inner member and the outer member can be further improved.
- the connecting means a pin member or a bolt can be provided. Further, as the connecting hole, the mounting hole is formed between the inner member and the outer member, and the brake disk is fastened to the wheel by the mounting bolt, and the inner member and the outer member are tightened together, It is also a preferred embodiment to restrict the relative movement of the inner member and the outer member in the thickness direction. In this case, the connecting means can be provided without increasing the number of parts of the brake disk.
- the inner member and the outer member are connected continuously without a step, and the friction damping surface is provided across the sliding portion and the hub portion.
- a step is formed between the surface of the inner member and the surface of the outer member. is there.
- the vibration damping function can be improved as compared with the case where the steps are continuously provided without a step.
- the height of the friction damping surface is set to 20% or more of the thickness of the brake disk in order to sufficiently secure the fitting strength between the inner member and the outer member on the friction damping surface,
- the step is preferably set to less than 80% of the thickness of the brake disc.
- a first method for producing a metal plate molded product according to the present invention is a method for producing a metal plate molded product comprising an inner member made of a metal plate and an outer member made of a metal plate fitted on the inner member.
- the metal plate is punched out by press forming to form the inner member and the outer member, and the inner member is fitted back to the outer member to form a friction damping surface that is pressed against the fitting surface of both. .
- a metal plate is punched out by press forming to form an inner member and an outer member, and then a part or all of the inner member is fitted back to the outer member, thereby performing a series of pressing operations.
- productivity is improved by performing a continuous series of pressing operations such as punching a metal plate with a punch and fitting the inner member back to the outer member when the punch returns to its original position.
- a metal plate molded product can be manufactured without lowering.
- a second method for producing a metal plate molded product according to the present invention is a method for producing a metal plate molded product comprising an inner member made of a metal plate and an outer member made of a metal plate fitted on the metal plate.
- the inner member and the outer member are manufactured, the outer member is externally fitted to the inner member, and one of the inner member and the outer member is press-pressed in the plate thickness direction, so that the mating surfaces of the two are mutually attached.
- a friction damping surface that is in pressure contact is formed.
- the outer member and the inner member are manufactured by machining such as press molding or cutting, the outer member is externally fitted to the inner member, and one of the inner member and the outer member is in the plate thickness direction.
- the metal plate molded product having an excellent vibration damping function can be easily and efficiently manufactured by press-pressing to form a friction damping surface that is in pressure contact with the mating surfaces of the two.
- the metal plate molded product includes a hub portion having a mounting hole for a mounting bolt to the wheel, and an annular sliding portion having a sliding surface to which the brake pad can be pressed.
- a preferred embodiment is a brake disc for a motorcycle equipped with With this configuration, it is possible to easily and efficiently manufacture a brake disk that can effectively suppress or prevent brake noise during braking.
- products that generate vibration and noise such as clutch disks, sprockets, gears, pulleys, etc., can also be configured by the metal plate molded product.
- the sliding portion is induction-quenched after the friction damping surface is formed.
- the friction damping surface is formed in pressure contact with the fitting surface of the inner member and the outer member, at the time of vibration of the metal plate molded product, As the metal structures of the inner member and the outer member rub against each other, vibrations acting on the metal plate molded product are attenuated. For this reason, if this metal plate molded product constitutes a product that generates vibration or noise, such as a brake disc, clutch disc, sprocket, gear, pulley, etc., the generation of vibration or noise can be effectively suppressed or prevented. It becomes possible.
- the friction damping surface is formed so as to surround the mounting holes individually or collectively, so that the brake pad is generated by the pressure contact between the brake pad and the sliding portion.
- the metal plate is punched out by press forming to form the inner member and the outer member, and then part or all of the inner member is fitted back to the outer member.
- a continuous series of pressing operations can easily and efficiently produce a metal plate molded product having an excellent vibration damping function without reducing productivity.
- the outer member and the inner member are manufactured by machining such as press molding or cutting, the outer member is externally fitted to the inner member, and the inner member is By pressing and pressing one of the member and the outer member in the thickness direction, and forming a friction damping surface that presses against the mating surface of both of them, a metal plate molded product having an excellent vibration damping function can be easily obtained. And it can manufacture efficiently.
- FIG. 10 Front view of brake disc with other configuration
- FIG. 10 Front view of brake disc with other configuration
- FIG. 11 Front view of brake disc with other configuration
- A) is a front view of the brake disc of Comparative Example 1
- (b) is a front view of the brake disc of Example 1.
- (A) to (c) are graphs showing the relationship between the time at vibration and the acceleration at the measurement point in the brake discs of Comparative Example 1 and Examples 1 and 2.
- the first metal plate molded body 1 includes an inner member 2 formed by punching a metal plate by press molding, and an outer member 3 formed by a punched frame after the inner member 2 is punched.
- a friction damping surface 4 that presses against the fitting surface of the inner member 2 and the outer member 3 is formed by fitting the inner member 2 back to the outer member 3. It constitutes the final product including various parts.
- metal material which comprises the 1st metal plate molded object 1 the thing which consists of arbitrary metal materials which can be press-molded including a punching process, for example, ferrous metal materials, such as carbon steel and stainless steel, is also employable.
- ferrous metal materials such as carbon steel and stainless steel
- non-ferrous metal material such as aluminum, copper, brass or titanium.
- the front shape of the first metal plate molded body 1 can be configured in an arbitrary shape according to the final product, and the plate thickness of the first metal plate molded body 1 is a plate thickness according to the final product, and is at least stamped. It is set to an arbitrary thickness that can be processed, and may be configured to have a uniform thickness as a whole, or may be configured so that the thickness is partially different.
- the friction damping surface 4 is formed in an endless annular belt shape having a width in the thickness direction of the first metal plate molded body 1, and its front shape is a circular shape, an elliptical shape, a polygonal shape such as a square or a rectangle, a four-leaf shape, and the like. It can be formed into a multi-leaf shape such as or eight leaves, or any other irregular shape. It is also possible to provide a plurality of friction damping surfaces on one first metal plate molded body 1 and provide an inner member inside each friction damping surface.
- the friction damping surface 4 is preferably formed so as to block the vibration transmission path in the first metal plate molded body 1, for example, so as to surround the fixed side portion so as to divide the fixed side and the vibration generating side. Preferably, it is formed so as to surround the vibration generating side portion.
- the inner member 2 is almost completely fitted back into the hole 3a of the outer member 3, and the surface of the inner member 2 and the surface of the outer member 3 are connected to be flush with each other.
- a part of the inner member 2 is fitted back into the hole 3a of the outer member 3, and is fitted back to the surface of the inner member 2 and the surface of the outer member 3.
- a step according to the amount H can also be formed.
- the width of the friction damping surface 4A becomes less than 20% of the plate thickness, and the inner member 2 and the outer member 3 Therefore, it is preferable to set it to 20% or more of the plate thickness, preferably 50% or more, more preferably 70% or more of the plate thickness.
- this metal plate molded body 1, 1 A the friction damping surfaces 4, 4 A are formed in pressure contact with the fitting surfaces of the inner member 2 and the outer member 3.
- the metal structures of the inner member 2 and the outer member 3 rub against each other, so that vibrations acting on the metal plate molded product are attenuated.
- this metal plate molded product constitutes a product that generates vibration or noise, for example, a power transmission member such as a brake disc, clutch disc, sprocket, gear, or pulley, it effectively suppresses the generation of vibration and noise. Or can be prevented.
- the press-molding die 10 used in this manufacturing method is inserted with a die 11 having a die hole 11a for punching the inner member 2 and a certain clearance C in the die hole 11a.
- a punching punch 12, a pressing punch 13 that is mounted in the die hole 11 a so as to be movable up and down, and a spring member 14 that constantly biases the pressing punch 13 upward are provided, and the upper surface of the pressing punch 13 is flush with the upper surface of the die 11.
- a position restricting protrusion 13a that protrudes outward is formed on the outer periphery of the lower end of the push punch 13 so that the upper end position of the push punch 13 is restricted by engaging the position restricting protrusion 13a on the die 11.
- the position restricting portion 11b is formed.
- the raw metal plate 1D is set on the die 11 as shown in FIG. At this time, the upper surface of the push punch 13 is arranged flush with the upper surface of the die 11 by restricting the upward movement of the push punch 13 by the position restricting portion 11b.
- the punching punch 12 is lowered, and the inner member 2 is punched out at the outer peripheral edge at the lower end of the punching punch 12 and the inner peripheral edge at the upper end of the die 11.
- An outer member 3 made of a punched frame after punching the member 2 is formed.
- the inner member 2 is sandwiched between the punching punch 12 and the pressing punch 13.
- the punching punch 12 is raised, and the punching punch 12 is extracted from the punching hole 3 a of the outer member 3.
- the inner member 2 is moved upward together with the pressing punch 13 by the biasing force of the spring member 14 while being sandwiched between the punching punch 12 and the pressing punch 13, and is disposed in the same plane as the outer member 3.
- the 1st metal plate molded object 1 by which the inner member 2 was fitted by the punching hole 3a of the outer side member 3 by being fitted back by the push punch 13 is obtained.
- the material metal plate 1D is punched out by press forming, the inner member 2 and the outer member 3 are formed, and then the inner member 2 is fitted back to the outer member 3 by a continuous series of pressing operations.
- the metal plate molded product 1 having an excellent vibration damping function can be easily and efficiently manufactured without reducing productivity.
- the press molding die 10A in which the position restricting portion 11Ab for restricting the upward movement of the push punch 13 is formed on the die 11A is used. And like the said 1st metal plate molded object 1, in the state which set the raw metal plate 1D on the die
- the outer member 3 made of a subsequent punching frame is formed, and then the punching punch 12 is raised, so that the inner member 2 is pushed and punched 13 until the position restricting projection 13a of the pushing punch 13 abuts against the position restricting portion 11Ab. At the same time, it is raised by the urging force of the spring member 14, and the inner member 2 is fitted back so as to protrude downward from the outer member 3, thereby obtaining the second metal plate molded body 1A.
- the inner member 2 is punched from the outer member 3, and then the inner member 2 is fitted back into the hole 3 a of the outer member 3.
- the inner member 2B and the outer member 3B fitted on the inner member 2B are manufactured by press molding or machining, and the inner member 2B is fitted into the fitting hole 3Ba of the outer member 3B. Then, one of the inner member 2B and the outer member 3B (outer member 3B in FIG. 5) is press-pressed in the thickness direction as indicated by an arrow F so that one of the inner member 2B and the outer member 3B is pressed.
- first metal plate molded body 1B having a friction damping surface 4B that is plastically deformed in the direction orthogonal to the plate thickness direction and press-contacts the both fitting surfaces.
- the inner member 2B is fitted into the fitting hole 3Ba of the outer member 3B so that the inner member 2B protrudes downward from the outer member 3B.
- one of the inner member 2B and the outer member 3B is press-pressed in the plate thickness direction as indicated by an arrow F so that one of the inner member 2B and the outer member 3B is in the plate thickness direction.
- second metal plate molded body 1C having a friction damping surface 4C that is plastically deformed in a direction orthogonal to the two and press-fitting to both fitting surfaces.
- the metal plate molded bodies 1, 1A to 1C can be applied to products that need to attenuate vibrations and noises.
- power transmission members such as brake disks, clutch disks, sprockets, gears, and pulleys, It can be suitably applied to sound insulation boards for various devices.
- the noise reduction brake disc 20 is a brake disc for a motorcycle, and has an annular sliding portion 21 having a sliding surface 21 a on which the brake pad BP is slidably contacted, and the sliding portion 21. And a hub portion 22 on the inner peripheral side (inside the annular boundary line L indicated by a virtual line).
- the hub part 22 includes an attachment part 23 for a wheel hub of a motorcycle, an annular ring part 24 on the outer periphery connected to the sliding part 21, a connection part 25 for connecting the attachment part 23 and the ring part 24, and an attachment.
- a plurality of pattern holes 26 for weight reduction formed between the portion 23 and the ring portion 24 and a plurality of small holes 27 for heat dissipation and weight reduction formed in the sliding portion 21 are provided.
- the brake disc 20 is configured to rotate with the wheel of the motorcycle in the direction of rotation indicated by the arrow A.
- the brake disc 20 is manufactured by press-molding a flat metal plate made of stainless steel or carbon steel having excellent wear resistance and then heat-treating the sliding portion 21.
- the brake disc 20 shown in FIG. 7 is manufactured by press-molding a stainless steel plate having a thickness of 7 mm, and the sliding portion 21 and the hub portion 22 of the brake disc 20 are set to have substantially the same thickness.
- the outer diameter of the brake disc 20 can be set as appropriate according to the configuration of the motorcycle. In the brake disc 20 shown in FIG. 7, the outer diameter is set to 300 mm.
- the sliding portion 21 is set to be slightly wider than the width of the brake pad BP.
- the sliding portion 21 and the hub portion 22 are arranged in the same plane. However, depending on the configuration on the vehicle body side, the sliding portion 21 and the hub portion 22 are connected to the brake disc 20. It is also possible to arrange them in parallel planes with a certain interval in the thickness direction.
- the attachment part 23 and the ring part 24 are connected by twelve arm-like connection parts 25, and a pattern hole 26 partitioned by the connection part 25 is formed between the attachment part 23 and the ring part 24.
- the shape and the number of the connecting portions 25 and the pattern holes 26 can be arbitrarily set.
- a plurality of small holes 27 made of round holes for heat dissipation and weight reduction are formed in the sliding portion 21 in a predetermined arrangement.
- the small holes 27 it is possible to form long and narrow slit-shaped holes other than the round holes, or to mix round holes having different diameters.
- the diameter, shape, number and arrangement of the small holes 27 are not limited to the brake holes. It is set appropriately in consideration of the design of the disk 20 and the heat dissipation in the sliding portion 21.
- a core hole 28 through which the end of the wheel hub is inserted is formed at the center of the mounting portion 23, and five mounting holes 29 through which mounting bolts to the wheel hub are inserted so as to surround the core hole 28. Is formed.
- the number of mounting holes 29 can be set as appropriate according to the number of mounting bolt holes formed in the wheel hub.
- the configuration of the brake disk 20 other than the friction damping surface 30 can adopt any configuration, and is described above.
- the configuration is not limited.
- the ring portion 24 is provided with a friction damping surface 30 that is annular when viewed from the front and has a width in the thickness direction so as to surround the connecting portion 25, the pattern hole 26, and the attachment portion 23. Also, the inner member 31 including the connecting portion 25 and the mounting portion 23 on the inner peripheral side and the annular outer member 32 including the sliding portion 21 on the outer peripheral side with respect to the friction damping surface 30 are divided.
- the friction damping surface 30 can be formed in an annular shape concentric with the sliding portion 21, but when the plurality of protrusions 30b are provided on the friction damping surface 30, the area of the friction damping surface 30 is increased, The vibration damping action during braking can be improved, and the relative rotational force between the inner member 31 and the outer member 32 during braking can be received by the concave-convex fitting between the fitting convex part 32a and the fitting concave part 31a.
- the number of the fitting convex part 32a and the fitting concave part 31a can be set arbitrarily.
- the inner member 31 and the outer member 32 are divided so as to be separate members on the frictional damping surface 30 by press-fitting or pressurization after fitting, similar to the first metal plate molded body 1 described above. In addition, they are pressed together and integrated.
- the friction damping surface 30 is composed of an outer peripheral surface of the inner member 31 and an inner peripheral surface of the outer member 32 that is externally fitted to the inner member 31, and traverses a vibration transmission path during braking from the sliding portion 21 to the wheel hub.
- the vibration at the time of braking acting on the brake disc 20 is configured to be damped by friction between the outer peripheral surface of the inner member 31 and the inner peripheral surface of the outer member 32 on the friction damping surface 30. Has been.
- the friction damping surface 30 can be configured to have an arbitrary front shape as long as it is arranged so as to cross part or all of the vibration transmission path from the sliding portion 21 to the wheel hub.
- the sliding portion 21 can be provided annularly in the middle in the width direction, and the sliding portion 21 and the hub portion 22 are provided on the inner peripheral side and the outer peripheral side.
- the friction damping surface 30 is formed in pressure contact with the fitting surface of the inner member 31 and the outer member 32, so that vibration during braking is caused in the friction damping surface 30 with the inner member 31.
- the metal structure of the outer member 32 is damped by rubbing against each other, thereby making it possible to suppress or prevent the generation of brake noise during braking.
- a method for manufacturing the brake disc 20 will be described.
- a material metal plate made of stainless steel or the like having a certain thickness is punched out to produce a disk-shaped molded body 35A having a size suitable for the outer diameter of the brake disc 20.
- the core hole 28 and the reference small hole 27 are punched out of the molded body 35A and molded, and the same as the first metal plate molded body 1.
- the inner member 31 is punched out, the inner member 31 is fitted back into the hole 32b of the outer member 32 so that the inner member 31 and the outer member 32 are flush with each other.
- the friction damping surface 30 is formed.
- the second metal plate molded body 1 ⁇ / b> A it is possible to fit back so that a part of the inner member 31 protrudes from the outer member 32.
- the pattern hole 26 is formed by punching the molded body 35B, and then the molding shown in FIG. 8D.
- the remaining small holes 27 are formed by punching the formed body 35C, and then the sliding portion 21 is quenched by induction hardening or the like on the formed body 35D, and then the outer peripheral surface.
- both side edges in the thickness direction of the inner peripheral surface are chamfered, and the mounting hole 29 is cut, and then necessary painting and polishing are performed to obtain the brake disk 20.
- the molded body 35 ⁇ / b> A is punched out by press molding, the inner member 31 and the outer member 32 are molded, and then part or all of the inner member 31 is fitted back to the outer member 32.
- the brake disc 20 that can suppress or prevent the generation of brake noise during braking can be easily and efficiently manufactured without reducing productivity.
- the inner member 31 is punched from the outer member 32, and then the inner member 31 is fitted back into the hole 3a of the outer member 32.
- the inner member 31 and the outer member 32 fitted to the inner member 31 are manufactured by press molding or machining, the inner member 31 is fitted into the fitting hole of the outer member 32, and then the inner member 31 and the outer member are fitted.
- a friction damping surface that pressurizes and presses one of the members 32 in the plate thickness direction so that one of the inner member 31 and the outer member 32 is plastically deformed in a direction orthogonal to the plate thickness direction and press-fits the fitting surfaces of the members. 30 can also be formed.
- connection means 41 which controls a movement.
- a through hole 42 is formed in the fitting convex portion 32 a of the outer member 32, and a fixing member 43 including a pin member or a bolt attached to the through hole 42 as the connecting means 41, and both surfaces of the brake disk 20.
- a pair of washers 44 disposed on the inner member 31 and having a pair of washers 44 whose outer peripheral portions extend onto the inner member 31 are provided.
- the outer member 32 is sandwiched and the relative movement of the members 31 and 32 in the thickness direction is restricted.
- a plurality of mounting portions 23 ⁇ / b> C protruding inwardly are formed on the inner peripheral portion of the sliding portion 21 at intervals in the circumferential direction. It is also possible to apply the present invention to a brake disc 20C in which an attachment hole 29C for a wheel hub is formed in the inner peripheral portion. In this case, as in the brake disc 20C shown in FIG.
- a friction damping surface 30C having a plurality of concentric arc portions 30Ca and a protruding portion 30Cb extending from the adjacent middle portion to the inner peripheral side and connected to the mounting hole 29C is formed in the mounting portion 23C. It is also possible to provide the inner member 31C and the outer member 32C divided by 30C and form the attachment hole 29C by the inner member 31C and the outer member 32C in the attachment portion 23C.
- a bottomed fixing bracket 46 having a flange 46a to the mounting hole 29C, and fixing this to the fixing portion 45 of the wheel hub with an attachment bolt 47, the flange 46a of the fixing bracket 46 and the wheel hub are fixed.
- the inner member 31C and the outer member 32C are sandwiched between the fixing portions 45, and the brake disk 20C is fixed to the wheel hub, and the inner member 31C and the outer member 32C are fastened together to fix the inner member 31C and the outer member.
- the relative movement in the thickness direction of 32C can be regulated, and the relative movement in the plate thickness direction of the inner member 31C and the outer member 32C can be regulated without providing a separate connecting means, which is preferable.
- the brake pad BP is pressed against not only the outer member 32C but also the inner member 31C, so both members 32C and 31C during braking are used. This is preferable because the force in the relative rotation direction can be reduced to prevent a large force from acting on the friction damping surface 30C.
- the arc-shaped arc portion 30Ca is formed, but instead of the arc portion 30Ca, for example, a friction damping surface 30D having a corrugated portion 30Da is formed as in the brake disc 20D shown in FIG.
- a friction damping surface 30D having a corrugated portion 30Da is formed as in the brake disc 20D shown in FIG.
- a core hole 28 having a diameter of 56 mm is formed at the center of a stainless steel disk having a diameter of 320 mm and a thickness of 5 mm, and a diameter of 6.3 mm.
- the brake disk 50A according to the first embodiment in which the friction damping surface 53 is formed by fitting back so as to be flush with each other and having five projecting portions 53a projecting inward with an outer diameter of 240 mm and spaced in the circumferential direction.
- the brake disc of the second embodiment having the same configuration as that of the first embodiment except that the amount of fitting back of the inner member 51 to the outer member 52 is set to 2.5 mm when the brake disc 50A of the first embodiment is manufactured. It was manufactured.
- the brake disc was concentrically aligned with the end of the horizontal fixed shaft of the support base, the bolt was inserted into the mounting hole 29, and the brake disc was fixed with three bolts. Then, a horizontal radial position passing through the center of the brake disc and a radial position of 143 mm from the center is set as the excitation point K, and the circumference from the excitation point K on the circumference passing through the excitation point K is set. The position 180 degrees apart in the direction was set as the measurement point S, and the acceleration sensor AS was provided facing the measurement point S.
- FIG. 14 shows that the vibrations of Examples 1 and 2 are attenuated in a shorter time than Comparative Example 1. Further, the vibration of the second embodiment in which the return amount of the inner member 51 is set to 2.5 mm is attenuated in a shorter time than the first embodiment in which the inner member 51 is returned to the same plane as the outer member 52. I know that.
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Abstract
Description
先ず、本発明の金属板成形体の概略構成について説明する。
図1、図2に示すように、第1金属板成形体1は、金属板をプレス成形により打ち抜いてなる内側部材2と、内側部材2を打ち抜いた後の抜き枠からなる外側部材3とを備え、内側部材2を外側部材3に嵌め戻すことにより、内側部材2と外側部材3の嵌合面に相互に圧接する摩擦減衰面4を形成したもので、内側部材2と外側部材3とで各種部品を含む最終製品を構成するものである。
図3に示すように、この製造方法で用いるプレス成形用金型10は、内側部材2を打ち抜くためのダイ穴11aを有するダイ11と、ダイ穴11aに一定のクリアランスCをあけて挿入される抜きパンチ12と、ダイ穴11aに上下移動自在に装着した押しパンチ13と、押しパンチ13を上方へ常時付勢するバネ部材14とを備え、押しパンチ13の上面がダイ11の上面と面一になるように、押しパンチ13の下端外周部に外方へ突出する位置規制突部13aを形成するとともに、ダイ11に位置規制突部13aに係合して押しパンチ13の上限位置を規制する位置規制部11bを形成したものである。
先ず、図8(a)に示すように、一定厚さのステンレス鋼などからなる素材金属板を打ち抜いて、ブレーキディスク20の外径に適合する大きさの円板状の成形体35Aを製作する。次に、図8(b)に示す成形体35Bのように、成形体35Aに対して芯孔28及び基準となる小孔27を打ち抜いて成形するとともに、前記第1金属板成形体1と同様に、内側部材31を打ち抜いた後、内側部材31を外側部材32の抜き孔32bに、内側部材31と外側部材32とが面一になるように嵌め戻して、内側部材31と外側部材32間に摩擦減衰面30を成形する。ただし、前記第2金属板成形体1Aと同様に、内側部材31の一部が外側部材32から突出するように嵌め戻すことも可能である。
ブレーキディスクとして、図13(a)に示すように、直径が320mmで厚さが5mmのステンレス鋼製の円板の中央部に直径56mmの芯孔28を形成するとともに、直径が6.3mmの3つの取付孔29を形成した比較例1のブレーキディスク50と、図13(b)に示すように、比較例1のブレーキディスク50に対して、内側部材51を打ち抜いた後、外側部材52に面一になるように嵌め戻して、外径が240mmで周方向に間隔をあけて内側へ突出する5つの突出部53aを有する摩擦減衰面53を形成した実施例1のブレーキディスク50Aと、実施例1のブレーキディスク50Aの製作時に、内側部材51の外側部材52への嵌め戻し量を2.5mmに設定した以外は実施例1と同じに構成した実施例2のブレーキディスクを製作した。
支持台の水平な固定軸の端部にブレーキディスクを同心状に位置合わせして、取付孔29にボルトを挿通させてブレーキディスクを3本のボルトで固定した。そして、ブレーキディスクの中心を通る水平な半径方向位置であって、中心から143mmの半径方向位置を加振点Kに設定し、加振点Kを通る円周上において、加振点Kから周方向に180°離れた位置を測定点Sに設定し、測定点Sに対面させて加速度センサASを設けた。
3 外側部材 3a 抜き孔
4 摩擦減衰面
1A 第2金属板成形体 4A 摩擦減衰面
1B 第1金属板成形体 2B 内側部材
3B 外側部材 3Ba 嵌合孔
4B 摩擦減衰面
1C 第2金属板成形体 4C 摩擦減衰面
1D 素材金属板
10 プレス成形用金型 11 ダイ
11a ダイ穴 11b 位置規制部
12 抜きパンチ 13 押しパンチ
13a 位置規制突部 14 バネ部材
10A プレス成形用金型 11A ダイ
11Ab 位置規制部
20 ブレーキディスク 21 摺動部
21a 摺動面
22 ハブ部 23 取付部
24 リング部 25 連結部
26 模様孔 27 小孔
28 芯孔 29 取付孔
30 摩擦減衰面 30a 円弧部
30b 突出部 31 内側部材
31a 嵌合凹部 32 外側部材
32a 嵌合凸部 32b 抜き孔
35A 成形体 35B 成形体
35C 成形体 35D 成形体
20A ブレーキディスク 40 凹部
20B ブレーキディスク 41 連結手段
42 貫通孔 43 固定具
44 座金
20C ブレーキディスク 23C 取付部
29C 取付孔 30C 摩擦減衰面
30Ca 円弧部 30Cb 突出部
31C 内側部材 32C 外側部材
45 固定部 46 固定金具
46a 鍔部 47 取付ボルト
20D ブレーキディスク 30D 摩擦減衰面
30Da 波形部
50 ブレーキディスク
50A ブレーキディスク 51 内側部材
52 外側部材 53 摩擦減衰面
53a 突出部
Claims (14)
- 金属板からなる内側部材と、それに外嵌される金属板からなる外側部材とを備えた金属板成形品であって、
前記内側部材と外側部材の嵌合面に相互に圧接する摩擦減衰面を形成した、
ことを特徴とする金属板成形品。 - 前記内側部材及び外側部材として、金属板をプレス成形により打ち抜いてなる内側部材と、前記内側部材を打ち抜いた後の抜き枠からなる外側部材とを備え、前記内側部材を外側部材に嵌め戻すことにより、前記内側部材と外側部材の嵌合面に相互に圧接する摩擦減衰面を形成した請求項1記載の金属板成形品。
- 前記請求項1又は2記載の金属板成形品からなるブレーキディスクであって、
ホイールへの取付ボルトが挿通する複数の取付孔を有するハブ部と、ブレーキパッドが圧接可能な摺動面を有する環状の摺動部とを備え、
前記摩擦減衰面を、前記取付孔を個別に或いは複数個纏めて取り囲むように設け、
前記摩擦減衰面の内外に内側部材と外側部材とを形成した、
ことを特徴とするノイズ低減ブレーキディスク。 - 前記摩擦減衰面を、前記取付孔の全てを取り囲むようにハブ部の外周部に沿って環状に形成した請求項3記載のノイズ低減ブレーキディスク。
- 前記外側部材の内周縁に周方向に間隔をあけて中央部側へ突出する複数の嵌合凸部を設け、前記内側部材の外周縁に前記嵌合凸部が嵌合する複数の嵌合凹部を設けた請求項4記載のノイズ低減ブレーキディスク。
- 前記内側部材と外側部材とを段差なく連設し、前記ブレーキパッドとの摺動面よりも内側において、前記内側部材と外側部材の一方或いは双方間に連結孔を形成し、該連結孔に、前記内側部材と外側部材とを連結する連結手段を設けた請求項3~5のいずれか1項記載のノイズ低減ブレーキディスク。
- 前記連結手段として、ピン部材又はボルトを設けた請求項6記載のノイズ低減ブレーキディスク。
- 前記連結孔として、前記内側部材と外側部材間に前記取付孔を形成し、前記取付ボルトにより、前記ブレーキディスクをホイールに締結するとともに、前記内側部材と外側部材を共締めして、前記内側部材と外側部材の厚さ方向への相対移動を規制した請求項6記載のノイズ低減ブレーキディスク。
- 前記内側部材と外側部材とを段差なく連設し、前記摩擦減衰面を摺動部とハブ部とにわたって設けた請求項3~8のいずれか1項記載のノイズ低減ブレーキディスク。
- 前記内側部材の表面と外側部材の表面間に段差を形成した請求項3~5のいずれか1項記載のノイズ低減ブレーキディスク。
- 金属板からなる内側部材と、それに外嵌される金属板からなる外側部材とを備えた金属板成形品の製造方法であって、
前記金属板をプレス成形により打ち抜いて、前記内側部材と外側部材を形成し、
前記内側部材を外側部材に嵌め戻して、両者の嵌合面に相互に圧接する摩擦減衰面を形成する、
ことを特徴とする金属板成形品の製造方法。 - 金属板からなる内側部材と、それに外嵌される金属板からなる外側部材とを備えた金属板成形品の製造方法であって、
前記内側部材と外側部材を製作し、
前記内側部材に外側部材を外嵌して、前記内側部材と外側部材の一方を板厚方向に加圧プレスすることで、両者の嵌合面に相互に圧接する摩擦減衰面を形成する、
ことを特徴とする金属板成形品の製造方法。 - 前記金属板成形品が、ホイールへの取付ボルトの取付孔を有するハブ部と、ブレーキパッドが圧接可能な摺動面を有する環状の摺動部とを備えた自動二輪車用のブレーキディスクである請求項11又は12記載の金属板成形品の製造方法。
- 前記摩擦減衰面を成形した後、前記摺動部を高周波焼き入れする請求項13記載の金属板成形品の製造方法。
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SG11201706973WA SG11201706973WA (en) | 2015-02-26 | 2016-02-24 | Metal plate molded article, noise-reduction brake disc using the same, and manufacturing method of metal plate molded article |
US15/553,354 US20180094680A1 (en) | 2015-02-26 | 2016-02-24 | Metal plate molded article, noise-reduction brake disc using the same, and manufacturing method of metal plate molded article |
JP2017502438A JP6455589B2 (ja) | 2015-02-26 | 2016-02-24 | 金属板成形品の製造方法 |
EP16755576.2A EP3263943A1 (en) | 2015-02-26 | 2016-02-24 | Metal plate molded object, reduced noise brake disc using same, and method for manufacturing metal plate molded object |
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JPWO2018173869A1 (ja) * | 2017-03-24 | 2020-02-06 | 東日本旅客鉄道株式会社 | 鉄道車両用ブレーキディスク |
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JP6912578B2 (ja) * | 2016-12-22 | 2021-08-04 | リサーチ インスティチュート オブ インダストリアル サイエンス アンド テクノロジー | ブレーキディスクおよびその製造方法 |
DE102018106609A1 (de) * | 2018-03-21 | 2019-09-26 | Knorr-Bremse Systeme für Schienenfahrzeuge GmbH | Verfahren zur Verringerung der Schirmung einer Radbremsscheibe für ein Schienenfahrzeug und Vorrichtung zur Durchführung des Verfahrens |
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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CN112776933A (zh) * | 2019-11-05 | 2021-05-11 | 世佳工业股份有限公司 | 一体成型自行车煞车盘片及其制造方法 |
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