Disk brake disk, disk brake and manufacturing method

A method for manufacturing a disk brake disk made in a single piece by co-casting two materials, comprising:

• a bell made of a first material and configured to connect said disk brake disk to a rotating support;
• a braking band made of a second material;
• said disk brake disk defining an axial direction (A-A) coinciding with, or parallel to, a rotation axis (X-X), a radial direction (R-R) orthogonal to said rotation axis (X-X) and defining a radially outer direction when moving away from said rotation axis (X-X), and a radially inner direction when moving close to said rotation axis (X-X), a circumferential direction (C-C) orthogonal to said axial direction (A-A) and to said radial direction (R-R), and a tangential direction (T-T) orthogonal to said axial direction (A-A) and to said radial direction (R-R) in a point of intersection of said axial direction (A-A) and to said radial direction (R-R);
• wherein
• said bell comprises a bell body having a radially outer bell body portion;
• said bell forms a plurality of bell projections in a single piece, which radially protrude from said radially outer bell body portion according to said radially outer direction;
• each bell projection comprises a projection base, arranged close to said radially outer bell body portion, and a distal projection portion, arranged far from said radially outer bell body portion;
• wherein
• said braking band comprises a braking band body;
• said braking band body is connected and intimately coupled to said distal projection portion, wrapping said distal projection portion all around and at the top;
• and
• wherein
• adjacent projection bases of said plurality of bell projections are joined to one another by a bell rib made in a single piece with said bell body;
• the bell rib comprises an inner axial rib face and an opposite outer axial rib face;
• and
• said braking band body is connected and intimately coupled to said inner axial rib face, leaving said outer axial rib face free and externally facing said disk brake disk,
• the method comprising:
• casting a first material into a first die to obtain a bell, obtaining, in a radially outer bell body portion, a plurality of bell projections, in one piece, which radially protrude from said radially outer bell body portion according to said radially outer direction, forming a projection base in each bell projection, arranged close to said radially outer bell body portion, and a distal projection portion, arranged far from said radially outer bell body portion;
• inserting said bell into a second die;
• casting a second material into said second die to obtain a braking band co-cast in a single piece with said bell, incorporating the distal projection portion of said bell projections, wrapping said distal projection portion all around and at the top;
• wherein
• with the step of obtaining said bell, bell ribs are made in a single piece with said bell body, connected to said adjacent projection bases of said plurality of bell projections, obtaining an inner axial rib face and an outer axial rib face for each bell rib;
• and
• with the step of obtaining said braking band, said braking band body is connected and intimately coupled to said inner axial rib face, leaving said outer axial rib face free from the second material of said braking band.

A disk brake disk, made in a single piece by co-casting two materials, comprising:

• a bell made of a first material and configured to connect said disk brake disk to a rotating support;
• a braking band made of a second material;
• said disk brake disk defining an axial direction (A-A) coinciding with, or parallel to, a rotation axis (X-X), a radial direction (R-R) orthogonal to said rotation axis (X-X) and defining a radially outer direction when moving away from said rotation axis (X-X), and a radially inner direction when moving close to said rotation axis (X-X), a circumferential direction (C-C) orthogonal to said axial direction (A-A) and to said radial direction (R-R), and a tangential direction (T-T) orthogonal to said axial direction (A-A) and to said radial direction (R-R) in a point of intersection of said axial direction (A-A) and to said radial direction (R-R);
• wherein
• said bell comprises a bell body having a radially outer bell body portion;
• said bell forms a plurality of bell projections in a single piece, which radially protrude from said radially outer bell body portion according to said radially outer direction;
• each bell projection comprises a projection base, arranged close to said radially outer bell body portion, and a distal projection portion, arranged far from said radially outer bell body portion;
• wherein
• said braking band comprises a braking band body;
• said braking band body is connected and intimately coupled to said distal projection portion, wrapping said distal projection portion all around and at the top;
• and
• wherein
• adjacent projection bases of said plurality of bell projections are joined to one another by a bell rib made in a single piece with said bell body;
• the bell rib comprises an inner axial rib face and an opposite outer axial rib face;
• and
• said braking band body is connected and intimately coupled to said inner axial rib face, leaving said outer axial rib face free and externally facing said disk brake disk,
• wherein
• said braking band is ventilated and comprises an inner folder and an outer folder connected by connection elements that are separate from one another to form a ventilation space;
• said outer folder comprises an inner enlarged folder portion which is enlarged in the axial direction (A-A) to incorporate distal projection portions.