JP5961501B2 - Processing method of disc brake caliper - Google Patents

Description

  The present invention relates to a method for processing a disc brake caliper.

  When manufacturing a disc brake caliper, an inner diameter surface of a cylinder portion is processed with a rotating blade (see, for example, Patent Document 1).

JP-A-6-179107

  By the way, in the disc brake caliper, machining of the surface of the claw portion facing the cylinder portion is complicated and increases the machining cost.

  Therefore, an object of the present invention is to provide a method for processing a disc brake caliper that can reduce processing costs.

  In order to achieve the above object, a method of processing a disc brake caliper according to the present invention holds a disc brake caliper in a state where the disc brake caliper is elastically deformed so that the tip end side of the claw portion is separated from the cylinder portion. It was set as the structure which cuts the cylinder part opposing surface which opposes the said cylinder part of a nail | claw part with a cutting tool.

  According to the disk brake caliper processing method of the present invention, the processing cost can be reduced.

It is a front view showing a disc brake caliper. It is the side view which made a part the cross section which shows a disk brake caliper. The principal part of the processing apparatus used with the processing method of the disc brake caliper concerning one embodiment of the present invention is shown, (a) is a front view and (b) is a side view. The processing method of the disc brake caliper which concerns on one Embodiment of this invention is shown, (a) is a front view, (b) is a side view. The processing method of the disc brake caliper which concerns on one Embodiment of this invention is shown, (a) is a front view, (b) is a side view. The processing method of the disc brake caliper which concerns on one Embodiment of this invention is shown, (a) is a front view, (b) is a side view. It is a side view which shows the processing method of the disc brake caliper which concerns on one Embodiment of this invention. It is a side view which shows the processing method of the disc brake caliper which concerns on one Embodiment of this invention.

  A method for processing a disc brake caliper according to an embodiment of the present invention will be described below with reference to the drawings. 1 and 2 show a disc brake caliper 10. The disc brake caliper 10 includes a disc rotor 11 that rotates together with a wheel (not shown), a piston 12 shown in FIG. 2, a pair of friction pads 13 and 13, and the like to constitute a disc brake for braking a vehicle such as an automobile.

  The disc brake caliper 10 holds the piston 12 and is supported by a carrier (not shown) fixed to a non-rotating portion of the vehicle. The disc brake caliper 10 is supported by the carrier so as to be slidable in the axial direction of the disc rotor 11 while straddling the disc rotor 11 as shown in FIG. The pair of friction pads 13 and 13 are also supported by this carrier so as to be slidable in the axial direction of the disk rotor 11.

  As shown in FIG. 1, the outer peripheral surface 15 of the disk rotor 11 has a cylindrical surface, and the surface 16 on one side in the axial direction and the surface 17 on the other side in the axial direction as shown in FIG. It spreads out orthogonally. In the following, the radial direction of the disk rotor 11 is referred to as a disk radial direction, the axial direction of the disk rotor 11 is referred to as a disk axial direction, and the rotational direction of the disk rotor 11 is referred to as a disk rotational direction.

  The disc brake caliper 10 includes a cylinder portion 20 that holds the piston 12, a disc path portion 21 that is integrally connected to the cylinder portion 20 at one end, and a claw portion that is integrally connected to the other end of the disc path portion 21. 22 and a pair of arm portions 23, 23 shown in FIG. As shown in FIG. 2, the disc brake caliper 10 has a cylinder portion 20 and a claw portion 22 at opposing positions sandwiching the disc rotor 11, and the cylinder portion 20 and the claw portion 22 are located at positions that straddle the disc rotor 11. The disk path portions 21 are connected and formed integrally.

  The cylinder portion 20 is disposed to face one surface 16 of the disk rotor 11. As shown in FIG. 1, the cylinder part 20 has a cylindrical part 25 and a bottom part 26 that closes one side of the cylindrical part 25. As shown in FIG. 1 is formed on the side opposite to the disk rotor 11 to form a bottomed cylindrical shape having one bore 30 shown in FIG. 1 which is open on the disk rotor 11 side and parallel to the disk axial direction. Since one bore 30 is formed, the center axis of the bore 30 becomes the cylinder center axis X of the cylinder portion 20. When two or more bores are formed at intervals in the disk rotation direction, the center of the center axis of all the bores becomes the cylinder center axis X. A supply hole 31 for supplying hydraulic fluid from the outside into the bore 30 is formed in the center of the bottom portion 26 of the cylinder portion 20.

  As shown in FIG. 2, the surface of the cylindrical portion 25 opposite to the bottom portion 26 is a claw portion facing surface 32 that faces the claw portion 22 in the cylinder portion 20. The claw portion facing surface 32 has a flat surface and extends so as to be orthogonal to the cylinder center axis X. In other words, the claw portion facing surface 32 is a flat surface extending so as to be orthogonal to the disk axial direction and extending in parallel with the surface 16 of the disk rotor 11.

  As shown in FIG. 1, the cylinder portion 20 is formed with planar seating surfaces 33 and 33 on both sides in the disk rotation direction on the outer side in the disk radial direction. These seating surfaces 33 and 33 are formed when the disc brake caliper 10 is cast, and are in the same plane perpendicular to the line extending in the disc radial direction through the center axis of the disc rotor 11 and the cylinder center axis X. Is arranged. A line connecting the bearing surfaces 33 on both sides in the disk rotation direction is divided into two equal parts by a plane including the center axis of the disk rotor 11 and the cylinder center axis X. In other words, the seating surfaces 33 on both sides are disposed at mirror-symmetric positions about a plane including the center axis of the disk rotor 11 and the cylinder center axis X.

  The cylinder portion 20 is formed with a flat pressing surface 34 in the center of the disk rotation direction inside the disk radial direction. The pressing surface 34 is orthogonal to a line extending in the disk radial direction through the center axis of the disk rotor 11 and the cylinder center axis X, and is parallel to the seating surfaces 33 and 33.

  The pair of arm portions 23, 23 extend from both sides in the disc rotation direction of the intermediate portion in the disc radial direction of the cylinder portion 20 to both outer sides in the disc rotation direction. In the pair of arm portions 23, 23, pin mounting holes 35, 35 are formed in parallel to the cylinder center axis X. In other words, pin mounting holes 35, 35 are formed in parallel to the disk axis direction. A line extending in the disk rotation direction by connecting the pin mounting holes 35 is divided into two equal parts by a plane including the center axis of the disk rotor 11 and the cylinder center axis X.

  Although not shown, sliding pins are coaxially attached to these pin mounting holes 35, 35, and these sliding pins are slidably fitted to a carrier (not shown). Thereby, the disc brake caliper 10 is supported so as to be slidable in the disc axial direction with respect to the carrier.

  The piston 12 is slidably inserted into the bore 30 of the cylinder portion 20 and is disposed so as to face one surface 16 of the disc rotor 11 as shown in FIG. It slides in the direction of the central axis X, that is, the disk axis direction. In a state where the piston 12 is inserted into the cylinder portion 20, the flat distal end surface 37 faces the claw portion 22, and the distal end surface 37 extends so as to be orthogonal to the cylinder center axis X. In other words, the front end surface 37 of the piston 12 is a flat surface extending so as to be orthogonal to the disk axial direction and extending in parallel with the surface 16 of the disk rotor 11.

  The disk path portion 21 is formed to extend in the disk axial direction outside the cylinder portion 20 in the disk radial direction so as to straddle the disk rotor 11. The inner surface 39 on the inner side in the disk radial direction of the disk path portion 21 is opposed to the cylindrical outer peripheral surface 15 of the disk rotor 11, and the center axis parallel to the cylinder center axis X as shown in FIG. It has a cylindrical surface shape. The inner surface 39 of the disk path portion 21 extends so as to form substantially equal intervals in the disk radial direction with respect to the outer peripheral surface 15 of the disk rotor 11.

  As shown in FIG. 2, the claw portion 22 extends inward in the radial direction of the disc from the side opposite to the cylinder portion 20 of the disc path portion 21 and faces the other surface 17 of the disc rotor 11. That is, the claw portion 22 is provided on the side opposite to the piston 12 with respect to the disk rotor 11. As shown in FIG. 1, the claw portion 22 has a recess 42 in the center of the extending tip side in the disk rotation direction and penetrating in the disk axial direction and recessed outward in the disk radial direction. The piston 12, that is, a portion facing the bore 30 of the cylinder portion 20 is formed. The recess portion 42 is a relief groove for allowing a tool or the like for machining the inside of the bore 30 of the cylinder portion 20 to pass therethrough. A recess forming surface 43 of the claw portion 22 forming the recess portion 42 extends in parallel to the cylinder center axis X so as to surround the cylinder center axis X.

  As shown in FIG. 2, the cylinder part opposing surface 45 which opposes the cylinder part 20 of the nail | claw part 22 has comprised the planar shape. The cylinder portion facing surface 45 has a plane orthogonal to the cylinder center axis X (a plane parallel to the surface 17 of the disc rotor 11) on the tip side of the claw portion 22 (the side opposite to the disc path portion 21 in the disc radial direction). Is inclined so as to be positioned on the cylinder portion 20 side in the disk axial direction over the entire disk rotation direction. In other words, the line perpendicular to the cylinder portion facing surface 45 is inclined so that the cylinder portion facing surface 45 is positioned inward in the disk radial direction within a plane including the center axis of the disk rotor 11 and the cylinder center axis X.

  A seating surface 48 is formed in the claw portion 22 at the center in the disk rotation direction outside the disk radial direction. The seating surface 48 is a plane orthogonal to a line extending in the radial direction of the disk through the central axis of the disk rotor 11 and the cylinder central axis X, and the side opposite to the cylinder portion 20 in the disk axial direction is in the disk rotation direction. It is inclined so as to be located inward in the radial direction of the disk throughout. In other words, the line perpendicular to the seating surface 48 is inclined so that the inner side in the disk radial direction is located closer to the cylinder portion 20 side in the disk axial direction in the plane including the central axis of the disk rotor 11 and the cylinder central axis X. The seat surface 48 extends in a direction substantially orthogonal to the cylinder portion facing surface 45. The seat surface 48 is also formed when the disc brake caliper 10 is cast, like the seat surfaces 33 and 33.

  The disc brake caliper 10 advances the piston 12 shown in FIG. 2 toward the disc rotor 11 by brake fluid introduced from a master cylinder or a hydraulic pressure control unit (not shown) into the bore 30 through the supply hole 31 shown in FIG. The piston 12 presses one friction pad 13 of the pair of friction pads 13, 13 to bring the friction pad 13 into contact with the disk rotor 11. Further, the disc brake caliper 10 moves in a direction in which the cylinder portion 20 moves away from the disc rotor 11 with respect to a carrier (not shown) due to the pressing reaction force of the piston 12, and the pair of friction pads 13, 13 are moved by the claw portion 22. The other friction pad 13 is pressed to bring the friction pad 13 into contact with the disk rotor 11. In this way, the friction pads 13 and 13 on both sides are sandwiched between the piston 12 and the claw portion 22 of the disc brake caliper 10 and pressed against the disc rotor 11 to generate a frictional resistance in the disc rotor 11, thereby increasing the braking force. generate.

  At that time, the disc brake caliper 10 has a shape in which the claw portion 22 is cantilevered by the disc path portion 21, so that the tip side of the claw portion 22 (the side opposite to the disc path portion 21 in the disc radial direction) It is elastically deformed in the direction away from the cylinder part 20 in the disk axial direction. Since the cylinder portion facing surface 45 is inclined as described above with respect to the surface 17 of the disk rotor 11, the cylinder portion facing surface 45 is parallel to the surface 17 of the disk rotor 11 during this elastic deformation. As a result, the claw portion 22 presses the friction pad 13 between the claw portion 22 and the disk rotor 11 against the surface 17 of the disk rotor 11 in an appropriate posture.

  Next, a processing apparatus 55 for cutting the above-described disc brake caliper 10 and a processing method of this embodiment performed using the same will be described.

  As shown in FIG. 3, the processing device 55 includes a clamp mechanism 57 that clamps the disc brake caliper 10 placed with the disc path portion 21 facing down, and the disc brake caliper 10 that is clamped by the clamp mechanism 57. A cutting tool 58 for milling the cylinder part 20, the disk path part 21 and the claw part 22 at once, and an inner diameter cutting tool (not shown) for machining the inner peripheral surface of the bore 30 of the cylinder part 20. .

  The clamp mechanism 57 includes a pair of support portions 62 and 62 for mounting the pair of seat surfaces 33 and 33 formed on the cylinder portion 20 of the disc brake caliper 10 on the upper surfaces 61 and 61, and a seat formed on the claw portion 22. And a support portion 65 for placing the surface 48 on the upper surface 64. The upper surfaces 61 and 61 are disposed on the same horizontal plane, and the upper surface 64 is also disposed horizontally.

  The clamp mechanism 57 includes a pair of support portions 62, 62 and a cylinder portion pressing portion 70 that presses the pressing surface 34 of the cylinder portion 20 of the disc brake caliper 10 in a state of being placed on the support portion 65, and a pair of supports. And a claw portion pressing portion 71 that presses the recess forming surface 43 of the claw portion 22 of the disc brake caliper 10 in a state of being placed on the portions 62 and 62 and the support portion 65. Although not shown, the clamp mechanism 57 includes a front / rear positioning mechanism that positions the disc brake caliper 10 in the direction of the cylinder center axis X (the disc axis direction), and a pair of arms 23 and 23 of the disc brake caliper 10. And a left / right positioning mechanism for positioning in the connecting direction (disk rotation direction).

  The cylinder portion pressing portion 70 includes a pressing tool 74 that contacts the pressing surface 34 of the disc brake caliper 10 and a drive cylinder 75 that moves the pressing tool 74 up and down. The cylinder portion pressing portion 70 clamps the cylinder portion 20 with the pair of support portions 62 and 62 by the drive cylinder 75 lowering the pressing tool 74 and pressing the pressing surface 34 downward with the horizontal lower surface 76 thereof. . In this clamped state, the disc brake caliper 10 has the seating surfaces 33 and 33 in surface contact with the upper surfaces 61 and 61 of the pair of support portions 62 and 62 disposed horizontally, and the lower surface 76 disposed horizontally of the pressing tool 74. Thus, the pressing surface 34 comes into surface contact, and the cylinder center axis X is in a horizontal state.

  The claw portion pressing portion 71 includes a pressing tool 80 that contacts the recess forming surface 43 of the disc brake caliper 10 and a drive cylinder 81 that moves the pressing tool 80 up and down. The claw portion pressing portion 71 clamps the claw portion 22 with the support portion 65 by the drive cylinder 81 lowering the pressing tool 80 and pressing the recess forming surface 43 downward with its horizontal lower surface 82.

  The cutting tool 58 includes an outer peripheral side cutting portion 85 that revolves on a cylindrical surface around the rotation center during rotation, an end-side cutting portion 86 that revolves on a plane orthogonal to the rotation center during rotation, and a rotation center during rotation. The other end side cutting part 87 which turns on the plane orthogonal to is included.

  In the processing method according to the present embodiment, first, as shown in FIG. 4, the disc brake caliper 10 with the disc path portion 21 facing down is placed on the clamp mechanism 57 of the processing device 55. At that time, the pair of seat surfaces 33, 33 formed on the cylinder portion 20 of the disc brake caliper 10 are placed on the upper surfaces 61, 61 of the pair of support portions 62, 62, and the seat surface formed on the claw portion 22. 48 is placed on the upper surface 64 of the support portion 65.

  Next, after positioning the disc brake caliper 10 in the horizontal direction by a front-rear positioning mechanism and a left-right positioning mechanism (not shown) of the processing device 55, before clamping the claw portion 22 by the claw pressing portion 71, the cylinder portion 20 is moved. The cylinder portion pressing portion 70 and the pair of support portions 62 and 62 are clamped as described above. In this state, in the disc brake caliper 10, the seat surface 48 of the claw portion 22 has a gap with respect to the upper surface 64 of the support portion 65.

  Next, the claw portion pressing portion 71 presses the recess forming surface 43 downward from this state. Then, as shown in FIG. 5, the claw portion pressing portion 71 elastically deforms the boundary portion between the claw portion 22 and the disc path portion 21 of the disc brake caliper 10, and the support portion disposed horizontally. The nail | claw part 22 is clamped with the support part 65 by making the seating surface 48 inclined before deformation | transformation surface-contact with the upper surface 64 of 65. FIG. As a result, the disc brake caliper 10 is clamped in a state in which the tip side of the claw portion 22 (the side opposite to the disc path portion 21 in the disc radial direction) is elastically deformed so as to be separated from the cylinder portion 20 in the disc axial direction. 57.

  Next, as shown in FIG. 6, one cutting tool 58 provided in the processing device 55 is connected to the claw portion facing surface 32 of the cylinder portion 20 of the disc brake caliper 10 in the holding state by the clamp mechanism 57 and the disc path. The inner surface 39 of the portion 21 and the cylinder portion facing surface 45 of the claw portion 22 are cut at a time. That is, when the cutting tool 58 rotates, the one end side cutting portion 86 cuts the claw portion facing surface 32 of the cylinder portion 20, and the other end side cutting portion 87 cuts the cylinder portion facing surface 45 of the claw portion 22. The inner surface 39 of the disk path portion 21 is processed in parallel by the portion 85. After cutting with the cutting tool 58 in this way, the cutting tool 58 is retracted from the disc brake caliper 10.

  After the above-described processing by the cutting tool 58, as shown in FIGS. 7 to 8, the claw portion 22 is clamped by the claw portion pressing portion 71 and the support portion 65, and the cylinder portion pressing portion 70 and the pair of support portions are released. The clamp of the cylinder part 20 by 62 and 62 is cancelled | released, and also the horizontal positioning by the front-rear positioning mechanism and the left-right direction positioning mechanism (not shown) is released.

  Then, as shown in FIG. 8, the disc brake caliper 10 is released from elastic deformation, and the tip side of the claw portion 22 (the side opposite to the disc path portion 21 in the disc radial direction) is in the cylinder portion 20. It returns to the state approaching in the disk axis direction. Then, as described above, the cylinder portion facing surface 45 of the claw portion 22 is inclined such that the tip end side of the claw portion 22 is positioned on the cylinder portion 20 side in the disk axial direction. That is, the disc brake caliper 10 is clamped with the claw portion 22 opened to process the cylinder portion facing surface 45, and the unclamping operation is performed to return the claw portion 22 to the closed side by the elastic force of the disc brake caliper 10 to the cylinder portion. The facing surface 45 is inclined.

  In the processing device 55, in the pre-process or post-process of processing the claw part facing surface 32 of the cylinder part 20, the inner surface 39 of the disk path part 21, and the cylinder part facing surface 45 of the claw part 22 by the cutting tool 58 described above. Then, the inside of the bore 30 of the cylinder portion 20 is processed by an internal diameter cutting tool (not shown). At this time, in order to avoid interference with the inner diameter cutting tool, the claw portion pressing portion 71 and the support portion 65 do not clamp the claw portion 22 but retract the claw portion pressing portion 71. Then, the disc brake caliper 10 is horizontally positioned by a front-rear positioning mechanism and a left-right positioning mechanism (not shown), and the cylinder portion 20 is clamped by the cylinder pressing portion 70 and the pair of support portions 62 and 62. The inside of the 20 bores 30 is processed.

  Here, the processing device 55 positions the disc brake caliper 10 in the horizontal direction by a front-rear positioning mechanism and a left-right positioning mechanism (not shown), and then the cylinder unit 20 includes the cylinder unit pressing unit 70 and the pair of support units 62, 62. Is once clamped, the claw part facing surface 32 of the cylinder part 20, the inner surface 39 of the disk path part 21, and the cylinder part facing surface 45 of the claw part 22 are processed by the cutting tool 58 without releasing the clamp in the middle. And machining in the bore 30 with an inner diameter cutting tool (not shown). That is, the processing device 55 performs processing with the cutting tool 58 and processing with an inner diameter cutting tool (not shown) with a single chuck on the disc brake caliper 10.

  Conventionally, in order to incline the cylinder portion facing surface 45 of the claw portion 22 without being orthogonal to the cylinder center axis X as described above, for example, the disc brake caliper 10 is clamped in a state of being inclined with respect to the horizontal. The cylinder portion facing surface 45 of the claw portion 22 is cut. In addition to this, the disc brake caliper 10 must be clamped horizontally to cut the bore 30 of the cylinder portion 20, which is complicated and increases the processing cost.

  On the other hand, according to the processing method of the present embodiment, the disc brake caliper 10 is held in a state of being elastically deformed so that the tip end side of the claw portion 22 is separated from the cylinder portion 20, and in this holding state, the claw portion 22 Since the cylinder portion facing surface 45 facing the cylinder portion 20 is cut by the cutting tool 58, the cutting tool 58 with one chuck and the inner diameter cutting tool (not shown) can be processed, and the disc brake caliper 10 can be processed. And the processing cost can be reduced. That is, the processing time can be shortened and the process can be consolidated, so that the number of equipment can be reduced and the equipment investment can be reduced.

  Moreover, since the machining of the cylinder part facing surface 45 of the claw part 22 by the cutting tool 58 and the machining of the bore 30 by an inner diameter cutting tool (not shown) can be performed with one chuck, the machining accuracy of the cylinder part facing surface 45 with respect to the bore 30 is improved. Thus, the maintenance of these dimensions is easy, and the dimensional defect rate can be reduced.

The present embodiment described above has a cylinder part and a claw part at opposing positions sandwiching the disk rotor, and the cylinder part and the claw part are connected by a disk path part disposed at a position across the disk rotor. A disc brake caliper formed integrally with the disc brake caliper, wherein the disc brake caliper is held in a state of being elastically deformed so that a tip end side of the claw portion is separated from the cylinder portion, and the claw is held in the held state. A cylinder part facing surface facing the cylinder part is cut with a cutting tool. As a result, the cylinder part facing surface can be tilted even if the cylinder part facing surface is processed without tilting the entire disc brake caliper with respect to the cutting tool. This makes it possible to reduce the processing cost of the disc brake caliper.
The present invention can also be applied to a caliper having two, three, or more pistons. Further, the present invention can also be applied to a caliper without the recess 43.
Furthermore, in the said embodiment, although the example which cuts the nail | claw part opposing surface 32, the inner surface 39 of the disc path | pass part 21, and the cylinder part opposing surface 45 of the claw part 22 was shown at once, it is not restricted to this, A claw part Only the facing surface 32 may be cut, or the claw portion facing surface 32 and the inner surface 39 of the disk path portion 21 may be cut at once. Further, the claw portion facing surface 32 and the cylinder portion facing surface may be used. You may use 45 for what cuts at once.
Furthermore, the clamp position at the time of caliper cutting is not limited to the embodiment.

DESCRIPTION OF SYMBOLS 10 Disc brake caliper 11 Disc rotor 20 Cylinder part 21 Disc pass part 22 Claw part 45 Cylinder part opposing surface 58 Cutting tool

Claims (7)

A disc brake caliper that has a cylinder portion and a claw portion at opposing positions sandwiching the disc rotor, and is integrally formed by connecting the cylinder portion and the claw portion by a disc path portion disposed at a position straddling the disc rotor. The processing method of
Holding the disc brake caliper in a state of being elastically deformed so that the tip side of the claw portion is separated from the cylinder portion;
A method for processing a disc brake caliper, wherein a cylinder portion facing surface of the claw portion facing the cylinder portion is cut with a cutting tool in the holding state. In the step of cutting by the cutting tool the cylinder unit opposed surfaces, said cutting opposing claw portions facing surface simultaneously with the claw portion of the cylinder portion with a cutting tool, machining of disc brake caliper according to claim 1 Method. In the step of cutting by the cutting tool the cylinder unit opposed surfaces, cutting an inner surface of said disc-path portion simultaneously by the cutting tool, processing method for a disk brake caliper according to claim 1 or 2. The method of processing a disc brake caliper according to claim 1, wherein the disc brake caliper is held in a state where the disc path portion is on a lower side. The disc brake caliper is formed with a plurality of flat seating surfaces on the outer side in the disc radial direction, and the disc brake caliper is held in a state where the plurality of seating surfaces are supported. Or the processing method of the disc brake caliper of 4. The at least one of the plurality of seating surfaces is formed on a claw portion side, and the seating surface on the claw portion side is formed to be inclined with respect to another seating surface. Disc brake caliper processing method. The claw portion of the disc brake caliper is formed with a recess forming surface that is recessed outward in the radial direction of the disc, and the recess forming surface is pressed to elastically deform the tip side of the claw portion away from the cylinder portion. 2. A method for processing a disc brake caliper according to 1.

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