JP4486796B2

JP4486796B2 - Caliper body manufacturing method and caliper body for disc brake for vehicle

Info

Publication number: JP4486796B2
Application number: JP2003192812A
Authority: JP
Inventors: 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: 2010-06-23
Anticipated expiration: 2023-07-07
Also published as: JP2005030419A

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、車両用ディスクブレーキのキャリパボディ製造方法に関する発明は、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それぞれ対向配置される複数の反力爪を設けた反作用部と、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、前記作用部に各シリンダ孔の下孔を形成するとともに前記反作用部に前記複数の反力爪となる複数の元爪を、隣接する元爪のそれぞれの間隔を切削加工後に最も小さい径の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、最も小さい径のシリンダ孔を形成するときに、隣接する元爪の対向面間を切削することなく鋳造時の間隔のまま切削工具を通して作用部側へ進入させて、前記最も小さい径のシリンダ孔となる下孔を切削加工して最も小さい径のシリンダ孔を形成し、それよりも大径のシリンダ孔を形成するときに、反作用部側から隣接する元爪の対向面を切削工具で切削しながら作用部側へ進入させて、前記大径のシリンダ孔となる下孔を切削加工して前記最も小さい径のシリンダ孔よりも大径のシリンダ孔を形成することを特徴としている。
【０００８】
車両用ディスクブレーキのキャリパボディに関する発明は、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それぞれ対向配置される複数の反力爪を設けた反作用部と、該反作用部と前記作用部とをディスクロ一夕の外周を跨いで連結するブリッジ部とを一体に形成した鋳造成形時のキャリバボディを、前記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において、前記作用部に鋳造形成された各シリンダ孔の下孔と、切削加工後の最も小さい径のシリンダ孔の開口端の径と同一の寸法の間隔で前記反作用部に鋳造形成された各反力爪の元爪とを、反作用部側から隣接する元爪の間を通して作用部側へ進入させた切削工具にて、隣接する元爪の対向面を切削することなく鋳造時の間隔のまま通して最も小さい径のシリンダ孔となる下孔を切削加工して最も小さい径のシリンダ孔を形成し、かつ、最も小さい径のシリンダ孔よりも大径のシリンダ孔に切削加工されるシリンダ孔の開口端の径と同一の間隔にて前記大径のシリンダ孔に対応する各元爪の対向面を切削加工するとともに前記大径のシリンダ孔となる各下孔を切削加工して複数の異径のシリンダ孔を形成したことを特徴としている。
【００１５】
【発明の実施の形態】
以下、本発明の一形態例を図１乃至図４に基づいて説明する。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、参考例を示すもので、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】
この参考例のキャリパボディ２０は、上述の形態例と同様、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、上述の形態例及び参考例の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】
上述の形態例における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】
上述の形態例に関するキャリパボディ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に示される一形態例のキャリパボディ４が形成される。
【００３０】
上述の参考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、上述の一形態例の小径シリンダ孔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に示される参考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、上述の一形態例のキャリパボディ４や参考例のキャリパボディ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のシリンダ孔７，８，９やキャリパボディ２０のシリンダ孔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、参考例のように、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。
【００３４】
さらに、シリンダ孔の数は上述の一形態例のように、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の下穴や反力爪の元爪の間隔を設定し、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】本発明の一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】本発明の一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】参考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…シリンダ孔、１０，１１，１２…ピストン、１３，１４，１５，１６…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, an invention relating to a caliper body manufacturing method for a vehicle disc brake includes a working portion in which a plurality of different-diameter cylinder holes opened on the disc rotor side are arranged in parallel in the disc circumferential direction, and the working portion. The reaction portion provided with a plurality of reaction force claws arranged opposite to each other on both sides of the outer periphery of each cylinder hole, and the reaction portion and the action portion are connected across the outer periphery of the disk rotor. A caliper body for a disc brake for a vehicle, in which the bridge portion is integrally formed by casting, and then the cylinder hole is cut by allowing the cutting tool to enter the action portion from the reaction portion side through the adjacent reaction claws. In the method
During casting of the caliper body, a plurality of source claws serving as the plurality of Hanchikaratsume to the reaction portion together to form a pilot hole for each cylinder bore to the working portion, each of the spacing between adjacent Mototsume When the cylinder hole with the smallest diameter among the plurality of cylinder holes is formed, the opposing surface of the adjacent original claw is formed with the same diameter as the diameter that becomes the opening end of the cylinder hole with the smallest diameter after machining. Enter the working part side through the cutting tool at the casting interval without cutting the gap, and cut the pilot hole that becomes the cylinder hole with the smallest diameter to form the cylinder hole with the smallest diameter. When the cylinder hole with a larger diameter is formed, the opposing surface of the adjacent original claw is cut from the reaction part side to the action part side while cutting with a cutting tool, and the lower hole to be the large diameter cylinder hole is formed. the smallest diameter by cutting It is characterized by forming a cylinder bore having a diameter larger than the cylinder bore.
[0008]
The invention relating to the caliper body of the disk brake for a vehicle has a working portion in which a plurality of cylinder holes of different diameters opened on the disc rotor side are arranged in parallel in the circumferential direction of the disc, and the working portion with the disc rotor interposed therebetween, A reaction part provided with a plurality of reaction force claws arranged opposite to each other on both sides of the outer periphery of the cylinder hole, and a bridge part that connects the reaction part and the action part across the outer periphery of the discrete device are integrally formed. In the caliper body of the disc brake for a vehicle in which the cutting tool is inserted into the action part from the reaction part side through the reaction force claws and the cylinder hole is machined, the caliper body at the time of casting is cast in the action part. Each of the reaction holes cast into the reaction portion is spaced at the same interval as the diameter of the opening of the cylinder hole having the smallest diameter after machining and the diameter of the cylinder hole having the smallest diameter after machining. With the cutting tool in which the original nail of the nail is moved from the reaction part side to the action part side through the adjacent original nail, the opposite surface of the adjacent original nail is passed through the gap at the time of casting without cutting. The lower end of the cylinder hole that is the smallest diameter is cut to form the smallest diameter cylinder hole, and the opening end of the cylinder hole is cut to a larger diameter than the smallest diameter cylinder hole. A plurality of cylinders with different diameters are formed by cutting the opposed surfaces of the respective original claws corresponding to the large-diameter cylinder holes at the same intervals as the diameters of the cylinders, and cutting the pilot holes serving as the large-diameter cylinder holes. It is characterized by the formation of holes .
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 1 is a cross-sectional view taken along the line II of FIG. 2, FIG. 2 is a front view of the caliper body, FIG. 3 is a cross-sectional view taken along the line III-III of FIG. is there.
[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 reference example. FIG. 5 is a VV cross-sectional view of FIG. 6, and FIG. 6 is a front view of the caliper body.
[0023]
The caliper body 20 of this reference example 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 above-described 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. Diameter of the open end of each cylinder bore 21, 22 and 23, a larger diameter than the diameter L1 of the opening end of the small-diameter cylinder bore 8 of the above form Tairei, the large-diameter cylinder hole 7 and 9 open end of the 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, the caliper body manufacturing method of the above-described embodiment and reference example 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 in the above-described embodiment 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. Are formed with lower holes 31, 32, 33 which become cylinder holes 7, 8, 9 after cutting, and the reaction part 30 b has original nails 34, which become reaction force claws 13, 14, 15, 16 after cutting. 35, 36, and 37 are 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 related to the above-described 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 after processing. Since the cylinder hole 8 is formed to have the same dimension L1 as the diameter L1 of the open end of the cylinder hole 8, when the small-diameter cylinder hole 8 is formed, the cutting tool for forming the cylinder hole 8 is moved against the original claws 35 and 36. It is located on the disk rotor side, and the cutting tool is passed 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 one embodiment shown in FIGS. 1 to 4 is formed.
[0030]
When manufacturing the caliper body 20 of the above-described reference example , cutting is performed in which cylinder holes 21, 22, and 23 are formed on the side opposite to the disc rotor 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 equal to the opening end of the small-diameter cylinder hole 8 of the above-described embodiment. Since it is formed in the same dimension L1 as the diameter L1, when forming the cylinder holes 21, 22, 23 having a diameter larger than that of the cylinder hole 8, between the opposing surfaces 34a, 35a, the opposing surfaces 35b, 36a and the opposing surfaces 36b, 37a are cut into the diameters L3 of the open ends of the cylinder holes 21, 22, 23, respectively, and a cutting tool is inserted into the lower holes 31, 32, 33, so that the lower holes 31, 32, 33 is cut to the diameter L3 of the opening end of the cylinder holes 21, 22, 23, and the seal grooves 21a, 21b, 22a, 22b, 23a, 23b are cut to form the cylinder holes 21, 22, 23, respectively. . Thereby, the caliper body 20 of the reference example shown in FIGS. 5 and 6 is formed.
[0032]
By manufacturing the caliper body 4 of the above-described embodiment and the caliper body 20 of the reference example by the method as described above, the caliper bodies 4 and 20 can be manufactured by using one casting mold. Further, by changing the blade of the cutting tool, the cylinder holes 7 , 8 , 9 of the caliper body 4 and the cylinder holes 21, 22, 23 of the caliper body 20 can be formed using the same cutting tool. Reduction can be achieved. Further, as in the reference example, when the diameters of the three cylinder holes are all the same as the diameter L1 of the small cylinder hole 8, the original claws 34, 35, 36, and 37 at the time of casting are not cut. It can be used as it is.
[0034]
Furthermore, the number of cylinder holes is not limited to three as in the above-described one embodiment, but can be applied to two or three or more. The diameter of the cylinder hole can also be set in various ways , and the distance between the pilot hole of the cylinder hole of the caliper body and the original nail of the reaction force claw at the time of casting molding according to the diameter of the smallest cylinder hole set in advance When the number of cylinder holes is the same, caliper bodies having cylinder holes of various diameters can be manufactured with a single 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 portion side for escaping the machining of the cylinder holes, and it is possible to secure the thickness of the reaction force claw.
[Brief description of the drawings]
[1] One embodiment of a front view of the caliper body showing one embodiment of a I-I section view of FIG. 2 [2] The present invention FIG. 3 III-III sectional view of FIG. 4 [4] The present invention Front view of the disc brake to which the caliper body of the example is applied. [FIG. 5] Cross-sectional view of VV in FIG. 6 [FIG. 6] Front view of the caliper body showing a reference example . 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 ... Cylinder hole, 10, 11, 12 ... Piston , 13, 14, 15, 16 ... reaction force claw, 30 ... caliper body during casting, 31, 32, 33 ... lower hole, 34, 35, 36, 37 ... original claw

Claims

A plurality of cylinder holes of different diameters opened to the disk rotor side are opposed to each other in a circumferential direction of the disk, with the disk rotor sandwiched between the action 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 for a vehicle disc brake in which the cutting tool is made to enter the working part from the reaction part side through the cutting part, and the caliper body is cast and formed, the pilot hole of each cylinder hole is inserted into the working part. a plurality of source claws serving as the plurality of Hanchikaratsume to the reaction portion together to form a opening of the cylinder bore of the smallest diameter of each of the intervals after cutting of adjacent Mototsume Formed in the same size as the diameter at, among the plurality of cylinder holes, when forming a cylinder bore of the smallest diameter, while the spacing of the casting without cutting between opposing surfaces of the original nail adjacent cutting When entering the working part side through a tool, cutting the pilot hole that becomes the cylinder hole with the smallest diameter to form the cylinder hole with the smallest diameter, and when forming a cylinder hole with a larger diameter than that, While cutting the opposing surface of the adjacent nail from the reaction part side to the action part side with a cutting tool, the pilot hole that becomes the large-diameter cylinder hole is cut to make a smaller hole than the cylinder hole with the smallest diameter. A caliper body manufacturing method for a vehicle disc brake, characterized in that a large-diameter cylinder hole is formed .

A plurality of cylinder holes of different diameters opened to the disk rotor side are opposed to each other in a circumferential direction of the disk, with the disk rotor sandwiched between the action parts, and opposed to both sides of the outer periphery of each cylinder hole. A caliber body at the time of casting molding in which 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 an outer periphery of a disco evening are integrally formed. In the caliper body of the disc brake for a vehicle that cuts the cylinder hole by causing a cutting tool to enter the action part from the reaction part side through the force claws, a pilot hole for each cylinder hole cast and formed in the action part, The original nail of each reaction force nail cast and formed on the reaction part at an interval having the same dimension as the diameter of the opening end of the cylinder hole with the smallest diameter after the cutting process is provided between the adjacent nail from the reaction part side. Through With the cutting tool that has entered the working side, the opposite diameter of the adjacent original claw is cut without cutting the pilot hole that becomes the smallest cylinder hole through the gap at the time of casting. Each corresponding to the large-diameter cylinder hole at the same interval as the diameter of the open end of the cylinder hole that is machined into a larger-diameter cylinder hole than the smallest-diameter cylinder hole. A caliber body for a disc brake for a vehicle, wherein a plurality of cylinder holes having different diameters are formed by cutting a facing surface of the original claw and cutting each pilot hole to be the large-diameter cylinder hole .