JP6133936B2 - Metal plate molded product and manufacturing method thereof - Google Patents

Description

  The present invention relates to a metal plate molded article suitable as a brake disk rotor for automobiles and a method for producing the same.

  The brake disc rotor of an automobile is generally in a hat shape, and like a brake disc rotor 100 shown in FIG. 13, a disc-shaped mounting surface portion 101 fixed to a wheel and an outer peripheral portion than the mounting surface portion 101. And a donut-shaped sliding surface portion 102 that is sandwiched between pads, and a connecting portion 103 that rises substantially perpendicularly from the sliding surface portion 102 and connects the sliding surface portion 102 and the mounting surface portion 101. .

  Such an automobile brake disc rotor 100 is generally a cast product. This is a shape in which the connecting portion 103 that connects the mounting surface portion 101 and the sliding surface portion 102 rises substantially vertically, and if casting, such a shape can be easily made and the degree of freedom of the shape is high. Usually manufactured by casting.

  However, although the cast product has the advantage of a large degree of freedom in shape, it has low toughness and tends to crack or chip. Therefore, there is a problem that the weight of the product inevitably increases because it is necessary to design a thick-walled part in order to ensure strength.

  However, in recent years, there is a potential demand for weight reduction of brake disc rotors in a situation where weight reduction of automobiles is aimed.

  On the other hand, in a brake disc rotor for motorcycles, the brake disc rotor itself is an element that affects not only the braking function but also the appearance design of the motorcycle because it is exposed to the outside, so it has excellent mechanical strength. At the same time, stainless steel with excellent rust resistance is widely used.

  As a method for manufacturing a brake disc rotor for a motorcycle, for example, as disclosed in Patent Document 1, a stainless steel plate is punched into a disk shape, and an opening is formed in a bracket portion (connecting portion 103) that connects a braking portion and a hub portion. In addition, an inclined surface is processed on the bracket portion (connecting portion 103) by drawing.

JP 55-36674 A

  As described above, the automobile brake disc rotor 100 made of a cast product has a problem that since it has low toughness and is likely to be cracked or chipped, it has to be a thick-walled part design to ensure strength.

  On the other hand, since the brake disc rotor for motorcycles is made of a stainless steel plate, there is an advantage that it has high toughness and can be reduced in thickness and weight.

  However, when the automobile brake disc rotor 100 is manufactured by the method for manufacturing a brake disc rotor for motorcycles described in Patent Document 1, the following problems occur.

  Although the bracket part (connecting part 103) of the brake disc rotor for motorcycles has an inclined surface, the connecting part 103 stands up substantially at right angles as shown in FIG. It is difficult to produce by drawing a stainless steel plate of meat.

  In this regard, as disclosed in Patent Document 1, even if a plurality of openings are provided in a circumferential direction in a portion corresponding to the bracket portion (connecting portion 103), the bracket portion (connecting portion 103) is substantially perpendicular. If the drawing process is performed, the bracket part (connecting part 103) becomes too thin and the strength of the brake disk rotor cannot be ensured, or there is a problem that it cannot be drawn and cannot be drawn.

  That is, a motorcycle brake disc rotor using a stainless steel plate has high toughness and can be thinned and reduced in weight, but has a problem of low flexibility in shape.

  Therefore, the current situation is that the brake disc rotor 100 for automobiles is classified as a cast product, and the brake disc rotor for motorcycles is a molded product of stainless steel plate.

  An object of the present invention is a metal plate molded article suitable as a brake disk rotor for an automobile that can be manufactured at low cost by press molding and that can sufficiently reduce mechanical thickness while ensuring sufficient mechanical strength, and a method for manufacturing the same. Is to provide.

  In the metal plate molded product according to the present invention, the inner part, the outer part provided on the outer peripheral side of the inner part, and the outer part and the inner part are arranged in parallel with a gap in the thickness direction of both. As described above, a hat-shaped metal plate molded product having a connecting portion that rises from the inner peripheral edge of the outer portion and connects the outer portion and the inner portion, and the connecting portions are spaced in the circumferential direction. A plurality of plate-like spoke portions having a width in the radial direction, with one end connected to the inner periphery of the outer portion and the other end connected to the outer periphery of the inner portion, Are provided with a plurality of spoke portions having an inclined arc portion that is inclined with respect to a plane orthogonal to the offset direction and extends in the circumferential direction.

  In this metal plate molded product, the connecting part that connects the outer part and the inner part is composed of a plurality of spoke parts, and the plurality of spoke parts connect one end part to the inner periphery of the outer part and the other end part. It is connected to the outer peripheral edge of the inner part, and is provided with an inclined arc part that is inclined with respect to the plane perpendicular to the plate thickness direction and extends in the circumferential direction in the middle part. It is possible to easily and easily manufacture the metal plate molded product. That is, when a metal plate is press-molded to produce a hat-shaped metal plate molded product, the inner portion is pressed in the plate thickness direction with respect to the outer portion. The spoke part mainly bends and deforms so that the displacement between the inner part and the outer part due to extrusion can be absorbed and a large tensile force can be prevented from acting on the spoke part. Even if the distance in the thickness direction is long (the offset amount is large) or the rising angle of the connecting portion is close to a right angle, the metal plate molded product does not cause cracks or decrease in strength in the connecting portion. Can be manufactured by pressing without difficulty. In this way, a metal plate molded product can be manufactured easily and easily by press molding, so that it can be manufactured at a lower cost compared to a metal plate molded product manufactured by casting, and sufficient mechanical strength is ensured. A thin and lightweight metal plate molded product can be realized.

  Here, the metal plate molded product is an automobile brake disc rotor, the inner part is a mounting surface part fixed to a wheel, the outer part is a sliding surface part clamped by a pad, and the connecting part Thus, the sliding surface portion and the mounting surface portion rise from the inner peripheral edge of the sliding surface portion so that the sliding surface portion and the mounting surface portion are arranged in parallel in the axial direction (plate thickness direction). Is a preferred embodiment. In this case, it is possible to realize a thin and light automotive brake disc rotor that can be manufactured at a lower cost than the automotive manufactured brake disc rotor and that has sufficient mechanical strength.

  In a preferred embodiment, the inclined arc portion is provided in a circumferential direction from a connection portion with the inner peripheral edge of the outer portion toward a connection portion with the outer peripheral edge of the inner portion. In this case, it is suitable when the distance between the outer portion and the inner portion in the plate thickness direction is relatively small, and the spoke portion can be configured to be short and wide so that the connection strength between the outer portion and the inner portion can be improved.

  Further, a folded portion is formed in the middle portion of the inclined arc portion, and an inner circumferential side portion from a connecting portion with the outer peripheral edge of the inner portion to the folded portion is formed on the inclined arc portion, and an outer portion from the folded portion to the outer portion. It is also a preferred embodiment to provide an outer peripheral side portion that reaches a connection site with the inner peripheral edge. In this case, it is suitable when the distance between the outer part and the inner part in the axial direction is large, the length of the spoke part is increased without reducing the number of the spoke parts, and the plate of the outer part and the inner part is obtained. The interval in the thickness direction can be set large.

  The space | interval with respect to the plate | board thickness direction of the said outer side part and inner side part can be set to 20 mm or more.

  Preferably, the plurality of spoke portions are formed rotationally symmetrical. With this configuration, for example, when the present invention is applied to an automobile brake disc rotor, it is possible to prevent blurring during rotation of the automobile brake disc rotor and to balance the sliding surface portion to the mounting surface portion during braking. The braking force can be transmitted well. Moreover, when press-molding, the outer portion and the inner portion can be separated in a balanced manner in the plate thickness direction (axial direction), and the dimensional accuracy of the metal plate molded product can be improved.

  In the method for manufacturing a metal plate molded product according to the present invention, the inner part, the outer part provided on the outer peripheral side with respect to the inner part, and the outer part and the inner part are parallel to each other with a gap in the plate thickness direction. A hat-shaped metal plate molded product formed by press-molding a metal plate, which is provided with a connecting portion that rises from the inner peripheral edge of the outer portion and connects the outer portion and the inner portion. A primary molded plate preparing step of punching out the metal plate to prepare a primary molded plate, and a plurality of slits extending in the circumferential direction in the annular surface portion corresponding to the connecting portion in the primary molded plate, in the circumferential direction. A slit forming step for forming the slits so that both ends of the slits overlap each other in the radial direction at a certain angle in the circumferential direction at both ends of the adjacent slits, and a portion corresponding to the inner portion, Previous by extruding in the direction Open slit, and is obtained by a press molding process of the outer portion and the inner portion to form the connection portion by press-forming so as to be parallel.

  In this manufacturing method, in the slit forming step, a plurality of slits extending in the circumferential direction are provided in the annular surface portion corresponding to the connecting portion in the primary molded plate, and the slits are spaced on both sides adjacent to each other. Each end of the slit is formed so as to overlap in the radial direction by a certain angle in the circumferential direction, and in the press molding process, the slit is opened by extruding a portion corresponding to the inner portion in the plate thickness direction, and the inner portion And the outer portion are press-molded so as to be parallel to form the connecting portion.At the time of press molding, the portion between adjacent slits is mainly bent and deformed, so that the inner portion and the outer portion by extrusion are Can absorb the displacement in the plate thickness direction and no large pulling force acts, so the distance between the inner and outer portions in the plate thickness direction is long (the offset amount is large) What are also even if the rise angle of the connecting portion is at a right angle close, without causing cracking or strength reduction at the junction, it is possible to manufacture by reasonably press forming a metal plate molded article. In this way, a metal plate molded product can be manufactured easily and easily by press molding, so that it can be manufactured at a lower cost compared to a metal plate molded product manufactured by casting, and sufficient mechanical strength is ensured. A thin and lightweight metal plate molded product can be realized.

  Here, the metal plate molded product is an automobile brake disc rotor, the inner part is a mounting surface part fixed to a wheel, the outer part is a sliding surface part clamped by a pad, and the connecting part Thus, the sliding surface portion and the mounting surface portion are connected to each other so that the sliding surface portion and the mounting surface portion rise from the inner peripheral edge of the sliding surface portion so that the sliding surface portion and the mounting surface portion are arranged in parallel in the axial direction. This is a preferred embodiment. In this case, it is possible to realize a thin and light automotive brake disc rotor that can be manufactured at a lower cost than the automotive manufactured brake disc rotor and that has sufficient mechanical strength.

  In a preferred embodiment, the slit comprises a straight line, a curved line, or a combination of a straight line and a curved line that is inclined with respect to the radial direction. In this case, it is suitable when the distance between the outer part and the inner part in the plate thickness direction is relatively small, and the spoke part formed between adjacent slits is configured to be short and wide to form the connecting part. The connection strength of the outer side part and inner side part by a some spoke part can be improved.

  Further, the slit is formed in a Y-shape comprising a combination of a U-shaped portion that opens toward one side in the circumferential direction and a curved portion that extends from the central portion of the U-shaped portion in the other circumferential direction. It is a preferred embodiment. In this case, since the spoke portion having the folded portion in the middle can be formed by the adjacent slit, it is suitable when the distance between the outer portion and the inner portion in the plate thickness direction is large, and the number of the spoke portions is reduced. Without increasing the length of the spoke portion, the distance between the outer portion and the inner portion in the plate thickness direction can be set large.

  The space | interval with respect to the plate | board thickness direction of the said outer side part and inner side part can also be set to 20 mm or more.

  It is also a preferred embodiment that the plurality of slits are formed so as to be rotationally symmetric with respect to the center of the primary molded plate. With this configuration, for example, when the present invention is applied to a method for manufacturing a brake disc rotor for automobiles, it is possible to prevent the occurrence of blurring during rotation of the manufactured automobile brake disc rotor, and from the sliding surface portion to the mounting surface portion during braking. In contrast, the braking force can be transmitted in a well-balanced manner. Moreover, when press-molding, the outer portion and the inner portion can be separated in a balanced manner in the plate thickness direction (axial direction), and the dimensional accuracy of the metal plate molded product can be improved.

According to the metal plate molded product and the manufacturing method thereof according to the present invention, the metal plate molded product can be manufactured easily and easily by press molding, so that it can be manufactured at a lower cost than a metal plate molded product manufactured by casting. In addition, a thin and lightweight metal plate molded product can be realized while sufficiently securing the mechanical strength.

Perspective view of automotive brake disc rotor (A)-(d) is explanatory drawing of the manufacturing method of the brake disc rotor for motor vehicles. Plan view of secondary molded product of the brake disc rotor for the car Plan view of secondary molded product with other configuration Plan view of secondary molded product with other configuration Plan view of secondary molded product with other configuration Plan view of secondary molded product with other configuration Plan view of secondary molded product with other configuration IX-IX sectional view of FIG. Perspective view of a brake disc rotor for automobiles with other configurations (A)-(d) is explanatory drawing of the manufacturing method of the brake disk rotor for the motor vehicles Explanatory drawing of the slit formed in the slit formation process of the brake disk rotor for the car A perspective view of a conventional brake disc rotor for automobiles

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the present embodiment, the present invention is applied to an automobile brake disc rotor.

[First Embodiment]
First, the structure of the brake disk rotor 1 for motor vehicles is demonstrated.
As shown in FIG. 1, the brake disc rotor 1 for an automobile has a circular shape as a whole in a plan view, a flat disc-shaped mounting surface portion 2 fixed to a wheel, and an outer peripheral portion than the mounting surface portion 2. And a connecting portion 5 comprising a plurality of spoke portions 4 that rise from the inner peripheral edge of the sliding surface portion 3 and connect the sliding surface portion 3 and the mounting surface portion 2. In addition, the brake disk rotor 1 for motor vehicles, the attachment surface part 2, and the sliding surface part 3 are respectively corresponded to a metal plate molded product, an inner side part, and an outer side part.

  When the brake disc rotor 1 for an automobile is assembled to a vehicle, the sliding surface portion 3 is disposed between a pair of brake pads of the brake device, and the sliding surface portion 3 is sandwiched between the pair of brake pads, It is comprised so that braking force can be given to a wheel.

  The automobile brake disc rotor 1 is manufactured by press-molding one flat metal plate such as a stainless steel plate or a carbon steel plate into the shape of the automobile brake disc rotor 1. The plate thickness of the brake disc rotor 1 for an automobile is configured to be a substantially uniform plate thickness as a whole, for example, a plate thickness of 3 to 13 mm. However, in order to reduce the weight or the like, it is possible to form a partially thin portion on the sliding surface portion 3 or the mounting surface portion by press molding or cutting.

  The mounting surface portion 2 is formed in a flat disk shape, and a circular hole 2a through which the axle is inserted is formed in the center portion in a penetrating manner. On the same circumference in the middle portion in the radial direction, there are four wheel mounting portions. Four mounting holes 2b through which the bolts are inserted are formed in a penetrating manner so as to surround the round hole 2a. The number of mounting holes 2b is set to a number corresponding to the number of bolts for wheel mounting.

  The sliding surface portion 3 is formed in a flat annular shape having a width that allows the brake pad to be pressed. Both surfaces of the sliding surface portion 3 can be formed on a flat surface without unevenness. However, in order to clean the brake pads and to make the brake disc rotor 1 for automobiles lightweight, as shown in FIG. A plurality of small holes 6 penetrating the moving surface portion 3 in the thickness direction are formed, or as shown in FIGS. 8 and 9, a plurality of arc-shaped bottomed groove portions 7 are angled with respect to the radial direction. It can also be formed at intervals in the circumferential direction.

  The connecting portion 5 is a plurality of elongated plate-like spoke portions 4 having a radial width provided at intervals in the circumferential direction, and connects the inner peripheral end portion 4 a to the inner peripheral edge of the sliding surface portion 3. The outer peripheral end portion 4b is connected to the outer peripheral edge of the mounting surface portion 2, and is composed of a plurality of spoke portions 4 each having an inclined arc portion 4c that is inclined with respect to a plane orthogonal to the axial direction and extends in the circumferential direction in the middle portion. An opening 8 is formed between the adjacent spoke portions 4. In plan view, the inner peripheral end 4a and the outer peripheral end 4b of the plurality of spoke portions 4 are arranged on the same side in the circumferential direction of the automobile brake disc rotor 1 with a phase shifted by a certain angle in the circumferential direction. The inclined arc portions 4c of the plurality of spoke portions 4 are arranged in an inclined manner with respect to the radial direction of the brake disc rotor 1 for an automobile, and both end portions of the spoke portions 4 are ends of the spoke portions 4 on both sides adjacent to each other in the circumferential direction. The portions are arranged so as to overlap each other in the radial direction by a certain angle in the circumferential direction. The connecting portion 5 is formed in a protruding shape so as to rise from the inner peripheral edge of the sliding surface portion 3 at a substantially right angle (80 degrees to 90 degrees) with respect to the sliding surface portion 3.

  The sliding surface portion 3 and the mounting surface portion 2 are arranged in parallel by an interval in the axial direction (plate thickness direction) by the connecting portion 5. The axial distance S between the mounting surface portion 2 and the sliding surface portion 3 can be arbitrarily set according to the configuration on the vehicle side, for example, 20 mm or more.

Next, the manufacturing method of the brake disk rotor 1 for motor vehicles is demonstrated.
The manufacturing method of the brake disk rotor 1 for automobiles includes a primary molded plate preparation process, a slit forming process, a press molding process, and a quenching process.

(1) Primary molded plate preparation step In the primary molded plate preparation step, as shown in FIG. 2 (a), a blank metal plate made of stainless steel plate or carbon steel plate is punched out and the outer diameter of the brake disc rotor 1 for automobiles The primary molded plate 11 is manufactured in a disc shape having a size suitable for the outer diameter and having a round hole 2a and four mounting holes 2b formed in the central portion of the mounting surface portion constituting portion 12 corresponding to the mounting surface portion 2.

(2) Slit forming step In the slit forming step, as shown in FIGS. 2B and 3, the inside of the annular connecting portion constituting portion 15 corresponding to the connecting portion 5 in the primary molded plate 11 (the phantom line in FIG. 3). This is a step of manufacturing a secondary molded plate 11A, in which a plurality of slits 18 are formed at intervals in the circumferential direction at an annular portion between C1 and C2. The connecting portion constituting portion 15 corresponds to an annular surface portion (annular surface portion).

  Inside the imaginary line C1 of the secondary molded plate 11A, there is provided an attachment surface portion constituting portion 12 that is formed on the attachment surface portion 2 by the next press molding step, and the imaginary line C2 of the secondary molded plate 11A. On the outside, there is provided a sliding surface portion forming portion 13 formed on the sliding surface portion 3 by the next press forming step, and a plurality of slits 18 are provided in the connecting portion forming portion 15 between the imaginary lines C1 and C2. A plurality of spoke part constituent parts 14 formed on the spoke part 4 and connecting the attachment surface part constituent part 12 and the sliding surface part constituent part 13 are formed to be inclined with respect to the radial direction.

  Each slit 18 includes an arc-shaped inner circumferential slit 18a disposed along the outer side of the virtual line C1, an arc-shaped outer circumferential slit 18b disposed along the inner side of the virtual line C2, and an inner circumferential slit. 18a and an outer peripheral slit 18b, and an arcuate intermediate slit 18c bulging outward of the secondary molded plate 11A. These slits 18a, 18b, 18c It is formed continuously through the plate thickness direction.

  As shown in FIG. 3, in the plan view of the secondary molded plate 11A, the inner circumferential side slit 18a and the outer circumferential side slit 18b are arranged with a phase shifted by a certain angle in the circumferential direction of the secondary molded plate 11A. The slit 18c is formed in an inclined shape with an angle with respect to the radial direction of the secondary molded plate 11A. Between the adjacent slits 18, the inner peripheral side slit 18a and the outer peripheral side slit 18b are only a certain angle R1 in the circumferential direction. They are arranged so as to overlap in the radial direction.

  The plurality of slits 18 are rotationally symmetric with respect to the center P of the secondary molding plate 11A in order to increase molding accuracy during press molding and to make the strength of the spokes 4 of the brake disk rotor 1 for automobiles uniform. It is formed at regular intervals in the circumferential direction so that However, in order to prevent the occurrence of brake squealing, the length of the specific slit 18 is changed, or the angle of the slit 18 with respect to the radial direction is changed, so that a plurality of brake disc rotors 1 for an automobile are formed. It is also possible to configure the slit 18 to be rotationally asymmetric.

  The number, the circumferential length, and the radial length of the slits 18 are appropriately set in consideration of the formability and strength rigidity of the spoke portion 4 by press molding. In addition, the shape of the slit 18 and the distance between adjacent slits 18 are set in consideration of the shape of the spoke portion 4 after press molding so that the spoke portion 4 has a uniform width as much as possible over its entire length. Become.

  In the next press molding process, the slit 18 rises when the slit 18 is opened, so that the connecting portion 5 composed of the plurality of spoke portions 4 can be formed. The thickness S1 in the plate thickness direction (offset amount) is 20 mm or more.

  The slit 18 can be formed by a known processing method such as laser, water jet, or wire saw. Although the width | variety of the slit 18 can be set arbitrarily, in order to raise the strength rigidity of the connection part 5, it is preferable to comprise as narrow width as possible, for example, it is preferable to set to 3 mm or less.

  In addition, you may make it form the small hole 19 for providing a round at both ends of the slit 18, like the secondary shaping | molding board 11AA shown in FIG. As a result, it is possible to prevent the end of the slit 18 from cracking during press molding.

  Further, the slit 18 can be configured by one to a plurality of straight lines, one to a plurality of curves, or a combination of one to a plurality of straight lines and one to a plurality of curves. For example, the secondary forming plate 11AB shown in FIG. As shown in FIG. 6, instead of the slit 18, a slit 18AB comprising a combination of two linear straight slits 18Ba and 18Bb on the inner peripheral side and the outer peripheral side is provided, or as in the secondary molded plate 11AC shown in FIG. Instead of the slit 18, it is also possible to provide a slit 18AC comprising a combination of a curved (arc-shaped) inner circumferential slit 18Ca and outer circumferential slit 18Cb, and a single linear slit 18Cc connecting both slits.

  Furthermore, in order to improve the cleaning performance of the brake pads and to make the brake disc rotor 1 for automobiles as light as possible, a plurality of penetrating parts are formed in the portion corresponding to the sliding surface portion 3 in the pre-process or post-process of the slit forming process. Through-holes can be formed, or bottomed groove portions 7 can be formed in the radial direction on the front and back surfaces of the portion corresponding to the sliding surface portion 3. Specifically, like the secondary molded plate 11AD shown in FIG. 7, a plurality of small holes 6 are formed in a penetrating manner at intervals in the circumferential direction in the sliding surface portion constituting portion 13D corresponding to the sliding surface portion 3. Alternatively, as in the secondary molded plate 11AE shown in FIGS. 8 and 9, a plurality of groove portions 7 are formed at intervals in the circumferential direction on the front and back surfaces of the sliding surface portion constituting portion 13E corresponding to the sliding surface portion 3. Is also preferable. The number, shape, and arrangement position of the small holes 6 and the groove portions 7 can be arbitrarily set, and can be set in the same manner as, for example, a well-known brake disc for motorcycles. When the small hole 6 is formed, the position of the small hole 6 in the circumferential direction adjacent to the circumferential direction so as to face the small hole 6 on the entire surface of the brake pad by one rotation of the brake disc rotor for an automobile. It is preferable to dispose them.

(3) Press molding process In the press molding process, as shown in FIG. 2C, the mounting surface portion constituting portion 12 of the secondary molded plate 11A is substantially parallel to the sliding surface portion constituting portion 13 in the plate thickness direction. As shown in FIG. 1 and FIG. 2 (d), the slit 18 is gradually opened, and press molding is performed so that the distance S1 in the plate thickness direction between the mounting surface portion 2 and the sliding surface portion 3 becomes a desired distance. And the connection part 5 which has the opening part 8 which opens the slit 18, and the several spoke part 4 which raises the spoke part structure part 14 to an axial direction is formed.

  The mold used in the press molding process is composed of a punch, a die, and a blank holder, and the clearance between the punch and the die is approximately the same as the length in the radial direction of the connecting portion constituting portion 15 between the virtual lines C1 and C2. This clearance becomes a space where the connecting portion 5 is formed by opening the slit 18.

  By the press molding process, the distance S1 between the mounting surface portion 2 and the sliding surface portion 3 in the plate thickness direction is 20 mm or more.

  In the press molding process, the spoke portion constituting portion 14 is plastically deformed so as to rise in an inclined manner with respect to a plane orthogonal to the axial direction of the secondary molding plate 11A, and the slit 18 extending in the circumferential direction is opened to open the connecting portion. 5 is formed, the spoke part 4 formed by the spoke part constituting part 14 is hardly thinned, is not cracked or warped, and the strength is not lowered.

(4) Quenching process The sliding surface portion constituting portion 13 is subjected to a quenching treatment with a high-frequency heating device or the like under a known heating condition corresponding to the material metal constituting the brake disc rotor 1 for an automobile, and the brake for the automobile. The disk rotor 1 is obtained.

  As described above, according to the present embodiment, even when the distance S1 between the mounting surface portion 2 and the sliding surface portion 3 is large (the offset amount is large), the rising angle of the connecting portion 5 Even when the angle is close to a right angle, the brake disc rotor 1 for an automobile using a metal plate such as a stainless steel plate can be manufactured without causing cracks or a decrease in strength in the connecting portion 5 and sufficient strength and rigidity. In addition, it is possible to reduce the thickness and weight of the brake disc rotor 1 for an automobile.

  Moreover, even if it is a shape like the brake disc rotor 100 for automobiles (see FIG. 13), it is considered that manufacturing by press molding is possible if the number of press molding steps is increased and it is sequentially deformed. In the method, an increase in manufacturing cost and time is a serious problem. However, according to the present invention, press molding can be performed in one stroke, and the manufacturing cost is not increased.

[Second Embodiment]
The brake disc rotor 21 for an automobile according to the second embodiment is obtained by changing the configuration of the spoke portion 4 and the slit 18 in the brake disc rotor 1 for an automobile according to the first embodiment, and other configurations are the same as those of the first embodiment. Since the configuration is the same as that of the brake disc rotor 1 for automobiles, the same reference numerals are given to the same members, and detailed descriptions thereof are omitted. In addition, the brake disc rotor 21 for automobiles corresponds to a metal plate molded product.

  As shown in FIG. 10, the brake disc rotor 21 for an automobile has a circular shape as a whole in plan view, and has a flat disc-shaped mounting surface portion 2 fixed to the wheel, and an outer peripheral portion than the mounting surface portion 2. And a connecting portion 25 comprising a plurality of spoke portions 24 that rise from the inner peripheral edge of the sliding surface portion 3 and connect the sliding surface portion 3 and the mounting surface portion 2.

  The connecting portion 25 is a plurality of elongated plate-like spoke portions 24 having a radial width provided at intervals in the circumferential direction, and connecting the inner peripheral end portion 24 a to the inner peripheral edge of the sliding surface portion 3. A plurality of spoke portions 24 having an inclined arc portion 24 c that connects the outer peripheral end portion 24 b to the outer peripheral edge of the mounting surface portion 2, and an opening portion 8 is formed between the adjacent spoke portions 24.

  The inclined arc portion 24c includes a partial arc-shaped inner circumference side arc portion 24d and an outer circumference side arc portion 24e that are arranged substantially in parallel on the inner circumference side and the outer circumference side in plan view, and an inner circumference side at one end in the circumferential direction. A folding portion 24f that connects the arc portion 24d and the outer circumferential arc portion 24e is provided. The inner circular arc portion 24d and the outer circular arc portion 24e are substantially mirror-symmetrically inclined with respect to an orthogonal plane orthogonal to the axial direction of the automobile brake disc rotor 21, and are arranged in a lateral V shape in a side view. .

  Both end portions of the spoke portion 24 are arranged at the same circumferential position of the vehicle brake disc rotor 21 in a plan view, and the plurality of spoke portions 24 formed on the vehicle brake disc rotor 21 are arranged on the vehicle brake disc rotor 21. It is formed with rotational symmetry about the center P. However, it is also possible to dispose both ends of the spoke part 24 in the circumferential direction. In consideration of the molding accuracy of the brake disc rotor 21 for an automobile, all the spoke portions 24 formed on the brake disc rotor 21 for an automobile are preferably configured to be rotationally symmetric. Therefore, it is also possible to change the shape and cross-sectional area of the specific spoke portion 24 to configure the plurality of spoke portions 24 formed in the automobile brake disc rotor 21 to be rotationally asymmetric.

Next, the manufacturing method of the brake disk rotor 21 for motor vehicles is demonstrated.
The manufacturing method of the brake disk rotor 21 for automobiles includes a primary molded plate preparation process, a slit forming process, a press molding process, and a quenching process.

  In the primary forming plate preparation process, as in the first embodiment, a blank metal plate made of stainless steel plate or carbon steel plate is punched out, and the outer diameter is a disc shape having a size that matches the outer diameter of the brake disc rotor 21 for automobiles. Thus, the primary molded plate 11 in which the round hole 2a and the four attachment holes 2b are formed in the central portion is manufactured.

  In the slit forming step, as shown in FIGS. 11 (b) and 12, the inside of the connecting portion constituting portion 35 corresponding to the connecting portion 25 in the primary molded plate 11 (the portion between the virtual lines C1 and C2 in FIG. 12). ), A plurality of slits 38 are formed at intervals, and the secondary molded plate 31A is manufactured.

  As shown in FIG. 12, the slit 38 includes an arc-shaped inner circumferential slit 38a disposed along the outer side of the imaginary line C1, and an arc-shaped outer circumferential slit 38b disposed along the inner side of the imaginary line C2. A semicircular slit 38c that connects one end of the outer peripheral slit 38b and the inner peripheral slit 38a, and an inner peripheral slit 38a and an outer peripheral slit 38b of the adjacent slit 38 from the middle of the semicircular slit 38c. An intermediate slit 38d extending to the approximate center of the arc of the semicircular arc slit 38c of the slit 38 that passes through and is formed in a substantially Y shape (piercing shape). The inner circumferential slit 38a, the outer circumferential slit 38b, and the semicircular arc slit 38c correspond to a U-shaped portion that opens toward one side in the circumferential direction, and the intermediate slit 38d is a central portion of the U-shaped portion. Corresponds to a curved portion extending in the other direction in the circumferential direction.

  The inner circumferential side arc portion constituting the inner circumferential side arc portion 24d and the outer circumferential side arc portion 24e of the spoke portion 24 and the outer circumferential side are formed on the inner circumferential side and the outer circumferential side of the intermediate slit 38d through the following press forming process. A side arc portion constituting portion 34e is formed, a folded portion constituting portion 34f constituting the turned portion 24f is formed inside the semicircular arc slit 38c, and an inner circumferential side arc portion constituting portion 34d, an outer circumference side arc portion constituting portion 34e, The spoke portion constituting portion 34 constituting the spoke portion 24 is formed by the folded portion constituting portion 34f.

  As shown in FIG. 12, in the plan view of the secondary molded plate 31A, the inner circumferential arc portion 34d, the outer circumferential arc portion 34e, and the intermediate slit 38d are arranged so as to overlap in the radial direction by a certain angle R2 in the circumferential direction. ing. However, the angle of the inner circumferential side arc portion 34d and the intermediate slit 38d overlapping in the radial direction and the angle of the outer circumferential side arc portion 34e and the intermediate slit 38d overlapping in the radial direction are the same angle R2 as shown in FIG. Although it is preferable to set, it can also set to a different angle.

  Similarly to the first embodiment, the slit 38 can be formed by a known processing method such as laser, water jet, or wire saw. Although the width | variety of the slit 38 can be set arbitrarily, in order to raise the intensity | strength rigidity of the connection part 25, it is preferable to comprise as narrow width as possible, for example, it is preferable to set to 3 mm or less.

  The plurality of slits 38 are rotationally symmetric with respect to the center P of the secondary molding plate 31A in order to increase molding accuracy during press molding or to make the strength of the spoke portions 24 of the brake disk rotor 1 for automobiles uniform. It is formed at regular intervals in the circumferential direction so that However, in order to prevent the occurrence of brake squealing, the length of the specific slit 38 is changed, or the angle of the slit 38 with respect to the radial direction is changed, so that a plurality of brake disc rotors 21 formed on the automobile are formed. It is also possible to configure the slit 38 to be rotationally asymmetric.

  In the press molding step, as shown in FIG. 11C, the attachment surface portion constituting portion 12 of the secondary forming plate 31A is extruded substantially parallel to the sliding surface portion constituting portion 13 in the plate thickness direction so that the slit 38 is formed. As shown in FIGS. 10 and 11 (d), the mounting surface 2 is press-molded until the distance S2 in the plate thickness direction with the sliding surface 3 reaches a desired distance, and the slit 18 is opened. The connecting portion 25 is formed by bending the opening portion 8 and the plurality of spoke portion constituting portions 34 into a V-shape in a lateral view when viewed from the side, and a plurality of spoke portions 24 raised in the axial direction.

  In the brake disc rotor 21 for an automobile, the length of the spoke portion 24 can be easily set long. Therefore, the spoke disc rotor 21 is suitable for a brake disc rotor having a large axial distance between the sliding surface portion 3 and the mounting surface portion 2. The length of the spoke part 24 can be increased without reducing the number of the distances, and the distance S2 in the plate thickness direction between the sliding surface part 3 and the mounting surface part 2 (the offset amount can be made larger than in the first embodiment). Has an effect.

  In the first and second embodiments, the case where the present invention is applied to the brake disk rotors 1 and 21 for automobiles has been described. However, the present invention is applied to a brake disk rotor other than for automobiles, for example, motorcycles. You can also. Further, the present invention can be similarly applied to gears, sprockets and the like arranged in the power transmission path. Furthermore, the present invention can also be applied to a metal plate molded article having any configuration other than these hat shapes. In this case, the inner portion and the outer portion have any shape other than a circle, for example, an oval. It can also be formed in a shape (oval, oval, oval, etc.) or a polygonal shape in plan view. For metal plate moldings other than automobile brake disc rotors 1 and 21, any metal material of any composition can be adopted as long as it is a press-moldable metal material, and the plate thickness is also arbitrary considering the mechanical strength, etc. The plate thickness can be set.

  The embodiment of the present invention has been described above. However, the present invention is not limited to the above-described embodiment, and it goes without saying that the configuration can be changed without departing from the gist of the present invention.

DESCRIPTION OF SYMBOLS 1 Automotive brake disc rotor 2 Mounting surface part 2a Round hole 2b Mounting hole 3 Sliding surface part 4 Spoke part 4a Inner peripheral edge part 4b Outer peripheral edge part 4c Inclined circular arc part 5 Connection part 6 Small hole 7 Groove part 8 Opening part 11 Primary forming plate 11A Secondary forming plate 12 Mounting surface portion constituting portion 13 Sliding surface portion constituting portion 14 Spoke portion constituting portion 15 Connecting portion constituting portion 18 Slit 18a Inner peripheral side slit 18b Outer peripheral side slit 18c Intermediate slit 11AA Secondary formed plate 19 Small hole 11AB Two Next forming plate 18AB Slit 18Ba Straight slit 18Bb Straight slit 11AC Secondary forming plate 18AC Slit 18Ca Inner peripheral side slit 18Cb Outer peripheral side slit 18Cc Linear slit 11AD Secondary forming plate 13D Sliding surface portion constituting portion 11AE Secondary forming plate 13E Sliding surface portion Component 21 Automotive brake disc rotor 24 Sport Part 24a Inner peripheral end part 24b Outer peripheral end part 24c Inclined arc part 24d Inner peripheral arc part 24e Outer peripheral arc part 24f Folding part 25 Connection part 31A Secondary forming plate 34 Spoke part constituent part 34d Inner peripheral arc part constituent Portion 34e outer circumferential side arc portion constituting portion 34f folded portion constituting portion 35 connecting portion constituting portion 38 slit 38a inner circumferential side slit 38b circumferential side slit 38c arcuate slit 38d intermediate slit

Claims (12)

A single metal plate is press-formed, and the inner part, the outer part provided on the outer peripheral side of the inner part, and the outer part and the inner part are arranged in parallel with a gap in the thickness direction of both. As described above, a hat-shaped metal plate molded product provided with a connecting portion that rises from the inner periphery of the outer portion and connects the outer portion and the inner portion,
The connecting portion is a plurality of plate-like spoke portions having a width in the radial direction provided at intervals in the circumferential direction, wherein one end portion is connected to the inner peripheral edge of the outer portion, and the other end portion is connected to the inner portion. Connected to the outer peripheral edge, and provided with a plurality of spoke parts having an inclined arc part extending in the circumferential direction and inclined with respect to a plane orthogonal to the offset direction in the middle part,
Metal plate molded product characterized by that.   The metal plate molded product is an automotive brake disc rotor, the inner part is a mounting surface part fixed to a wheel, the outer part is a sliding surface part clamped by a pad, and the connection part 2. The sliding surface portion and the mounting surface portion are connected to each other so as to rise from an inner peripheral edge of the sliding surface portion so that the sliding surface portion and the mounting surface portion are arranged in parallel with a gap in the axial direction. Metal plate molded article as described.   The metal plate molded product according to claim 1 or 2, wherein the inclined arc portion is provided in a circumferential direction from a connection portion with the inner peripheral edge of the outer portion toward a connection portion with the outer peripheral edge of the inner portion.   A folded portion is formed in the middle of the inclined arc portion, an inner peripheral side portion extending from a connecting portion with the outer peripheral edge of the inner portion to the folded portion, and an inner peripheral edge of the outer portion from the folded portion. The metal plate molded product according to claim 1, further comprising an outer peripheral side portion that reaches a connecting portion.   The metal plate molded product according to any one of claims 1 to 4, wherein an interval between the outer portion and the inner portion in the plate thickness direction is set to 20 mm or more.   The metal plate molded product according to any one of claims 1 to 5, wherein the plurality of spoke portions are formed rotationally symmetrically. From the inner peripheral edge of the outer portion so that the inner portion, the outer portion provided on the outer peripheral side of the inner portion, and the outer portion and the inner portion are arranged in parallel in the thickness direction of the both. A method for producing a hat-shaped metal plate molded product obtained by press-molding a metal plate, comprising a connecting portion that rises and connects the outer portion and the inner portion,
A primary molded plate preparation step of punching the metal plate to prepare a primary molded plate;
A plurality of circumferentially extending slits are provided in the annular surface portion corresponding to the connecting portion of the primary molded plate, and circumferentially spaced from each other at both ends of the adjacent slits in the circumferential direction. A slit forming step of forming a certain angle so as to overlap in a radial direction;
A press forming step of opening the slit by extruding a portion corresponding to the inner portion in the plate thickness direction and press forming so that the inner portion and the outer portion are parallel to form the connecting portion; A method for producing a metal plate molded product, comprising:   The metal plate molded product is an automotive brake disc rotor, the inner part is a mounting surface part fixed to a wheel, the outer part is a sliding surface part clamped by a pad, and the connection part 8. The sliding surface portion and the mounting surface portion are connected to each other so as to rise from an inner peripheral edge of the sliding surface portion so that the sliding surface portion and the mounting surface portion are arranged in parallel with a gap in the axial direction. The manufacturing method of the metal plate molded product of description.   The manufacturing method of the metal plate molded product according to claim 7 or 8, wherein the slit is a straight line, a curved line, or a combination of a straight line and a curved line that is inclined with respect to the radial direction.   The said slit is formed in the Y-shape which consists of a combination of the U-shaped part opened toward one side of the circumferential direction, and the curved part extended in the other direction of the circumferential direction from the center part of this U-shaped part. Item 9. A method for producing a metal plate molded article according to Item 7 or 8.   The manufacturing method of the metal plate molded product of any one of Claims 7-10 which set the space | interval with respect to the plate | board thickness direction of the said outer side part and an inner side part to 20 mm or more.   The method for manufacturing a metal plate molded product according to any one of claims 7 to 11, wherein the plurality of slits are formed so as to be rotationally symmetric with respect to a center of the primary molded plate.

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