JP2005030419A

JP2005030419A - Manufacturing method for caliper body of disc brake for vehicle, and caliper body

Info

Publication number: JP2005030419A
Application number: JP2003192812A
Authority: JP
Inventors: Kenichi Fujii; 健一藤井
Original assignee: Nissin Kogyo Co Ltd
Current assignee: Nissin Kogyo Co Ltd
Priority date: 2003-07-07
Filing date: 2003-07-07
Publication date: 2005-02-03
Anticipated expiration: 2023-07-07
Also published as: JP4486796B2

Abstract

<P>PROBLEM TO BE SOLVED: To mold a plurality of kinds of caliper bodies having various cylinder hole diameters by using a common cast mold to reduce the cost by improving the versatility of the cast mold, and further to secure a thickness of a reaction claw. <P>SOLUTION: Prepared holes 31, 32, 33 of the cylinder holes are formed on an action part 30a of the caliper body 30 in cast molding, and a space between adjacent original claws of the original claws 34, 35, 36, 37 as the reaction claws is determined to be same as a diameter L1 of the smallest cylinder hole after the cutting work. When the smallest cylinder hole among the plurality of cylinder holes is formed, a cutting tool is advanced from a non-action part 30b side to an action part 30a side through between the original claws, and the prepared hole for the smallest cylinder hole is cut and worked by cutting and working the prepared hole. When the cylinder holes of larger diameters are formed, the cutting tool is advanced from the non-action part 30b to the action part 30a side while cutting an opposite face of the original claw, to cut and work the prepared hole for the cylinder holes of larger diameters. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、四輪自動車や自動二輪車等の車両に搭載される車両用ディスクブレーキのキャリパボディ製造方法及びキャリパボディに係り、詳しくは、作用部にシリンダ孔を、反作用部に反力爪をそれぞれ備え、該反作用部と前記作用部とをブリッジ部で一体に連結したモノコックタイプのキャリパボディの製造方法及びキャリパボディに関する。
【０００２】
【従来の技術】
従来、ディスクロータ側に開口したシリンダ孔が形成された作用部と、該作用部にディスクロータを挟んで対向し、前記シリンダ孔の外周両側に対向配置されるよう反力爪が設けられた反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成したモノコックタイプのキャリパボディは、鋳造成形時に、作用部にはシリンダ孔の下孔となる有底孔がディスクロータ側に開口して設けられるとともに、反力爪には、有底孔用の中子を引き抜くための開口がディスクロータ軸方向に貫通形成されている。キャリパボディの鋳造成形後には、シリンダ孔の外周に対向する一対の反力爪の間から切削工具を前記有底孔に差し入れて、有底孔を仕上げ加工し、所要精度のシリンダ孔に形成していた（例えば、特許文献１及び２参照）。
【０００３】
【特許文献１】
登録実用新案第２５０５３０５号公報（第２−３頁、図３）
【０００４】
【特許文献２】
意匠登録第９１１８８６号公報
【０００５】
【発明が解決しようとする課題】
しかし、上述のものでは、シリンダ孔の径を変更すると、それに伴って反力爪の形成位置も変更しなくてはならないため、シリンダ孔の径に応じた個別の鋳造型が必要となっていた。また、シリンダ孔が隣接する場合、シリンダ孔の加工を逃げるために、反作用部側の鋳抜き形状を大きくしなければならず、反力爪の肉厚を確保することができなかった。
【０００６】
そこで本発明は、径の異なるシリンダ孔を備えた数種類のキャリパボディを同一の鋳造型を用いて成形でき、鋳造型の汎用性を高めることによりコストの低減を図るとともに、反力爪の肉厚を確保することができる車両用ディスクブレーキのキャリパボディ製造方法及びキャリパボディを提供することを目的としている。
【０００７】
【課題を解決するための手段】
上記の目的を達成するため第１の発明では、ディスクロータ側に開口した１つのシリンダ孔が形成される作用部と、該作用部にディスクロータを挟んで対向し、前記シリンダ孔の外周両側に対向配置されるよう一対の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した後、前記一対の反力爪の間を通して反作用部側から作用部に切削工具を進入させて前記シリンダ孔を切削加工する車両用ディスクブレーキのキャリパボディ製造方法において、該キャリパボディの鋳造成形時に、前記作用部にシリンダ孔の下孔を形成するとともに、一対の反力爪の間隔を切削加工後のシリンダ孔の開口端となる径よりも小さい寸法で形成し、前記下孔をシリンダ孔に切削加工するときに、反作用部側から、前記一対の反力爪の対向面を切削しながら作用部側へ切削工具を進入させて、下孔の切削加工をすることを特徴としている。
【０００８】
第２の発明では、ディスクロータ側に開口した複数の同径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した後、隣接する反力爪の間を通して反作用部側から作用部に切削工具を進入させて各シリンダ孔を切削加工する車両用ディスクブレーキのキャリパボディ製造方法において、該キャリパボディの鋳造成形時に、前記作用部に各シリンダ孔の下孔を形成するとともに、隣接する反力爪の間隔を、切削加工後のシリンダ孔の開口端となる径よりも小さい寸法で形成し、各下孔をシリンダ孔に切削加工するときに、反作用部側から隣接する反力爪の対向面を切削しながら前記作用部側へ切削工具を進入させて、各下孔を切削加工することを特徴としている。
【０００９】
また、第３の発明では、ディスクロータ側に開口した複数の異径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した後、隣接する反力爪の間を通して反作用部側から作用部に切削工具を進入させて各シリンダ孔を切削加工する車両用ディスクブレーキのキャリパボディ製造方法において、該キャリパボディの鋳造成形時に、前記作用部に各シリンダ孔の下孔を形成するとともに、隣接する反力爪の間隔を、切削加工後に最も小さいシリンダ孔の開口端となる径と同一の寸法で形成し、複数のシリンダ孔のうち、最も小さいシリンダ孔を形成するときには、反作用部側から反力爪の間を通して前記作用部側へ切削工具を進入させて、下孔を切削加工し、それより大径のシリンダ孔を形成するときには、反作用部側から、反力爪の対向面を切削しながら前記作用部側へ切削工具を進入させて、前記大径のシリンダ孔となる下孔を切削加工することを特徴としている。
【００１０】
第４の発明では、ディスクロータ側に開口した複数の異径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した後、隣接する反力爪の間を通して反作用部側から作用部に切削工具を進入させて各シリンダ孔を切削加工する車両用ディスクブレーキのキャリパボディ製造方法において、該キャリパボディの鋳造成形時に、前記作用部に各シリンダ孔の下孔を形成するとともに、隣接する反力爪の間隔を、切削加工後に最も小さいシリンダ孔の開口端となる径よりも小さい寸法で形成し、各シリンダ孔をシリンダ孔に切削加工するときに、反作用部側から、隣接する反力爪の対向面を切削しながら前記作用部側へ切削工具を進入させて、各下孔を切削加工することを特徴としている。
【００１１】
さらに、第５の発明では、ディスクロータ側に開口した１つのシリンダ孔が形成される作用部と、該作用部にディスクロータを挟んで対向し、前記シリンダ孔の外周両側に対向配置されるよう一対の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した車両用ディスクブレーキのキャリパボディにおいて、前記一対の反力爪の対向面を、鋳造成形後に切削工具によって切削加工したシリンダ孔開口端の径と同一の間隔に切削形成していることを特徴としている。
【００１２】
第６の発明では、ディスクロータ側に開口した複数の同径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した車両用ディスクブレーキのキャリパボディにおいて、反力爪の対向面を、鋳造成形後に切削工具によって切削加工したシリンダ孔開口端の径と同一の間隔に切削形成していることを特徴としている。
【００１３】
また、第７の発明では、ディスクロータ側に開口した複数の異径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した車両用ディスクブレーキのキャリパボディにおいて、前記反力爪のうち、切削後に最も小さいシリンダ孔に対応する反力爪の対向面を除く他の反力爪の各対向面を、鋳造成形後に切削工具によって切削加工したそれぞれ対応するシリンダ孔開口端の径と同一の間隔に切削形成していることを特徴としている。
【００１４】
第８の発明では、ディスクロータ側に開口した複数の異径のシリンダ孔がディスク周方向へ並設される作用部と、該作用部にディスクロータを挟んで対向し、各シリンダ孔の外周両側に対向配置されるよう複数の反力爪が設けられる反作用部と、該反作用部と前記作用部とをディスクロータの外周を跨いで連結するブリッジ部とを鋳造成形により一体に形成した車両用ディスクブレーキのキャリパボディにおいて、前記反力爪の各対向面を、鋳造成形後に切削工具によって切削加工したそれぞれ対応するシリンダ孔開口端の径と同一の間隔に切削形成していることを特徴としている。
【００１５】
【発明の実施の形態】
以下、本発明の各形態例を図面に基づいて詳しく説明する。図１乃至図４は、本発明の第１形態例を示すもので、図１は図２のＩ−Ｉ断面図、図２はキャリパボディの正面図、図３は図４のＩＩＩ−ＩＩＩ断面図、図４は図１のキャリパボディを用いたディスクブレーキの正面図である。
【００１６】
本形態例のディスクブレーキ１は、矢印Ａ方向へ回転するディスクロータ２の一側部で車体に固設されるキャリパブラケット３に、キャリパボディ４が一対の摺動ピン５，５を介してディスク軸方向へスライド可能に支持されており、キャリパボディ４の作用部４ａと反作用部４ｂとの間には、一対の摩擦パッド６，６がディスクロータ２を挟んで対向配置されている。
【００１７】
キャリパボディ４は、ディスクロータ２の一側に配設される作用部４ａと、ディスクロータ２の他側に配設される反作用部４ｂと、該反作用部４ｂと前記作用部４ａとをディスクロータ２の外周を跨いで連結するブリッジ部４ｃとを一体に鋳造成形したモノコックタイプで、作用部４ａに３つのシリンダ孔７，８，９がディスク周方向に並設されている。また、作用部４ａには、取り付け腕４ｄ，４ｄがディスク半径方向内側とディスクロータ回出側へ向けて突設され、キャリパブラケット３に設けられた、ディスク軸方向へ突出する摺動ピン５，５を、前記取り付け腕４ｄ，４ｄに挿通することによって、キャリパボディ４がキャリパブラケット３にディスク軸方向へ移動可能に支持される。
【００１８】
シリンダ孔７，８，９は、ディスクロータ２側を開口した有底円筒状に形成されており、作用部４ａのディスク回出側とディスク回入側に大径で深底のシリンダ孔７，９が配設され、中央部に小径で浅底のシリンダ孔８が配設される。各シリンダ孔７，８，９には、ピストンシールを装着するシール溝７ａ，８ａ，９ａと、ダストシールを装着するシール溝７ｂ，８ｂ，９ｂがそれぞれ形成されている。大径のシリンダ孔７，９の内部には大径で長いピストン１０，１２が、小径のシリンダ孔８の内部には、小径で短いピストン１１が、前記ピストンシール及びダストシールを介してそれぞれ液密且つ移動可能に内挿され、シリンダ孔７，８，９の底部には液圧室がそれぞれ画成される。
【００１９】
反作用部４ｂには、シリンダ孔７，８，９の外周両側に対向配置されるように、４つの反力爪１３，１４，１５，１６が設けられ、ディスク回入側の大径のシリンダ孔７の外周に反力爪１３，１４が、小径のシリンダ孔８の外周に反力爪１４，１５が、ディスク回出側の大径のシリンダ孔９の外周に反力爪１５，１６がそれぞれ配設されている。反力爪１３，１４，１５，１６の鋳造成形時には、隣接する反力爪１３，１４、反力爪１４，１５、反力爪１５，１６の間隔を、小径のシリンダ孔８の開口端の径Ｌ１と同一の間隔Ｌ１で形成し、小径のシリンダ孔８の外周に対向する一対の反力爪１４，１５の対向面１４ａ，１５ａは鋳造成形時の間隔Ｌ１のまま使用される。大径のシリンダ孔７の外周に対向する反力爪１３，１４の対向面１３ａ，１４ｂは、鋳造成形後に大径のシリンダ孔７を切削加工する切削工具により、大径シリンダ孔７の開口端の径Ｌ２と同一の間隔Ｌ２に切削され、同様に、大径のシリンダ孔９の外周に対応する反力爪１５，１６の対向面１５ｂ，１６ａは、鋳造成形後に大径のシリンダ孔９を切削加工する切削工具により、大径シリンダ孔９の開口端の径Ｌ２と同一の間隔Ｌ２に切削されている。
【００２０】
また、作用部４ａと反作用部４ｂとの間に配設される一対の摩擦パッド６，６は、ディスクロータ２の側面と摺接するライニング６ａが、金属製の裏板６ｂに接合されて構成され、裏板６ｂにはハンガーピンが挿通され、ディスク軸方向へ移動可能に吊持されている。
【００２１】
液圧室は、連通孔を介してユニオン孔に連通し、運転者が制動操作を行うと、別途の液圧マスタシリンダで昇圧した作動液が、ユニオン孔から各液圧室に供給され、ピストン１０，１１，１２をシリンダ孔７，８，９のディスクロータ方向へ押動して、作用部４ａ側の摩擦パッド６をディスクロータ２の一側面へ押圧する。次に、この反作用によって、キャリパボディ４が摺動ピン５，５に案内されながら作用部４ａ方向へ移動し、反作用部４ｂの反力爪１３，１４，１５，１６が、他方の摩擦パッド６をディスクロータ２の他側面へ押圧して、制動作用が行われる。
【００２２】
図５及び図６は、本発明の第２形態例を示すもので、図５は図６のＶ−Ｖ断面図、図６はキャリパボディの正面図である。
【００２３】
本形態例のキャリパボディ２０は、第１形態例と同様、作用部２０ａと反作用部２０ｂとをディスクロータ２の外周を跨いで連結するブリッジ部２０ｃとを一体に鋳造成形したモノコックタイプで、作用部２０ａには、同径の３つのシリンダ孔２１，２２，２３がディスク周方向に並設されている。シリンダ孔２１，２２，２３は、ディスクロータ２側を開口した有底円筒状に形成されており、作用部２０ａのディスク回出側とディスク回入側に深底のシリンダ孔２１，２３が配設され、中央部に浅底のシリンダ孔２２が配設される。各シリンダ孔２１，２２，２３の開口端の径は、上述の第１形態例の小径のシリンダ孔８の開口端の径Ｌ１よりも大径で、大径のシリンダ孔７，９の開口端の径Ｌ２よりも小径の径Ｌ３で形成されている。また、各シリンダ孔２１，２２，２３には、ピストンシールを装着するシール溝２１ａ，２２ａ，２３ａと、ダストシールを装着するシール溝２１ｂ，２２ｂ，２３ｂがそれぞれ形成されている。
【００２４】
反作用部２０ｂには、シリンダ孔２１，２２，２３の外周両側に対向配置されるように、４つの反力爪２４，２５，２６，２７が設けられ、ディスク回入側のシリンダ孔２１の外周に反力爪２４，２５が、中央のシリンダ孔２２の外周に反力爪２５，２６が、ディスク回出側のシリンダ孔２３の外周に反力爪２６，２７がそれぞれ配設されている。反力爪２４，２５，２６，２７の鋳造成形時には、隣接する反力爪２４，２５、反力爪２５，２６、反力爪２６，２７の間隔を、シリンダ孔２１，２２，２３の開口端の径よりも小さい寸法、例えば、第１形態例の小径シリンダ孔８の開口端の径Ｌ１で形成し、鋳造成形後に各シリンダ孔２１，２２，２３を切削加工する切削工具により、反力爪２４，２５の対向面２４ａ，２５ａ及び、反力爪２５，２６の対向面２５ｂ，２６ａ及び、反力爪２６，２７の対向面２６ｂ，２７ａが、各シリンダ孔２１，２２，２３の開口端の径Ｌ３と同一の間隔に切削されている。
【００２５】
次に、上述の両キャリパボディの製造方法について説明する。図７は、図８のＶＩＩ−ＶＩＩ断面図、図８は反作用部と作用部とブリッジ部とを一体に成形した鋳造成形時のキャリパボディの正面図を示し、キャリパボディ４，２０は、図７及び図８に示される鋳造成形後のキャリパボディ３０を切削加工することによって形成される。
【００２６】
鋳造成形時のキャリパボディ３０は、アルミニウム合金や鋳鉄等の金属材料を用いて、作用部３０ａ、反作用部３０ｂ、ブリッジ部３０ｃを一体に鋳造成形したもので、作用部３０ａには、切削加工後シリンダ孔７，８，９となる下孔３１，３２，３３が形成され、反作用部３０ｂには、切削加工後に反力爪１３，１４，１５，１６となる元爪３４，３５，３６，３７が形成されている。元爪３４，３５，３６，３７は、隣接する元爪３４，３５、元爪３５，３６、元爪３６，３７の間隔が、小径のシリンダ孔、例えば形態例１のシリンダ孔８の開口端の径Ｌ１と同一の寸法Ｌ１に設定されている。
【００２７】
このように形成された元爪３４，３５，３６，３７の反ディスクロータ側に、シリンダ孔を形成する切削工具を位置させ、該切削工具をディスクロータ方向へ移動させて、元爪３４，３５の対向面３４ａ，３５ａ間、元爪３５，３６の対向面３５ｂ，３６ａ間、元爪３６ｂ，３７ａ間から切削工具を作用部３０ａの下孔３１，３２，３３へ挿入し、下孔３１，３２，３３を所定の径で、所定の深さまで切削して、所要の寸法精度のシリンダ孔にそれぞれ切削加工する。
【００２８】
形態例１のキャリパボディ４を製造するときには、元爪３４，３５，３６，３７の隣接する元爪３４，３５、元爪３５，３６、元爪３６，３７の間隔が、加工後の小径シリンダ孔８の開口端の径Ｌ１と同一の寸法Ｌ１に形成されていることから、小径のシリンダ孔８を形成する際には、シリンダ孔８を形成する切削工具を元爪３５，３６の反ディスクロータ側に位置させ、元爪３５，３６の対向面３５ｂ，３６ａ間から切削工具を通す。そして、該対向面３５ｂ，３６ａを削ることなく切削工具をディスクロータ方向へ移動させ、下孔３２をシリンダ孔８の開口端の径Ｌ１に切削し、さらにシール溝８ａ，８ｂを切削加工してシリンダ孔８を形成する。
【００２９】
一方、下孔３１，３３を切削加工して、シリンダ孔８より大径のシリンダ孔７，９を形成する際には、シリンダ孔７，９を形成する切削工具を元爪３４，３５，３６，３７の反ディスクロータ側に位置させ、元爪３４，３５の対向面３４ａ，３５ａ及び元爪３６，３７の対向面３６ｂ，３７ａを切削しながら下孔３１，３３へ切削工具を進入させる。該切削工具によって、前記対向面３４ａ，３５ａ間と対向面３６ｂ，３７ａ間をそれぞれシリンダ孔７，９の開口端の径Ｌ２に切削しながら、下孔３１，３３をシリンダ孔７，９の開口端の径Ｌ２に切削し、さらに、シール溝７ａ，７ｂ，９ａ，９ｂをそれぞれ切削加工してシリンダ孔７，９を形成する。これにより、図１乃至図４に示される第１形態例のキャリパボディ４が形成される。
【００３０】
第２形態例のキャリパボディ２０を製造する場合は、鋳造成形した後のキャリパボディ３０の元爪３４，３５，３６，３７の反ディスクロータ側に、シリンダ孔２１，２２，２３を形成する切削工具を位置させて、該切削工具をディスクロータ方向へ移動させ、元爪３４，３５の対向面３４ａ，３５ａ間、元爪３５，３６の対向面３５ｂ，３６ａ間、元爪３６，３７の対向面３６ｂ，３７ａ間から切削工具を作用部３０ａの下孔３１，３２，３３へ挿入する。
【００３１】
このとき、元爪３４，３５，３６，３７の隣接する元爪３４，３５、元爪３５，３６、元爪３６，３７の間隔が、形態例１の小径シリンダ孔８の開口端の径Ｌ１と同一の寸法Ｌ１に形成されていることから、前記シリンダ孔８よりも大径のシリンダ孔２１，２２，２３を形成する際には、前記対向面３４ａ，３５ａ間、対向面３５ｂ，３６ａ間、対向面３６ｂ，３７ａ間をそれぞれシリンダ孔２１，２２，２３の開口端の径Ｌ３に切削しながら、下孔３１，３２，３３へ切削工具を進入させて、下孔３１，３２，３３をシリンダ孔２１，２２，２３の開口端の径Ｌ３に切削し、さらに、シール溝２１ａ，２１ｂ，２２ａ，２２ｂ，２３ａ，２３ｂをそれぞれ切削加工してシリンダ孔２１，２２，２３を形成する。これにより、図５及び図６に示される第２形態例のキャリパボディ２０が形成される。
【００３２】
上述のような方法でキャリパボディ４，２０を製造することによって、１つの鋳造型を用いて、キャリパボディ４，２０を製造することができる。また、切削工具の刃を変更すれば、同一の切削工具を用いてキャリパボディ４，２０のシリンダ孔７，８，９，２１，２２，２３を形成することができ、コストの低減化を図ることができる。さらに、３つのシリンダ孔の径をすべて小径のシリンダ孔８の径Ｌ１と同一にする際には、鋳造成形時の元爪３４，３５，３６，３７を切削せずにそのまま用いることができる。
【００３３】
なお、本発明は上述の形態例に限るものではなく、１つのシリンダ孔を備えたモノコックタイプのキャリパボディにも適用でき、この場合、鋳造成形時には、キャリパボディの作用部にあらかじめ設定された小径の下孔を形成し、反作用部に該下孔の径と同一寸法の間隔で反力爪を形成しておく。これにより、下孔をシリンダ孔に切削加工する際に、反力爪の対向面を切削しながら、作用部側へ切削工具を進入させて、所望の径のシリンダ孔を形成することができ、１つの鋳造型を用いてシリンダ孔の径が異なる数種類のキャリパボディを製造することができる。
【００３４】
さらに、シリンダ孔の数は上述の各形態例のように、３つに限るものではなく、２つのものや、３つ以上のものにも適用できる。シリンダ孔の径も、様々に設定することができ、予め設定された最も小さい径のシリンダ孔の径に合わせて鋳造成型時のキャリパボディのシリンダ孔や反力爪の間隔を設定し、切削加工によって仕上げることによって、シリンダ孔の個数が同一であれば、様々な径のシリンダ孔を有したキャリパボディを、１つの鋳造型で製造することができるようになる。
【００３５】
【発明の効果】
以上説明したように、本発明によれば、径の異なるシリンダ孔を備えた数種類のキャリパボディを、シリンダ孔の数が同一であれば、同一の鋳造型を用いて成形できるようになり、鋳造型の汎用性を高めることによりコストの低減を図ることができる。さらに、シリンダ孔が隣接する場合でも、シリンダ孔の加工を逃げるための反作用部側の鋳抜き形状が大きくなることを抑制させることができ、反力爪の肉厚を確保することができる。
【図面の簡単な説明】
【図１】図２のＩ−Ｉ断面図
【図２】本発明の第１形態例を示すキャリパボディの正面図
【図３】図４のＩＩＩ−ＩＩＩ断面図
【図４】本発明の第１形態例のキャリパボディを適用したディスクブレーキの正面図
【図５】図６のＶ−Ｖ断面図
【図６】本発明の第２形態例を示すキャリパボディの正面図
【図７】図８のＶＩＩ−ＶＩＩ断面図
【図８】反作用部と作用部とブリッジ部とを一体に成形した鋳造成形時のキャリパボディの正面図
【符号の説明】
１…ディスクブレーキ、２…ディスクロータ、４…キャリパボディ、４ａ…作用部、４ｂ…反作用部、４ｃ…ブリッジ部、６…摩擦パッド、７，８，９，２１，２２，２３…シリンダ孔、１０，１１，１２…シリンダ孔、１３，１４，１５，１６，２４，２５，２６，２７…反力爪、３０…鋳造時のキャリパボディ、３１，３２，３３…下孔、３４，３５，３６，３７…元爪[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a caliper body manufacturing method and a caliper body for a vehicle disc brake mounted on a vehicle such as a four-wheeled vehicle or a motorcycle, and more specifically, a cylinder hole in a working part and a reaction force claw in a reaction part, respectively. And a manufacturing method of a caliper body of a monocoque type in which the reaction part and the action part are integrally connected by a bridge part, and a caliper body.
[0002]
[Prior art]
Conventionally, a reaction portion provided with a reaction force claw provided with a cylinder hole opened on the disk rotor side, opposite to the action portion with the disk rotor interposed therebetween, and disposed opposite to both sides of the outer periphery of the cylinder hole. The monocoque type caliper body, in which the part and the bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, has a cylinder hole in the action part during casting. A bottomed hole serving as a lower hole is provided to open to the disk rotor side, and an opening for pulling out the core for the bottomed hole is formed through the reaction force claw in the disk rotor axial direction. After the caliper body is cast and molded, a cutting tool is inserted into the bottomed hole between a pair of reaction claws facing the outer periphery of the cylinder hole, and the bottomed hole is finished to form a cylinder hole with the required accuracy. (For example, refer to Patent Documents 1 and 2).
[0003]
[Patent Document 1]
Registered Utility Model No. 2505305 (page 2-3, FIG. 3)
[0004]
[Patent Document 2]
Design Registration No. 9111886 Publication [0005]
[Problems to be solved by the invention]
However, in the above-mentioned one, if the diameter of the cylinder hole is changed, the formation position of the reaction force claw must be changed accordingly. Therefore, an individual casting die corresponding to the diameter of the cylinder hole is required. . Further, when the cylinder holes are adjacent to each other, in order to escape the processing of the cylinder holes, the cast shape on the reaction part side must be increased, and the thickness of the reaction force claw cannot be ensured.
[0006]
Therefore, the present invention is capable of molding several types of caliper bodies having cylinder holes with different diameters using the same casting mold, and reducing the cost by increasing the versatility of the casting mold and increasing the thickness of the reaction force claw. It is an object of the present invention to provide a caliper body manufacturing method and a caliper body for a vehicle disc brake.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, according to the first aspect of the present invention, there is provided an action portion in which one cylinder hole opened on the disk rotor side is formed, and the action portion is opposed to each other with the disc rotor interposed therebetween, on both sides of the outer periphery of the cylinder hole. A reaction part provided with a pair of reaction force claws so as to face each other and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then the pair In a caliper body manufacturing method for a disc brake for a vehicle, in which a cutting tool is made to enter the action part from the reaction part side through the reaction force claws of the carcass and the cylinder hole is cut. In addition to forming a pilot hole for the cylinder hole, the gap between the pair of reaction force claws is formed with a size smaller than the diameter that becomes the opening end of the cylinder hole after the cutting process. When cutting the hole, the reacting portion side, the pair of the cutting tool by advancing the opposed surfaces of the reaction force claws to cutting while working side, it is characterized in that the cutting of the lower hole.
[0008]
In the second invention, a plurality of cylinder holes of the same diameter opened to the disk rotor side are arranged in parallel in the disk circumferential direction, and the action parts are opposed to each other with the disk rotor interposed therebetween, and both outer peripheral sides of each cylinder hole The reaction part provided with a plurality of reaction force claws so as to be opposed to each other, and the bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then adjacent to each other. In a caliper body manufacturing method for a vehicle disc brake in which each cutting hole is cut by allowing a cutting tool to enter the action part from the reaction part side through the reaction force claws, and when the caliper body is cast, In addition to forming a pilot hole for each cylinder hole, the interval between adjacent reaction claws is formed with a size smaller than the diameter that becomes the opening end of the cylinder hole after machining, and each pilot hole is formed into a cylinder hole. When cutting, the by advancing the cutting tool to the working unit side while cutting the opposing surfaces of the reaction force claws adjacent the reacting portion side, characterized by cutting each pilot hole.
[0009]
In the third invention, a plurality of cylinder holes of different diameters opened on the disk rotor side are arranged in parallel with each other in the circumferential direction of the disk, and the action parts are opposed to each other with the disk rotor interposed therebetween. After integrally forming a reaction portion provided with a plurality of reaction force claws so as to face each other on both sides of the outer periphery and a bridge portion connecting the reaction portion and the action portion across the outer periphery of the disk rotor by casting. In the caliper body manufacturing method for a disk brake for a vehicle, in which a cutting tool is entered from the reaction part side to the action part through the adjacent reaction force claws to cut each cylinder hole, the action is performed at the time of casting the caliper body. In addition to forming a pilot hole for each cylinder hole in the part, the interval between adjacent reaction claws is formed with the same dimension as the diameter of the opening end of the smallest cylinder hole after cutting, When forming the smallest cylinder hole among the Linda holes, a cutting tool is entered from the reaction part side to the action part side through the reaction force claw, the lower hole is cut, and a cylinder hole having a larger diameter than that is cut. Is formed, a cutting tool is advanced from the reaction part side to the action part side while cutting the opposing surface of the reaction force claw, and the pilot hole to be the large-diameter cylinder hole is cut. Yes.
[0010]
In the fourth invention, a plurality of cylinder holes of different diameters opened to the disk rotor side are arranged in parallel in the disk circumferential direction, and the action parts are opposed to each other with the disk rotor interposed therebetween, and both outer peripheral sides of each cylinder hole The reaction part provided with a plurality of reaction force claws so as to be opposed to each other, and the bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then adjacent to each other. In a caliper body manufacturing method for a vehicle disc brake in which each cutting hole is cut by allowing a cutting tool to enter the action part from the reaction part side through the reaction force claws, and when the caliper body is cast, In addition to forming a pilot hole for each cylinder hole, the interval between adjacent reaction force claws is formed with a size smaller than the diameter that becomes the opening end of the smallest cylinder hole after cutting. When cutting a hole into a cylinder hole, a cutting tool is entered from the reaction part side to the action part side while cutting the opposing surface of the adjacent reaction force claw, and each pilot hole is cut. It is said.
[0011]
Furthermore, in the fifth aspect of the present invention, the working portion formed with one cylinder hole opened on the disk rotor side is opposed to the working portion with the disk rotor interposed therebetween, and is disposed opposite to both sides of the outer periphery of the cylinder hole. In a caliper body of a vehicle disc brake in which a reaction portion provided with a pair of reaction force claws and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disc rotor are integrally formed by casting, The opposing surfaces of the pair of reaction force claws are cut and formed at the same interval as the diameter of the cylinder hole opening end cut by a cutting tool after casting.
[0012]
In the sixth invention, a plurality of cylinder holes of the same diameter opened on the disk rotor side are arranged in parallel in the disk circumferential direction, and the action parts are opposed to each other with the disk rotor interposed therebetween. A vehicle disk in which a reaction part provided with a plurality of reaction force claws so as to be opposed to each other and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting. The caliper body of the brake is characterized in that the opposing surface of the reaction force claw is cut and formed at the same interval as the diameter of the cylinder hole opening end cut by a cutting tool after casting.
[0013]
In the seventh invention, a plurality of cylinder holes of different diameters opened on the disk rotor side are arranged in parallel with each other in the circumferential direction of the disk, and the action parts are opposed to each other with the disk rotor interposed therebetween. A vehicle in which a reaction portion provided with a plurality of reaction force claws so as to face each other on both sides of the outer periphery, and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disk rotor are integrally formed by casting. In the caliper body of a disc brake, the opposing surfaces of the reaction force claws other than the reaction force nail facing surface corresponding to the smallest cylinder hole after cutting are cut by a cutting tool after casting. It is characterized by being cut and formed at the same interval as the diameter of the corresponding cylinder hole opening end.
[0014]
In the eighth invention, a plurality of cylinder holes of different diameters opened on the disk rotor side are arranged side by side in the circumferential direction of the disk, and the action parts are opposed to each other with the disk rotor interposed therebetween, and both outer circumferential sides of each cylinder hole A vehicle disk in which a reaction part provided with a plurality of reaction force claws so as to be opposed to each other and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting. In the caliper body of the brake, each opposing surface of the reaction force claw is cut and formed at the same interval as the diameter of the corresponding cylinder hole opening end cut by a cutting tool after casting.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. 1 to 4 show a first embodiment of the present invention. FIG. 1 is a sectional view taken along the line II in FIG. 2, FIG. 2 is a front view of the caliper body, and FIG. 3 is a sectional view taken along the line III-III in FIG. 4 and 4 are front views of a disc brake using the caliper body of FIG.
[0016]
The disc brake 1 according to the present embodiment includes a caliper bracket 4 fixed to a vehicle body on one side of a disc rotor 2 rotating in the direction of arrow A, and a caliper body 4 via a pair of sliding pins 5 and 5. A pair of friction pads 6, 6 are arranged opposite to each other with the disc rotor 2 interposed between the action portion 4 a and the reaction portion 4 b of the caliper body 4.
[0017]
The caliper body 4 includes an action portion 4a disposed on one side of the disk rotor 2, a reaction portion 4b disposed on the other side of the disk rotor 2, and the reaction portion 4b and the action portion 4a. This is a monocoque type in which a bridge portion 4c connected across the outer periphery of 2 is integrally cast, and three cylinder holes 7, 8, and 9 are arranged in parallel in the disk circumferential direction in the action portion 4a. Further, on the action portion 4a, mounting arms 4d and 4d are provided so as to project toward the inner side in the disk radial direction and toward the disk rotor delivery side, and are provided on the caliper bracket 3 and slide pins 5 projecting in the disk axial direction. The caliper body 4 is supported by the caliper bracket 3 so as to be movable in the disk axial direction.
[0018]
The cylinder holes 7, 8, 9 are formed in a bottomed cylindrical shape having an opening on the disk rotor 2 side. The cylinder holes 7, 7 having a large diameter and a deep bottom are formed on the disk delivery side and the disk delivery side of the action portion 4 a. 9 is disposed, and a shallow and small cylinder hole 8 is disposed in the center. The cylinder holes 7, 8 and 9 are respectively formed with seal grooves 7a, 8a and 9a for attaching piston seals and seal grooves 7b, 8b and 9b for attaching dust seals. Large-diameter and long pistons 10 and 12 are inside the large-diameter cylinder holes 7 and 9, and small-diameter and short pistons 11 are inside the small-diameter cylinder hole 8 via the piston seal and dust seal, respectively. In addition, a hydraulic chamber is defined at the bottom of each of the cylinder holes 7, 8, 9.
[0019]
The reaction portion 4 b is provided with four reaction force claws 13, 14, 15, and 16 so as to be opposed to both sides of the outer periphery of the cylinder holes 7, 8, 9. Reaction force claws 13, 14 on the outer periphery of the cylinder 7, reaction force claws 14, 15 on the outer periphery of the small diameter cylinder hole 8, and reaction force claws 15, 16 on the outer periphery of the large diameter cylinder hole 9 on the disk delivery side, respectively. It is arranged. When the reaction force claws 13, 14, 15, 16 are cast, the distance between the adjacent reaction force claws 13, 14, reaction force claws 14, 15, and reaction force claws 15, 16 is set at the opening end of the small-diameter cylinder hole 8. The opposing surfaces 14a and 15a of the pair of reaction force claws 14 and 15 that are formed at the same interval L1 as the diameter L1 and oppose the outer periphery of the small-diameter cylinder hole 8 are used at the interval L1 at the time of casting. The opposing surfaces 13a and 14b of the reaction force claws 13 and 14 that oppose the outer periphery of the large-diameter cylinder hole 7 are open ends of the large-diameter cylinder hole 7 by a cutting tool that cuts the large-diameter cylinder hole 7 after casting. Similarly, the opposing surfaces 15b, 16a of the reaction force claws 15, 16 corresponding to the outer periphery of the large-diameter cylinder hole 9 are formed in the large-diameter cylinder hole 9 after casting. It is cut at the same interval L2 as the diameter L2 of the open end of the large-diameter cylinder hole 9 by a cutting tool for cutting.
[0020]
Further, the pair of friction pads 6 and 6 disposed between the action part 4a and the reaction part 4b is configured such that a lining 6a that is in sliding contact with the side surface of the disk rotor 2 is joined to a metal back plate 6b. A hanger pin is inserted through the back plate 6b and is suspended so as to be movable in the disk axial direction.
[0021]
The hydraulic chamber communicates with the union hole through the communication hole, and when the driver performs a braking operation, the hydraulic fluid pressurized by a separate hydraulic master cylinder is supplied to each hydraulic chamber from the union hole, 10, 11 and 12 are pushed toward the disc rotor in the cylinder holes 7, 8 and 9, and the friction pad 6 on the acting portion 4 a side is pressed against one side of the disc rotor 2. Next, due to this reaction, the caliper body 4 is moved in the direction of the action part 4a while being guided by the sliding pins 5, 5, and the reaction force claws 13, 14, 15, 16 of the reaction part 4b are moved to the other friction pad 6. Is pressed against the other side of the disk rotor 2 to perform a braking action.
[0022]
5 and 6 show a second embodiment of the present invention. FIG. 5 is a cross-sectional view taken along line VV of FIG. 6, and FIG. 6 is a front view of the caliper body.
[0023]
The caliper body 20 of this embodiment is a monocoque type in which the bridge portion 20c that connects the action portion 20a and the reaction portion 20b across the outer periphery of the disk rotor 2 is integrally cast and molded, as in the first embodiment. In the portion 20a, three cylinder holes 21, 22, and 23 having the same diameter are provided side by side in the disk circumferential direction. The cylinder holes 21, 22, and 23 are formed in a bottomed cylindrical shape having an opening on the disk rotor 2 side, and deep bottom cylinder holes 21 and 23 are arranged on the disk feeding side and the disk feeding side of the action portion 20a. A shallow cylinder hole 22 is provided at the center. The diameters of the open ends of the cylinder holes 21, 22, 23 are larger than the diameter L1 of the open end of the small-diameter cylinder hole 8 of the first embodiment, and the open ends of the large-diameter cylinder holes 7, 9 are used. The diameter L3 is smaller than the diameter L2. Further, in each of the cylinder holes 21, 22, 23, seal grooves 21a, 22a, 23a for mounting piston seals and seal grooves 21b, 22b, 23b for mounting dust seals are formed, respectively.
[0024]
The reaction portion 20b is provided with four reaction force claws 24, 25, 26, and 27 so as to be opposed to both sides of the outer periphery of the cylinder holes 21, 22, 23, and the outer periphery of the cylinder hole 21 on the disk entry side. The reaction force claws 24, 25 are disposed on the outer periphery of the central cylinder hole 22, and the reaction force claws 26, 27 are disposed on the outer periphery of the cylinder hole 23 on the disk delivery side. When casting the reaction force claws 24, 25, 26, 27, the intervals between the adjacent reaction force claws 24, 25, the reaction force claws 25, 26, and the reaction force claws 26, 27 are set to the opening of the cylinder holes 21, 22, 23. The reaction force is reduced by a cutting tool that is formed with a dimension smaller than the diameter of the end, for example, the diameter L1 of the opening end of the small-diameter cylinder hole 8 of the first embodiment and cuts each cylinder hole 21, 22, 23 after casting. The opposing surfaces 24a, 25a of the claws 24, 25, the opposing surfaces 25b, 26a of the reaction force claws 25, 26, and the opposing surfaces 26b, 27a of the reaction force claws 26, 27 are openings of the cylinder holes 21, 22, 23. It is cut at the same interval as the end diameter L3.
[0025]
Next, a method for manufacturing both the above caliper bodies will be described. 7 is a cross-sectional view taken along the line VII-VII in FIG. 8, and FIG. 8 is a front view of the caliper body at the time of casting in which the reaction part, the action part, and the bridge part are integrally formed. 7 and FIG. 8 are formed by cutting the caliper body 30 after casting.
[0026]
The caliper body 30 at the time of casting is formed by integrally casting the action part 30a, the reaction part 30b, and the bridge part 30c using a metal material such as an aluminum alloy or cast iron. Lower holes 31, 32, 33 to be the cylinder holes 7, 8, 9 are formed, and the reaction portion 30 b has original claws 34, 35, 36, 37 to be the reaction force claws 13, 14, 15, 16 after cutting. Is formed. The former claws 34, 35, 36, and 37 are adjacent to the former claws 34 and 35, the former claws 35 and 36, and the gap between the former claws 36 and 37 are small diameter cylinder holes, for example, the opening ends of the cylinder holes 8 of the first embodiment. Is set to the same dimension L1 as the diameter L1.
[0027]
A cutting tool for forming a cylinder hole is positioned on the opposite side of the disk claw 34, 35, 36, 37 of the original claw formed in this way, and the cutting claw is moved toward the disk rotor so that the original claw 34, 35 is moved. The cutting tool is inserted into the lower holes 31, 32, 33 of the action portion 30a between the opposing surfaces 34a, 35a, the opposing surfaces 35b, 36a of the original claws 35, 36, and between the original claws 36b, 37a. 32 and 33 are cut to a predetermined depth with a predetermined diameter, and are respectively cut into cylinder holes having a required dimensional accuracy.
[0028]
When manufacturing the caliper body 4 of the first embodiment, the distance between the adjacent original claws 34, 35, the original claws 35, 36, and the original claws 36, 37 of the original claws 34, 35, 36, 37 is a small diameter cylinder after processing. Since the diameter L1 is the same as the diameter L1 of the opening end of the hole 8, when the small-diameter cylinder hole 8 is formed, the cutting tool for forming the cylinder hole 8 is used as an anti-disk of the original claws 35 and 36. Positioned on the rotor side, the cutting tool is passed through between the opposing surfaces 35b, 36a of the original claws 35, 36. Then, the cutting tool is moved in the direction of the disk rotor without cutting the facing surfaces 35b and 36a, the lower hole 32 is cut to the diameter L1 of the opening end of the cylinder hole 8, and the seal grooves 8a and 8b are further cut. A cylinder hole 8 is formed.
[0029]
On the other hand, when the lower holes 31 and 33 are cut to form the cylinder holes 7 and 9 having a diameter larger than that of the cylinder hole 8, the cutting tools for forming the cylinder holes 7 and 9 are used as the original claws 34, 35, and 36. 37, the cutting tool is inserted into the lower holes 31, 33 while cutting the opposing surfaces 34a, 35a of the original claws 34, 35 and the opposing surfaces 36b, 37a of the original claws 36, 37. The lower holes 31 and 33 are opened to the cylinder holes 7 and 9 while cutting between the opposed surfaces 34a and 35a and the opposed surfaces 36b and 37a to the diameter L2 of the opening ends of the cylinder holes 7 and 9 by the cutting tool. Cutting to the end diameter L2 and further cutting the seal grooves 7a, 7b, 9a, 9b respectively to form the cylinder holes 7, 9. As a result, the caliper body 4 of the first embodiment shown in FIGS. 1 to 4 is formed.
[0030]
When manufacturing the caliper body 20 according to the second embodiment, cutting is performed in which cylinder holes 21, 22, and 23 are formed on the non-disc rotor side of the original claws 34, 35, 36, and 37 of the caliper body 30 after casting. The tool is positioned, and the cutting tool is moved in the direction of the disk rotor, between the opposed surfaces 34a and 35a of the original claws 34 and 35, between the opposed surfaces 35b and 36a of the original claws 35 and 36, and opposed to the original claws 36 and 37. A cutting tool is inserted into the prepared holes 31, 32, 33 of the acting portion 30 a from between the surfaces 36 b, 37 a.
[0031]
At this time, the distance between the adjacent original claws 34, 35, the original claws 35, 36, and the original claws 36, 37 of the original claws 34, 35, 36, 37 is the diameter L1 of the opening end of the small diameter cylinder hole 8 of the first embodiment. Therefore, when the cylinder holes 21, 22, and 23 having a diameter larger than that of the cylinder hole 8 are formed, the distance between the opposed surfaces 34a and 35a and the distance between the opposed surfaces 35b and 36a are defined. The cutting tool is inserted into the lower holes 31, 32, 33 while cutting the gaps between the facing surfaces 36 b, 37 a to the diameter L 3 of the open ends of the cylinder holes 21, 22, 23. The cylinder holes 21, 22, and 23 are cut to the diameter L3 of the open ends, and the seal grooves 21a, 21b, 22a, 22b, 23a, and 23b are cut to form the cylinder holes 21, 22, and 23, respectively. As a result, the caliper body 20 of the second embodiment shown in FIGS. 5 and 6 is formed.
[0032]
By manufacturing the caliper bodies 4 and 20 by the method as described above, the caliper bodies 4 and 20 can be manufactured by using one casting mold. Further, if the blade of the cutting tool is changed, the cylinder holes 7, 8, 9, 21, 22, 23 of the caliper bodies 4, 20 can be formed using the same cutting tool, thereby reducing the cost. be able to. Furthermore, when making the diameters of the three cylinder holes all the same as the diameter L1 of the small cylinder hole 8, the original claws 34, 35, 36, 37 at the time of casting can be used as they are without being cut.
[0033]
The present invention is not limited to the above-described embodiment, and can also be applied to a monocoque type caliper body having a single cylinder hole. A reaction force claw is formed in the reaction portion at intervals equal to the diameter of the lower hole. Thereby, when cutting the lower hole into the cylinder hole, the cutting tool can enter the action portion side while cutting the opposing surface of the reaction force claw, and a cylinder hole with a desired diameter can be formed. Several types of caliper bodies with different diameters of cylinder holes can be manufactured using a single casting mold.
[0034]
Further, the number of cylinder holes is not limited to three as in each of the above-described embodiments, and can be applied to two or three or more. The diameter of the cylinder hole can also be set in various ways, and according to the diameter of the smallest cylinder hole set in advance, the distance between the cylinder hole of the caliper body and the reaction force claw during casting is set, and cutting If the number of cylinder holes is the same, the caliper body having cylinder holes of various diameters can be manufactured with one casting mold.
[0035]
【The invention's effect】
As described above, according to the present invention, several types of caliper bodies having cylinder holes with different diameters can be formed using the same casting mold as long as the number of cylinder holes is the same. Costs can be reduced by increasing the versatility of the mold. Furthermore, even when the cylinder holes are adjacent to each other, it is possible to suppress an increase in the cast shape on the reaction part side for escaping the machining of the cylinder holes, and it is possible to ensure the thickness of the reaction force claw.
[Brief description of the drawings]
1 is a cross-sectional view taken along the line II in FIG. 2. FIG. 2 is a front view of the caliper body showing the first embodiment of the present invention. FIG. 3 is a cross-sectional view taken along the line III-III in FIG. Fig. 5 is a front view of a disc brake to which a caliper body of one embodiment is applied. Fig. 5 is a cross-sectional view taken along line VV of Fig. 6. Fig. 6 is a front view of a caliper body showing a second embodiment of the present invention. VII-VII cross-sectional view of FIG. 8 is a front view of a caliper body at the time of casting in which a reaction part, an action part, and a bridge part are integrally formed.
DESCRIPTION OF SYMBOLS 1 ... Disc brake, 2 ... Disc rotor, 4 ... Caliper body, 4a ... Action part, 4b ... Reaction part, 4c ... Bridge part, 6 ... Friction pad, 7, 8, 9, 21, 22, 23 ... Cylinder hole, 10, 11, 12 ... cylinder hole, 13, 14, 15, 16, 24, 25, 26, 27 ... reaction force claw, 30 ... caliper body during casting, 31, 32, 33 ... pilot hole, 34, 35, 36, 37 ... original nails

Claims

A working portion in which one cylinder hole opened on the disc rotor side is formed, and a pair of reaction force claws are provided so as to face the working portion with the disc rotor interposed therebetween and to be opposed to both sides of the outer periphery of the cylinder hole. The reaction part and the bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then the action part is inserted from the reaction part side through the pair of reaction force claws. In a caliper body manufacturing method for a disk brake for a vehicle in which a cutting tool is inserted into the caliper body, a pilot hole for the cylinder hole is formed in the action portion during casting of the caliper body, and a pair of reaction The gap between the force claws is formed with a dimension smaller than the diameter that becomes the opening end of the cylinder hole after cutting, and when the lower hole is cut into the cylinder hole, from the reaction part side The pair of the cutting tool by advancing the opposed surfaces of the reaction force claws to cutting while working side, the caliper body manufacturing method for a vehicle disc brake, characterized in that the cutting of the lower hole.

A plurality of cylinder holes of the same diameter opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk, with the disk rotor sandwiched between the working parts, and opposed to both sides of the outer periphery of each cylinder hole. A reaction part provided with a plurality of reaction force claws and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then between adjacent reaction force claws. In the caliper body manufacturing method of a vehicle disc brake for cutting each cylinder hole by causing a cutting tool to enter the action part from the reaction part side through the pilot hole of each cylinder hole in the action part when casting the caliper body And the distance between adjacent reaction claws is smaller than the diameter of the opening end of the cylinder hole after cutting, and each pilot hole is cut into a cylinder hole. And manufacturing a caliper body for a disc brake for a vehicle, characterized in that a cutting tool is inserted into the action part side while cutting the opposing surface of the reaction force claw adjacent from the reaction part side to cut each pilot hole. Method.

A plurality of cylinder holes of different diameters opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk with the disk rotor sandwiched between them. A reaction part provided with a plurality of reaction force claws and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then between adjacent reaction force claws. In a caliper body manufacturing method for a disc brake for a vehicle, in which a cutting tool is made to enter the working part from the reaction part side through the working part, and when the caliper body is cast, the pilot hole of each cylinder hole is inserted into the working part. The distance between the adjacent reaction claws is formed with the same dimension as the diameter of the opening end of the smallest cylinder hole after cutting. When forming the cylinder hole, the cutting tool is inserted from the reaction part side through the reaction force claw to the action part side to cut the lower hole, and when forming a larger diameter cylinder hole, the reaction A disk brake for a vehicle, wherein a cutting tool is advanced toward the working part side while cutting the opposing surface of the reaction force claw from the part side to cut the pilot hole that becomes the large-diameter cylinder hole. Caliper body manufacturing method.

A plurality of cylinder holes of different diameters opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk with the disk rotor sandwiched between them. A reaction part provided with a plurality of reaction force claws and a bridge part that connects the reaction part and the action part across the outer periphery of the disk rotor are integrally formed by casting, and then between adjacent reaction force claws. In the caliper body manufacturing method of a vehicle disc brake for cutting each cylinder hole by causing a cutting tool to enter the action part from the reaction part side through the pilot hole of each cylinder hole in the action part when casting the caliper body And the distance between adjacent reaction claws is smaller than the diameter that becomes the opening end of the smallest cylinder hole after cutting, and each cylinder hole is formed into a cylinder hole. A vehicle disc characterized in that when cutting, a cutting tool is advanced from the reaction part side to the action part side while cutting the opposing surface of the adjacent reaction force claw to cut each prepared hole. Brake caliper body manufacturing method.

A working portion in which one cylinder hole opened on the disc rotor side is formed, and a pair of reaction force claws are provided so as to face the working portion with the disc rotor interposed therebetween and to be opposed to both sides of the outer periphery of the cylinder hole. In the caliper body of a vehicle disc brake in which a reaction portion and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disc rotor are integrally formed by casting, the pair of reaction force claws are opposed to each other. A caliper body for a disk brake for a vehicle, wherein the surface is cut and formed at the same interval as the diameter of the cylinder hole opening end machined by a cutting tool after casting.

A plurality of cylinder holes of the same diameter opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk, with the disk rotor sandwiched between the working parts, and opposed to both sides of the outer periphery of each cylinder hole. In a caliper body of a vehicle disc brake in which a reaction portion provided with a plurality of reaction force claws and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disc rotor are integrally formed by casting, A caliper body for a disc brake for a vehicle, wherein the opposing surface of the reaction force claw is cut and formed at the same interval as the diameter of a cylinder hole opening end machined by a cutting tool after casting.

A plurality of cylinder holes of different diameters opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk with the disk rotor sandwiched between them. In a caliper body of a vehicle disc brake in which a reaction portion provided with a plurality of reaction force claws and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disc rotor are integrally formed by casting, Among the reaction force claws, each corresponding surface of the reaction force claw other than the reaction surface of the reaction force claw corresponding to the smallest cylinder hole after cutting is cut into a corresponding cylinder hole by a cutting tool after casting. A caliper body for a disc brake for a vehicle, wherein the caliper body is cut at the same interval as the end diameter.

A plurality of cylinder holes of different diameters opened on the disk rotor side are opposed to each other in such a manner that they are arranged in parallel in the circumferential direction of the disk with the disk rotor sandwiched between them. In a caliper body of a vehicle disc brake in which a reaction portion provided with a plurality of reaction force claws and a bridge portion that connects the reaction portion and the action portion across the outer periphery of the disc rotor are integrally formed by casting, A caliper body for a disk brake for a vehicle, wherein each opposing surface of the reaction force claw is cut and formed at the same interval as the diameter of the corresponding cylinder hole opening end cut by a cutting tool after casting. .