JP2007064380A - Method of manufacturing steel plate-support for disc brake - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a support of high accuracy, having the desired shape and free from a connecting portion for connecting a rotor rotating-in side and a rotor rotating-out side at an outer side end portion. <P>SOLUTION: A raw plate 20a comprising a base plate portion 13a and a pair of arm portions 14b, 14b extending from circumferential both end portions of the base plate portion 13a is manufactured by punching out a steel plate. A part near the base plate portion 13a of the raw plate 20a is pressed down by a first upper die and a first lower die 31 of a bending device 29. Tip parts of the pair of arm portions 14b, 14b are bent while being pressed to an upper face of a second lower die 33 of the bending device. In the bending work, a receiving member 42 fixed to the second lower die 33 is placed between the tip portions of both arm portions 14b, 14b, thus deformation of the tip portions of the arm portions 14b, 14b is controlled. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an improvement in a manufacturing method of a sheet metal support which is manufactured by subjecting a sheet metal to bending by press working or the like among the supports constituting a disc brake used for braking an automobile.

  Various types of disc brakes used for braking automobiles have been known in the past, but those using a sheet metal support made by bending a sheet metal such as a thick steel sheet reduce cost and weight. Research is being promoted from the aspect of achieving this. FIGS. 13 to 16 show one described in Patent Document 1 as an example of a disc brake incorporating such a sheet metal support. First, this conventional structure will be briefly described.

  The disc brake is configured such that a caliper 3 is attached to a support 2 fixed to a suspension device in a state adjacent to a rotor 1 that rotates together with wheels, and a pair of guide pins 4a and 4b is used to move the caliper 3 in the axial direction (see FIG. 13). It is supported so as to be freely displaceable in the vertical direction and the horizontal direction in FIG. The support 2 includes an outer pad 5a on the outer side (outer side in the vehicle width direction) and an inner pad 5b on the inner side (center side in the vehicle width direction) across the rotor 1 in the axial direction of the rotor 1. Supports displaceability. Further, the front end surface (left end surface in FIG. 14) of the piston 7 fitted to the cylinder portion 6 of the caliper 3 is abutted against the pressure plate 8b constituting the inner pad 5b, and is brought into contact with the outer side end portion of the caliper 3. The inner side surface of the formed caliper claw 9 is brought into contact with the pressure plate 8a constituting the outer side pad 5a.

  When braking is performed, the inner pad 5 b is pressed against the side surface of the rotor 1 by the piston 7 by feeding pressure oil into the cylinder portion 6. As a reaction of this pressing, the caliper 3 is displaced toward the inner side, so that the caliper claw 9 presses the outer side pad 5 a against the side surface of the rotor 1. As a result, the rotor 1 is strongly held from both sides by the linings 10a and 10b of the pair of pads 5a and 5b, and braking is performed. The braking torque applied to the pads 5a and 5b due to the friction between the linings 10a and 10b and the rotor 1 during the braking is supported by the pressure plates 8a and 8b of the pads 5a and 5b. 2 is supported.

  In the case of the conventional structure constructed and operated as described above, all of the braking torque transmitted to each of the pads 5a and 5b is transferred to the rotation side of the rotor 1 in the support 2 (at the front in the rotational direction of the rotor 1). For example, when the rotor 1 rotates in the direction of arrow α in FIG. Therefore, in order to ensure the strength and rigidity of the outlet side portion, the outer end of the support 2 is connected to the inlet side (the rotor 1 rotates in the direction of the arrow α in FIG. In this case, a connecting portion 11 is provided to connect the both ends on the delivery side.

  In the case of the above-described conventional sheet metal support for disc brakes, the connection portion 11 is provided at the outer end of the support 2, so that not only the yield of the thick steel plate as the material is deteriorated, but also the installation space of the disc brake is reduced. Causes it to become bulky. For example, FIG. 17 shows a base plate 12 made of sheet metal that constitutes a support having the same shape as the support 2 described above. The base plate 12 is formed in a ring shape by punching a sheet metal, and a substrate portion 13 provided at one end (the lower end in FIG. 17) and the rotor 1 of the substrate 13 (see FIGS. 13 and 14). ) In the circumferential direction (left and right direction in FIG. 17), a pair of arm portions 14 and 14 provided in both ends extending in the same direction, and the tip ends of these arm portions 14 and 14 (the upper end in FIG. 17) Part) which is connected to each other. Among these, the board | substrate part 13 becomes an inner side attaching part for attaching to a vehicle body. Further, a pair of outer pad support portions 16 and 16 for supporting the outer pad 5a (see FIGS. 13 and 14) are provided at both ends of the connecting portion 11. Such a base plate 12 forms an intermediate material having an overall L shape by bending the first half of each of the arms 14 and 14 at the chain line portion of FIG. This intermediate material forms a pair of first screw holes 17 (see FIG. 16) for bolt connection to be attached to the vehicle body at both ends in the circumferential direction of the rotor 1 of the board portion 13, and each arm portion 14. , 14 is formed with a pair of second screw holes 18 (see FIGS. 13, 15, and 16). Then, the base end portions of the guide pins 4a and 4b (see FIGS. 13, 15, and 16) are coupled and fixed to the second screw holes 18 to complete the support.

  In the case of the base plate 12 shown in FIG. 17, there is a connecting portion 11 that connects the pair of arm portions 14 and 14 to the other end portion (upper end portion in FIG. 17) serving as an outer side end portion. For this reason, since the connecting portion 11 is provided, the yield of the material is deteriorated, which causes an increase in cost. Further, the presence of the connecting portion 11 requires a large space for installing the disc brake, and the layout (degree of freedom of arrangement) becomes severe.

  Under such circumstances, conventionally, the base plate 12 shown in FIG. 17 described above is omitted in which the connecting portion 11 that connects the end portions that are the outer side end portions of the pair of arm portions 14 and 14 is omitted. It is considered to make a sheet metal support. 18-20 has shown the support 19 described in patent document 2, and the base plate 20 and the intermediate | middle raw material 21 for obtaining this support 19 among the sheet-metal supports made from such a base plate. First, the support 19 shown in FIG. 18 is integrally formed by bending a sheet metal such as a thick steel plate, and the substrate portion 13a and a pair of inner pad support portions 24 and 24, respectively. The connecting plate portions 22 and 22 and the protruding plate portions 23 and 23 are provided. Of these, the board portion 13a is formed with first screw holes 17 for mounting bolts for fixing to the vehicle body.

  The pair of inner pad support portions 24, 24 are formed at two positions in the circumferential middle portion of the substrate portion 13a in a state where the outer peripheral edge side of the substrate portion 13a is opened. The inner pad support portions 24, 24 are formed with locking notches 25, 25 symmetrical to each other. The locking notches 25 and 25 formed at both ends of the pressure plate 8b constituting the inner pad 5b are inserted into the locking notches 25 and 25, respectively. With this configuration, the inner pad 5b is supported with respect to the support 19 so as to be displaceable in the axial direction of the rotor 1 (see FIGS. 13 and 14) and to support the braking torque applied to the inner pad 5b during braking. .

  Further, each of the connecting plate portions 22 and 22 is bent from the outer peripheral edge portion at both end portions in the circumferential direction of the substrate portion 13a to the outer side (the front side in FIG. 19). The inner peripheral surfaces of the plate portions 22 and 22 are opposed to the outer peripheral edge of the rotor 1. And each said protrusion board part 23, 23 is extended in the direction which mutually approaches from the front-end | tip part of these each connection board part 22 and 22. As shown in FIG. Further, locking grooves 27, 27 are formed on the outer peripheral edges of the protruding plate portions 23, 23, respectively. The outer pad 5a can be displaced in the axial direction of the rotor 1 by engaging the hooks 28, 28 provided at both ends of the pressure plate 8a constituting the outer pad 5a. Moreover, the braking torque applied to the outer pad 5a during braking is supported in a freely supporting manner.

  Further, the caliper 3 (see FIGS. 13 and 14) is supported on the support 19 so as to be displaceable in the axial direction of the rotor 1. For this purpose, a pair of guide pins 4a and 4b (see FIGS. 13, 15 and 16) are formed in the second screw holes 18 and 18 formed at both ends of the rotor 3 on the rotor 1 entrance side and on the exit side. Screw and fix the base end. And the guide cylinder part provided in a part of caliper 3 is externally fitted to these guide pins 4a and 4b so that the displacement of the rotor 1 in the axial direction is possible.

  Next, the manufacturing method of the support 19 will be described with reference to FIGS. In order to manufacture the support 19, first, a base plate 20 as shown in FIG. 19 is manufactured by stamping and forming a sheet metal such as a thick steel plate. The base plate 20 has a shape corresponding to the substrate portion 13 a and the inner pad support portions 24, 24. Further, a pair of arm portions 14a and 14a, which respectively constitute the connecting plate portions 22 and 22 and the protruding plate portions 23 and 23 (see FIG. 18), are provided at both ends in the circumferential direction of the base plate 20, They extend in the same direction.

  Next, the intermediate material 21 shown in FIG. 20 is obtained by bending the portions shown by chain lines a and b in FIG. 19 at a right angle. That is, by this bending, a pair of connecting plate portions 22 and 22 bent at right angles from the outer peripheral edges of both ends of the portion corresponding to the substrate portion 13a, and the end portions of these connecting plate portions 22 and 22 are mutually connected. An intermediate material 21 having a pair of protruding plate portions 23 and 23 extending in the approaching direction is obtained. Then, the projecting plate portions 23, 23 are formed in a desired shape on the intermediate material 21, and press working is performed to form the engaging grooves 27, 27 in the projecting plate portions 23, 23. This pressing is performed by holding the portion between the upper die and the lower die while suppressing the front end surface of the portion corresponding to each of the protruding plate portions 23, 23 by the stationary die. Finally, the first and second screw holes 17 and 18 (FIG. 18) are formed in the substrate portion to obtain a finished product of the support 19 as shown in FIG.

As described above, when the support 19 is manufactured by the base plate 20 that does not connect the tip portions of the pair of arm portions 14a and 14a by the connecting portion, this bending process is generally performed conventionally. If performed in the same manner as the manufacturing method, a part of the base plate 20 may be greatly deformed into an undesired shape. For this reason, as shown in FIG. 19 described above, the support 19 having a desired shape is accurately obtained by the base plate 20 that does not connect the distal ends of the pair of arm portions 14a and 14a by the connecting portion 11 (see FIG. 17). It ’s difficult to build well. For example, the portion near the substrate portion 13a of the base plate 20 shown in FIG. 19 is sandwiched between the upper die and the lower die constituting the mold, and the portion near the tip of the pair of arm portions 14a, 14a is lowered. It is considered to bend the portions near the tip by pressing down the portions near the substrate portion 13a while pressing against the upper surface of the mold. In this case, if no special consideration is given to the mold, the chain line i (FIG. 19), which is the starting point of bending, is a linear shape close to an arc along the outer periphery of the rotor 1 (see FIGS. 13 and 14). Therefore, if it is bent at the chain line a part, the part indicated by B in the figure will enter inside. For this reason, the portions closer to the tip shown in FIG. Then, the portions near the tip of the pair of arm portions 14a, 14a are deformed so as to incline toward the substrate portion 13a side in the directions indicated by arrows c and c in FIG. Moreover, the amount of deformation at the tip end portion is not constant, and it is difficult to perform a finishing process on this portion thereafter. When the tip portions of the pair of arm portions 14a and 14a are deformed into an undesired shape in this way, the locking grooves 27 and 27 are processed with high accuracy in the protruding plate portions 22 and 22 of the obtained support 19. Since this makes it difficult, there is a possibility that the projecting plate portions 22 and 22 may not be able to favorably support both end portions of the pressure plate 8a constituting the outer pad 5a. This causes the yield to deteriorate in the conventional sheet metal support manufacturing method. In addition, it has been conventionally considered that a line (a chain line a in FIG. 19) serving as a starting point of the bending is an arc having a shape along the outer periphery of the rotor 1. However, also in this case, a portion near the tip of the pair of arm portions 14a, 14a enters inside.
As prior art documents related to the present invention, there are Patent Documents 3 and 4 in addition to Patent Documents 1 and 2.

Japanese Utility Model Publication No. 52-80839 JP 2002-295538 A JP-A-57-6138 JP-A-52-72067

  In view of such circumstances, the manufacturing method of the disk brake sheet metal support according to the present invention can reduce the size and cost of the sheet metal support having a desired shape without providing a connecting portion at the outer side end. It was invented to realize well.

The method of manufacturing a sheet brake support for a disc brake according to the present invention supports an outer pad and an inner pad on both sides of a rotor rotating together with a wheel so as to be axially displaceable, and presses both the pads against both sides of the rotor. The caliper of the rotor is supported to be displaceable in the axial direction of the rotor, and is formed to support the inner pad on the board portion provided adjacent to one side of the rotor to be attached to the vehicle body. The inner pad support portion, a pair of connecting plate portions extending from the both circumferential ends of the substrate portion to the other side beyond the outer peripheral edge portion of the rotor, and the tip portions of the connecting plate portions approach each other. It is a manufacturing method of the sheet-metal-support for disk brakes provided with a pair of protrusion board part extended in the direction.
And in the manufacturing method of the sheet brake support for disc brakes of the present invention, a pair of substrate parts formed by punching the sheet metal and a pair extending in the same direction at both circumferential ends of the substrate part. In order to form each of the connecting plate portion and each protruding plate portion by a part of the base plate provided with the arm portion, when bending the pair of arm portions, The receiving member disposed between the two restricts the deformation of both arms.
In the present specification and claims, “circumferential direction” refers to the circumferential direction of the rotor unless otherwise specified, and “axial direction” refers to the axial direction of the rotor unless otherwise specified. In the specification, “radial direction” refers to the radial direction of the rotor unless otherwise specified.

In the case of the method for manufacturing a disc brake sheet metal support of the present invention configured as described above, the outer side end of the sheet metal support to be obtained is connected to the rotor turn-in side (rotary direction rear side of the rotor) and the rotor rotation. There is no need to provide a connecting portion that connects the outlet side (the front side in the rotational direction of the rotor). For this reason, the cost of the disc brake provided with the sheet metal support can be reduced as much as the connecting portion can be omitted, and the installation space can be effectively used.
Moreover, in the case of the present invention, such a sheet metal support can be made efficiently and accurately. That is, when bending the base plate, in order to regulate the deformation of the tip of the arm portion by the receiving member arranged between the tip portions of the pair of arm portions, in the obtained sheet metal support, Deviations from the desired shape of the tip of each arm can be minimized. For this reason, a sheet metal support can be made efficiently and accurately. In addition, in order to obtain such a sheet metal support, it is only necessary to provide a receiving member part on either the upper mold or the lower mold used in the conventional manufacturing method, and the manufacturing cost can be reduced. It will never be expensive.

Preferably, when carrying out the present invention, preferably, as described in claim 2, the receiving member is a receiving part integrally coupled and fixed to a lower mold used in the bending process, and at the time of bending process, The receiving portion is disposed between the tip portions of the pair of arm portions, and the arm portions are bent while sliding the side surfaces of the both arm portions on both side surfaces of the receiving portion.
According to this preferable configuration, the sheet metal support can be manufactured more efficiently and accurately.

  FIGS. 1-10 has shown Example 1 of the manufacturing method of the metal brake support for disk brakes of this invention. The feature of the present embodiment is that the flat plate 20a (FIG. 2) for constituting the sheet metal support 19a (FIG. 1) is bent to form a circumferential direction (left and right in FIGS. 1 to 3). Direction) The point is that the method for producing the intermediate material 21a (FIG. 3) in which both ends are bent into a substantially L shape is devised. The structure of the finished product of the support 19a is substantially the same as the support 19 of the conventional structure shown in FIG. 18, and the basic structure of the base plate 20a and the intermediate material 21a is also shown in FIGS. This is almost the same as the conventional manufacturing method. Accordingly, the same parts as those of the base plate 20 and the intermediate material 21 manufactured by the conventionally known manufacturing method shown in FIGS. 18 to 20 described above are denoted by the same reference numerals, and redundant description is omitted or simplified. The description will focus on the features of the present embodiment and the portions different from the conventionally known manufacturing method shown in FIGS.

  First, the support 19a obtained by the manufacturing method of this embodiment shown in FIG. 1 will be described. This support 19a is formed integrally by bending a sheet metal such as a thick steel plate, like the support 19 having the conventional structure shown in FIG. 18, and relates to the rotor 1 (see FIGS. 13 and 14). A substrate portion 13a provided on the inner side, a pair of connecting plate portions 22, 22 and protruding plate portions 23, 23 are provided. Further, an inner pad support portion that can lock both ends of the pressure plate 8b (see FIGS. 13, 14, and 18) constituting the inner pad 5b on a portion near the outer periphery of the substrate portion 13a (portion near the upper end in FIG. 1). 24a and 24a are provided. The braking torque applied to the inner pad 5b from the rotor 1 (see FIGS. 13 and 14) during braking is the inner side surface of each of the inner pad support portions 24a and 24a (the surfaces on the sides facing each other between the inner pad support portions 24a and 24a). ) Is supported by the support 19. The inner pad support portions 24a, 24a have locking grooves formed on the outer peripheral surface (upper side surface of FIG. 1) of the substrate portion 13a, and both ends of the pressure plate 8b of the inner pad 5b are formed in these locking grooves. It is also possible to lock the collar provided on the part. On the other hand, locking grooves 27a, 27a are formed on the outer peripheral surfaces (upper side surfaces of FIG. 1) of the protruding plate portions 23, 23 provided on the outer side (front side of FIG. 1). 27a, the flange portions 28, 28 of the pressure plate 8a constituting the outer pad 5a can be locked.

  In the case of the present embodiment in order to obtain the support 19a as described above, the support 19a is manufactured as follows. First, a base plate 20a as shown in FIG. 2 is manufactured by stamping and forming a sheet metal such as a thick steel plate. The base plate 20a has a shape corresponding to the substrate portion 13a and the inner pad support portions 24a and 24a. In addition, a pair of arm portions 14b and 14b, which respectively constitute the connecting plate portions 22 and 22 and the protruding plate portions 23 and 23 (see FIG. 1), are arranged at both ends in the circumferential direction of the base plate 20a. They extend in the same direction. Further, a pair of inner pad support portions 24a and 24a are provided at both ends in the circumferential direction of the substrate portion 13a so as to protrude in the same direction in a stepped manner.

  Next, the intermediate material 21a shown in FIG. 3 is bent by bending the arc-shaped portion along the outer circumference of the rotor 1 (see FIGS. 13 and 14) indicated by chain lines a and b in FIG. To do. That is, by this bending process, a pair of connecting plate portions 22 and 22 bent substantially at right angles from the outer peripheral edges of both ends of the portion corresponding to the substrate portion 13a, and the tip portions of these connecting plate portions 22 and 22 are formed. An intermediate material 21a having a pair of protruding plate portions 23, 23 extending in a direction approaching each other is obtained. For this reason, in the case of the present embodiment, a bending apparatus 29 as shown in FIGS. 4 to 8 is used. The bending apparatus 29 includes a first upper mold 30 and a first lower mold 31 that face each other in the vertical direction, and a second upper mold 32 and a second lower mold 33 that face each other in the vertical direction. . Among these, the first upper mold 30 and the first lower mold 31 have a function of sandwiching a portion of the base plate 20a close to the substrate portion 13a. The first upper mold 30 is movable up and down together with a support portion 37 (FIG. 8) provided above. On the other hand, the first lower mold 31 is supported on the upper surface of the base 34 so as to be movable up and down via an elastic member 35 that can expand and contract in the vertical direction. The elastic member 35 includes a spring, and the spring force is set high in order to cope with the bending force. The lower end of the elastic member 35 is fixed to a groove 58 provided on the upper surface of the base 34.

  Further, the upper surface of the first lower mold 31 is shaped so that the portion of the base plate 20a close to the substrate portion 13a can be installed without rattling. That is, the first wall 53 is placed on one end (the right end in FIGS. 4 to 6 and 8) of the upper surface of the first lower mold 31 and the length of the other end (the right end in FIGS. 4 to 6 and 8). A second wall portion 54 is formed at the center in the vertical direction (the vertical direction in FIGS. 4 and 6 and the front and back direction in FIGS. 5 and 8). Further, a concave portion 56 into which a pair of protrusions 55, 55 provided on the base end portion of the base plate 20a can be inserted on one side of the first wall portion 53 (the left side surface in FIGS. 4 to 6 and 8). 56 is formed. Of the upper surface of the first lower mold 31, the portion that is removed from the first and second wall portions 53, 54 is a mounting surface 41 on which the portion closer to the substrate portion 13 a can be mounted. While the second wall portion 54 is inserted into the concave portion 57 provided in the substrate portion 13a, a portion close to the substrate portion 13a is installed on the placement surface 41, and the first lower side of the base plate 20a is placed. The displacement with respect to the mold 31 is restricted by the first and second wall portions 53 and 54.

  On the other hand, the second upper mold 32 has a pair of leg portions 36, 36 projecting downward, and is movable up and down together with the support portion 37 (FIG. 8). The lower surfaces of these leg portions 36 and 36 are first inclined surfaces 38 and 38 that are inclined in a direction away from the first upper mold 30 and the first lower mold 31 toward the tip with respect to the horizontal direction. . The second lower mold 33 is supported on the upper surface of the base 34 so as to be able to move in the horizontal direction with respect to the first lower mold 31, and is on one side (the left side of FIGS. 4 to 6 and 8). ) A pair of second inclined surfaces 39, 39 are formed on the upper surface, each of which is parallel to the first inclined surfaces 38, 38 and inclined with respect to the horizontal direction. With such a configuration, when the first inclined surfaces 38, 38 and the second inclined surfaces 39, 39 are engaged with each other as the second upper mold 32 is lowered, both the inclined surfaces are engaged. By pressing the surfaces 38 and 39 together, the second lower mold 33 moves in a direction approaching the first lower mold 31 (rightward in FIGS. 4 to 6 and 8). That is, the first and second inclined surfaces 38 and 39 function as cam surfaces. Further, an inclined surface 40 is formed on the upper surface of the other side of the second lower mold 33 (the right side in FIGS. 4 to 6 and 8) so as to be closer to the first lower mold 31 as it goes downward. The inclined surface 40 is substantially orthogonal to a virtual plane provided on the upper surface of the first lower mold 31 and including the mounting surface 41 on which the base plate 20a can be installed.

  In particular, in the case of the present embodiment, the width direction of the portion where the inclined surface 40 is formed on the other upper surface of the second lower mold 33 (the vertical direction in FIGS. 4 and 6 and the front and back directions in FIGS. 5 and 8). A receiving member 42 serving as a receiving portion is coupled and fixed to the central portion. The receiving member 42 has a rectangular parallelepiped shape, and is integrally coupled and fixed to the second lower mold 33 by a fastening member such as a bolt. Then, both side surfaces of the receiving member 42 in the width direction (the vertical direction in FIGS. 4 and 6 and the back and front direction in FIGS. 5 and 8) are flat surfaces 43 and 43 parallel to each other. For example, when a bolt is used as the fastening member, the tip of the bolt inserted into a through hole (not shown) that penetrates the receiving member 42 in the thickness direction is formed on the second lower mold 33 (not shown). The receiving member 42 is integrally coupled and fixed to the second lower mold 33 by screwing and tightening into the screw hole.

Further, the interval (the total length in the width direction) L ₄₂ (FIG. 4) between the flat surfaces 43 and 43 of the receiving member 42 is the interval between the inner side surfaces of the pair of arm portions 14b and 14b of the base plate 20a. It is slightly smaller than L _14b (FIG. 2) (L ₄₂ <.L _14b ) For example, the mounting surface 41 provided on the upper surface of the first lower mold 31 is closer to the substrate portion 13a of the base plate 20a. In a state where the receiving member 42 is located between the inner side surfaces of the tip end portions of the pair of arm portions 14b, 14b of the base plate 20a, the inner side surfaces and the flat surfaces 43 of the receiving member, 43 are opposed to each other through a gap of 0.1 mm or less.

  The bending operation of the base plate 20a by the bending apparatus 29 configured as described above is performed as follows. First, in a state where the first upper mold 30 and the first lower mold 31 are separated in the vertical direction, a portion of the material 20a near the substrate portion 13a is placed on the placement surface 41 of the first lower mold 31. Install. Further, the receiving member 42 coupled and fixed to the second lower mold 33 is positioned between the tip portions of the pair of arms 14b and 14b of the material 20a. In this state, the first upper mold 30 is lowered, and the material 20a is sandwiched between the first upper mold 30 and the first lower mold 31 and pressed. Along with this, the first lower mold 31 is lowered. The first upper mold 30 and the first lower mold 31 sandwich the material 20a slightly later, and the second upper mold 32 is lowered so that the first and second The inclined surfaces 38 and 39 are pressed against each other, and the second lower mold 33 is moved toward the first lower mold 31. As a result, the first half of the pair of arm portions 14b and 14b of the base plate 20a is pressed against the upper surface of the second lower mold 33, and the portion of the base plate 20a closer to the substrate portion 13a is the first upper portion. It is pushed down by the mold 30 and the first lower mold 31. The pair of arm portions 14b, 14b are bent into a substantially L shape along the chain line a portion of FIG. 2, and as shown in FIG. 8, a pair of connecting plate portion 22 and protruding plate portion 23 are paired. It becomes the intermediate material 21a provided with. It should be noted that the chain line A, which is the starting point of bending, may be a straight line as shown in FIG. 19 instead of an arc shape as shown in FIG.

  In addition, along with such bending processing, a force is applied in a direction in which the inner side surfaces of the tip end portions of the pair of arm portions 14b, 14b approach each other because they are bent at right angles along the chain line a portion. Then, these inner side surfaces are in sliding contact with the respective flat surfaces 43, 43 of the receiving member 42 while moving relative to each other in a linear direction or a curved direction, or a combination thereof. Thereby, the deformation of the tip portions of the arm portions 14 b and 14 b is restricted by the receiving member 43. Further, with the first and second upper molds 30 and 32 reaching the lowest point (bottom dead center) of the stroke, as shown in FIG. The base plate 20a including the tip portion of the protruding plate portion 23 is pressed between the upper surfaces of the two lower molds 33, and the tip portions of the protruding plate portions 23 are corrected to a desired shape. Then, as described above, the distal end portions of the respective arm portions 14b and 14b are deformed during bending, and the inner side surfaces of the respective distal end portions are brought into sliding contact with the respective flat surfaces 43 and 43 of the receiving member 42. The inner surface of the tip of the protruding plate part 23 maintains the accuracy of each other.

  In this way, the material 20a is bent at both ends in the circumferential direction by the bending device 29, and includes a pair of connecting plate portions 22, 22 and protruding plate portions 23, 23 as shown in FIG. Intermediate material 21a. After bending, the first upper mold 30 and the second upper mold 32 are raised to their original positions, and the second lower mold 33 is also moved away from the first lower mold 31. 21a can be easily removed from the bending apparatus 29. After the second upper mold 32 is raised, the second lower mold 33 is pulled leftward in FIG. 8 by a moving mechanism (not shown) provided with a tension spring.

  Next, in the next step, this intermediate material 21a is subjected to press forming to form the locking grooves 27a, 27a (FIG. 1) on the protruding plate portions 23, 23, and the second intermediate material 52 (FIG. 9, 10). That is, this press work is for forming a locking groove 27a as shown in FIG. 9 in each protruding plate portion 23, 23 of the intermediate material 21a shown in FIG. 3, as shown in FIG. The protruding plate portions 23 are sandwiched between the pressing die 44 and the receiving die 45 to press the protruding plate portions 23. Further, at the time of this press working, the front end surface (the right side surface in FIGS. 9 and 10) of each protruding plate portion 23 is suppressed by the stationary mold 46. The stationary mold 46 and the receiving mold 45 can be integrated.

  Further, in the case of the present embodiment, the pressing portion 47 for forming the locking grooves 27a is formed on one side (the lower surface in FIG. 10) of the pressing die 44 facing the protruding plate portions 23. is doing. Further, a concave portion 48 is formed on one side of the receiving mold 45 (the upper surface in FIG. 10) at a portion facing the pressing portion 47 with the protruding plate portions 23 interposed therebetween. Further, the volume in the recess 48 is substantially the same as or slightly smaller than the volume of the portion of the push portion 47 where the locking groove 27a is formed (portion shown in FIG. 10). The volume of the portion of the pressing portion 47 that forms the locking groove 27a is 0-5% smaller). Further, the dimensions of the pressing portion 47 and the concave portion 48 in the thickness direction (front and back direction in FIG. 10) of the pressing die 44 and the receiving die 45 are substantially the same. When the locking grooves 27 a are formed, the protruding plate portions 23 are pressed between the pressing mold 44 and the receiving mold 45. Accordingly, each of the protruding plate portions 23 is plastically deformed by the pressing portion 47, and the radial direction of the rotor 1 (see FIG. 9) is formed on the outer peripheral surface (the upper surface of FIGS. 9 and 10) which is one side of each of the protruding plate portions 23. 9 and 10 in the vertical direction) is formed. At the same time, a protrusion 49 is formed on the inner peripheral surface (the lower surface in FIGS. 9 and 10), which is the other surface opposite to the locking groove 27a of each protruding plate portion 23. The protrusion 49 enters the recess 48 of the receiving mold 45. As a result, the volume of the locking groove 27a of each protruding plate portion 23 and the volume of each protruding portion 49 (the volume of the portion indicated by the diagonal lattice in FIG. 10) are substantially the same.

  In this way, the second intermediate material 52 in which the locking groove 27a is formed in each projecting plate portion 23 is formed in the first and second screw holes 17 (FIG. By forming only the screw hole 17 and omitting the illustration of the second screw hole, a finished product of the support 19a shown in FIG. 1 is obtained. When such a support 19a is used, the flange portions 28, 28 formed at both ends of the pressure plate 8a constituting the outer pad 5a are displaced in the locking grooves 27a of the protruding plate portions 23 in the axial direction of the rotor 1. Lock freely. The braking torque applied to the outer pad 5a during braking can be supported on the support 19a by the flanges 28 and 28 and the locking grooves 27a and 27a. Further, both end portions of the pressure plate 8b (see FIGS. 13 and 14) constituting the inner pad 5b are engaged with the inner pad support portions 24a and 24a so as to be displaceable in the axial direction of the rotor 1. The board portion 13a is coupled and fixed to the vehicle body by bolts that are screwed into and tightened into the first screw holes 17 and 17 formed in the board portion 13a of the support 19a, and the caliper is fixed to the second screw hole. The base end portions of guide pins 4a and 4b (see FIGS. 13 and 14) for supporting 3 are coupled and fixed. Since the structure and operation of this part are well known in the art including the structures shown in FIGS. 13 to 14 described above, detailed illustration and description thereof will be omitted.

In the case of the method for manufacturing the disc brake sheet metal support of the present invention configured as described above, the rotor 19 is inserted into the outer side end (front side end in FIG. 1) of the obtained support 19a. No need to provide a connecting portion for connecting the rear side in the rotational direction) and the first outlet side of the rotor (the front side in the rotational direction of the rotor 1). For this reason, the cost of the disc brake provided with the support 19a can be reduced and the installation space can be effectively used as much as the connecting portion can be omitted.
Moreover, in the case of the present invention, such a support 19a can be made efficiently and accurately. That is, when the base plate 20a is bent, deformation of the tip portions of the arm portions 14b and 14b is restricted by the receiving member 42 disposed between the tip portions of the pair of arm portions 14b and 14b. For this reason, in the obtained support 19a, the deviation from the desired shape of the tip portions of the respective arm portions 14b and 14b can be made small. For this reason, the support 19a can be manufactured efficiently and accurately. For example, when the base plate 20a is bent, when the bending device 29 shown in FIGS. 4 to 8 described above, in which the second lower mold 33 is not provided with the receiving member 42, the bending is performed. Along with the processing, the pair of arm portions 14b and 14b of the base plate 20a is deformed so that the tip portions approach the substrate portion 13a side. In this case, the front ends of the protruding plate portions 23 and 23 are inclined in a C shape, and it is difficult to accurately form the locking grooves 27a and 27a in the protruding plate portions 23 and 23.

  Further, in the case of the present embodiment, in order to obtain a finished product of the support 19a as described above, the receiving member 42 is simply provided on the second lower mold 33 used in the conventional manufacturing method. It does not increase the manufacturing cost.

  In the case of this embodiment, the receiving member 42 is integrally coupled and fixed to the second lower mold 33 used for the bending process, and at the time of the bending process, the pair of arm portions 14b, 14b These arm portions 14b and 14b are bent while sliding the side surfaces of both arm portions 14b and 14b on both side surfaces of the receiving member 42 disposed between the tip portions. For this reason, the support 19a can be made more efficiently and accurately.

  Further, in the case of the present embodiment, a pair of connecting plate portions 22, 22 and protruding plate portions 23, 23 are formed by bending a pair of arm portions 14b, 14b of the base plate 20a. After that, when the projecting plate portions 23 and 23 are pressed between the pressing die 44 and the receiving die 45 to form the locking grooves 27a, the pressing portion 47 of the pressing die 44 is used as the receiving die 45. Are used in which a concave portion 48 is formed in a portion opposite to. Further, the volume in the recesses 48 is the same as or slightly smaller than the volume of the portions of the push portions 47 that form the locking grooves 27a. Then, by pressing the projecting plate portions 23 and 23 between the pressing mold 44 and the receiving mold 45, the inner surfaces of the projecting plate portions 23 and 23 on the opposite side to the locking grooves 27a are provided. A protrusion 49 is formed on the peripheral surface. For this reason, the accuracy of the locking grooves 27a among the protruding plate portions 23 and 23 is improved, the accuracy of engagement of the outer pad 5a with the flange portion 28 is improved, and the braking torque is smoothly transmitted to the support 19a. it can. Further, it is possible to prevent the thickness of the portion where the locking groove 27a is formed from becoming excessively small. In addition, it is possible to reduce the pressing force when pressing the protruding plate portions 23 and 23 between the pressing die 44 and the receiving die 45. For this reason, the lifetime of the metal mold | die used for the operation | work of this press can be improved, and the manufacturing cost per unit of the support 19a can be reduced. Further, since the applied pressure can be reduced, the accuracy of the overall shape including the inner side and the outer side of the support 19a can be increased, and the yield can be improved.

  In addition, in the case of simple coining that has been generally performed in the past, a part of the work piece is pressurized and the thickness of this part is reduced. Internal strain (deformation) may remain over a long period of time. On the other hand, in the case of the present embodiment, since the locking groove 27a is formed as described above, the accuracy of the locking groove 27a is improved, and the engagement accuracy with the outer pad 5a is also improved. The braking torque is smoothly transmitted to the support 19a. Further, it is possible to suppress the internal strain from remaining in the product, and to improve the shape accuracy of the entire product, thereby improving the reliability. Moreover, since it can prevent that the thickness of each protrusion board part 23 which is a to-be-processed part becomes too small, and it does not need to trim in a post process, the fibrous structure of sheet metal, such as a steel plate obtained by rolling The flow is not cut off. For this reason, it can prevent that the intensity | strength of the outer side edge part of the support 19a falls. For example, when each of the locking grooves 27 is processed by a simple coining process that is generally performed conventionally, the flatness of the side surface in the thickness direction of the substrate portion 13a of the support 19a is 1.9 to 2.1 mm. There is a possibility that the center part is deformed to the inner side (the side opposite to the rotor 1). In this case, the dimension of each locking groove 27a in the axial direction of the rotor 1 may be reduced, and the manufacturing error may be as large as 0.7 mm.

  Note that the shapes of the locking grooves 27a and the protrusions 49 formed in each protruding plate portion 23 are not limited to the shapes shown in FIGS. 1, 9, and 10 described above. For example, FIG. It can also be set as various shapes like the locking groove 27b-27d of 3 examples of another example shown to (c), and convex part 49a-49c.

  Next, FIG. 12 shows a method for manufacturing a sheet metal support according to the second embodiment of the present invention. In the case of this embodiment, by punching out three positions of one rectangular sheet metal 50, each has the same shape as the base plate 20a constituting the support 19a described in the first embodiment. Individual base plates 51a to 51c are made. Each of these base plates 51a to 51c has the same shape. Further, in the case of the present embodiment, a portion of the sheet metal 50 in which the two element plates 51a and 51c of the element plates 51a to 51c are punched is defined as the width direction of the sheet metal 50 (the horizontal direction in FIG. 12). ) At the same position and at positions separated in the length direction (vertical direction in FIG. 12), the shapes are oriented in the same direction.

  And between the part which punches out the said 2 base plates 51a and 51c among the said sheet metal 50 regarding the length direction, it is set as the part which punches the remaining base plates 51b. This remaining base plate 51b is made by punching out a shape of the sheet metal 50 that faces in a direction different from the portion where the two base plates 51a and 51c are punched. Further, one of the two base plates 51a and 51c (the lower side in FIG. 12) is provided between the portions to be the pair of arm portions 24a and 24a of the portion for punching the remaining base plate 51b. One of the parts to be punched 51c (right side in FIG. 12) is made to enter the part that becomes the arm part 14b. That is, the portions to be the arm portions 14b and 14b of the remaining base plate 51b and the one base plate 51c are overlapped in the width direction of the sheet metal 50, and the portions to be the arm portions 14b and 14b are The portions that become the remaining base plate 51b and the portions that become the one base plate 51c are alternately positioned in the width direction. The three base plates 51a to 51c obtained by punching the sheet metal 50 in this way are subjected to bending processing, pressing processing, and the like in the subsequent process, so that the three supports 19a (refer to FIG. 1). Completed product. Of course, it is also possible to make a finished product of two supports 19a and four supports 19a from the sheet metal 50.

According to such a present Example, unlike the case where a plurality of base plates having the same shape are formed by punching out the same shape in the same direction among the rectangular sheet metals 50, the sheet metal 50 is wasted. The area of the portion can be made sufficiently small, and the yield can be improved. That is, in the case of punching out the same shape in the same direction among the sheet metal 50, it is necessary to increase the lengthwise dimension of the sheet metal 50, and between the pair of arm portions 14b, 14b. The material in the middle is wasted. On the other hand, in the case of the present embodiment, it is possible to reduce the waste of the material between the portions that become the pair of arm portions 14b, 14b of the at least two base plates 51b, 51c.
Since other configurations and operations are the same as those in the first embodiment, the same reference numerals are given to the same parts, and overlapping illustrations and descriptions are omitted.

  It should be noted that, as in the present embodiment, the present invention is not limited to the case where three supports 19a are made from one sheet metal 50, and many supports 19a can be made continuously from a long sheet metal 50 in a roll shape. For example, as shown by a two-dot chain line d in FIG. 12, when the sheet metal 50 is formed into a roll-shaped sheet metal having a long sheet metal connected to the upper and lower sides of the sheet metal 50, the sheet Of the three base plates 51a to 51c, a pair of arm portions 14b constituting the base plate 51a in the opposite direction to the uppermost base plate 51a, that is, in the same direction as the base plate 51b. , 14b, and another part of the base plate is punched out so that one arm part thereof enters between the parts. Further, the portions that become the base plate are sequentially combined on the upper side so that the directions are alternately reversed. Thus, when a plurality of base plates are made of the rectangular metal plate 50, the yield can be further improved.

The figure which shows the support obtained by the manufacturing method of Example 1 of this invention in the state combined with the outer pad. The figure which shows the base plate produced first in order to comprise the support shown in FIG. The figure which shows the intermediate material obtained by performing a bending process to this base plate. The schematic plan view which shows the lower mold | type part of the bending apparatus for obtaining this intermediate material in the state which installed the base plate. AA sectional drawing of FIG. The perspective view which looked at a part of lower mold part of the above-mentioned bending device from the upper part. The perspective view which looked at a part of 2nd upper mold | type and 2nd lower mold | type from the left of FIG. 6 similarly. The figure similar to FIG. 5 which shows the last stage of the bending process in the case of bending a base plate with the said bending apparatus. FIG. 3 is an enlarged view corresponding to a portion B in FIG. 1 showing a state in which a locking groove is formed in the protruding plate portion of the intermediate material to obtain a second intermediate material. The same figure as FIG. 9 which shows the state which press-processes to a protrusion board part in order to form this latching groove. The figure similar to FIG. 9 which shows three examples of the another shape of the latching groove | channel and protrusion which form in a protrusion board part. The figure which shows the sheet metal for punching three positions and making three base plates in the manufacturing method of Example 2 of this invention. The figure which cut | disconnected a part of one example of the conventional structure of a disc brake, and was seen from the outer-diameter side. CC sectional drawing of FIG. The figure which took out only the support of FIG. 13 and was seen from the outer diameter side. The figure seen from the inner side equivalent to the downward direction of FIG. The figure which shows the base plate which connected the front-end | tip parts of a pair of arm part by the connection part first made in order to comprise the support similar to the support of FIG. The figure which shows the support of another example of a prior art example combining outer and an inner pad. The figure which shows the base plate made first in order to comprise the support of FIG. The figure which shows the intermediate material obtained by performing a bending process to this base plate.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rotor 2 Support 3 Caliper 4a, 4b Guide pin 5a Outer pad 5b Inner pad 6 Cylinder part 7 Piston 8a, 8b Pressure plate 9 Caliper claw 10a, 10b Lining 11 Connection part 12 Base plate 13, 13a Substrate part 14, 14a, 14b Arm Part 16 Outer pad support part 17 First screw hole 18 Second screw hole 19, 19a Support 20, 20a Base plate 21, 21a, 21b Intermediate material 22 Connection plate part 23 Projection plate part 24, 24a Inner pad support part 25 Engagement Notch 26 Locking hook part 27, 27a to 27d Locking groove 28 Hook part 29 Bending device 30 First upper mold 31 First lower mold 32 Second upper mold 33 Second lower mold 34 Base 35 Elastic member 36 Leg 37 Support portion 38 First inclined surface 39 Second inclined surface 40 Inclined surface 41 Mounting surface 42 Receiving member 43 Flat surface 44 Pushing die 45 Receiving die 46 Stationary die 47 Pushing portion 48 Recessed portion 49, 49a to 49c Protruding portion 50 Sheet metal 51a to 51c Base plate 52 Second intermediate material 53 First wall portion 54 First Second wall 55 Projection 56 Recess 57 Recess 58 Groove

Claims (2)

The outer pad and the inner pad are supported on both sides of the rotor rotating together with the wheels so as to be axially displaceable, and calipers for pressing these pads against both side surfaces of the rotor are supported so as to be displaceable in the axial direction of the rotor, A board part provided adjacent to one side of the rotor for mounting on the vehicle body, an inner pad support part formed to support the inner pad on the board part, and both circumferential ends of the board part A pair of connecting plate portions extending to the other side from the outer peripheral edge portion of the rotor, and a pair of projecting plate portions extending in a direction approaching each other from the front end portions of the two connecting plate portions. A method for manufacturing a sheet metal support for a disc brake comprising:
Each of the connecting plate portions and the base plate portion formed by punching a sheet metal, and a part of a base plate provided with a pair of arm portions extending in the same direction at both circumferential ends of the substrate portion. A disc brake that restricts deformation of both arms by means of a receiving member arranged between the tips of the arms when bending the pair of arms to form each protruding plate Method for sheet metal support.   The receiving member is a receiving part that is integrally coupled and fixed to a lower mold that is used in bending, and at the time of bending, the receiving part is disposed between the tip ends of the pair of arm parts. 2. The method for manufacturing a sheet brake support for a disc brake according to claim 1, wherein each arm portion is bent while sliding side surfaces of both arm portions on both side surfaces of the receiving portion.

Images