Disk for toroidal type continuously variable transmission

Abstract

The disk has a traction surface having a concave-arc-shaped cross section which is interposed between a small diameter end portion and a large diameter end portion. In the central portion of the end face of the disk on the small diameter end portion side, there is formed a through hole which extends through the disk up to the large diameter end portion side end face of the disk, while the inner peripheral surface of the through hole is used as an inside diameter surface of the disk. Here, when, among metal flows existing in the disk, a metal flow, which has such a positional relationship with respect to the surface of the disk that an angle θ formed between a metal flow on the traction surface side and the tangent of the traction surface is smaller than or equal to 30 degrees, is defined as a “metal flow along the disk surface”, the disk is structured such that the “metal flow along the disk surface” exists at least in the traction surface.

1. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave-arc-shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller frictionally engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and
 said disk comprising metal flows existing along a part of all surfaces of said disk at least including the traction surface, wherein said metal flows have such a positional relationship with respect to the surface of said disk that an angle θ formed between said metal flow existing along the surface and a tangent of the surface is greater than or equal to  2  degrees and smaller than or equal to 30 degrees.  
 
     
     
       2. A disk for use in a toroidal type continuously variable transmission according to  claim 1 , wherein said metal flows along the surface exist along the traction surface in a range of an angle α of at least 45 degrees or more in a peripheral direction of the traction surface, where the angle α is an angle formed by the traction surface with respect to a horizontal line passing through a center of a radius of the traction surface and parallel to an axis of the disk in a cross section of the disk. 
     
     
       3. A disk for use in a toroidal type continuously variable transmission according to  claim 1 , wherein said all surfaces of said disk has an inside diameter surface, and said metal flows exist along said inside diameter surface in a distance of h which is a distance from an end surface on the small diameter end portion, and if a length of said disk in an axial direction thereof is expressed as A, the following relationship is achieved: h≧⅓ A. 
     
     
       4. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave-arc-shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller fictionally  frictionally engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and
 said disk comprising high-density non metallic inclusions,  
 wherein a small radius of a contact ellipse between the traction surface and the power roller is expressed as b when the power roller is set horizontal so as to be parallel an axis of said disk, and said high-density nonmetallic inclusions do not exist in an area which is distant at least by 1.5 b or shorter in a depth direction from the traction surface.  
 
     
     
       5. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave-arc-shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller frictionally engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and  according to  claim 3 ,
   wherein  said disk comprisingcomprises high-density non metallic inclusions and  
 wherein said high-density non metallic inclusions do not exist in an area in a range of the distance h which is a distance from an end surface on the small diameter end portion, and if a length of said disk in an axial direction thereof is expressed as A, the following relationship is achieved: h≦⅓ A .  
 
     
     
       6. A method for manufacturing a disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave-arc-shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller frictionally engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, said manufacturing method comprising the steps of:
 preparing a first cylindrical-shaped material with metal flows existing on cross sections of said first material and extending along an axial direction thereof;  
 preparing a first upper mold comprising: 
 a plane portion perpendicular to an axis of the first material;  
 a circular projecting portion being projected from the plane portion, having a diameter smaller than a diameter of the first material and being concentrical with the first material; and  
 a curve molding surface connecting the plane portion and the circular projecting portion;  
 
 preparing a first lower mold comprising: 
 a plane portion perpendicular to the axis of the first material; and  
 a recessed portion formed in the plane portion, being concentrical with the first material so that the first material being fitted into the recessed portion;  
 
 swaging the first material in the axial direction thereof with the first upper mold and the first lower mold so as to obtain a second material;  
 preparing a second lower mold comprising: 
 a plane portion perpendicular to an axis of the second material;  
 a projecting portion being projected from a center of the plane portion and being concentrical with the second material; and  
 an inclined portion located outside of the plane portion and inclined obliquely and upwardly;  
 
 preparing a second upper mold comprising: 
 a plane portion perpendicular to the axis of the second material; and  
 a first middle mold projected concentrically with the second material and being formed in a substantially conical shaped;  
 
 molding the second material in an axial direction thereof with the second upper mold and the second lower mold so as to obtain a third material;  
 preparing a third lower mold comprising: 
 a large diameter end portion molding surface perpendicular to an axis of the third material for molding the large diameter end portion of the disk;  
 a projecting portion being projected from a center of the large diameter end portion molding surface and being concentrical with the third material; and  
 an outer mold for regulating a diameter the large diameter end portion of the disk;  
 
 preparing a third upper mold comprising: 
 a small diameter end portion molding surface perpendicular to the axis of the third material for molding the small diameter end portion of the disk;  
 a traction surface molding surface located outside of the small diameter end portion molding surface for molding the traction surface of the concave-arc-shaped cross section; and  
 a second middle mold located at a center of the small diameter end portion molding surface and being concentrical with the third material for molding a part of an inside diameter surface of the disk; and  
 
 molding the third material in an axial direction thereof with the third upper mold and the third lower mold so as to obtain a fourth material from which a raw disk to finish the disk is obtained.  
 
     
     
       7. A method for manufacturing a disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave-arc-shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller frictionally engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, said manufacturing method comprising the steps of:
 preparing a first cylindrical-shaped material with metal flows existing on cross sections of said first material and extending along an axial direction thereof;  
 preparing a first upper mold comprising: 
 a plane portion perpendicular to an axis of the first material; and  
 a recessed portion formed in a center of the plane portion, a lower end portion of the first material being fitted into the recessed portion;  
 
 preparing a first upper mold comprising: 
 a flat surface perpendicular to the axis of the first material;  
 a tapered recessed portion located outside of the flat surface, the tapered recessed portion decreasing in diameter in an upward direction and being concentrical with the recessed portion of the first lower mold;  
 
 swaging the first material in the axial direction thereof with the first upper mold and the first lower mold so as to obtain a second material;  
 preparing a second lower mold comprising: 
 a large diameter end portion molding surface perpendicular to an axis of the second material for molding the large diameter end portion of the disk;  
 a recessed portion formed at a center of the large diameter end portion molding surface and being concentrical with the second material, a lower end portion of the second material being fitted into the recessed portion; and  
 an outer portion located outside of the large diameter end portion molding surface, being concentrical with the second material and having a diameter for regulating a diameter of the large diameter end portion;  
 
 preparing an outer mold comprising: 
 a small diameter end portion molding surface perpendicular to the axis of the second material for molding the small diameter end portion of the disk;  
 a traction surface molding surface located outside of the small diameter end portion molding surface for molding the traction surface of the concave-arc-shaped cross section; and  
 a second upper mold located at a center of the small diameter end portion molding surface and having a cylindrical shape, the second upper mold having a tapered recessed portion decreasing in diameter in an upward direction and having a diameter larger than a diameter of the second material, and a flat surface formed at a bottom of the tapered recessed portion and having a diameter larger than an area of nonmetallic inclusions existing at a center of an upper end of the second material;  
 
 molding the second material in an axial direction thereof with the outer mold and the second lower mold so as to obtain a third material from which a raw disk to finish the disk is obtained.  
 
     
     
       8. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave- arc - shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller rollingly engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and      said disk comprising metal flows existing along a surface of said disk including at least of part of the traction surface, wherein said metal flows have such a positional relationship with respect to the surface of said disk that an angle θ formed between each of said metal flows existing along the surface and a tangent of the surface is greater than or equal to  2  degrees and smaller than or equal to  30  degrees.     
     
     
       9. A disk for use in a toroidal type continuously variable transmission according to  claim 8 , wherein said metal flows along the surface exist along the traction surface in a range of an angle α of at least  45  degrees or more in a peripheral direction of the traction surface, where the angle α is an angle formed by the traction surface with respect to a horizontal line passing through a center of a radius of the traction surface and parallel to an axis of the disk in a cross section of the disk. 
     
     
       10. A disk for use in a toroidal type continuously variable transmission according to  claim 8 , wherein said surface of said disk further includes an inside diameter surface, and said metal flows exist along said inside diameter surface in a distance of at least h which is a distance starting at an end surface of the small diameter end portion and extending towards an end surface of the large diameter end portion, and if a length of said disk in a axial direction thereof is expressed as A, the following relationship is achieved: h=A/ 3 . 
     
     
       11. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave- arc - shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller rollingly engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and      said disk comprising high - density non metallic inclusions,        wherein a small radius of a contact ellipse between the traction surface and the power roller is expressed as b when the power roller is set so as to be parallel an axis of said disk, and said high - density nonmetallic inclusions do not exist in an area which is distant at least by  1 . 5  b or shorter in a depth direction from the traction surface.     
     
     
       12. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave- arc - shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller rollingly engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and      said disk comprising metal flows existing along a surface of said disk including at least of part of the traction surface, wherein said metal flows have such a positional relationship with respect to the surface of said disk that an angle θ formed between each of said metal flows existing along the surface and a tangent of the surface is smaller than or equal to  30  degrees, and        wherein said metal flows along the surface exist along the traction surface at least in a range of an angle α of at least  45  degrees or more in a peripheral direction of the traction surface, where the angle α is an angle formed by the traction surface with respect to a horizontal line passing through a center of a radius of the traction surface and parallel to an axis of the disk in a cross section of the disk, and        said angle θ varies for said metal flows exist along the traction surface at least in said range of said angle α.     
     
     
       13. A disk for use in a toroidal type continuously variable transmission according to  claim 12 , wherein said surface of said disk further includes an inside diameter surface, and said metal flows exist along said inside diameter surface in a distance of at least h which is a distance starting at an end surface of the small diameter end portion and extending towards an end surface of the large diameter end portion, and if a length of said disk in a axial direction thereof is expressed as A, the following relationship is achieved: h=A/ 3 . 
     
     
       14. A disk for use in a toroidal type continuously variable transmission according to  claim 12 , wherein said angle θ is greater than or equal to  2  degrees and smaller than or equal to  30  degrees. 
     
     
       15. A disk for use in a toroidal type continuously variable transmission according to  claim 14 , wherein said angle θ is greater than or equal to  5  degrees and smaller than or equal to  20  degrees. 
     
     
       16. A disk for use in a toroidal type continuously variable transmission which comprises an input disk and an output disk each including a traction surface of a concave- arc - shaped cross section interposed between a small diameter end portion and a large diameter end portion and disposed concentrically with each other with their respective traction surfaces opposed to each other, and a power roller rollingly engageable with the respective traction surfaces of the input disk and the output disk to thereby transmit power, wherein said disk is used as one of the input disk and the output disk, and      said disk comprising metal flows existing along at least a part of the traction surface of said disk, wherein said metal flows have such a positional relationship with respect to the surface of said disk that an angle θ formed between each of said metal flows existing along the surface and a tangent of the surface is greater than or equal to  2  degrees and smaller than or equal to  30  degrees.     
     
     
       17. A disk for use in a toroidal type continuously variable transmission according to  claim 15 , wherein said angle θ is greater than or equal to  5  degrees and smaller than or equal to  20  degrees. 
     
     
       18. A disk for use in a toroidal type continuously variable transmission according to  claim 10 , wherein said disk comprises high- density non metallic inclusions, and said high - density non metallic inclusions do not exist in an area along said inside diameter surface at least in a range of the distance h.