JP4877756B2 - Manufacturing method of disc brake sheet metal support - Google Patents

Description

  The present invention relates to an improvement in a manufacturing method of a sheet metal support that is manufactured by bending a metal plate by pressing 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 metal plate such as a thick steel plate are costly and heavy. Research is being carried out from the aspect of reduction. 10 to 13 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 with a wheel, and a pair of guide pins 4a and 4b is used to axially move the caliper 3 (see FIG. 10). A displacement in the vertical direction (left and right direction in FIG. 11) is supported. The support 2 has an outer side (outside in the vehicle width direction) pad 5 a and an inner side (in the center side in the vehicle width direction) pad 5 b across the rotor 1, and the axial displacement of the rotor 1. I support it. Further, the tip end face (left end face in FIG. 11) 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 the outer end of the caliper 3 is placed. The inner surface of the caliper claw 9 formed in the portion is brought into contact with the pressure plate 8a constituting the outer 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 the pressing, the caliper 3 is displaced toward the inner side, so that the caliper claw 9 presses the outer pad 5a 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.

  Patent Document 2 describes a sheet metal support 11 as shown in FIGS. 14 to 17 and a disk brake incorporating the sheet metal support 11 as shown in FIGS. 14 to 17 as a disk brake sheet metal support that can be efficiently and accurately manufactured. Yes. The sheet metal support 11 is integrally formed by bending and forming a metal plate having sufficient rigidity such as a thick steel plate, and each of the substrate portion 12 and the inner pad storage portion 13 includes a pair. The connecting plate portions 14a and 14b, the protruding plate portions 15a and 15b, and the locking portions 16a and 16b are provided. Of these, the substrate portion 12 is for attaching the sheet metal support 11 to the vehicle body (a holding member such as a knuckle constituting the suspension device), and both circumferential ends on the radially inner end side (the lower side in FIG. 15). Screw holes 17 and 17 for screwing bolts for fixing to the vehicle body are formed in the left and right ends).

  The inner pad storage portion 13 is formed in the intermediate portion in the circumferential direction of the substrate portion 12 as described above so that the outer peripheral edge side of the substrate portion 12 is open. With respect to the rotational direction of the rotor 1, such an inner pad storage portion 13 enables the displacement of the pressure plate 19 constituting the inner pad 18 in the axial direction of the rotor 1 (front and back direction in FIG. 16) and braking. It is supported to support the braking torque applied to the inner pad 18 at times. For this purpose, symmetrical notches 20 and 20 are formed at both ends of the inner pad storage portion 13, and the locking protrusions 21 are formed at the openings of the both notches 20 and 20. , 21 are formed. At both ends of the pressure plate 19 of the inner pad 18 supported by the inner pad storage portion 13, the engagement notches 20 and 20 and the engagement protrusions 21 and 21 can be engaged. Stopping portions 22 and 22 are formed. The inner pad 18 can be displaced in the axial direction of the rotor 1 in the inner pad storage portion 13 in a state in which the locking hooks 22 and 22 are inserted into the locking notches 20 and 20, respectively. I support it.

  Each of the connecting plate portions 14a and 14b is bent outward from the outer peripheral edge portions at both ends in the circumferential direction of the substrate portion 12. When the connecting plate portions 14a and 14b are attached to the vehicle body, The inner peripheral surface and the outer peripheral edge of the rotor 1 face each other. And each said protrusion board part 15a, 15b is extended in the direction which mutually approaches from the front-end | tip part of each of these connection board part 14a, 14b. Further, the both locking portions 16a and 16b are formed to be bent radially outward (upward in FIGS. 15 to 16) from the distal end portions of the both protruding plate portions 15a and 15b. The pressure plate 24 of the outer pad 23 is supported between the two locking portions 16a and 16b so that the rotor 1 can be displaced in the axial direction, and the braking torque applied to the outer pad 23 during braking can be supported. is doing. That is, the outer pad housing portion 25 is constituted by the protruding plate portions 15a and 15b and the locking portions 16a and 16b.

  In the case of the sheet metal support 11 which is integrally formed by bending one metal plate, whether it is the structure described in Patent Document 1 described above or the structure described in Patent Document 2 described above. In addition, it is difficult to secure the allowance between the inner pad storage portion 13 and the pressure plate 19 of the inner pad 18. This point will be described with reference to FIG. With the pressure plate 19 locked to the inner pad storage portion 13, both end edges of the pressure plate 19 are part of the substrate portion 12 with respect to the rotation direction of the rotor 1, and the inner pad storage portion 13 is opposed to the inner peripheral edge. In this state, as long as the end edge portion of the pressure plate 19 is engaged with the inner peripheral edge portion, the inner pad 18 does not move in the rotational direction of the rotor 1 regardless of the braking torque. However, it is necessary that the end edge portion and the inner peripheral edge portion are engaged with a sufficient margin so that the braking torque can be supported (not plastically deformed by the braking torque).

On the other hand, as apparent from FIG. 14, the width dimension W ₁₃ of the inner pad storage portion 13 in the axial direction of the rotor 1 remains the thickness dimension of the metal plate. In this respect, the inner pad storage portion 13 is different from the outer pad storage portion ₂₅ that can secure a width dimension W ₂₅ larger than the thickness dimension of the metal plate. In any case, the width W ₁₃ of the inner pad housing 13, when can not be increased beyond the thickness dimension of the metal plate, usable inner pad 18 is limited. Specifically, the inner pad 18 having a large lining thickness cannot be used. For this reason, the degree of freedom in designing the disc brake including the sheet metal support 11 is limited, and the frequency of replacement of the brake pads including the inner pad 18 is increased. The reason for this is as follows.

  The lining 10b (see FIGS. 10 to 11) of the inner pad 18 (of course, the outer pad 23 is the same, but the present invention relates to the improvement of the inner pad storage portion 13, so the talk is advanced with the inner pad 18). As the process repeats, it gradually wears and becomes thinner. In addition, the disc brake incorporates a gap adjusting mechanism for keeping a constant gap between the lining 10b and the side surface of the rotor 1 in the non-braking state. Accordingly, the pressure plate 19 constituting the inner pad 18 approaches the side surface of the rotor 1 regardless of braking or non-braking as the lining 10b wears. For example, in a state where the lining 10b is not yet worn, the pressure plate 19 exists at a position relatively distant from the side surface of the rotor 1, as indicated by a broken line in FIG. On the other hand, in a state where the lining 10b has been worn, the lining 10b is present at a position relatively close to the side surface of the rotor 1, as indicated by a chain line in FIG. The displacement L between the broken line and the chain line in the axial direction of the rotor 1 (vertical direction in FIG. 14) is the wear amount of the lining 10b.

In order to reliably support the braking torque (without causing the plastic deformation) in the inner pad storage portion 13 from a state in which the inner pad 18 is new to a state immediately before replacement, the state shown by the broken line is used. Even if the allowance δ _N between the outer peripheral edge of the pressure plate 19 and the inner peripheral edge of the inner pad storage portion 13 or the same allowance δ _O in the state indicated by the chain line is sufficiently secured. There is a need. In addition, in order to secure an allowable wear amount of the lining 10b ("thickness when new"-"thickness in a state where replacement is required" = L), and to increase the above-described interlocking allowances δ _N and δ _O Needs to increase the width W ₁₃ of the inner peripheral edge of the inner pad storage portion 13. However, in the case of the conventional structure disclosed in the Patent Documents 1 and 2, as described above, since the width W ₁₃ remains thickness of the metal plate, the both engagement allowance [delta] _N, from the viewpoint of increasing the [delta] _O is disadvantageous.

Of course, if a metal plate having a large thickness is used as the metal plate, both the interlocking allowances δ _N and δ _O can be increased. However, in this case, not only the material cost increases, but also the load required to process the metal plate increases, and the manufacturing cost of the sheet metal support 11 increases. In addition, since the weight of the sheet metal support 11 that becomes a so-called unsprung load increases, it causes a decrease in the performance of the automobile centering on ride comfort and running stability. It is not preferable to make it larger than necessary from the viewpoint of securing strength.

  As a structure conceived in view of such circumstances, Patent Document 3 discloses that the inner peripheral edge portion of the inner pad storage portion is pressed in the surface direction with a part of the metal plate 26 constituting the support as shown in FIG. In addition, a structure is described in which concave portions 27, 27 are formed on one side and convex portions 28, 28 are formed on the other side, respectively, so that the shape of the inner peripheral edge portion is a crank shape. According to such a structure described in Patent Document 3, the apparent width W of the pad storage portion can be made larger than the thickness dimension t of the metal plate. However, the structure described in Patent Document 3 still has the following problems.

  First, by forming the convex portions 28, 28 on the other surface side of the metal plate 26, the apparent width W of the pad storage portion can be increased, but the concave portion 27, Since 27 is formed, the area of the portion for supporting the braking torque cannot be secured. In short, in a state where the pressure plate is biased toward the one side or the other side, the contact area between the outer peripheral edge of the pressure plate and the inner peripheral edge of the pad storage portion is reduced, and the braking torque is supported. Thus, the plastic deformation as described above may occur.

  Further, it is considered inevitable that shear stress remains in the portions surrounding the concave portions 27 and 27 and the convex portions 28 and 28 at the inner peripheral edge portion pressed in the surface direction by a part of the metal plate. It is done. The portions where the concave portions 27, 27 and the convex portions 28, 28 are formed not only support a large braking torque during braking, but are also portions to which vibration accompanying braking is applied. It is considered that damage such as cracks is likely to occur.

Japanese Utility Model Publication No. 52-80389 JP 2002-295538 A JP-A-8-128468

  In view of the circumstances as described above, the present invention can sufficiently secure the engagement allowance and the contact area between the inner peripheral edge of the inner pad storage portion and the outer peripheral edge of the pressure plate constituting the inner pad, if necessary. In addition, the present invention has been invented to realize a manufacturing method capable of obtaining a disc brake sheet metal support that is less susceptible to damage such as cracks.

A sheet brake support for a disc brake, which is a target of the manufacturing method of the present invention, is made of a metal plate, and includes a substrate portion for attachment to a vehicle body, and an inner pad storage portion provided at a circumferential intermediate portion of the substrate portion. .
More specifically, for example, by bending a single metal plate, the outer pad storage portion and the inner pad storage portion are integrally provided. An outer pad and an inner pad are supported on both sides of the rotor rotating together with the wheels so that the axial displacement of the rotor can be supported, and a caliper for pressing the two pads against both side surfaces of the rotor is provided by guide pins. The rotor is supported in such a manner that it can be displaced in the axial direction.
Such a disc brake sheet metal support includes a substrate portion, an inner pad storage portion, and an outer pad storage portion.
Of these, the board portion is provided adjacent to the rotor on the inner side of the rotor for attachment to the vehicle body.
Further, the inner pad storage portion is formed in a state in which the outer peripheral edge side of the substrate portion is opened at a circumferential intermediate portion of the substrate portion.
Further, the outer pad storage portion is close to each other from a pair of connecting plate portions extending from the circumferential end portions of the substrate portion to the outer side beyond the outer peripheral edge portion of the rotor, and the tip portions of the two connecting plate portions. It is comprised by a pair of protrusion board part extended in the direction to fit.

  The manufacturing method of the disc brake sheet metal support of the present invention for producing the disc brake sheet metal support as described above is as follows. First, the inner pad storage portion is a part of the metal plate and the rotation direction of the rotor Coining is applied to both ends of the. In this coining process, a part of the metal plate is crushed in the thickness direction from one side of the metal plate, and a part on the other side of the metal plate is bulged from the other part to be crushed. The thickness dimension of the part adjacent to the raised part is made larger than the original thickness dimension of the metal plate. In the coining process, for example, as shown in FIG. 1, a part of the metal plate 31 placed on the upper surface of the lower die 29 and pressed by the pressing die 30 is directed toward the upper surface of the lower die 29 by the coining punch 32. This is done by crushing.

  A recess 33 is formed in a part of the upper surface of the lower die 29 where the thickness of the metal plate 31 is to be increased. Further, at the tip of the coining punch 32, a restraining portion 34 for restraining the metal material constituting the metal plate 31 from flowing (flowing) to the inside (left side in FIG. 1) of the inner pad housing portion. Exists. Therefore, the metal material that has flowed as it is crushed by the coining punch 32 enters the recess 33. As a result, a part of the metal plate 31 having a thickness dimension T larger than the original thickness dimension t of the metal plate 31 at a portion adjacent to the crushed portion 35 by the coining punch 32. An increased thickness portion (upset portion) 36 is formed.

  If the plate thickness increasing portion 36 is formed by the coining process as described above, then a part of the plate thickness increasing portion 36 {FIG. The oblique lattice portion A) is removed including the crushed portion 35 (the entire crushed portion 35) crushed by the coining process. And the width dimension T regarding the axial direction of the rotor of the both ends of the inner pad storage part in the rotational direction of the rotor is larger than the original thickness dimension t of the metal plate 31 (T>). t).

When the above-described method for manufacturing a sheet brake support for a disc brake according to the present invention is carried out, as shown in FIG. 2, for example, as shown in FIG. Dimension L relating to the rotational direction of the rotor (left-right direction in FIG. 2), which protrudes in the thickness direction from the other part (lower surface in FIG. 2) and in the thickness direction from the other part. ₃₈ in the same direction greater than the dimension _{L 37 (L 38> L 37} ) flat portion 38 of the recess 37 are formed respectively. Since the dimension L ₃₈ of the flat portion 38 coincides with the dimension of the bottom surface portion of the concave portion 33 of the lower mold 29, it can be arbitrarily regulated by the design of the lower mold 29. Thereafter, as shown in FIGS. 2A to 2B, the metal plate 31 is moved from the tip of the flat portion 38 (left end of FIG. 2) beyond the dimension L ₃₇ of the recessed portion 37. It is removed at a position where it enters the inside of the plate 31. In this case, the maximum value of the dimension L _S of the shaving portion, and the dimension L ₃₈ of the flat portion _{38 (L 38 ≧ L S>} L 37).

  Alternatively, as described in claim 3, as shown by a diagonal grid in FIG. 3, the width dimension of the inner surface is determined by the coining process in at least one of the parts constituting both ends of the inner pad storage part. The portion where the thickness of the metal plate 31 is larger than the original thickness dimension may be only a part of the portion facing the edge of the pressure plate of the inner pad.

  Preferably, as described in claim 4, the disc brake sheet metal support is integrally provided with an outer pad storage portion and an inner pad storage portion by bending a single metal plate. And And the step of making the width dimension in the axial direction of the rotor of both ends of the inner pad storage part in the rotational direction of the rotor larger than the original thickness dimension of the metal plate, This is performed after the plate is bent to form the outer pad storage portion.

According to the disk brake sheet metal support manufacturing method of the present invention configured as described above, the engagement allowance and the contact area between the inner peripheral edge of the inner pad storage portion and the outer peripheral edge of the pressure plate constituting the inner pad, It is possible to obtain a sheet brake support for a disc brake that can be sufficiently secured as required, and that is less susceptible to damage such as cracks.
First, the reason why the engagement allowance and the contact area can be sufficiently secured as necessary is that the width dimension of the inner surface of the inner pad storage portion can be actually increased rather than apparent. That is, in the case of the present invention, the thickness dimension T of the portion (plate thickness increasing portion 36) adjacent to the portion crushed by the coining process is larger than the original thickness dimension t of the metal plate 31. Utilizing this, the width of the inner surface is increased, so that the contact area is not reduced by the presence of the recesses 27, 27 as in the structure of the third example of the conventional structure shown in FIG. For this reason, the engagement allowance between the inner peripheral edge of the inner pad storage portion and the outer peripheral edge of the pressure plate constituting the inner pad can be increased while ensuring a contact area. Further, when the lining constituting the inner pad is unevenly worn and the pressure plate is inclined with respect to the inner pad storage portion, the outer peripheral edge of the pressure plate and the concave portions 27 and 27 (there is a concave portion). Therefore, the inner pad can be smoothly displaced with respect to the axial direction of the rotor.

  In addition, the effect that damage such as cracks is difficult to occur can be obtained by increasing the width dimension of the inner surface by the coining process. When a part of the metal plate 31 is crushed by coining to increase the plate thickness of the adjacent portion, the metal plate 31 includes a portion where the plate thickness increases (plate thickness increasing portion 36). Thus, stress in the compression direction is applied. Even after a part of the plate thickness increasing portion 36 is removed and the inner surface of the inner pad storage portion is constituted by the remaining portion of the plate thickness increasing portion 36, the residual compressive stress is applied to the inner surface and the vicinity thereof. Exists. As is well known in the field of metal processing, if there is residual compressive stress inside the metal part, crack damage is unlikely to occur. For this reason, the sheet metal support produced by the production method of the present invention is easy to ensure sufficient durability. In addition, since the hardness of the plate thickness increasing portion 36 is higher than the hardness of the metal plate 31 as a material by work hardening, the wear resistance of the inner surface of the inner pad storage portion is also improved.

Moreover, if the structure described in claim 2 is adopted, the area of the plate thickness increasing portion 36 in the inner pad storage portion can be reduced, and the weight of the entire sheet metal support can be reduced. Further, the proportion of the inner pad housing portion other than the plate thickness increasing portion 36 (the portion in which the thickness dimension is the same as the thickness dimension of the metal plate 31 as a material) can be increased. For this reason, it becomes easy to prevent interference between the sheet metal support and other members such as a caliper, and the degree of freedom in designing the sheet metal support is improved.
Even when the configuration described in claim 3 is adopted, the degree of freedom in designing the sheet metal support is improved from another aspect. For example, as shown in FIG. 3, plate thickness increasing portions 36a, 36a are provided at a plurality of intervals at each end of the inner pad storage portion, and the plate thickness increasing portions 36a, 36a are provided between each other. It is possible to design such that the pad clip 39 is prevented from slipping by engaging the claw portion 40 of the pad clip 39 with the existing thickness portion of the metal plate as the raw material. Become.

  Further, when the configuration described in claim 4 is adopted, the size and shape of the plate thickness increasing portion 36 are prevented from being distorted by bending the metal plate 31 to form the outer pad storage portion. it can. Therefore, by removing a part of the plate thickness increasing portion 36 after the coining process, the process of increasing the width dimension of both end portions in the rotation direction of the rotor in the inner surface of the inner pad housing part can be completed. In other words, the process for correcting the distortion accompanying the processing of the outer pad storage portion is not necessary.

[First example of embodiment]
FIGS. 4-6 has shown the 1st example of embodiment of this invention corresponding to Claim 1,2. In the case of this example, a metal plate as a material is punched by a press to form a flat intermediate material 41 as shown in FIG. The thickness of the portion that should become both ends of the storage portion is increased. The intermediate material 41 corresponds to the metal plate 31 (see FIGS. 1 and 2) in the above description. In order to increase the plate thickness, first, the oblique lattice portion of FIG. 4 is crushed by the coining processing device 42 shown in FIG. 5, and then the oblique lattice portion is surrounded by the trimming processing device 43 shown in FIG. The inner portions of the chain lines α and α in FIG. Through these series of processing, the end portions of the pressure plate 19 (see FIG. 16) of the inner pad 18 having a width dimension T larger than the original plate thickness t of the intermediate material 41 are provided on the chain lines α and α. A guide surface 44 (see the left half of FIG. 6) for guiding is formed. Hereinafter, the processing steps for obtaining the guide surface 44 will be described in order.

  First, the intermediate material 41 is placed on the upper surface of the fixed lower die 29 constituting the coining apparatus 42 as shown in the right half of FIG. A concave portion 33 is provided in a portion of the upper surface of the lower mold 29 that faces a portion where the thickness of the intermediate material 41 is to be increased. Further, a coining punch 32 is fixed to the center of the lower surface of a lifting frame 45 fixed to the lower surface of a ram (not shown) of a press machine provided above the lower die 29, and the coining punch 32 is moved downward by the ram. It is possible to press strongly toward. At the front end (lower end) of the coining punch 32, a pressing surface 46 for crushing the oblique lattice portion of FIG. 4 and the intermediate material 41 when the intermediate material 41 is crushed by the pressing surface 46 are shown. Is provided with a restraining portion 34 for restraining the metal material constituting the fluid from flowing into the inner pad housing portion (the center in the left-right direction in FIG. 5). A holding die 30 is supported on the lower surface of the elevating frame 45 around the coining punch 32 so that the elevating frame 45 can be slightly raised and lowered. While the coining punch 32 crushes a part of the intermediate material 41, the presser mold 30 presses the intermediate material 41 against the upper surface of the lower mold 29 by its own weight or the elasticity of a spring. Stabilize the posture.

  When the intermediate material 41 is placed on the upper surface of the lower mold 29 of the coining processing device 42 having the above-described configuration as shown in the right half of FIG. 5, the lifting frame 45 is lowered by the ram. Let Then, the pressing surface 46 of the coining punch 32 is pressed against a part of the intermediate material 41 (the oblique lattice portion in FIG. 4) while pressing the intermediate material 41 with the pressing die 30. As a result, as shown in the left half of FIG. 5, a part of the intermediate material 41 is crushed by the coining punch 32 to form a crushed portion 35, which is adjacent to the crushed portion 35. A plate thickness increasing portion 36 is formed in a portion (surrounding the crushed portion 35). As described above, the thickness T of the plate thickness increasing portion 36 is larger than the original thickness t of the intermediate material 41.

  Thus, if the said board | substrate thickness increase part 36 is formed in a part of said intermediate material 41, and it is set as the 2nd intermediate material 47, this 2nd intermediate material 47 will be shown in the right half part of FIG. Similarly, the trimming device 43 is placed on the upper surface of a fixed lower mold (receiving mold) 48. The lower mold 48 has an upper surface shape in which the lower surface of the second intermediate material 47 is brought into close contact with the exception of the tip of the plate thickness increasing portion 36, and a chain line α in FIG. A receiving hole 49 having a shape corresponding to α is provided. A lifting frame 50 is fixed to the lower surface of a ram (not shown) of a press machine different from the coining device 42 provided above the lower die 48. Further, a trimming punch 51 is fixed to the center of the lower surface of the elevating frame 50, and the trimming punch 51 can be strongly pressed downward by the ram. The shape of the outer peripheral edge (the outer peripheral edge of the lower end) of the trimming punch 51 substantially matches the shapes of the chain lines α and α in FIG. A pressing die 52 is supported on the lower surface of the lifting frame 50 around the trimming punch 51 so that the lifting frame 50 can be slightly lifted. While the trimming punch 51 crushes a part of the second intermediate material 47, the presser mold 52 presses the second intermediate material 47 against the upper surface of the lower mold 48 by its own weight or spring elasticity. The posture of the second intermediate material 47 is stabilized.

  If the second intermediate material 47 is placed on the upper surface of the lower mold 48 of the trimming device 43 having the above-described configuration as shown in the right half of FIG. Is lowered. Then, the outer peripheral edge of the front end of the trimming punch 51 is pressed against a part of the second intermediate material 47 (parts indicated by chain lines α and α in FIG. 4) while the second intermediate material 47 is pressed by the pressing mold 52. As a result, as shown in the left half part of FIG. 6, the plate thickness increasing portion 36 in a part of the second intermediate material 47 is scraped off in the peripheral portion of the crushed portion 35.

By the trimming process performed as described above, a third intermediate in which the width dimension T of the surface that guides both edge portions of the pressure plate 19 (see FIG. 16) of the inner pad 18 is larger than the thickness t of the original metal plate. The material 53 can be obtained. Therefore, the third intermediate material 53 is folded back at the portion between the chain lines β and β in FIG. 4 and the projecting plate portions 15a and 15b are appropriately bent and then subjected to shaving for finishing. A sheet metal support similar to the second example of the conventional structure shown in FIGS. The sheet metal support obtained in this way can sufficiently secure the engagement allowance and the contact area between the inner peripheral edge of the inner pad storage portion and the outer peripheral edge of the pressure plate 19 and is less likely to cause damage such as cracks. Is as described above. If the folding process between the chain lines β and β and the bending process of the projecting plate portions 15a and 15b are performed prior to the trimming process, the processing of the sheet metal support can be completed by the trimming process. (Shaving can be omitted).
In addition, the shape of the intermediate material that increases the thickness of a part by the method of this example is not limited to that shown in FIG. For example, in the intermediate material 41a as shown in FIG. 7, the thickness dimension of the portion indicated by the oblique lattice in the same figure can be increased as described above.

[Second Example of Embodiment]
8 to 9 show a second example of an embodiment of the present invention corresponding to claims 1, 2, and 4. FIG. In the case of this example, a process for increasing the thickness of a part of the metal plate corresponding to both end portions of the inner pad storage part is performed by bending the metal plate to store the inner pad storage part 13 and the outer pad storage part. This is performed after the portion 25 is formed. That is, the fourth intermediate material 54 formed by bending the intermediate materials 41 and 41a as shown in FIG. 4 or FIG. 7 to form the inner pad storage portion 13 and the outer pad storage portion 25 as shown in FIG. After the coining process is performed by the special coining apparatus 42a, the trimming process is performed by the trimming apparatus 43a as shown in FIG. Regarding the configurations of the coining processing device 42a and the trimming processing device 43a, the object (workpiece) to be subjected to coining processing and trimming processing is changed from the flat intermediate materials 41 and 41a to the solid fourth intermediate material 54, and the holding die 30a. , 52a, etc. are the same as in the case of the first example described above, except that the shape is changed to prevent interference with the fourth intermediate material 54.

In the case of this example, as in the first example of the embodiment, the third intermediate material 53 having a plate shape in which the thickness of a part of the inner pad storage portion 13 has already been increased (see the left half of FIG. 6). ) Is not bent to form the outer pad storage portion 25. For this reason, it can prevent that the dimension and shape of the board thickness increase part 36 are distorted with the process of this outer pad accommodating part 25. FIG. Therefore, by removing a part of the plate thickness increasing portion 36 after coining, the processing for increasing the width dimension of both ends of the inner pad storage portion 13 in the rotational direction of the rotor can be completed. That is, a process (shaving process for finishing) for correcting distortion associated with the processing of the outer pad storage portion 25 is not necessary, and the processing cost can be reduced.
In the case of carrying out the present invention, the direction in which the thickness dimension of the metal plate is increased with the coining process is not particularly limited. In each example of the embodiment, the flat portion 38 may be formed on the side facing the rotor, or may be formed on the opposite side (on the opposite rotor side).

The fragmentary sectional view which shows the coining process performed when implementing this invention. The partial sectional view which similarly shows trimming processing in order of a process. The state which provided the board | plate thickness increase part intermittently is shown, (A) is a partial front view, (B) is a figure which shows the state which mounted | wore the pad clip, (C) is a II cross section of (B). Figure. BRIEF DESCRIPTION OF THE DRAWINGS The 1st example of embodiment of this invention is shown, (A) is a top view which shows an example of an intermediate material, (B) is a roll sectional view of (A). Sectional drawing which shows the implementation condition of coining process. Sectional drawing which shows the implementation condition of trimming. The other example of an intermediate material is shown, (A) is a top view, (B) is a ha sectional view of (A). Sectional drawing which shows the implementation condition of the coining process in the 2nd example of embodiment of this invention. Sectional drawing which similarly shows the implementation condition of a trimming process. The figure which shows the 1st example of the conventional structure of the disc brake provided with sheet-metal support in the state cut | disconnected and seen from the outer-diameter side. FIG. 11 is a knee cross-sectional view of FIG. 10. The figure shown in the state which took out only the support of FIG. The figure seen from the inner side equivalent to the downward direction of FIG. The figure which shows the 2nd example of the conventional structure of a sheet-metal support in the state seen from the radial direction outer side of the rotor. The figure shown in the state seen similarly from the outer side. Similarly, it is built into the disc brake, and a part is cut and seen from the outer side. The figure which took out the sheet metal support and the outer pad, and was seen from the outer side. The perspective view which shows the 2nd example of the conventional structure of a sheet-metal support.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rotor 2 Support 3 Caliper 4a, 4b Guide pin 5a, 5b Pad 6 Cylinder part 7 Piston 8a, 8b Pressure plate 9 Caliper claw 10a, 10b Lining 11 Sheet metal support 12 Substrate part 13 Inner pad accommodating part 14a, 14b Connecting plate part 15a, 15b Projecting plate portion 16a, 16b Locking portion 17 Screw hole 18 Inner pad 19 Pressure plate 20 Locking notch 21 Locking protrusion 22 Locking flange 23 Outer pad 24 Pressure plate 25 Outer pad storage portion 26 Metal plate 27 Recessed portion 28 Convex part 29 Lower mold 30, 30a Holding mold 31 Metal plate 32 Coining punch 33 Concave part 34 Constraining part 35 Crushed part 36, 36a Thickened part 37 Concave part 38 Flat part 39 Pad clip 40 Claw part 41, 41a Interim material 42, 42a Coining device 43, 43a Trimming device 44 Guide surface 45 Elevating frame 46 Pressing surface 47 Second intermediate material 48 Lower die 49 Receiving hole 50 Elevating frame 51 Trimming punch 52, 52a Holding die 53 Third intermediate material 54 Fourth intermediate material

Claims (4)

  A method of manufacturing a metal plate support for a disc brake comprising a metal plate and a board portion for mounting on a vehicle body, and an inner pad storage portion provided at a circumferential intermediate portion of the board portion, A part of the metal plate is crushed in the thickness direction from one side of the metal plate to a portion constituting both end portions of the inner pad storage portion with respect to the rotation direction of the rotor, and the other of the metal plate After performing a coining process in which a part of the surface side is swollen more than the other part and the thickness dimension of the part adjacent to the crushed part is larger than the original thickness dimension of the metal plate, By removing a part of the plate thickness increasing part whose thickness dimension has increased with the coining process, including the part crushed by the coining process, among the inner surface of the inner pad storage part, Rotor times Both end portions in the direction, the width in the axial direction of the rotor, a manufacturing method of a sheet metal support disc brake having a step larger than the original thickness of the metal plate.   Due to the coining process, the concave portion on one side of the metal plate is protruded in the thickness direction from the other portion on the other side, and the dimension in the rotational direction of the rotor is larger than the dimension in the same direction of the concave portion. 2. The disk according to claim 1, wherein after each of the larger planar portions is formed, the metal plate is removed from the tip of the planar portion at a position that has entered the interior of the metal plate beyond the size of the recessed portion. Manufacturing method of sheet metal support for brakes.   In at least one of the parts constituting both ends of the inner pad storage part, a part that makes the width dimension of the inner surface larger than the original thickness dimension of the metal plate by the coining process is The manufacturing method of the metal brake support for disk brakes according to any one of claims 1 to 2, wherein only a part of a portion of the inner pad facing the edge of the pressure plate is opposed. The disc brake sheet metal support is integrally provided with an outer pad storage portion and an inner pad storage portion by bending a single metal plate, and of the inner surface of the inner pad storage portion. The step of increasing the width dimension of the both ends of the rotor in the rotational direction in the axial direction of the rotor to be larger than the original thickness dimension of the metal plate is obtained by bending the metal plate to form the outer pad storage portion. The manufacturing method of the sheet-metal-brake support for disc brakes as described in any one of Claims 1-3 implemented after forming.

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